Maintenance and Service Manual 28000 Powershift I Transmission I R & HR MODEL 3 & 6 SPEED I LONG DROP WITH RANGE SHIFT CLARI-HURTE> COMPONENTS | SM RHR 283810 (Rev. 7.95)Service Publications 1293 Glenway Drive Statesville, NC 28677 TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive, rear wheels off the ground or disconnect the disconnect both front and rear drivelines, driveline to avoid damage to the trans- Because of the design of the hydraulic mission during towing. system, the engine cannot be started by pushing or towing. ‘©Copyright Clark Equipment Company, 1998 ‘Unpubished mater! {mites Oaibution No par ofthis work may be reprecuced in any orm under ny means winout rect witton permsscn ot Clark Equpment CompanyFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low 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 Clark- Hurth Components-approved parts as listed in the applicable parts inanual should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repair or replacement ‘parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette... 2002... eee eee cee Fig. A Converter Assembly . . Fig. B Converter and Transmission Case Group ................ Fig. C 3 Speed Clutch and Gear Group 2.00.0... cece eee eens Fig. D Clutch Group 2... eee eee ee eee eeeeeeeeeeeeee Fig. E Regulating Valve, Charging Pump and Filter Group ........ Fig. F Control Valve Assembly... 0.0... cece cece eee eee » Fig. G Axle Disconnect and Mechanical Parking Brake .......... Fig. H Assembly Instruction Drawing .......6.2. 0622 00cceceee DISASSEMBLY OF TRANSMISSION CLEANING AND INSPECTION ..............00.0004 114 REASSEMBLY OF TRANSMISSION ............. 15 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL . 29 SPECIFICATION AND SERVICE DATA . 30 LUBRICATION ...............2.. - 30 TROUBLE SHOOTING GUIDE .... HR MODEL EXTERNAL PLUMBING DIAGRAM . HR MODEL TYPICAL THREE SPEED POWER FLOW ............. 33 CLUTCH AND GEAR ARRANGEMENT . SHIELDED BEARING INSTALLATION RING GEAR INSTALLATION . ‘SPEED SENSOR INSTALLATION 6 SPEED SECTION R-MODEL SECTION . DRIVE PLATE INSTALLATION ......200......0..00005 e+. 64-65 NOTE: Metric Dimensions Shown in Brackets [ _].NOTES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 function and how they operate. The-transmission and torque converter function together and operate through a common hydraulic system. It 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 Silhouette Converter Assembly Converter and Transmission Case Group Three Speed Clutch and Gear Group Cluteh Group Regulating Valve, Charging Pump and Filter Group Control Valve ‘Axle Disconnect and Mechanical Parking Brake Typical 28000 Cross Section External Plumbing Diagram Typical Three-Speed Power Flow Clutch and Gear Arrangement Ring Gear Installation Shielded Bea 9 Install The R, HR, and MHR Model Transmissions are of three basic 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 a mid-mount torque converter and transmission assembly connected to the engine by means of a 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 n cover, oF 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 made on certain models to neutralize the transmission when the brakes are applied. red through use of a brake actuated shutoff valve, The speed and direction clutch assem- 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 gear 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 manual shifting.HOW THE UNITS OPERATE With the engine running, the converter charging pump draws oil from the transmission sump through the ing valve and oil filter. removable oil suction screen and directs it through the pressure regul. ‘The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc- tion and speed clutches. This requires @ small portion of the total volume of oil used in the system, The remaining: volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. Thi regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in @ closed position, When a specific pressure is achieved, the valve spool works against the spring until @ 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 Then through a series of tubes and passages lubricates the transmission be: gravity drains to the transmission sump. ing on the transmission. ings and clutches. The oil then 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 meter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the ischarges at its center. Fluid directed n of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. torque converter. This element receives fluid at its outer diameter and by the impeller out into the particular do: 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 ‘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 multiplication is increasing. is decreasing in speed the torque 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, oil 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 direction clutch as desired.When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool. The same procedure is used in the speed 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 disc with external splines is “inserted into the drum and rests against the piston. Noxt, a friction dise with splines at the inner diameter ié inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with @ snap ring. A Hub with ©.D. splines is inserted into the splines of dises 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 oil under pressure to flow from the control valve, through @ tube, to a chosen clutch shaft. This shaft has the desired position. This allows a drilled passageway for oil 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 discs 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-28000 HR-28000 ‘MHR-28000 FIG. A¥ \TEM ONVOnKONH ~ n 12 13 14 15 16 7 18 19 20 21 22 23 24 25 26 27 28 29 30 HR 28000 CONVERTER GROUP (See page 56 for R Model Front Cover Group) DESCRIPTION Bearing Support Screw.... Bearing Support Screw Lockwasher.. Driving Gear Snap Ring...... Drive Gear Bearing, Drive Gear Bearing Support .. Drive Gear .... Snap Ring (Internal—See item 8. Drive Gear Hub Sleeve and Snap Ring Assembly — Ine. items 7 and 9. Snap Ring (External) — See mB... Valve Body to Converter Housing Gasket ....... Valve Body to Converter Housing MOM RING enn eee Valve Body to Converter Housin; “O" Ring, Valve Body to Converter Housing O” Ring... -1 Regulator Valve, Charging Pump and Filter Assembly ..... Oil Seal. Impeller Hub Gear Impeller Hub Gear Snap Ring Stator Support Oil Sealing Ring Sealing Ring Expander Spring «2... Stator Support Turbine Shaft .. Turbine Shaft Gear Turbine Shaft Gear Retainer Ring . Converter Housing and Tube Assembly Turbine Shaft Bearing. Turbine Shaft Oil Sealing Ring. Stator Support Screw Lockwasher...... Stator Support Sere Hub to Impeller Serew .. Hub to Impeller Screw Washer eaooerr eww TEM 31 32 33 34 35 36 37 38 39 40 Al 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 DESCRIPTION Impeller Hub Bearing Impeller Hub .. Impeller Hub “O” Ring Impeller .. Baffle Retainer Oil Baffle oe Oil Baffle Seal Ring Detent Spring .. Detent Ball . Valve to Converter Gasket. Control Valve Housing Assembly. Valve to Converter Housing Screw Lockwasher Valve to Converter Housing Scres Turbine Hub Screw Washer Hub Screw .. Ring Gear Screw . Ring Gear Screw Plain Washer . Flywheel Ring Gear Impeller Cover Sleeve Impeller Cover to Impeller Screw and Lockwasher .. Impeller Cover Impeller Cover “O” Ring ... Turbine Retainer Ring .. Turbine Turbine Hub Turbine Locating Ring .. Reaction Member Retainer ing .. Rea Member cnn Reaction Member Spacer Impeller Hub Bearing Retainer Ring...HR 28000 CONVERTER AND TRANSMISSION CASE GROUP Item DESCRIPTION 1° Suction Tube Assembly 2 Converter Housing and Tube Assembly 3 Tube Sleeve 4 Tube Sieove 5 Converter Housing Sleeve 6 Converter Housing Sleeve Lock 7 Converter Housing Sleeve Screw Lockwasher 8 Converter Housing Sleeve Screw 9 Converter Housing Sleeve Screw 10 Converter Housing Sleove Screw Lockwasher 11 Converter Housing Sleove Lock 12 Converter Housing Sleove 13° Breather 14 Sweet EI 18 Reducing Bushing 16 Tube Sleeve 17 Pipe Plug 18 Converter Housing to Transmission Housing Screw Lockwasher 19 Converter Housing to Transmission Housing Sciew. 20 Converter Housing to Transmission Housing Lockwasher 21 Converter Housing to Transmission Housing Screw. 22 Lube Tube Retaining Screw 23 Lube Tube Retaining Screw Lockwasher 24 Valve Oil Supply Tube 25 3rd Speed Tube "0" Ring 26 34d Speed Tube Assembly 27 Tube Clip 28 Tube Clip Lockwasher 29° Tube Clip Screw 30 Lube Tube Assembly 31 Lube Tube Retainer Screw Lockwasher 32 Lube Tube Retainer Soxew 33 Reverse Tube "0" Ring 34 Reverse Tube Assembly . 38 Tube Clip 36 Tube Clip Screw Lockwasher 37 Tube Clip Screw aty. item DESCRIPTION 38 Suction Tube "0" Ring . 39 Suction Tube Spacer Ring 40 Suction Tube Retainer Lockwasher 41 Suction Tube Retainer Screw 42 Tube Sleeve 48 Pressure Tube "0" Ring 44 Suction Lina Tube Clip Rivet 45. Conveter Housing to Transmission Case Gasket 46 Converter Housing to Transmission Case Dowel Pin 47 Low Speed Clutch Pressure Tube 48 Transmission Case to Converter Housing Screw Lockwasher 49 Transmission Case to Converter Housing Screw 50 Transmission Case Assembly 51 Transmission Case to Rear Cover Dowel Pin 52 Transmission Case to Rear Cover Gasket 53 Transmission Case Rear Cover 4 Rear Cover to Case Screw Lockwasher 55 Rear Cover to Case Screw 56 Roar Cover Pipe Plug 57 Rear Cover to Transmission Case Stud Nut 58 Rear Cover to Transmission Case Lockwasher 59 Tube Sleeve “O" Ring 60 Tube Sleeve 61 Transmission Case to Rear Cover Stud 2 Drain Plug 63 OilLevel Plug 64 Screen Assembly Gasket 65 Screen Assembly 66 Suction Tube Assembly 67 Suction Tube Cip Washer 68 Suction Tupe Clip 69 Pipe Plug 7 Suction Tube “O" Ring 71 Suction Tube Retainer Washer 72 Suction Tube Retainer Washer Screw 73 Oil Baffle(6 speed only) ty.28000 THREE SPEED CASE AND CLUTCH GROUP ITeM DESCRIPTION 1 1A BISSRISALLGSVSSSSS HRS Reverse and 3rd Clutch Shalt Piston Ring Piston Ring Expander S Reverse and 3rd Shatt Front Bearing Reverse and 3rd Shaft Front Bearing Front Beating Retainer Ring...» Clutch Driven Gear Bearing ‘Guutch Driven Gear Bearing Snap Ring ‘Guuteh Driven Gea CCluteh Hub Oi Baie Ring ‘Glutch Driven Gear Bearing Shap Ring (Clutch Driven Gear Bearing Retum Spring Retainer Snap Ring ‘Snap Ring Retainer Spring Retainer Piston Return Spring Spring Retainer Reverse and 3rd Clutch Shaft and Dram Spring Retainec Piston Retin Spring Spring Retainer Shap Ring Retainer Retuen Spring Retainer Snap Ring. 31d Gear Bearing ‘3d Gear Bearing Shap Ring Clutch Hub Oil Battie Ring 3rd Gear 31d Gear Bearing Spacer ‘3d Gear Bearing Shap Ring 31d Gear Beating Reverse and 3rd Shalt Rear Bearing 2nd Gear Clutch Hub Oi Battie Ring 2nd Gear Retainer Ring Return Spring Retainer Snap Ring Snap Ring Retainer Spring Retainer . Piston Return Spring ‘Spring Retainer Forward and 2nd lich Sha and Oram ‘Spring Retainer Piston Return Spring ‘Spring Retainor ‘Snap Ring Retainer Return Spring Retainer Snap hing ‘Clutch Driven Gear Bearing ‘Clutch Driven Gear Bearing Snap Ring ‘Clutch Hub Oil Baffle Ring CCluteh Driven Gear. ‘Clutch Driven Gear Bearing Snap Ring (Clutch Driven Gear Bearing Front Bearing Retainer Ring Front Bearing Locating Ring Forward and 2nd Shaft Front Bearing Front Bearing Retainer Ring Forward and 2nd Shaft Piston Ring Piston Ring Expander Springs ‘Low Spoed Clutch Shaft Pilot Bearing 2nd Gear Bearing Low Gear Bearing Retainer Fing Low Gear Bearing Low Gear Bearing Locating Ring Low Gear Low Gear Oi Bate Ring Low Geer Bearing Locating Ring arty ITEM DESCRIPTION ary 63 64 65 Low Gear Bearing Low Gear Bearing Retainer Ring Roturn Spring Retainer Snap Ring ‘Snap Ring Retainer Return Spring R Return Spring Return Spring Retainer Low Speed Clutch Shatt and Drum Bearing Cap Scrow Beating Cap Screw Lockwasher Drive Gear Retainer Ring Low Speed Drive Gear Idler Shaft Gear Low Shatt Rear Bearing ‘Low Shaft Rear Beating Retainer Ring ‘Low Shatt Piston Ring Low Shaft Piston Ring Rear Bearing Cap Gasket fear Bearing Cap "0" Ring ‘Low Shaft Rear Bearing Cap Low Shaft Rear Beating Cap Plug Idler Shaft Bearing Cap Screw Idler Shaft Bearing Cap Screw Lockwasher Ider Shaft Rear Bearing Lock Ball Idler Shaft Rear Bearing Rear Beating Locating Ring Idler Shatt Nut Idler Shaft Bearing Cap Gasket Idle Shaft Bearing Cap Rear Beating Cap Oi Seal Rear Bearing Cap "0" Ring Rear Beating Cap Screw Rear Beating Cap Serew Lockwasher Output Shaft Rear Bearing Cap Bearing Cap "0" Ring Rear Bearing Cup Rear Bearing Cone Output Shaft Gear - Output Gear Output Shatt Gear Spacer Output Shaft Bearing Cone Output Shaft Bearing Cup Front Bearing Cap "0" Ring Front Bearing Cap Shim a Front Bearing Cap. Front Bearing Cap Screw Lockwasher Front Besting Cap Screw Flange Nut Flange Nut Washer Flange Nut "O" Ring ‘Output Flange Front Bearing Cap Oil Seal Bearing Retaining Ring Idler Shatt Front Bearing Ialer Shatt Idler Shatt Gear Locating Ring Flange Nut Flange Nut Washer Flange Nut “O” Ring ‘Companion Flango ‘Output Shaft (Used with Disconnect oniy) Bushing (Used with Disconnect only Disconnect (OptionalTEM TEM ITEM LOW CLUTCH GROUP DESCRIPTION TEM DESCRIPTION ary, End Plate Retainer Ring 1 5 Clutch Piston... End Plate see T 6 Clutch Piston Outer Seal Ring Clutch Inner Dise coe 9 7 Clutch Piston Inner Seal Ring, Clutch Outer Disc 8 Low Speed Clutch Drum and Shaft...... 1 REVERSE AND 3rd CLUTCH GROUP DESCRIPTION ary. tem DESCRIPTION ary. End Plate Retainer Ring .. 2 5 Clutch Piston End Plate ..... -2 6 — Clutch Piston Outer Seal Ring... Clutch Inner Disc 7 Clutch Piston Inner Seal Ring. Clutch Outer Dise 8 Reverse and 3rd Clutch Drum and Shaft FORWARD AND 2nd CLUTCH GROUP DESCRIPTION ary. TEM DESCRIPTION End Plate Retainer Ring .2 5 Clutch Piston .. End Plate .. 2 6 Clutch Piston Outer Seal Ring... Clutch Inner Dise 7 Clutch Piston Inner Seal Ring... Clutch Outer Disc ..... 8 Forward and 2nd Clutch Drum and ShaftITEM DESCRIPTION ary. 1 2 3 4 5 6 7 8 9 10 "1 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... Valve Body “0” Ring Pipe Plug...... Safety Valve Seat... Safety Valve Spacer............ 05 : Safety Valve Plunger Safety Valve Spring Valve Stop "0" Ring . Valve Stop... ...e.eeeeee eee Valve Stop Roll Pin ..... Valve Stop Roll Pin ..... Valve Stop..........++ Valve Stop “O" 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 ary. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 42 43 44 45 46 a7 48 49 50 Valve to Housing Stud Lockwasher Valve to Housing Stud Nut . Thrust Plate & Bearing Assembly Wave Spring Pump Shaft Seal.....0.....00ee2 eee 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 ... RN RARoccuuten oceturew ron ase ro " oecwren nevense ony mewn 2»—@ te x8 “Te 9 r—e a—@ ae | i : I s—8 eS | HYDRAULICALLY OPERATED CONTROL VALVE Figure 6TEM eNaunnroena nu 12 13 14 15 16 7 18 19 20 21 38 39 40 41 42 43 CONTROL VALVE ASSEMBLY DESCRIPTION ary. Valve Spool Oil Seal ...... Valve Spool Oil Seal Retainer Ring Valve Spool Oil Seal Washer Forward and Reverse Valve Spool ... - . Control Valve Assembly — Incl. items 1 thru 9, 15, 16 and 18 thru 20... Neutral Switch Detent Ball Neutral Switch ... Valve Housing Plug Valve Housing Plug “O” Ring .. Overshift Spacer Detent Spring Plug Detent Spring Plug Washer Detent Spring .....--.-- Detent Ball... Speed Selector Spool Speed Selector Overshift Spacer... Valve Spool Oil Seal Washer .. Valve Spool Oil Seal Retainer Ring ... Valve Spool Oil Seal Hydraulic Piston Housing Assembly NOTE: Items 22 thru 25, 32, 33 and 37 are various declutch options. Adaptor to Converter Housing Screw .. Adaptor to Converter Housing Screw Lockwasher..... Valve Adaptor Housing Converter Housing to Valve Adaptor Housing Gasket . Adaptor Housing to Converter Housing Screw .. Adaptor Housing to Adaptor Plate Gasket... Valve Adaptor Plate .. = soso neITEM ITEM AXLE DISCONNECT DESCRIPTION ary. Disconnect Housing Capscrew .. 4 Disconnect Housing Capscrew Lockwasher cscs 4 Disconnect Housing 1 ‘onnect Housing Plug coe Shift Hub ...... ee Shift Fork ....... 1 Shift Fork Lockscrew .. ITEM 8 9 10 W 12 13 14 15 DESCRIPTION ary. Disconnect Shaft ce 1 Detent Ball - od Detent Spring ... a 1 Shift Rail Shift Rail Oil Seal Bearing Retainer Ring... Bearing... Bearing Retainer Ring MECHANICAL PARKING BRAKE DESCRIPTION Backing Plate Assembly... Actuating Lever Brake Flange Brake Drum Brake Drum to Flange Screw Lockwasher Brake Drum to Flange Screw... 6 TEM 10 u 12 13 DESCRIPTION Return Spring... Brake Shoe (see item 3). Brake Lining .... Rivet Backing Plate Screw .. Backing Plate Screw Lockwasher ..MAINTENANCE AND SERVICE ‘The instructions comained herein cover tho disassembly and reassembly of the transmission in a sequence that would normaly be followod after the unt has been removed trom the machine and is to be complatoly overhauled. It must aloo be Understood that this a basic 28000 twersmission wath many ‘options, Companion flanges and output shafts with ana without ‘sconnect assemblies may vary on specific models, The urits are vory similar 10 trouble shoot disassemble, repair, and reassemble, CAUTION: Cieaniiness is of extreme importance and en absolute must in the ropalr and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be ‘thoroughly cleaned to provant he possibilty of dt and fereign matter entering the mechanism. NOTE: For A-Model (remote mounted) front cover removal, service and installation on transmission see page 59 Figure 1 DISASSEMBLY Remeve filter housing and filter element. NOTE: See lubrication section fer filler cartridge change interval. Figure 3 raging pump to regulating valve stud nuts, Remove pump and filter adapter. Figure 4 Remove pressure regulating valve assembly.Figure 5 Figure 8 Remove pump drive sleeves. Install two bolts in threaded holes 180° apart to remove cover from impaller. NOTE: Some units may have pry slots Insteed of threaded heles. Figure 6 Remove control valve bolts and washers. Remove Figure 9 control valve. Use eaution as not to lose detent springs and balls, Figure 10 Figure 7 If impeller cover bearing is to be replaced remove Remove Impeller cover bolts. retainer ring. Pry bearing from pocket. -2-Figure 14 Figure 14 Remove turbine retaining ring, Romove reaction member releiner ring Figuro 15 Remove turbine and hub assembly. NOTE: For special turbine Remove reaction member and spacer, 1 hub assembly see page 40. Figure 13 Figure 16 Remove turbine locating ring. Remove oil baffle retainer ring.Figure 20 Using pry slots in converter housing, pry oil baffle Remove bolts securing converter housing fo trans: ‘ond impeller fram housing. NOTE: Impeller, cil baffle mission housing. and impeller hub gear are removed as an assembly. Figure 21 Figure 18 Suppor converter housing with 9 chain fal Using Zemove stator support to houting bolts reading type snap ring pliers, spread ears on for- x "ator support 10 housing bolts ward eluteh front bearing retaining ring. Holding snap ring open tap converter housing from transmission housing. Figure 19 Figure 22 Remove stator support. NOTE: Support must be Converter housing removed. Note front bearing turned to clear pump drive gear. ing ring relieved of front bearing,z 2 Figure 26 Figure 23 Remove center pump drive gear. Remove pump drive gear bearing support bolts Figure 27 Figure 24 Remove turbine shaft gear retainer ring and gear. Move center gear toward the roar of converter housing. Remove pump drive gear on the right, Figure 28 From rear of converter housing tap turbine shaft Remove pump drive gear on the left. and bearing frem housing,Figure 29 - Figure 32 Remove impeller hub goar retainer ring. Remove impeller to hub bolts. Figure 33 Remove impeller hub "O" ring. Figure 34 Figuro 31 1 forwerd and 2nd clutch essembly remained in transmission Lift oil baffle and oil seal assembly from impeller. case, remove from caseFigure 35 Rear view of trensmission utilizing a mechanical parking brake option Figure 36 Remove output flange nut, washer and “O” ring. Figure 39 IF parking brake is not used, remove companion flange Remove brake shoes. and proceed to Figure 42. Figure 37 Remove parking brake drum and flange. Figure 40 Remove brake actuator armFigure 44 Figure 41 Remove brake backing plate belts. Figure 45 Remove low clutch rear bearing locating ring. igure 42 Remove idler shaft bearing cap bolts, bearing cap and idler shaft nut Figure 46 Remove rear cover bolts. Using pry slots provided, pry cover from transmission housing tapping an low clutch and idler shaft to allow caver to be removed Remove idler shaft rear bearing locating ring. without shaft binding, aFigure 47 Figure 50 Remove low eluich reat bearing retaining ring. Remove low speed drive gear retainer ving end NOTE: See page 42 for disassembly of low clutch utilizing a drive gear. ‘82: double taper beating (helical gears) Figure 48 . Romove low clutch roar bearing. Figure 5 Remove 2nd gear retaining ring. Figure 49 HW wansmission is a 6 speed sae page 51 figure 49A for idler Figure 52 shaft and output shaft removal. Tap idler shaft from housing, Remove 2nd gear. NOTE: Do not iose roar bearing lock bal,- Figure 56 Figure $3 Remove front output flange nut, washer, "O" ring Romove reverse and 3rd clutch assembly. and companion flange. Foe Be Figure 57 output shat removal Remove output shaft front bearing cap bolts and cap. Figure 58 Figure 55 Block output gear. Push output shaft from rear Remove rear output shaft bearing cap bolts end cap. through bearing and gear. —10-Cluich Disassembly NOTE: Two clutches are shown being disassembled. The low clutch, and the forward and second. All clutches are disassombled in a similar manner. The quantity of clutch discs will differ between the low clutch and the forward, reverse, second and third. Do. not mix the friction discs in the low clutch with the {riclion dises of any of the other clutches. (See note, Figure 92). Low Clutch Disassembly NOTE: See page 44 fr disassembly of low clutch utlizing taper Desrings in the low cluteh ge. Figure 59 Remove low clutch shaft rear bearing, Figure 62 Figure 6 Remove clutch end plate and inner and outer clutch Remove low speed gear retainer ring. discs. neRemove clutch piston return spring. A sleeve ' portion removed is recommended for removing 1 lutch piston return spring, washer, and retainer ring. Sleeve’ shown is a common pipe, with a 1-1/2 x 1 [39,0x26,0mml opening, The pipe is 6 x3-1/4x23/4 1155,0x85,0x78,0mm]. Compress spring rotainer wash- cer. Through opening remeve spring retainer snap rin: Release tension on spring retainer. Remove sprin finer and pring. Tuen cluieh over and tap clutch fon @ block of woed te remove clutch piston. Forward and 2nd Clutch Disassembly Figure Remove clutch shaft pision rings and expender springs. Instal piston rings and expander springs por instructions on page €€. — Figure 67 ~ Remove front bearing retainer ring Figure 68 Remove front bearing. Remove front bearing locating ring.: Figure 71 Compress return spring retainer. Remove retsiner Remove inner bearing. en Pring ring from groove, Figure 75 Relieve spring compression. Remove retainer ring, Figure 72 Remove end plate retainer ring. retainer and spring.Figure 76 Remove inner and outer clutch dises, Turn clutch ‘over and tsp clutch shait on 2 block of wood to re- move clutch piston. CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent ing fluid. If ie rocammended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and paris are thoroughly cleaned. CAUTION: Care should be exercised to avoid skin rashes, fire Razerds and inhalation of vapors when Using Selvent type cleaners. Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubrieont. Immerse again in cleaning fivid 0 Flush ‘out particles, Repeat ebove operation until bearings are thoroughly ciean. Dry bearings using moisture- free compressed air. Be careful to diroet sir stroam acrose bearing 10 avoid spinning. Do not spin bearings ihen drying. Bearings may be rotated slowly by hand {0 facilitate drying process Housings Clean interior and exterior of housing, bearing caps ere, moroughy., Cau pars may bo cleaned. In hot SSin aks wih a sel selon providing these ovis do not have ground or polished surfaces” Pars routd remain in scloven lng enough to be oroughe iy deaned and Rested. This wil sid the evaporation of the'eleaning solution and rinse water Pare cleaned im soluron fenke must bo thoroughly rinsed with loan rater fo remove til aces of kal. Cost part may Sco be ceaned with soom eleanor. CAUTION: Care should be exorsiiad 10. avoid in Falatfon of vapors tnd skin reshen wien using. alka Sener. ~ue All ports cleaned must be thoroughly dried imme ately by using moisture-free compressed sir or soft, Tintiess ebsorben! wiping rags free of abrasive materi als such a= metal filings, contaminated oil or lapping compound. INSPECTION The impertance of careful and thorough inspection of all parts cannot be oversiressed. Replacement of All pans showing Indication of wear or sires will alim= inate costly and avoidable failures at 2 later date, Bearings Carefully inspect all rollers, eagos and cups for weer, chipping or nicks to determine fitness of bearings for further use. De not replace 2 beering cone oF cup. individually without replacing the mating eup or cone al the same time. After inspection, dip bearings ‘Automatic Transmission Fluid and wrap in clean lint less cloth or paper fo protect them until installed. Oil Seals, Gaskets, Ete Replacement of spring load cil seals, "O" rings, metal sealing rings, gaskets and snap rings is more economical when unit is disassembled than premature: ‘overhaul to repiaee these parts at a furure time. Fur- ther loss of lubricant through a worn seal may result in failure of other more expensive parts of the assom- bly. Sealing members should be handled careful particularly when being installed. Cutting, seratehing, or curling under of lip of seal seriously impairs its efficiency. Apply a thin coat of Permatex No. 2 on the outer diameter of the oil seal to assure an oll tight fir into the retainer. When assembling new 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 SO" rings and seals with recommended type Automatic Transmission Fluid before assembly. Gears and Shafts If magna-flux process is available, use process to check parts. Examine teeth on ail gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear feet show spots where cata hardening is warn through oF eracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and thot shafts are true. Housing, Covers, ete. Inspect housings, covers end bearing caps to be certain they are thoroughly cloaned and that mating surfaces, bearing bores, ete., are free from nicks oF burrs. Check all parte carefuily for evidence of cracks cor condition which would cause subsequent cil leaks or failures.REASSEMBLY Forward and 2nd Clutch Reassembly (See page 46 for modulated clutch cross section! discs until the proper amount of dises are Firat disc noxt 19 the piston it steal, lat dine imtaled Figure 77 Install new clutch piston inner and outer sealing rings. Figure 78 yn in clutch drum. Use caution as Figure 79 . Install clutch piston return spring, spring retainer Figure 82 and rotsiner snap ring. Insert ono steel dias. Install end plate reteiner sing. --Figure 83 Figure 86 Install cluttk driven gear inner bearing. Insllduth div gear Ilo ich dum Align splines on clutch geet wil internal teeth of fletion igure 87 Fina tep gear inte postion. De no! force this oper tion. Gear splines must be in full position wiht ine Install front bearing. NOTE: Snap ring groove in ternal teeth of all friction dises. front bearing must be down. Figure 85 Install diven goar outer beating. Bearing shila must face in SEE PAGE 35 FOR PROPER SHIELDED BEARING INSTALLATION 16Figure 89 Install clutch shaft oll sealing rings and expandor springs por instnictions on page 66, Low Clutch Reassembly and outer sealing ring. Insert piston into clutch drum using caution ae not to damoge seals Position piston return spring, spring retainer and retainer sop ‘ing. Compress spring and rotanor and install snap ing. NOTE: For assembly of low clutch uthizig tapar bearings in the iow clutch guar see page 44, Figure 91 Install low gear inner bearing Figure 92 Install one friction dies. NOTE: The friction discs in the low clutch has higher co-efficient rating than the {tition dacs In tho othor clutches, therefore the dl ‘must nol be mixed, The low clutch inner dise can bo Hlentifed by'an°X" stamped on one side of the inner tet The iw ch aera ho fs Sip non soluble yellow paint sprayed on the outer edge of tho dine. ‘Alternate steel and fiction dive until he proper amoun’ of lacs are Insaled. Fire dise next {fo the piston Is steal, ast csc instaled Is fiction. Figure 94 Install end plate and retainer cing.Figure 95 Install low gear into cluteh drum, Align splines on low gear with intornal teoth of friction dises. Top gear into position. Do not force this operation, Gear spi rust bo in full pasition with internal tecth of ail friction discs. Figure 96 Insiall low gear outer bearing. NOTE: When in- tailing the Srd gear in the 3rd speed clutch a bearing spacer is used between the inner and outor 3rd gear bearing. Figure 97 Install low gear retainer ring. Figure 98 Install low clutch shaft rear bearing. Reassembly of the Output Shaft For 6 speed transmission see page 52 Fig. 5. View of eutput shaft as it would be positioned in transmission eace. Note front cone bearing shouldered fon shaft with large diameter of bearing in. Figure 100 ition output gear in transmission case with pro- truding hub toward front of ente. See Fig. 99. ‘output shaft, gear spacer end taper beering from front of case and through output gear. Insiall front taper bearing cup. Block output shaft and install rear tapor bearing with large diameter in. a18—Using new O" rings install rear output bearing csp and taper bearing eup on transmission «ase, Lube Figure 104 ‘opening in bearing cap must be sligned with lube 16 0" ring, Tighton bearing cap bolts te speci- ‘washer and flange nut, Block output gear. See elastic stop nut torque chart) torquo chart. Figure 102 Install front bearing cap and shims. Tighten bolts to specified torque. Tap output shaft front and rear Jo seat taper boarings. Loosen front baring caps bolts Figure 105 From the rear of the transmission case install the low clutch assembly. Using an inch ib. terque wrench, deteie the roling torque ofthe output shat end recor. Tighten rant basing cap bolts to pected torque. Check ong argue with bots tt. Torgue must be 6 to 8 inh tbs. (0.68 = 080 Num more than wen 7 Bening cap bolts were foes. Ad! ot omit shins on the front From the front of e208, vat oh a cap to ‘the proper preioad. reverse and 3rd clutch assembly. ~19-Figure 110 Install icler shaft and bearing assembly. NOTE: The 6 speed nit will have te gears and @ heavier front bearing, Figure 107 Install 2nd speed gear on low clutch shaft, ; Figure 11 Figure 108 Install low clutch reer bearing with bearing ring groove to the Install 2nd speed gear retainer ring. soa, NOTE: Fo oassmbly of ow et ing ear SOU taper bearings see page 42, Figure & Figure 109 Figure 112 Install low speed drive gear and retainer ring. Install low clutch rear bearing retainer ring. =20—sls = ~ Figure 113 Figure 116 Position 2 new gasket on rear transmission case. Install low clutch shaft piston sings, Install new Align lock ball in idler shaft rear bearing with natch gasket and “O" ring on low shaft bearing cap. in rear transmission cover. Tap cover in place and secure with bolts and lockwaehers. Figure 117 Figure 114 Install bearing cap and secure with lockwashers and Torque rear cover bolts to specified torque. bolts, Tighten to specified torque. Figure 115 From front of transmission ense tap low clutch ene idler shaft 10 rear. This will allow clearance to install Figure 18 reor bearing snap ring, Install idler shaft rear bearing locating ring. 2Figure 118 Install idler shaft nut, Block idler cea, tighten nut. See elastic stop nut torque chart. With a new gasket in position instal idler Figure 122 shaft besring eap. Tightan boits to specified torque. Locate brake shoes. If a mechanical parking brake is not used proceed to figure 125. Figure 120 Figure 123 Install brake backing plate assembly. Tighten bolts Install upper and lower brake shoe return springs. to specified torque. Figure 124 Install brake drum and flange assembly.Secure flange with @ new "0" ring, washer and flange mt Figure 128 Block output shaft and tighten nut. See elastic stop nut torque Apply a light coat of Permatex No. 2 on tho outer cohort, ply a lie 2 on thi diameter of the oil baffle sesl, Press seal in oil baffle down. Figure 126 Position low speed clutch shaft front pilot bearing on 2nd ‘clutch she, alight cost of groasa will hold beating in position, From the front of the wansmission ease install the forward Figure 129 land 2nd clutch sssembly. Use caution as not to damage pilot bearing, NOTE: For R Mode! front end s00 page 60, Fig. 9 Install ¢ new oil baffle seal ring Figuro 127 NOTE: See page 40 for 13 inch spacial impeller hub bear. ing and 12 boit assembly instructions. Insta now "0" ring on impeller hub. Align holes in impale hub with holes in impeller. Install bolts and tightan to spoitiod torave. Lockwaite in pats to prevent loosenine Figure 130 Install oil baffle on impeller assombly. 23J ZO GEAR RETAINER RING TURBINE SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD RETAINER RING Figure 194 Figure 191 Tap turbine shaft and bearing assembly into convert Install impeller hub gear fr housing from frent. At the rear of the convertor Housing install turbine sheft gear and retainer ring #6 shown. Figure 132 Secure impeller hub gear with retainer ring. Figure 135 Position center pump drive gear. Figure 133 Install new turbine shaft piston ring. Figure 136 Install loft pump drive gear. = 24Figure 137 Install ight pump drive gear Align holes in pump crive gear bearing supports with holes in eorvertor housing, Install ats and washers and tighten to specified torque Figure 188 Position new gasket and "0 ings on housing, light coat of ‘grease wil hold gasket and “0” rings in place, install alignment ‘studs in transmission housing to facilitate converter housing t9 ‘ranemission housing assembly. Figure 139 Support converter housing with a chain fall, Spread forward lurch front bearing retainer ring. | Position converter housing to transmission case astombly. Tap housing into place using caution as not to damage any of the clutch shaft pisten rings Figure 140 Secure converter housing to transmission case with bolls and washers, Tighten fo specified torque, Figure 141 Install new sealing ring expander spring and oil sealing ring on support. NOTE: Expander spring gap to be 180 from sealing ring hook joint.” Position support on turbine shaft to cloar pump drive gear Align support holes with converter housing. igure 142 Install stator support belts and tighten to specified torque.Grease stator support piston ring, cil baffle oil seal Figure 146 and seal ring to focitete reassembly. Install impeller Install rection member retainer ring and oil baffle essembly In converter housing. in housing, Secure with oil baffle Figure 147 re ring is in full position in ring Install turbine locating ring on tu Figure 145 Insta reaction member spacer with tang of spacer out Install reaction member. NOTE: Casted keiob on reaction member must be positioned batwion the 3 & 8 o'clock lation on sup Figur 148 port, preferably betwoan 4 & 8 o'clock Install turbine, =26—Align holos in impeller cover with holes in impel- ler. Instell bolls and washers and tighten to specified torque. Figuro 150 If impeller caver bearing was removed, press bear Figure 153, Ing in position and secure with retainer ring. Locate detent balls and springs in control valve Position new gasket. Secure valve with bolts and washers. Tighten to specified torque, Figure 151 Install a new impeller cover “O" ring and greate Figure 154 lightly to facilitore reassembly. Install pump drive sleeves. 27 ~igure 155 Figure 157 Potition new gasket and YO" rings on pressure reg Install new 0" ring in fitor adaptor housing. Instalt iter vlator valve, Install valve on studs. cloment and housing. Tighten fiter housing 20 to 25 ft. Ibs. torque [27,2 - 33,8 Nm Figure 156 With new valve body to pump gasket in position insert pump drive shaft through valve body. Use caus tion as not to damage valve body oil soal. It may be necessary fo turn impeller one align pump shaft with drive sleSERVICING MACHINE AFTER TRANSMISSION OVERHAUL hydraulic tystem are important links in the drive line between the engine and the wheels. The proper oper- ation of either unit depends greatly on the con and operation of the other; therefore, whenever repai for overhaul of one unit is performed, the balance of the system’must be considered before the job can be considered completed. ‘After the overhauled or repaired transmission has been instlled in the machine, the oll cooler, and con- necting hydraulic system must be thoroughly cleaned. This can be accomplished in soveral manners and a ‘gree of judgment must be exercised as to the method employed. ‘The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from 3. Replace cil filter elements, cleaning out filter cates thoroughly. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” ‘compressed removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If neces- sary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT vse flushing compounds for cleaning purposes. 7 Recheck all dr: smote mounted torque converters remove plug from torque converter and inspect interior of converter housing, gears, etc. If presence of considerable foreign material i noted, it will be necessary that converter be re- moved, disassembled end cleaned thoroughly. It is realized this entails exira labor; however, such labor is a minor cost compared to cost of di which can result from presence of such foreign material in the system. . Reassemble all components and use only type cll recommended in lubrication section, ill fransmiation through filer opening. until laid ‘ipo LOW mark on transmission dipstick, NOTE: If the dipstick is not accessible oil level check pluge sre provided. Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine two minutes at 500-600 RPM to prime torque converter and hydraulic lines. Re- check level of fluid in transmission with engine running at i Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER cil level check plug hole. Install oil level plug or dipstick. ‘Recheck with hot oil (180-260""F) (82, 2.98, 3° Cl. Bring oil level to FULL mark on dipstick or cuns freely from UPPER cil level plug. plugs, lines, connections, ete., for leaks and tighten where necessary. TORQUE IN (LBS.—FT.) BOLTS, CAPSCREWS, STUDS AND NUTS Grade 5 Identification, 3 Radial Dashes 120° Apart on Head of Bolt erase 5 @ Torque Specifeation for Lubieates ‘or Patod Screw Threads Grade 8 Identification, 6 Radial Dashes 60° Apart on Head of Bolt Grade 8 zi] 3 ~~ SOARSE THREAD NE WREXD | CORRE THREAD See) wet ny wat wen wor ea wer fo) SE | Sios[ ae ao | pany eral [ies te | [98a lf as we Pp 0 30 [1353.08] seo] ea | [saw | oa | ja. oe if or P12 ee |e ah soe[ateas | [seeeia [a= a1 | [soe sg. || see [17 ean | so. sy | [ms- ral Scoot “se yo Lees oaa_[ sree | [778 ene || o-oo | tion tony | — 00. s8 | (ons 1103) Sexe] otioo"[ iss tass) [ee oo | irre veng) || vas ver [irae wonsy | vista | sso wraay “Seso| Tae at [ [as org | Tastee | isda tees] || 00 too | Laas 268) | isos | ers0-227 | Heol eessees [foes osea | eww aod | teria zona |[_ats-ae7 | pors-aos} | 200-310 | (825-209) -29-SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION ‘AND TORQUE CONVERTER aescune wea 933°C. 2SPSI INTRA Kol mie precise a 000, [e828 Mol ute prem wh engine opting Sooo Seetion — Manual uo dacs eaten a Seat cuten ouTeR oc LUBRICATION Ful ow ft ste bys, ho star sre 260-0 ps E48 20604 KPa} Wah ping 1s22°" 985°C eng ate 0010 60 AP Prosi mutta egest ve © px 45 Pa It fan epee cha, TYPE OF OL See tube cher Const Operator Manes teuchine del for system capac Converter Trenumistion a sed yeas Bocmiee epscty ccecx PERIOD Wr 1608 we 00" {2 98,3" €)" Maintain oi level Fut NORMAL very 500 hows, change all fer lament Evry 1000 hours dna and veil natn at Fhe Bint with oi at 150" 10 200° (esre"99,3" ch itor 30 and 100 hows oF ope sand abut or ropes on © Dian tanaminion and move sump ® ° efi tanamison to 1OW mach fun angine at 500.600 RPM. to prime Soverar and Fos. (0) Racha level with eng 1300" 600 BPH ond ‘aaa ier fo LOW marks When oil tra tore thot 180200" F) [882.933 C] inaks final il lye cheks BRING OL eva To uu nae. ‘Normal deain Severe or sustained high op temperatures or very dusty atm: ‘ted deterioration and contamination. For extreme conditions ju: required change intervals. —30- 1d filer change intervals are for average environmental and duty. rorpheric conditions yment must be used to determine theTROUBLE SHOOTING GUIDE For The R and HR Model, 28000 Transmission The following data is presented as an aid to locating the others. By studying the principles of oper the source of difficulty in a malfunctioning unit. I is together with data in this section, if mey be possible necessary to consider the torque converter charging 10 correct any molfunction which may occur in the pump. transmission, oil cooler, and connecting lines sys¥er. 26 2 complete system shen running down the source TROUBLE SHOOTING PROCEDURE BASICALLY CON. of trouble since the proper operation of any unit here- _SISTS OF TWO CLASSIFICATIONS. MECHANICAL AND in depends greatly on the condition and operations of | HYDRAULIC. MECHANICAL CHECKS Prior to checking any part of the system from @ 2. Chock shift levers and rods for bindling or resirie hydraulic standpoint, the following mechanical checks tions in travel that would prevent full engagement. should be made: Shift levers by hand at control valve, if full engage- 1. A check should be made to be sure all control ment cannot be obtained, difficulty may be in control lever linkage is properly connected and adjusted at all cover and valve assembly. connecting points. HYDRAULIC CHECKS Before checking on the torque converter, transmis- the converter. Where the former means is impractical, sion, and allied hydraulic system for pressures and the latter means should be employed as fellows: rate of oil flow, it is estential that the following pro- Engage shift levers in forward and high speed and liminary checks be made: apply brakes, Accelerate engine half to three-quarter Check oil level in transmission. This should be done throttle. with oil temperatures of 180 to 200° F. [82,2-93,4° C] Hold stall until desired converter outlet temperature DO NOT ATTEMPT THESE CHECKS WITH COLD OL is reached. CAUTION: FULL THROTTLE STALL SPEEDS To bring the oil temperature to this specification it FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT is necessary to either work the machine or “stall” out THE CONVERTER. LOW CLUTCH PRESSURE Caure Remedy 1. Low oil level 1. Fill to proper level 2. Clutch pressure regulating velve spool stuck open. 2. Clean valve spool and housing. 3. Faulty charging pump, 3. Replace pump, 4. Broken or worn clutch shaft or piston sealing rings 4. Replace sealing rings. 5. Clutch’ piston bleed valve stuck open, 5. Cloan bleed valves thoroughly. LOW CONVERTER CHARGING PUMP OUTPUT 1. Low oil level 1. Fill to proper level 2. Suction screen plugged. 2, Clean suction sereen. 3. Air leaks at pump intake hose and connections or 3, Tighten all connections or replace hore if necessary. collapsed hose. (R-28000 only) 4. Defective oil pump. 4. Replace pump, OVERHEATING 1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem: bly. 2. Wern oil pump. 2. Replace. 3. Low oil level. 3. Fill to proper level. 4. Pump suction line taking air. (R-28000 only) 4. Check oil line connections and tighten securely. NOISY CONVERTER 1. Worn coupling gears 1. Replace, 2. Wern oil pump. 2. Replace. 3. Worn or damaged bearings 3. A complete disassembly will be necessary to deter- mine what bearing is faulty. LACK OF POWER 1. Low engine RPM at converter stall. 1. Tune engine check governor. 2. See “Overheating” and make same checks, 2. Make corrections as explained in “Overheating.” =31-To COOLER ‘COOLER FROM CONVERTER INSTALL GAUGE IN THIS LINE FOR CONVERTER “OUT” PRESSURE* CLUTCH PRESSURE CHECK POINT** OIL LEVEL. FROM COOLER TO CHECK POINT TRANSMISSION LUBE DISTRIBUTOR OIL SUCTION SCREEN 28000 SERIES PLUMBING DIAGRAM coo ” 70 COOLER FROM CONVERTER TYPE “A” FILTER USE REPLACEMENT ELEMENT 215502 INSTALL GAUGE IN THIS DO NOT SUBSTITUTE LINE FOR CONVERTER “OUT” PRESSURE" ‘CLUTCH PRESSURE ‘CHECK POINT** ol Leven FROM COOLER TO Steck rom TRANSMISSION DISTRIBUTOR LUBE DISTRIBUTO! NOTE: ALL TYPE “A” FILTERS: USE CLARK FILTER REPLACEMENT cine P ELEMENT PART NO. 216602. CHARGING PUMP OIL ARNG o Not suasTiTUTE 28000 SERIES PLUMBING DIAGRAM (WITH REMOTE FILTER)meee 1ST (LOW) mam mm 2ND y @ © ee 3A (HIGH) ar HR MODEL 3 SPEED TRANSMISSION28000 SERIES-3 SPEED CLUTCH & GEAR ARRANGEMENTBEARING SHIELD ‘MUST FACEIN BEARING SHIELD ‘MUST FACE OUT FRONT BEARING SHIELD BEARING SHIELD MUST FACE OUT ——— BEARING SHIELD. ‘MUST FACEIN SHIELDED BEARING INSTALLATION —36—16 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear) Remove all burs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface ‘and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean, Check engine flywheel and housing or housing adaptor for conformance to standard S.A. No. 3 — SAE J827 and J1033 tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Moasure and record engine crankshaft end play Install torque converter ring gear as shown, NOTE: Assembly of the ring gear must be completed within a fifteen minute period from start of screw installation. The screws are prepared with an epoxy Coating which begins to harden after installation in the flywheel mounting holes. f not tightened to proper torque within the fifteen minute period insufficient screw clamping tension will result Install backing ring and sixteen (16) special screws to approximately .06 inch [1,5 mml of seated position. Itis permissible to use ‘a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque [40,7 44,7 Nam To obtain maximum effectiveness of the special screw's locking feature, @ minimum time period after screw instalation of twelve (12) hours is suggested before engine startup, ‘The special screw is to be used for ONE installation only Ifthe screw is removed for any reason it MUST BE REPLACED. Itis, recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a NEW screw for reinstallation. ‘Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment ‘serows. This may require more than one tial to match the drive gear teeth, Puling the converter into position with housing attachment bolts is not recommended. Measure engine cronkshatt end play after assembly of torque converter. This value must be within one thousandth 001) of an inch [0,0254mmi of end play racorded (in Paragraph #2) before assombly of torque converte, 02553 ~ 1. INCH (38,1] 16 SCREW RING GEAR KIT ‘802554 — 1.5 INCH 138,11 16 SCREW RING GEAR KIT 1249947 Torque Converter ing Goar 1249241 Torque Convert Ring Gear 16 236288 ing Gear Scrow 1.5 Inch [38,11 16 236288 Ring Gear Screw 1.8 Inch (98,11 1 802565 Installation Instruction Sheet 1249767 Backing Ring 1902555 instalation Instwcton Sheet 243767 Backing Ring not included in 802563 Ring Geer Kit, Must be Ordered! Separstely Dimensions ate in inches ~ Dimensions in |_| are mm, SEE PAGE 37 FOR INSTALLATION ILLUSTRATIONS aBACKING RING ENGINE FLYWHEEL ‘TORQUE CONVERTER RING GEAR RING GEAR SCREW RING GEAR SCREW (16) 206288 1500 (38,1) 4 [ 1 co ENGINE FLYWHEEL SEE PAGE 38 FOR INSTALLATION PROCEDURE AND, BOLT TORQUE BACKING RING 243767 TORQUE CONVERTER RING GEAR 24934132 SCREW RING GEAR INSTALLATION PROCEDURE (Non-Asbestos Ring Gear) 1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywhes! mounting surface ‘and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean. 2. Check engine flywheel and housing or housing adaptor for conformance to standard S.AE. No. 3 — SAE J827 and J1033, tolerance specifications for pilot bores size, pilot bores eccontrcities and mounting face deviations. Measure and record engine crankshaft end play. 3, Install torque converter ring gear as shown. NOTE: Assembly of the ring gear must be completed within a fifteen minute period from start of screw installation. The screws ate prepared with an epoxy ‘Coating which Begins to harden after installation in the flywheel mounting holes. If not tightened to proper torque within the fifteen minute period insufficient screw clamping tension will result. ‘4, Install backing ting and thirtyAwo (32) special screws to approximately .06 inch 1,5 mm} of sested position. itis permissible to tuse a power wrench for this instalation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque (31,2 -338 Ne To obtain maximum effectiveness of the special scraw’s lacking feature, @ minimum time period after screw installation of twelve (12) hours is suggested before engine star-up. ‘The special screw isto be used for ONE installation only Ifthe sctew is removed for any reason it MUST BE REPLACED. Itis recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a NEW screw for reinstallation. 5. Assemble torque converter to engine flywheal by sliding converter into position by hand before fastening housing attachment ‘screws, This may requite mora than one trial to match the drive gear teeth. Pulling the converter into position with housing attachment bolts is not recommenced 6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousancth (001) of an inch 10,0254mm) of end play recorded (in Paragraph #2) before assembly of torque converter 802544 — 1.5 INCH (58.1) 32 SCREW RING GEAR KIT 02547 — 25 INCH [63:5] 32 SCREW RING GEAR KIT 1249265 Torque Converter Ring Gear 1 248285 Torque Convertor Ring Goat 382249970 Ring Gear Screw 1.5 Inch [38,1) 32 237183 Ring Gear Serew 25 inch (635) 1 802850. Instlation Instruction Sheet 1 BZESO Installation Instueion Sheet 202645 — 1.75 INCH [44,4] 32 SCREW RING GEAR KIT 1902548 ~ 3.0 INCH (76,21 32 SCREW RING GEAR KIT 1 249265 Torque Converter Ring Gear 1249285 Torque Converter Ring Gear 32244903 ing Gear Screw 1.75 Inch (4,4) 238838 Ring Gear Screw 30 Inch 17521 1 802550 _Instalation Instruction Sheet 1802550 Installation Instuction Sheet 02546 — 2.0 INCH (50.81 32 SCREW RING GEAR KIT 202549 — MB:2 SCREW RING GEAR KIT 1 248265 Torque Converter Ring Gear 1 249265 Torque Converier Ring Gear 2240718 Ring Gost Screw 20 Inch 50.8) 324200087 ing Gear Serow MB x 1.251 1802650 Installation insuction Sheet 1 B02550 instillation instvction Sheet 226997 Backing Ring Not Inckided in Ring Geor Kt. Must be Ordered Separately NOTE: The intial installation dive gear mounting kit includes a converter air breather. This breather is used on C & CL 2701C & CL 320 converters only and is nat required for the HR & LHR 2B000/HA & LHF 32000 applicstions. SEE PAGE 39 FOR INSTALLATION ILLUSTRATIONS —28-BACKING RING ENGINE FLYWHEEL TORQUE CONVERTER RING GEAR RING GEAR SCREW ENGINE FLYWHEEL RING GEAR SCREW (32) 243970 1/500 (38,1) (90) 2449s 1 750 ae al (32) 240318 2.000 (50.81 Be 237163 2500 835) | SEE PAGE 28 698 : Re INSTALLATI (32) 4200087 Ma x 1.25} i Pr Mao l PROCEDURE AND ( BOLT TORQUE Lol = BACKING RING N 236837 TORQUE CONVERTER RING GEAR 249265/ a ees 13 convenrens| TURBINE HUB BACKING RING 8-TURBINE HUB. ‘SCREWS REFERENCE - 12 IMPELLER HUB ‘SCREWS ON 13” CONVERTERS 12" CONVERTERS MUST BE LOOSE INTERNAL FIT BEARING. SEE PARTS LIST IMPELLER HUB, TURBINE HUB AND BACKING RING WITH SPECIAL SCREWS 1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THOROUGHLY BEING CERTAIN TAPPED HOLES ARE DRY AND CLEAN. 2. INSTALL BACKING RING AND SPECIAL SELF-LOCKING SCREWS TO APPROXIMATELY 06 INCH [15] OF ‘SEATED POSITION, WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FT. [5433 - 619 Nem] TORQUE, iGTE. ASSEMBLY OF HUB MUST BE COMPLETED WITHIN A FIFTEEN MINUTE PERIOD FROM START OF SCREW INSTALLATION. THE SCREWS ARE PREPARED WITH AN EPOXY COATING WHICH BEGINS TO HARDEN AFTER INSTALLATION. IF NOT TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN MINUTE PERIOD, INSUFFICIENT SCREW CLAMPING TENSION WILL RESULT THIS SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY. IF THE SCREW IS REMOVED FOR ANY REASON IT MUST BE REPLACED. THE EPOXY LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND CLEANED WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION, ASSEMBLY INSTRUCTIONS FOR 28000 CONVERTER WITH SPECIAL APPLICATION IMPELLER HUB BEARING. —40—4.060.007 (26 94.17) ‘Stake 3 places approx. 2h rE © B ter curing of Lotte speed sensor bushing must be secure with 40 Fi. Lb. [54.2 N-m] torque. ny 1.9904 .007 [95.34.17] ‘Assemble Speed Sensor Bushing in housing to specified REAR VIEW dimension with Loctite 262 and stake (3) three places. SPEED SENSOR BUSHING INSTALLATION —a—DISASSEMBLY OF LOW CLUTCH UTILIZING REAR DOUBLE TAPER BEARING {HELICAL GEARS) Figure A Remove fow eluteh double bearing cup, outer cone and spacer. Figure B CAUTION: Outer cone, double bearing cup. spacer and inner bearing cone are replaced as a sot ring cone, NOTE: To remove the inner cone bearing without damage, a special bearing Remove low clurch inner b puller must be made (see diagram Fig. D| orthe outer cage fand rollers may bo pulled from the bearing inner race anc the inner race.can be cemoved stterthe low clutch assembly thas boon removed from the transmission. See caution in Figue 8. cur wre is RUBBER WHEEL AFTER HOW. 7 atures “o'RING~ bia Figure D ‘A timkon bearing cup, No, 29520 must be used with the ‘above bearing puller. REASSEMBLY Figure E Instell ow elurch inner taper bearing, NOTE: Heat bearing in hot oi! bath prior to installation. Install bearing spacer. =42—Figure J Install bolts and block gears. Torque bolts to specifications and lock wire together. Figura H Figure K Install outer taper besring, NOTE: Hest bearing in hot oil Install low clutch shaft sealing ring, bath prior to installation, Figure 1 Install retainer plate, inner diameter chamfer toward bearing, 4aLOW CLUTCH DISASSEMBLY UTILIZING TAPER BEARINGS IN LOW CLUTCH GEAR Remove clutch end plate retainer ring. Remove clutch end plate and inner and outer clutch dises, Figure 5 Remove low gear inner taper bearing. REASSEMBLY Install low gear inner taper bearing Install one steel dise. Install one friction dise. NOTE: The friction dises in the low clutch has a higher co-efficient rating than the friction discs in the other clutches, therefore the discs must not be mixed. The low clutch inner dise can bo identified by an "X" stamped on ane side of the inner teeth, The low clutch inner disc also has a strip of non-solublo yellow paint sprayed on the outer edge of the i and friction dises until the ralled. First dice next installed is friction. Romove low speed gear and outer teper bearing.Figure 7 Install low gear outer taper bearing. Install low clutch taper besring retsiner ring, NOTE: Retainor ring is solected at assombly for propor ‘thickness. A snap ting kit is available, Select the thickest of the three ings inthe kt that ‘can be fited into the snap ting groove to assuro a proper taper bearing tightness. Check ring as shown fer tight ring to bearing fit. to civich drum. Align splines on al teeth of friction discs. Tap gear . into position. Do not foreo this operation. Gear splines Figure 12 must be in full position ternal teeth of all friction Install low clutch shaft front bearing Inner race with large diameter of race down. 45Clutch Modulation Cross Section __ c ir - - | 2 PLATE “T im + MODULATION) J rev RO, Tl 2 pare: TT Low Sai MODULATION] ios |_/ wo 2ND. Ls Fw on nev 6 PLATE MODULATION28000 6-SPEED SECTION -47—6-SPEED CLUTCH AND GEAR GROUP iTem DESCRIPTION verse and Sed Gitch Shaft Piston Ring Piston fing Exoonder Springs Front Bearing Raines Ring Reverse ana Sra shat Front Baring Front Bearing Retainer Ring ‘luteh Brwon Gear Bsarng ‘Guten Driven Gear Baring Srp Ring Guten Deven Gear Guten Hub On Bate ig CGuteh Driven Geet Searing Srp Ring Clutch Driven Goa Bearing Return Spring Retsinee Sra ing Shap Rtg Retainer Spring Retainer Petar Return Sing ‘Spring Retaner Rvorao ana Se Cutch Shaftand Brut Spring Reta Piston Return Spring Spring Retainer Shap fing Rotiner Snap ing Shap ing etainer Sra Geer Beorng 3rd Gear Bearing Snap fing ‘Ghuzh Hub O1 Batt Ring ‘Sd Seer ‘34 Gear Gearing Seacsr ‘3d Guar Bearing Soop leg 5rd Geer Bearing, over and irs Shaft Ree Being Frwad and 2nd Shaft Peto Fins ston Ring Expander Sorings Front Bearing Rene: Ring Forward ana 2nd Shaft From sting Front Bearing Locating Ring Front Bearing Retainer fing ‘huteh Orwen Gear Beary ‘Gutch Driven Gear Beating Srp Ring {Guteh Driven Gear {Guten Hub Ot Bat ing {Guten Driven Gear Searing Sip ing {uten Driven Gear Beating Foturn Spring Retainer Snap Ring Sap ing Raines Sprng Rainer Beton Return Sina ‘Soring Retainer Forward and2nd Gch’ Shut nd Ors Spring Retainer Paton Return Spring Spring Retainer Shap ing Retin Return Soving Retane: Snap ing 2nd Gear Fane fing Ghee Hub On Bat ig Bad Goor tow Speed Giuch Shai is Boing 2nd Gear Bearing {ove Gear Bearing Fetsine Ring Low Gear Bearing on Gear Bearing Locating Ring tow Gear Low Gear Gist Fang ow Gear Bearing Locating Ring eww Gear esting ow Gear Bearing Retain Ring Return Spring Retainer Snep Rang ‘Shap hing Retainer pring Retoner Plston Retain Sing Spring Retainer {bw Speed cach Shai and Gra Low Speed Brive Ger Fearing fing Low Saft Roar Searing Low Shaft Rear Bearing Faint Ping Lowe Shaft Piston fing, aty Tem DESCRIPTION 76 Low Shel Piston Ring 7) ear Bearing Cap Gasket 78 Rear Bearing Cap, 72 Rat Bering Cap Siew Lackwaaher 8 Rear Bsarng Cap Seow 8) fo Bearing Gap Pus 82 fee Bearing Cap "0" Alng 82 Ider Saft Rear Bearing Lock Ball 4 lar Soft Rear Bearing 5 te Shaft Rear Bearing Locating Ring {8 Speedometer Drive Goaror Basing Spacer. 8) hor Sha Nut BE Idler Shaft Searing Cop Gaskat 39 Ider Shatt Gearing Cap 50 ler Shatt Bearing Cap Scxoe 81 Spacaomoter Driven Goar 82. Speecomate Tube ut 83 _ lor shat Bearing Caper 84 lor Shaft Bearing Capecrew Lockwethe: 85 ler Shaft Font Beanng Retsinee Ring 98 Ider Sha Font Searing 3) Ider Shaft Gow Locating Ring 8S later Share 93 Rango Shit al Suopot "Ong 100 ange Shift Ra Support 101 Range Shit Fal Support Ser Lockiasher 102 Range Shut Ral Support Stew 103. Range Shit Ra Oi Soa 108 Range Shit Rat 105 Range Shit Ral Getent Soxing 108 Range Shit Ral Detont Sa 10? Range Sit Ral Detont u 103 leh Low Range Gear 109 lor ShartGoar Spacer M0 ler Shat Gear MI Output shoe M12. Output Shot Front esting Cup M13 Output Shatt Font Bearing Cane 34 Output Gear Titus Washer 1 Output Gear Bearing 18 Outpor Gear Bearing 117 Outpet Goar Baring Inne Race M8 Output flange Net M8 Output ange Wesher 120 Output Flange "0" Ring 12) Output Flange 122 Output Shat Front Beoring Cap Oi Seal 323 Output Shate Front Bearing Cap Screw 124 Output Shot Front Bearing Cap Locknathor 125 Output Shat Front Bearing Cap 128 From Bearing Cap Shim 12) Font Bearing Cap "0" Ring 128 Low Range Gear 123 High Cow Shift id 13). Shit Hub Siow TSI High Range Goor 132 Output Gea ner Race 135 Output Gos: Bowring 134 Output Gea Bosring 135. Output Gear Thrust Waser 138 Outpur Shaft Rear Beoring Cond 137 Output Shaft fear Bearing Cop 138 Output Shaft Rear Bearing C3p “0” Ring 133 Output Shaft Roar Boarng Cap "0" hing 140 Output Shaft Rea Boarng Cap Sern 141 Output Shalt Rear Boarng Cap Screw Lochwashor 142 Output Shan Rear Beary Cop 143 igh and tow Range Sit For Mad SiitFork uss Sew 143. Rear Beating Cop 1 Seal 188 Rear Output ange 87 Output Range "0" Ring 148 Output Range Washer 149 Output Range Net 150 Busing (Weed with Disconnect Oy 151 Output Shat (Used wah Disconseet Only 182 Disconnect (Optonad 153 Bearcg Cap Bore Pu iOpional =49— aryR & HR MODEL 6-SPEED ‘The R & HR 28000 6 speed transmission isthe samo 05 tho 3 speed F & HA 28000 except the dference being inthe idler and output shots. The 6 spoed unit has @ gear added to the idler shalt and the ouput shaft nas @ fagh and low range shift ‘The speed transmission has 3 working range shits and 3 travel ange shits. Gear ratio determines working and travel anges. Thay are 98 follows: ‘st ~ 2nd and dn working range. Sed ~ Bth and 6th travel ange NOTE: Range shift from low to high must be made with machine stopped. For R-Model front end removal, see F-fodl section, page 59 DISASSEMBLY For HR Medel front end removal, use Figures 1 through 9 land 35 and Figures 42 trough 48 inthe R & HR 26000 3-Spead Section, Figure 49 shows the kdler shaft with one gear. Tho Speed unit will have two goare ands heavier front bearing, ‘See Figure 48A below: Figure 2 Remove range shift rail support bolts, Remove rail support, rail and range shift fork. Figure 498, {speed isler shat, gear and baring assembiy. NOTE: Do not lose rear bearing lock ball Procood with figure 60 through 54 in the R& HR 28000 ‘3Spead Soction. 6-SPEED QUTPUT DISASSEMBLY Figure 3 With all clutchos and shafts removed, cut lockwire: Remove output shaft rear bearing cep bolts and con range shift fork lockscrew. Remove fork lockserew. bearing cep. 51Figure 6 Position high and low range gears, shift hub, hub sleove snd nosdle bearings in transmission case as Shown in Figure 5. Insert output shaft, front b ana thrust washer through eutput gears. Use caution Figure as not to damage high and low range goer noodle Remove front outout flange nut, wesher, "Oring lange and bearings. bearing cop from housing. Block output gears. Push output shaft from rear through gears and taper bearing. Proceed with Figures 68 through 88 in the R & HR 28000 Soviea 8Speed Maintenance Soction then reler to Figure 5 blow. REASSEMBLY {See cleaning and inspection page.] Figure 7 Position output gear thrust washer and rear taper bearing on output shaft. Figure 5 View of output shaft as it would be positioned in iransmission case, Note front bearing cone and ovt- Figure 8 put goar thrust washer shouldered on shaft with large Block output shaft from the front and install rear diameter of bearing In. taper bearing.Using new “O* rings install rear ouput bearing cap 1nd taper bearing cupon transmission case. Lube open: ing in bearing eap must be aligned with tube opening in ease. Tighten bearing cap bolls to specified torque. (See torque chart.) Install front bearing cap and shims. Tighten bolts to specified torque. Tap output shaft front and rear 10 seat taper bearings. Loosen front bearing cap bolts. Figure 19 Using an inch Ib. torque wrench, dotarmine tho rolling torque of tho output shatt and recor. Tighten front beating cap bolts to speafied torque. Check rolling tacque with bolts tight. Tarcue ust bo 6 0 8 inch Ibs. 0.68 -0.90 Nim] more than when beat ing cap bolts were looso. Add or omit shims on the front bearing ‘cap to achieve the proper prelaad —s3— we} Figuro 11 locate high-low cange shift fork in shift hub with offset of fork toward rear. Insert shift rail support and rail inte bore in transmission housing and into shift fork. Figure 12 Tighten support bolts to specified torque. (See torque chart). Locate lockscrew hole in shit ral with hole in sit fork, Install locksereW, tighten securely and lockwire to prevent loosening. Proceed with Figure 108 in the R & HR 2000 3:Speed SeoKEY mums 1ST (LOW) mm mmm 2ND @@e@e 3D (HIGH) ooo RANGE SHIFT 6 SPEED TRANSMISSION LOW RANGE6 SPEED TRANSMISSION HI RANGER MODEL SECTION R MODEL COVER AND CASE GROUP —56—R MODEL COVER AND CASE GROUP DESCRIPTION Flange Nut Cotter. Flange Nut Flange Nut Washer. Flange “O” Ring. Input Flange. Input Flange Oil Seal Input Shaft Front Bearing Retainer Input Shaft Front Bearing. Input Shaft Front Bearing Retainer Ring ing. Cover to Case Screw. Cover to Case Screw Lockwather Front Cover and Tube Assembly ipe Plug, . “0” Ring, - 3rd Speed Tube Assembly. Tube Clip, Tube Clip Serew Lockwasher Tube Clip Screw. Reverse Tube Assembly... Breather. Front Cover Sleeve. Front Cover Sleeve Lock Sleeve Lockscrew Lockwasher. Sleeve Lockscrew Input Shaft on Input Shaft Rear Bearing, Input Shaft Gear... . Input Shaft Gear Retainer Ring. Front Cover Plug. Control Valve Plate Gasker, Control Valve Assembly. Valve Serew. Valve Serew Lockwasher. Detent Ball Detent Spring. Tube Sleeve... Cover to Case Screw Lockwasher. Cover to Case Screw. Front Cover Plug Gasket. Front Cover Plug ary. -s7- mem 41 42 a 44 45 46 a7 43 0 30. 31 $2 53 54 35 56 7 58 59 60 6 6 63 64 65 o7 68 “o 70 n 72 73 74 75 DESCRIPTION ary. Cover 10 Case Screw Lackwasher 4 Cover to Case Screw. 4 Pipe Plog 1 Clutch Pressure Tube °O” Ring 1 Tube Sleeve. 1 Low Speed Clutch Pressure Tube. 1 Rear Cover Dowel 2 Rear Cover to Transmission Case Gasket... 1 Roar Cover. 1 Rear Cover to Transmission Case 13 Serew Lockwasher, Rear Cover to Transmission Tube Sleeve. Tube Sleeve “O" Ring Case Screw... 1 Rear Cover Pipe Plug. . Rear Cover to Transmission Case Stud Nut. Rear Cover to Transmistion Case Stud Lockwasher Rear Cover to Transmission Case Stud Front Cover to Transmission Case Screw, Front Cover to Transmission Case Screw Lockwasher. Drain Plug... Oil Level Plug il Baffle (6 Speed only) Screen Assembly .. Screen Assembly Gasket vo Transmission Case Assembly Front Cover Gasket Transmission Case Plug .. Suction Tube Clip Washer Suetion Tube Clip, Suction Tube Assembly Retainer Washer Screw Retainer Washer Suction Tube “O" Ring. Front Cover Dowel Pin. Suction Tube Clip Rivet.R MODEL 3 & 6-SPEED (REMOTE MOUNTED TRANSMISSION FROM CONVERTER) CAUTION: Cleanliness is of extreme imacciance and an absolute must in the repaie and overhaul ofthis unit. Before attempting any Lena, the extvir of the unt must be thoroughly ‘leaned to prevont the possibilty of dit and foreign matter entering the mechanism: DISASSEMBLY Remove control valve bolts and washers, Remove control valve. Use caution as not fo lose detent springs and balls Figure 2 Remove bolis securing frent cover to transmission Romove compenion flange nut, washer and “O” Ring. housingHf inout shaft is to be remeved, ap on threaded end of shat remove input shaft, gear anc’ beating, Figure 5 Support fron} cover with a chain fall. Using sproad ing type snap ring pliors, spevad ears on forward clutch Front bearing retaining ring, Holding snap ring open ‘See page € Figure 34 for complete transmission disassembly. pry front cover from transmission housing. ‘Soe page 18 Figure 29 for vansmission reassembly R MODEL FRONT END REASSEMBLY & INSTALLATION ON TRANSMISSION {See cleaning & inspection page.) DRIVE GEAR Uae RING INPUT SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD Figure 6 RETAINER RING If forward and 2nd clutch comes out with front cover spread ears on front bearing snap ring and separate Figure 9 clutch from front cover, Inout shat, tsar boring, dive and snap ring. Figure 10 {nora input chat into front boating. Position new gasket and 0" rings on housing. A light cost of grease will hold gesker and "O" rings in place, Install alignment studs in transmission Figure 7 housing to fecltate converter housing t0 transmission housing Front cover removed with forward and 2nd and assembly. reverse and 3rd clutch in transmission case.Figure 11 Position forward clutch front hearing locating ring in front Figure 12 ‘Supper front cover with o chain fall. Spread forward clutch front hearing retainer ring. Position front cover ta transmission case. Tap cover into place using caution as not to damage any of the clutch shaft piston rings. Figure 13, cover plug. re Figure 15 Insta companion flange, flange "0" ting, washer end mut Tighton standard slored nut or elaste stop nut to spociied torque. [Soe elastic top nut torque char.) Figure 16 LLocete detent bats and springs in contral value, Position new gasket, Secura valve with bolts and washers. Tighten to specrted torque,‘A FoRWARO} KEY +e mmm 1ST (LOW) mm mmm 2ND @@ 6 3AD (HIGH) R MODEL 3 SPEED TRANSMISSIONR28000—C270 EXTERNAL PLUMBING DIAGRAM hoc pnt =" Pa Asya) E28er et pres. Not: Check point “* Line tom pump must be connected Coster Bue presse {on ade or “-Gheck pon." Line tom pga and ‘Sooter butt temperate ‘om fet fog ave, 1 ter opening cera Saco Shock point 8" omer et pressure. \ Pressure reg ae creck point“ ‘Suc presse ‘240205 PSI 6560-19810 KP) WAY Soles onest neal! ter graniy ran fo rane. settee! | heck point “D" sump t pump. Check post °C" converter ‘Gravity deain—must nave ulat presse. Commer Sit toma 180° 00°F evtnisus ope fem fearsosee) ‘Severe torent. Nraneiettenm neta . Speaing spectators: ae: EFS thao teal mum Hose ne porting eciremnts izes 2000 PEM ene {-Preseute LnesSulte for opaton tom Matic mensions show ‘Beet ans mssrnam oh PSL Erotntto °F Ha) sons perina were i530 se eat poss. ismperate. Mun wisn 36 St 0G Pe trim engine epeatg a ortnou prossre wih E00 P(t KPa Note: Do not deviate any Hine sie, Mba gored spec iiematen surges Ret SAE. Spee ta LBITAO0R Hjaratc Hose Specteton, 2. Suction Line be protected from eolapse byinforwevon soo wie. Rot, SAE, Spee No, “Br7s00R Hyeraulo Nose Speceaten Sule for operaten trom ambient to 250%. [121°]. Cominuaus operating emperatue eis [ ere comes a [ omer, |e aerss | acrose {ouaing temperature: Re SAE Spa No. J 00 Sige Can 1502 _| single Ehme Hyereule Hose Speciation ae ee 4 Al Hose nes used rust cof o SAE. a Gan Dea Eoment Spec Ne. 8 Tet Process gh ‘ana. Tansmisson OF Hose 5. See Lubeston Specteatons.DRIVE PLATE INSTALLATION ‘SUBJECT: 28000/32000 Series Transmission and C-270/C-320 Series Converter Drive Plate Kits. REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter. ‘Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below. ‘ALIGNMENT HOLES (0 DRIVE PLATE AND. WELD NUT ASSEMBLY (INTERMEDIATE DAVE PLATES BACKING FING “A” Dimension (Bolt Circle Diameter) 13.125" [333,375 mm] Diameter Kit No. 802336 13.50” [342,900 mm] Diameter Kit No, 802333, 17.00" [431,800 mm] Diameter Kit No. 802454 ach kit will include the following parts: 4. Intermediate Drive Plates 1. Drive Plate and Weld Nut Assembly. 1) Backing Ring. 10 Screw and Lockwasher Assembly. 1. Instruction Sheet. ‘TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN ORIVE PLATES — SEE ILLUSTRATION ABOVE. Position crive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and backing ting with holes in impeller cover. NOTE: Two dimples 180° apart in backing ring must be out (toward engine flywheel Install capsorews and washers. Tighten 23 to 26 ft. Ibs. toraue (31,2 - 33,8 Nm. ‘SEE PAGE 65 FOR TRANSMISSION TO ENGINE INSTALLATION PROCEDURETRANSMISSION TO ENGINE INSTALLATION PROCEDURE Remove ail burrs from flywheel mounting face and ‘nose pilot bore. Clean drive plate surface with solvent. . Check engine flywheel and housing for conformance to standard SAE. #3 - SAE. J927 tolerance specifications for pilot bore size, pilot bore runout and ‘mounting face flatness. Measure and record engine ‘crankshaft end play. Install two 3.50 188,90 mm) long transmission to fiywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align 2 drive plate mounting screw hole with the flywheel housing access hole. {Install a 4.00 {101,60 mm] long drive plate locating stud .3750-24 fine thread in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. Locate tansmission on flywheel housing aligning dive plate to flywheel and transmission to flywheel housing. Install transmission to flywheel housing screws. Tighten screws to specified torque. Remove trans mission to engine guide studs. Install remaining ‘screws and tighten to specified torque. Remove drive plate locating stud. Install drive plate attaching screw and washer. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywhoe! will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. ASter all eight () screws are installed torque each one 25 to 30 ft. Ibs. torque (33,9 - 40,6 Num). This will ‘quire torquing each screw and rotating the engine flywheel until the full amount of eight (8) screws have been tightened, Measure engine crankshaft end play after trans- mission has been completely installed on engine flywheel. This value must be within .001 10,025 mm] of the end play recorded in step No. 2. Se) eg Ue EEPROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS. Fill the ol sealing ring grooves with a good grade of grease, this will help stabilize the teflon ting and expander spring in the ting {groove for instalation. Position the expander spring in the inner groove of the now piston ring, with the expander sping gap 180° from the hook joint gap ofthe piston ring, Carefully position the piston ring and expander spring on the clutch shaft in the inner most ring groove. Hook the piston piston ring joi. Repeat steps 1, 2 and 3 forthe remaining ring or rings meking certain all hook joints are fastened securely. ‘Apply & heavy coat of grease to the outer diameter ofthe rings and clutch shat. Center the piston ring’s in the ring groove. Before instaling the clutch assembly in the front cover or converter housing itis recommended @ piston ring sleave PIN's 281309, 237576 or 234265 be used to center all of the piston rings in ther respective ring grooves. Use extreme caution to not damage pleton rings when instaling the clutch shaft in the front trasnmission cover or converter housing, USED FOR POSITIONING —_ PISTON RING. PISTON RING OF PISTON RINGS GLERVE 234265 Seve es908-OF 297575 [+ BEARING Hf é Hf Coxuton suarr LUT SHAFT ~ “| BEARING PISTON RINGS' PISTON FINGS' ‘Bo sure that lead in chamfer and Intersaction of lead in. chamfer to piston fing bore Is tree of burrs and rics. Zi Son Bing a NX i nna AP / 0825 } expander Ring SPRING GAP AND RING GAP ‘ARE 180" APART