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2. 1 3 PIPE ancien maa ayy rete ene 1 35 Clutch Pressure Tube O Ring 1 4 Pipe luet sa ae eee ee 2 36 Tube Sleeve 1 5 Converter Housing Sleeve 1 37 Clutch Pressure Tube O Ring 1 z sal D 1 38 Transmission Case Assembiy 1 7 Clip Screw Lockvvasher 1 39 Tube Sleeve 1 ssla 1 40 Clutch Pressure Tube O Ring 1 9 Clip Sere aka a xanla 1 41 Rear Cover to Transmission Case Gasket 1 10 Clip Screvv Lockvvasher 1 42 Transmission Case to Rear Cover ER a la E 1 5 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 Lockvvasher 17 46 Rear Cover to Case Screw Lockwasher 20 15 Converter to Transmission 47 Transmission Case to Rear Cover Case SCEOWS eigen dese uera 17 Dowel PUSS us caet eee 1 Yo Pipe Eee 2 45 Pipe Pl gz zt vec B 1 TV IBIUga s e a eee EE 1 49 Pipe Plug 1 18 Hole Plug Gasket 1 50 Magnetic Drain Plug 2 19 Case Assembly Hole Plug 1 51 Oil
3. High Low Shuttle Spool Shuttle Spool Spring Shuttle Valve Body Pipe Plug iv eR ee Valve Mounting Screw Lockwasher ITEM 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Valve Mounting Screw DESCRIPTION Valve Mounting Screw Lockwasher Valve Mounting Screw Shuttle Valve Solenoid Solenoid Coil Shuttle Valve Solenoid O Ring Shuttle Valve Solenoid Ring Shuttle Valve Solenoid O Ring 1st Speed Shift Spool Plug Stoner PROPIO Spool Stop ses ie Shift Sbool Spool Position Spring Bore Plug O Ring Valve Housing Spool Bore Plug Piston Housing Assembly Stop Plug ges Plug O Ring Piston O Ring Giyd Ring Pistah 22 22 EE ER 52 Note tems 53 thru 56 are options various declutch Date Apr 2000 HR24000 4 Speed LD Maintenance amp Service manual FIGURE G Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD CHARGING PUMP amp VALVE ASSEMBLY GROUP ITEM DESCRIPTION OTY 1 Malvg stop Rol Bin asas MN EEN SE ODUN o EE n 5 Valve Stop O Ring Br MR PRE eh 7 Valve Spring nner 8 Valve Spring Outer 9 Regulating Valve Filter Ada
4. ring and flange Figure 37 Remove the low clutch and idler shaft rear bearing cap bolts Figure 38 Remove low clutch rear bearing cap Figure 39 Remove idler shaft bearing cap Figure 40 Figure 43 Remove the rear output flange nut washer O ring and Remove flange spacer or speedometer drive gear flange Figure 41 Figure 44 Remove output shaft rear bearing cap bolts Remove the 1st clutch rear bearing locating ring xt 5 Figure 42 Figure 45 Remove bearing cap Remove the idler shaft rear bearing locating ring Figure 46 Remove rear cover to case bolts Figure 47 The use of aligning studs will facilitate the rear cover removal Using pry slots provided pry cover from trans mission case Using a soft hammertap on the 1st clutch and idler shaft to prevent cover from binding Figure 48 Remove rear cover Figure 49 Remove output shaft assembly Figure 50 Remove 1st clutch rear bearing retainer ring y Figure 51 Remove rear bearing Figure 52 Figure 55 Remove bearing spacer Remove idler shaft front bearing Figure 53 Figure 56 Remove idler shaft assembly Remove oil sump oil baffle Figure 57 Figure 54 Remove forward clutch drive gear retainer ring and driv Remove 1st speed clutch assembly gear See Figure 57 A 10 Figure 57 A Figure 60 Remove sealing ring sleeve Figure 58 Figure 61 Remove for
5. lt fana gt SPICER Off Highway Products Service Manual Powershift Transmission 24000 Series HR 4 Speed Long Drop TSM 0009 April 2000 Maintenance amp Service manual HR24000 4 Speed LD FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the Spicer Off Highway Power Shift Transmission 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 transmission its principal of operation trouble shooting and adjustments it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Spicer Off Highway approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Spicer Off Highway does not warrant repair or replacement parts nor failures resulting from the use thereof which are not supplied by or a
6. 1 Le Stab Shaft Lock Bell acm sans oo arse 1 55 Drive Plate Assembly a seme eels 1 17 Piston Ring Expander Spring 1 87 Drive Plate sere EE EE deaeque e EE pens 1 58 Drive Plate Backing Ring T 197 Stator Sup OR en ewes 1 59 Drive Plate Mounting Nut 10 4U Bearing Shap Ye sees 1 60 Drive Plate Mounting Stud Lockwasher _ 0 21 Piston Bing TNR evt 4 61 Impeller Cover Stud 10 22 Bearing Retaining Ring 1 62 Impeller to Cover Screvv a 23 Bearing Locating Washer 1 63 Impeller to Cover Screw Lockwasher 24 24 Turbine Shaft Beoring oii sisi 0e eee 1 IAE S Illi Natr PORTIO m z si b 1 25 Turbine Shaft ess ERNST CR Kem 1 65 Freewheel Outer Race Retainer Ring 1 26 Battles Must NEEN EE SNE SEENEN emacs 1 66 Freewheel Assembiy 1 s Stator Support DCrew ETT a A aa 6 67 Reaction Member Ein 1 28 Auxiliary Pump Drive Bearing Support 1 68 Impeller to Hub Bearing Spacer ee 29 Bearing Retaining Ring 1 69 Impeller to Hub Screw 8 30 Pump Drive Gear Bearing 1 70 Impeller to Hub Screw Lock Tab 4 31 Bearing Locating Ring 1 MEL HSNO EN
7. 37 Spring Retainer Snap Ring Are 1 101 Pump Drive Sleeve 38 3rd Clutch Disc Hub Retaining Ring 1 102 Idler Shaft Nut 39 Baffle Ring 1 103 Idler Gear Spacer 40 3rd 8 4th Shaft Rear Bearing dee aba EET 1 104 Idler Shatt Gear Al GOLES DUIS HUM renti crm Als 1 105 Idler Shaft Gear 42 Clutch Driven Gear Bearing Spacer 1 106 Idler Shaft Bearing Cap Backed 4418 43 4th Gear 8 Hub Assembly sce d Pu 1 107 Idler Shaft Bearing Cap ae 44 Clutch Driven Gear Bearing 1 108 Idler Shaft Bearing Cap Screw L a sales 45 Rear Driven Gear Thrust VVasher 1 109 Idler Shaft Bearing Cap Screw nS a 45 Threat Washer tock Bell oorr Ra 1 110 Output Shaft 47 Thrust Washer Locating Ring 1 111 Output Gen Spacer See al al 48 Spring Retainer Snap Ring 1 112 Output Shaft Gesr adm EH 49 Buruq ReteinBr c Vay aa a s la Yalla aie nada 1 113 Rear Bearing Cone 50 Piston Retum Spring n s 410 AUER 1 114 Rear Bearing Cup St 51 sth Shaftflston eiu el Sees v 3 115 Rear Bearing Cap o Ring Ne GT 52 Front Bearing Retaining Ring 1 116 Rear Bearing Cap O Ring ms s l 53 Front Bearing Snap Ring 1 117 Rear Bearing Cap Kek
8. L and M These ports are to be used as check points for normal vehicle Production Line test Port F Clutch Pressure It is recommended that clutch pressure be monitored by a gauge having an indicator dial range of 0 to 400 PSI 0 to 2758 kPa and located in the Operator Compartment Ports G and H Back up Warning These ports are provided for installation of Back up Pressure Switch for Warning Light or Horn Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD Charge Pump amp Filter Shielded Bearing Emergency Steering Pump Drive Option 4 Speed with 6 plate clutch Shielded Bearing 4 Speed with 1 1313 3 12 plate clutch 2 S MECHANICAL DISCONNECT Front Shown Rear Available MECHANICAL DISCONNECT WITH SPEEDO Rear Shown Figure Date Apr 2000 Maintenance amp Service manual Assemble oil filter and tighten 20 to 25 Lbs Ft 27 2 33 8 N m A Teflon seals must be sized prior to ass y A A A A IN Tighten 200 to 250 Lbs Ft 271 2 338 9 N m A Ad Must be loose internal fit bearing with a No 3 etched on the bearing 10 outer steel plates 10 inner friction plates Alternately assemble starting with outer steel plate 6 outer steel plates 6 in
9. 16 3 21 6 28 32 380 43 3 26 30 1353 40 6 3750 26 29 35 3 39 3 23 25 31 2 33 8 37 41 50 2 55 5 33 36 44 8 488 4375 41 45 _ 55 6 610 37 41 1 50 2 55 5 58 64 178 86 7 52 57 1 70 6 77 2 5000 64 70 86 8 94 9 57 63 77 3 854 90 99 122 1 134 2 80 88 _ 108 5 119 3 5625 91 100 123 4 13551 82 90 111 2 122 0 128 141 173 6 191 1 115 127 156 0 1722 6250 128 141 1735 191 2 113 124 193 2 168 1 180 198 224 0 268 5 159 175 215 6 237 3 7500 223 245 1302 3 332 2 200 220 271 2 298 3 315 347 427 1 470 5 282 310 382 3 420 3 j Figure I Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD Figure J Date Apr 2000 MAINTENANCE AND SERVICE The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence thet would normally be followed after the unit has been removed from the machine and is to be completely overhauled t must also be understood that this is a basic 24000 4 speed long drop output transmission with many options The units are very similar
10. 21 Spring Retainer rm zu B5 1st Clutch Shaft Drum amp Bleed Valve Assembly 22 Piston Return Spring Belleville Washer vele dics Mie Melo 7 B6 151 Speed Shaft Rear Bearing Spacer 23 Piston Return Spring Spacer RE TUE renier ire 1 87 1st Speed Shaft Rear Bearing 24 Reverse amp 2nd Clutch Drum 8 Plug r 1 88 Ist Shaft Beanng Retainer Ring 2B Pinto Retunm Baris ee Ve ege cue ra Fra oh en Nos rA 1 89 1st Shaft Piston fing 26 Spring Beamer SEENEN E NEE ARA A it 90 Bearing Cap Gasket 27 Spring Retainer Snap Ring is 57 wut 91 Bearing Cap Ring 28 Retainer Locating Ring 82 BUR es EA is Ee EE wees 29 Retaining Ring Retainer ailes 93 Rear Bearing Cap 30 2nd Clutch Disc Hub Retaining Ring PPP PCO b d f 1 94 Bearing Cap Screw ERE TOC T ome 21 BEH TING ye E ees in bitin I sen wer j rer ree n vj 95 Bearing Cap Screw 32 Reverse amp 2nd Shaft Rear Bearing 1 96 Idler Shaft Front Bearing z 33 2nd Clutch Disc H b 99 vi nv o ev 22 97 Idler Shaft eda tes 34 3rd 4th Shaft Drum 8 Plug Ats rnibiy 1 98 dier Shaft Rear Bearing b 35 Piston Return Spring 3rd Clutch 1 99 Idler Shaft Rear Bearing Lock Ball 38 ASO HOMO D ose o qs ewes see rs 100 Rear Bearing Locating Ring
11. Install forward clutch pilot bearing Figure 308 The use of two aligning studs will facilitate aligning the converter housing to the transmission housing Install converter housing assembly to transmission assembly using extreme caution as to align the clutch pilots into the clutch disc hubs As the clutch pilots enter the disc hubs turn the turbine shaft and output shaft back and forth This will help align all of the clutch inner discs 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 to housing capscrews and lockwashers Remove aligning studs Install remaining capscrews and lockwashers Tighten capscrews to specified torque See torque chart Figure 309 Apply a light coat of Permatex 2 to the outer diameter of the oil baffle oil seal Press seal in baffle with lip of seal toward impeller hub bearing Position new oil baffle sealing ring on oil baffle Position oil baffle in housing and install retaining ring Be sure ring is in full position in ring groove Figure 310 install impeller and hub assembly using caution as not to damage the oil baffle oil seal NOTE Use extreme caution as not to cut break or unhook the oil sealing ring on the support Figure 311 Position impeller hub bearing spacer on stator support Figure 312 For fixed reaction member install reaction member with thick
12. rings with oil before assembly Apply a thin coating of grease between seal lips on lip type seals prior to assembly Apply a very light coat of Permatex No 2 to O D of all oil seals and bore plugs before assy Apply a light coat of Loctite No 92 to all plug threads Apply a light coat of Permatex No 2 to all thru hole stud threads After assembly of parts using Loctite or Permatex there must not be any free or excess material which might enter the oil circuit VIEW v VIEW T REVERSE IDLER piston ring amp expander Note Expander gap to be Enlarged view of stator support bin approx 180 from ring hook joint to aid assembly 1ST Low Assembly of stator support to converter housing must be completed within a 15 minute period from start of screw installation The special screw is to be used for one installation only If 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 Dry hole thoroughly and use a new screw for reinstallation VIEW S or Plated Screw Threads Grade 5 Co Grade 8 NOM FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD SIZE LB FT IN ml LB FT IN m LB FT Nm LB FT IN mi 2500 9 11 123 149 1 8 10 10 9 135 11 13 15 0 17 6 J 9 11 12 3 149 3125 16 20 21 7 27 1 12 16
13. ITEM DESCRIPTION QTY ITEM DESCRIPTION OTY 1 Bearing Support Screw 8 Lockwasher 2 a Ree d E Car EE Nen RA min et 1 2 Idler Gear Bearing Locating Ring 1 42 Idler Gear Bearing Thrust Plate 2 3 Idler Gear Bearing Retaining Ring 1 43 Bearing Retaining Plate Nut 2 4 Pump Drive dler Gear sremue 1 44 Turbine Retaining Ring 1 5 Idler Stub Shaft Bearing 1 45 Turbine to Hub Screvv ac o b 6 Bearing Retaining Ring 1 46 Turbine Hob Rio ACEN Sass e EEN EE 1 Bearing Locating Rings susa aaa az E sa 1 AT Turme s S Se See EE 1 8 Bearing Support Screw 8 Lockwasher 2 AB TDR H z y adim 1c CRI D Roe ti IN 9 Bearing Locating Ring 1 49 Impeller to Cover O Ring 1 10 Pump Drive Bearing Support 1 BO Impeller Gover ates VRS OES 1 11 Bearing Retaining Ring 2 1 51 Turbine Hub Bearing 1 12 Pump Drive Gear Bearing 1 52 Impeller Cover to Bearing Cap O Ring 1 13 Bearing Locating Ring immune 1 53 Turbine Hub Bearing Retaining Ring 1 114 Pump Drive Genr 25 243 Eeer eut Ce 1 54 Turbine Retaining Ring 1 15 Idler Gear Stub Shaft 1 55 Impeller Cover Bearing Cap
14. and rear to seat taper bearings Loosen front bearing cap bolts Using an inch b 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 N m more than when bearing cap bolts were loose Add or omit shims on the front bearing cap to achieve the proper preload Figure 270 Install capscrews and washers tighten to specified torque See torque chart Figure 273 Install output flange new O ring washer and nut Figure 271 Position new gasket on idler shaft bearing cap Install bearing cap bolts and lockwashers tighten to specified tighten flange nut 200 to 250 ft Ibs torque 271 2 338 9 torque See torque chart N m Figure 274 Using a flange retainer to prevent output shaft from turning ET Figure 275 Install front output flange O ring washer and nut Tighten as explained in Figure 274 Figure 276 Position the 3rd clutch disc hub on the idler shaft Install disc hub retainer ring Figure 278 Install ring retainer retainer ring Figure 279 Install the 2nd clutch disc hub on the 1st clutch shaft Install disc hub retainer ring Figure 277 Install disc hub retainer ring retainer Figure 280 Install retainer ring retainer Figure 281 Install retainer retainer ring Figure 282 Position new O rings and
15. 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 draulically 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 Next a friction disc with splines at the inner diameter is inserted Discs are alternated until the required total is achieved A heavy back up plate is then inserted and secured with a snap ring A Hub with O D splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direc tion as long as no pressure is present in that specific clutch Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD To engage the clutch as previously stated the control valve is placed in the desired position This allows oil under pressure to flow from the control valve through a passageway to a chosen clutch shaft This shaft has a drilled passageway for oil under pressure to enter the shaft Oil pressure sealing rings a
16. four intermediate drive plates ALIGNMENT HOLES 1 DRIVE PLATE AND WELD NUT ASSEMBLY A s v 3 INTERMEDIATE BOLT CIRCLE DIA 4 INTERMEDIATE BOLT CIRCLE DIA E a DRIVE PLATES BACKING RING BACKING RING 5 320 601 IMPELLER A Dimension Bolt Circle Diameter COVER A Dimension Bolt Circle Diameter 4 1 Ss mm Diameter gtyp FIN A 13 50 342 900 mm Diameter it No Kit No 802217 13 125 oe mm Diameter 13 125 333 375 mm Diameter Kit No 802216 Kit No 802263 13 50 342 900 mm Diameter Kit No 802214 Each kit will include the following parts 4 Intermediate Drive Plates 17 00 431 800 mm Diameter 1 Backing Ring Kit No 802264 10 Studs Each Kit will include the following parts 10 Lockwashers 3 Intermediate Drive Plates 10 Stud Nuts 1 Drive Plate and Weld Nut Assembly 1 Instruction Sheet 1 Backing Ring 10 Studs 10 Lockwashers 10 Stud Nuts 1 Instruction Sheet Drive Plate Installation Procedure A TO FACILITATE ASSEMBLY ALIGN SMALL HOLES IN DRIVE PLATES SEE ILLUSTRATION ABOVE Clean tapped holes and studs thoroughly with Loctite 755 Solvent Must be free of any grease or oil Spray Loctite 747 Primer T in tapped holes and on studs and allow to dry Apply Loctite 262 Threadlocker to both tapped holes and 16 NC thread stud end Assemble to standout shown Remove excess Loctite after assembly Allow 30 minutes minimum before installi
17. gasket on front of transmission housing A light coat of chassis grease will hold O rings and gasket in place See cleaning and inspection page CONVERTER HOUSING REASSEMBLY See Figure 333 for oil sealing ring sleeve information Figure 283 Install new sealing ring expander spring and oil sealing ring on support Expander spring gap to be 180 from sealing ring hook joint Press support bearing into position NOTE Bearing part number must be up Clean stator support mounting surface and tapped holes with solvent Dry thoroughly being certain tapped holes are clean and dry lt Ie Figure 284 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 Ibs 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 screw 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 Dry hole thoroughly and use a new screw for reinstallation Figure 285 Position auxiliary pump drive gear bearing and support in housing Figure 286 Align holes in bearing support with holes in housing Install support screws and washers
18. may be cleaned in hot solution nks 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 This 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 should be 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 absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound INSPECTION The importance of careful and thorough inspection of all 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 inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing cone or cup individ ually without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lintless cloth or paper to protect them until installed Oil Seals Gaskets and Retaining Rings Replacement of spring load oil seals O rings metal s
19. side of blades out For freewheel reaction member see Figure 314 Figure 313 install reaction member retainer ring Proceed to Figure 318 FREEVVHEEL REASSEMBLY NOTE The freevvheel assembiy cannot be serviced f the freewheel is damaged it must be replaced as an assembly 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 315 Install outer race to reaction member retainer ring VIEWED FROM THIS DIRECTION OUTER RACE FREEWHEELS CLOCKWISE Figure 316 MUST FREEWHEEL IN CLOCKWISE ENGINE ROTATION Figure 317 Position reaction member to impeller hub gear spacer on reaction member support Install reaction member on support Check rotation of freewheeling reaction member to be sure of proper freewheel assembly Install reaction member retaining ring Figure 318 Install turbine locating ring on turbine shaft Figure 319 With a new impeller cover to impeller O ring in place install turbine and impeller cover assembly on turbine shaft Figure 320 Install turbine hub to turbine shaft retainer ring Figure 321 Install impeller cover to impeller screws and lockwashers Tighten to specified torque See torque chart Figure 322 Position a new O ring over impeller cover bearing Figure 326 Install new oil filter cartridge NOTE It is recommended Figure 323 tha
20. standpoint the following mechanical checks should be made 1 A check should be made to be sure all control lever linkage is properly connected and adjusted at all connecting points 2 Check shift levers and rods for binding or restric tions in travel that would prevent full engagement Shift levers by hand at control valve if full engage ment cannot be obtained difficulty may be in control cover and valve assembly HYDRAULIC CHECKS Before checking on the torque converter transmis sion and allied hydraulic system for pressures and rate of oil flow it is essential that the following pre liminary checks be made Check oil level in transmission This should be done with oil temperatures of 180 to 200 F 82 2 93 3 C DO NOT ATTEMPT THESE CHECKS WITH COLD OIL To bring the oil temperature to this specification it is necessary to either work the machine or stall out LOW CL Cause Low oil level Clutch pressure regulating valve spool stuck open Faulty charging pump Broken or worn clutch shaft or piston sealing rings Clutch piston bleed valve stuck open x ndi the converter Where the former means is impractical the latter means should be employed as follows Engage shift levers in forward and high speed and apply brakes Accelerate engine half to three quarter throttle Hold stall until desired converter outlet temperature is reached CAUTION FULL THROTTLE STALL SPEEDS FOR AN EXCES
21. vA mala H 54 4th Clutch Shaft Front Beanng 1 118 Rear Bearing Cap Screw Lockwasher ais 55 Front Driven Gear Thrust Washer 1 119 Rear Bearing Cap Screw 66 Thiust Washer Lock hee eee so oe ek 1 120 Rear Bearing Cap Oi Seal 57 Clutch Driven Gear Bearing asi l 121 Rear Output Flange 58 Front Bearing Cap Screw Lockwasher 4 122 Hange D 59 Front Bearing Cap Screw Wee 4 123 Range Washer isi ere neo diret EN Nit eu sa ses ab a sea rra s 1 124 Flange Nut KEEN WEE Ae EE EEN AC AR TT EE 1 125 Rear Searing Cap Screw A Ee 62 Flange O Ring oret Ai podere E Fin 1 126 Rear Bearing Cap Screw ree ea 63 Front Output Flange ZALLAR LLL 1 64 Front Bearing Cap Ou Seal 1 A R As Required HR24000 4 Speed LD Date Apr 2000 cA p ma 8 c a w zeg si m b et o bb a Maintenance amp Service manual ITEM ZS WN ITEM WN ITEM On Oo P WH ITEM on mo P t NH CLUTCH ASSEMBLY 1ST DESCRIPTION QTY Backing Plate Retaining Ring Clutch Disc Backing Plate Clutch nner Dio A age ER Glutch Outer Disc 7 es CLUTCH ASSEMBLY FO
22. 0 amp HR34000 series having converter lock up or the C270 series converter having lock up UNLESS IT MEETS THE APPROVED C 3 SPECIFICATIONS Any deviation from this chart must have written approval from the application department of the Clark Components Inter national Engineering and Marketing Department Normal drain periods and filter change intervals are for average environmental and duty cycle conditions Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause acceler ated deterioration and contamination For extreme conditions judgment must be used to determine the required change intervals 00 CLARK TROUBLE SHOOTING GUIDE For The R amp HR Model 24000 Transmission The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit It is necessary to consider the torque converter charging pump transmission oil cooler and connecting lines as a complete system when running down the source of trouble since the proper operation of any unit there in depends greatly on the condition and operations of the others By studying the principles of operation together with data in this section it may be possible to correct any malfunction which may occur in the system TROUBLE SHOOTING PROCEDURE BASICALLY CON SISTS OF TWO CLASSIFICATIONS MECHANICAL AND HYDRAULIC MECHANICAL CHECKS Prior to checking any part of the system from a hydraulic
23. 62 on upper right hand screw Remove front oil sealing ring sleeve retainer screw and Tighten screws to specified torque See torque chart washer Remove sleeve lock Figure 335 Using a sleeve puller like the one shown remove sleeve Figure 336 Sleeve being removed NOTE When installing a new sleeve it is recommended a press or a driver be used to prevent damage to the sleeve and be sure the notch in the sleeve is aligned with sleeve lock notch CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning Quid and moved up and down slowly until 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 larger 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 Housings Clean interior and exterior of housings bearing caps etc thoroughly Cast parts
24. Assembly Instructions Fig 1 HR24000 Typical Cross Section Fig J DISASSEMBLY OF TRANSMISSION 1 REASSEMBLY OF TRANSMISSION 42 CLEANING AND INSPECTION 59 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL 60 TOWING OR PUSH STARTING 60 SPECIFICATIONS AND SERVICE DATA 61 LUBRICATION fica EIDEM Cei ed M aa 61 TROUBLE SHOOTING GUIDE 62 CLUTCH AND GEAR ARRANGEMENT 63 POWER FLOW fen cai 0600 ee Raga 7 64 ELECTRIC SOLENOID CONTROL 67 CONTROL WIRING DIAGRAM 68 DRIVE PLATE INSTALLATION 2 00 reii nia SRS tenets 69 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 70 NOTE Metric Dimensions Shown in Brackets Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD HOW THE UNITS OPERATE 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 a
25. B aoa A pma 32 Auxiliary Pump Drive Gear 1 72 Impeller Hub O Ring CCRT i el 33 Pump Mounting Cover Gasket 1 73 impeller Hub Goar 2c EOE ER 1 34 Pump Mounting Cover 1 74 Impeller Hub Gear Bear ng 1 35 Pump Mounting Cover Capscrew Lockwasher 4 75 dier Shaft O Ring r saa arene ajc wena 2 36 Pump Mounting Cover Capscrew 4 ell r hat ooa Sastre diste e dads 2 37 kiler Shaft Lockball 22271522122 2 1 SERS 2 77 Oil Baffle Retaining Ring eg ME 38 Idler Gear Bearing Thrust Plate 2 Fr Sie ENS ones E yeaa kot sise l 39 Idler Gear Bearing Assembly 2 39 4A Eege ial kale dace Wate E NT AR 1 40 toler Gear 57r dE ET 1 80 Ou Baffle Seal Ring 11011111012 Date Apr 2000 HR24000 4 Speed LD Maintenance amp Service manual Figure D Date Apr 2000 Maintenance amp Service manual CLUTCH AND GEAR GROUP ITEM DESCRIPTION QTY ITEM DESCRIPTION 1 Forward Shaft Pilot Bearing 1 65 Front Bearing 665 25 2 Spring Retainer Ring 1 66 Bearing Cap Shim 3 Spring Retainer eu P 1 67 Front Bearing Cap O Ring WEE 4 Piston Return Spring Belleville Washer Ya taa ea g l 7 68 Front Beating Cup 5 Piston Return Spring Spa
26. Battles eee hk Le 1 20 Converter Housing 1 52 Tube Clip Mantes ones De 2 21 Screen Assembly Gasket 1 53 Clip Screw Lockvvasher 1 22 Screen Assembly 1 54 Clip Screvv 1 23 Converter Housing to Transmission 55 Suction Line Assembly O Ring 1 Case Gasket 1 56 Suction Tube Assembly 1 24 Converter Housing to Case Dowel Pin 1 57 Screw Lockvvasher 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 Ring 1 61 High Speed Clutch Pressure Tube 1 29 Tube Sleeve 1 62 Low Speed Clutch Pressure Tube 1 30 Clutch Pressure Tube O Ring 1 63 Dipstick Tube Assembly 1 31 Tube Sleeve at 1 64 Dipstick 1 32 Clutch Pressure Tube O Ring 1 Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD e 34 35 36 2 1 9 33 VIEWEO FROM THIS DIRECTION OUTER RACE FREEWHEELS CLOCKWISE Figure C Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD CONVERTER amp PUMP DRIVE GROUP
27. Figure 194 Compress return spring and install spring retainer ring Figure 195 Install one steel disc Figure 197 Install end plate Figure 198 Install end plate retainer ring 4 Figure 199 Figure 202 Install inner thrust washer locating ring Install clutch gear inner bearing Figure 200 Position lock ball in hole in shaft A small amount of grease Figure 203 will hold ball in place Install bearing spacer m ox Figure 201 Position inner thrust washer on shaft aligning notch in Figure 204 washer with lock ball Install outer bearing mr UE Figure 205 Figure 208 Install clutch driven gear and hub into clutch drum Align Install clutch shaft front bearing NOTE Bearing outer splines on clutch hub with internal teeth of friction discs diameter locating ring groove must be up Figure 206 Figure 209 Position lock ball in hole in shaft Install bearing retainer Figure 207 Figure 210 Position outer thrust washer on shaft aligning notch in Install clutch shaft oil sealing rings Grease rings to washer with lock ball facilitate reassembly into front housing FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 214 Compress piston return springs Belleville washers Remove return spring retainer ring and ring retainer Figure 211 Remove clutch disc end plate retainer ring Figure 215 Remove piston return springs Belleville washers
28. Figure 212 pe Remove end plate i Figure 213 Figure 216 Remove inner and outer clutch discs Remove piston spacer Figure 217 Remove clutch piston Remove clutch shaft oil sealing rings and expander springs Figure 220 Position piston return spring spacer over clutch shaft See cleaning and inspection page FORWARD CLUTCH REASSEMBLY Figure 221 Install Belleville washers First washer with large diameter toward spacer Alternate seven 7 washers See Figure Figure 218 222 A Install clutch piston outer and inner seal rings Size as explained in Figure 98 Figure 222 Install piston return spring retainer ring retainer and Figure 219 retainer ring on clutch shaft Compress return springs and Install clutch piston in clutch drum Use caution as not to install retainer ring Be sure ring is in full position in damage seal rings retainer PISTON REV Figure 222 A Figure 225 Install clutch disc end plate Figure 226 Install end plate retainer ring Install new expander springs Figure 223 and clutch shaft oil sealing rings Install one steel disc OUTPUT SHAFT DISASSEMBLY Figure 224 Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next Figure 227 to the piston is steel last disc installed is friction Remove rear taper bearing OUTPUT SHAFT REASSEMBLY 2 Fig
29. ION QTY Clutch Piston Seal Inner 1 Clutch Piston Seal Outer 1 Clutch Piston 2nd 1 Gluten Outer Disc es 6 Clutch Inner Disc 6 Clutch Disc Backing Plate 1 Backing Plate Retaining Ring 1 Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD S SE Ne LESS DECLUTCH o 20 2 PUS 53 78 e FORW V ARO ENCE REV 9M 1 D Pa SE ae l 53 18 55 i 40 AT Ba pog f a f 5 lt 1 5 55 54 E E 5 2 d 2 EZ 5 rx T T R 1 7 L Figure F Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD CONTROL VALVE ASSEMBLY ITEM DESCRIPTION 400 P WN a a et a 00 o o P WN N N N NY N N Oo P O Valve Plug Forward amp Reverse Shift Spool Spool Position Spring Forward amp Reverse Shift Spool Ground Wire Harness Receptacle Mounting Screw Receptacle amp Wire Assembly Dust Cover Mounting Stud Lockwasher Dust Cover Mounting Stud Nut Grommet Dust Cover Mounting Stud Valve Spool Stop Control Valve Housing ml Shuttle Valve to Electric Control Gasket Port Plug i i te Eden Spool Stop
30. RWARD DESCRIPTION OTY Backing Plate Retaining Ring Clutch Disc Backing Plate Clutch Inner Disc Clutch Outer Disc i CLUTCH ASSEMBLY 4TH amp 3RD DESCRIPTION QTY Backing Plate Retaining Ring Clutch Disc Backing Plate Clutch Inner Disc Clutch Outer Disc Ath amp 3rd Clutch Drum Assembly CLUTCH ASSIEMBLY REVERSE 2ND DESCRIPTION QTY Backing Plate Retaining Ring Clutch Disc Backing Plate Clutch Inner Disc Clutch Outer Disc Clutch Piston Reverse Clutch Piston Seal Outer Clutch Piston Seal Inner Reverse amp 2nd Clutch Drum Assembly cese sme e 1 1 1 1 ITEM on O O ITEM 5 6 7 8 ITEM 9 10 11 12 13 14 15 ITEM 9 10 11 12 13 14 15 HR24000 4 Speed LD DESCRIPTION QTY Clutch Piston 1 Clutch Piston Seal Outer 1 Clutch Piston Seal Inner 1 1st Clutch Drum Assembly 1 DESCRIPTION QTY Clutch Piston 1 Clutch Piston Seal Outer 1 Clutch Piston Seal Inner 1 Forward Clutch Drum Assembly 1 DESCRIPTION QTY Clutch Piston Seal Inner 1 Clutch Piston Seal Outer 1 Clutch Piston 3rd 1 Clutch Outer Disc 6 Clutch Inner Disc 6 Clutch Disc Backing Plate 1 Backing Plate Retaining Ring 1 DESCRIPT
31. SIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER UTCH PRESSURE Remedy Fill to proper level Clean valve spool and housing Replace pump Replace sealing rings Clean bleed valves thoroughly m LOW CONVERTER CHARGING PUMP OUTPUT 1 Low oil level 2 Suction screen plugged 3 Air leaks at pump intake hose and connections or collapsed hose R24000 only 1 Fill to proper level 2 Clean suction screen 3 Tighten all connections or replace hose if necessary 4 Defective oil pump 4 Replace pump OVERHEATING 1 Worn oil sealing rings 1 Remove disassemble and rebuild converter assem bly 2 Worn oil pump 2 Replace 3 Low oil level 3 Fill to proper level 4 Pump suction line taking air R24000 only 4 Check oil line connections and tighten securely NOISY CONVERTER 1 Worn oil pump 1 Replace 2 Worn or damaged bearings 2 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 7 1 22 2 ud r UPS A N4 Cl lt 2 N Up 2 ANZ 1 7 FENN S Ga Nani ROE N NAME K HR 24000 4 SPEED TRANSMISSION HR 24000 4 SPEED TRANSMISSION CLARK
32. Tighten to specified torque See torque chart Figure 287 Position charging pump drive gear bearing and support in housing Install support screws and washers tighten to specified torque See torque chart Figure 288 Position pump drive idler gear and bearing on idler gear stub shaft Install idler gear to stub shaft retainer ring Figure 289 If bearing was removed press turbine shaft bearing into position NOTE Bearing outer locating ring groove down Install bearing washer and retainer ring Install new turbine shaft oil sealing ring Spread ears on turbine shaft bearing retainer ring located in reaction member support Tap turbine shaft and bearing into position being certain bearing snap ring is in full position in snap ring groove Figure 290 With new O ring on shaft position reverse idler shaft in housing Align groove in shaft with notch in housing Install lock ball Figure 291 Tap shaft into position use caution as not to lose lock ball Figure 292 Install shaft spacer Figure 293 Figure 296 Install inner taper bearing on shaft with large diameter of Install shaft retainer nut Tighten nut 200 to 250 ft Ibs taper down Position bearing spacer on shaft torque 271 2 338 8 N m 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 notc
33. a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter This element receives fluid at its outer diameter and discharges at its center Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero RPM Therefore we can say that as the output shaft is decreasing in speed the torque multiplication is increasing The shift control valve assembly consists of a valve body with selector valve spools A detent ball and spring in the selector spool provides one position for each speed range A detent ball and spring in the direction spool provides three positions one each for forward neutral and reverse With the engine running and the directional control lever in neutral position oil pressure from the regulating valve is blocked at the
34. and or reverse will not give a true reading ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS RECOMMENDED LUBRICANTS FOR CLARK POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS See Lube Chart Consult Operator s Manual on applicable machine model for system capacity Torque Converter Transmission and allied hydraulic system must be considered as a whole to determine capacity Check oil level DAILY with engine running at 500 600 RPM and oil at 180 to 200 F 182 2 93 3 C Maintain oil level to FULL mark Every 500 hours change oil filter element Every 1000 hours drain and refill system as follows Drain with oil at 150 to 200 F 165 6 93 3 C NOTE It is recommended that filter elements be changed after 50 and 100 hours of op eration on new and rebuilt or repaired units a Drain transmission and remove sump screen Clean screen thoroughly and replace using new gaskets b Drain oil filters remove and discard filter elements Clean filter shells and install new elements Refill transmission to LOW mark d Run engine at 500 600 RPM to prime converter and lines Prevailing Ambient Temperature a C 2 Grade 30 Temperature b C 3 Grade 30 Range 1 c Engine Oil Grade 30 API CD SE or CO SF d MIL L 2104C Grade 30 e MIL L 21040 Grade 30 a MIL L 2104C Grade 10 b MIL L 2104D Grade 10 Temperature sige c C 2 Grade 10 Range d C 3 Grade 10 te Engin
35. cer 1 69 Front Bearing Cone 6 Forward Clutch Shaft Drum amp Plug Assembly _ 1 70 Forward Shaft 7 Piston Ring Expander Spring uc 3 71 Gear Retaining Ring B Forward Shaft Piston Ring 3 72 1st Speed Clutch Shaft Front Bearing 9 Piston Ring Sleeve Retaining Ring 1 73 Front Bearing Spacer e 10 Piston Ring Sleeve LURKER IDEO FRA l 74 1st Speed Shaft Rear Bearing ewe he 11 Forward Shaft Rear Bearing TE 75 1st Speed Gear Bearing Loceting Ring d 12 Reverse amp 2nd Shaft Piston Ring vie RO kB 76 1st Speed Gear Bearing Spater 13 Front Bearing Retaining Ring 1 77 1st Gear 8 Hub Assembly sess 14 Front Bearing Snap Ring 1 78 Baffle Ring i 15 Reverse amp 2nd Shaft Front Bearing 1 79 Low Speed es Bearing Ring 16 Front Bearing Retaining Ring hee not 1 80 Low Speed Gear Bearing 17 Clutch Driven Gear Bearing Medi pi 1 81 Belleville Washer Retainer biq A 18 Reverse Clutch Gear amp Hub Assembly 1 82 Spring Retainer Snap Ring d s 19v ao a 2212209202 1 ES M lodie Washers io Fie VA a s n 20 Spring Retaining Snap Ring 1 84 Belleville Washer Spacer
36. ch over and tap clutch shaft on a block of wood to remove clutch piston See cleaning and inspection page 1st CLUTCH REASSEMBLY e A 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 a round object against the new seal ring as shown Rotate piston until seal ring is flush with outer diameter of piston 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 A Figure 99 Install clutch piston inner seal and size as explained in Figure 98 Figure 103 Install piston return spring Belleville washers retainer ring Figure 100 on clutch shaft Position piston in 1st clutch drum as shown Use caution as not to damage inner and outer piston sealing rings Figure 104 Using sleeve with the proper inner diameter drive the Figure 101 Belleville washer ring into position NOTE Be certain Position piston return spring spacer over clutch shaft retainer ring is in full position in ring groove ee Figure 107 Install one friction disc NOTE The friction discs in the low Figure 105 clutch has a higher co efficient rating than the friction discs Position ring retainer washer over retainer ring in the other clutches therefore the discs must not be mixed T
37. e Oil Grade 10 API CD SE or CD SF f Quintolubric 822 220 Non Phosphate Ester Fire Tempeciture beten Resistant Fluid Range b Dexron l See Caution Below Temperature a MIL L 46167 Range b MIL L 46167 A Temperatur gies ai 5 a Conoco Polor Start DN 600 Fluid NOTES Temperature ranges 2 and 3 may be used to lower Dexron is registered trademark of General Motors Corporation e Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil tempera ture is hot 180 200 F 82 2 93 3 C make final oil level check BRING OIL LEVEL TO FULL MARK ambient temperatures when sump preheaters are used Temperature range 4 should be used only in ambient temp erature range shown MODULATED SHIFT TRANSMISSIONS H125 H200 H500 H600 18000 24000 28000 32000 amp 34000 series transmis sions with modulated shift use only C 3 or temperature range 3 items a amp b Dexron or Dexron l D SEE CAUTION BELOW 3000 4000 5000 6000 8000 amp 16000 series transmissions with modulated shift use only C 3 ortemperature range 3 items a only Dexron Do NOT use Dexron Il D SEE CAUTION BELOW CAUTION Dexron l D is not compatible with graphitic clutch plate friction material UNLESS IT MEETS THE APPROVED C 3 SPECIFICATIONS Dexron I D cannot be used in the 3000 4000 5000 6000 8000 or 16000 series power shift trans missions or the HR28000 HR3200
38. ealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn 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 a thin coat of Permatex No 2 on the outer diameter of the oil seal to assure an oil tightfit 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 O 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 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 hone 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 all parts caref
39. eed LD Filter Se back Check Point A A b Heat Exchanger Outlet Temperature A Port A HR MODEL Bi Output Rear Output Front Auxiliary Pump Drive Breather Port M SEE NOTE Port L SEE NOTE Port J Port J Check Point C C Heat Exchanger Inlet Temperature Check Point Ban Heat Exchanger Outlet Pressure Port A Lube Pressure Check Point 15 25 PSI 104 172 kPa at 2000 RPM and 180 200 F 82 93 C at Converter Outlet FRONT VIEW Figure H Parking Brake Option Port K Converter Inlet Pressure Check Point Dipstick 1st Clutch Pressure Check Point Steering Pump Drive amp Mounting Option Port U Drain Piugs or Optional Vendor Dipstick Ports REAR VIEW Date Apr 2000 Maintenance amp Service manual i ae HR24000 4 Speed LD Charge Pump for Remote Filter Option REMOTE FILTER OPTION Port Check Point for Forward Regul Modulated Clutch M Port G Port H Oil Screen Notes Hose Line Operating Requirements 1 Pressure Lines Suitable for operation from ambient to 250 F 121 C continuous operating temperature Must withstand 300 PSI 2068 kPa continuous pr
40. el housing aligning drive plate to flywheel and transmission to fly wheel housing NOTE Fig 4 installation align drive plate holes with flywheel studs 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 7 Install drive plate attaching screw and washer Snug screw but do not tighten NOTE Fig 4 in stallation install drive plate attaching washers and SPECIAL STUD WASHER AND nuts Tighten each nut 28 to 30 ft lbs torque BY ENGINE MANUFACTURER 38 0 40 6 N m Some engine flywheel housings have a hole located on the flywheel housing cir cumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate in stallation of the drive plate screws Rotate the en gine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed torque each one 25 to 30 ft Ibs torque 33 9 40 6 Nm This will require torquing each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened 2772777357 P 22 CU ESSI 8 Measure engine crankshaft end play after transmis sion has been completely installed on engine fly wheel Thi
41. essure with 600 PSI 4137 kPa intermittent surges Ref SA E Spec No J517 100R1 Hydraulic Hose Specifications 2 See Lubrication Specifications 3 All hose lines used must conform to SAE Spec No J 1019 Tests and Procedures for High Temperature Transmission Oil Hose Port L Converter Outlet Temperature Port is to be used for Converter Outlet Temperature pick up Gauge is to be located in the Operator Compartment See Oil Temperature Gauge Specifications Port M Converter Outlet Pressure Pressure must be measured during normal vehicle Production Line test Converter outlet pressure equals the total pressure drop of the Heat Exchanger Heat Exchanger Lines and back pressure of the transmission lubrication system Figure H F ator Valve Pressure 240 280 PSI 1655 1931 kPa Forward Clutch Pressure Reverse Clutch Pressure Modulated Reverse Clutch Pressure Port on Modulator Valve Oil Temperature Gauge Specifications 1 Normal Operating Temperature 180 250 F 82 121 C 2 Red Lined Temperature 2509F 121 C Test Conditions 1 Converter Outlet Oil Temperature 180 220 F 82 104 C 2 Transmission in Neutral Operating Specifications 1 25 PSI 173 kPa Min pressure at 2000 RPM engine speed and a max of 70 PSI 483 kPa outlet pressure at a no load governed speed Ports A F K L and M These ports can be used for field Trouble Shooting or vehicle Production Line tests Ports F
42. eturn spring retainer ring Figure 181 Remove spring retainer and spring EN b b b Figure 182 Remove clutch piston See cleaning and inspection page REASSEMBLY OF 3rd SPEED CLUTCH ll 3 8 aa a Figure 183 Install clutch piston outer and inner seal rings Size as explained in Figure 98 P N Figure 184 Install clutch piston in clutch drum Use caution as not to damage seal rings Figure 185 Position return spring and spring retainer on clutch shaft Figure 186 Compress return spring and install spring retainer ring 32 Figure 187 Figure 190 Install one steel disc Install end plate retainer ring REASSEMBLY OF 4th SPEED CLUTCH Figure 188 Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next Figure 191 to the piston is steel last disc installed is friction Install clutch piston outer and inner seal rings Size as explained in Figure 98 Figure 192 Figure 189 Install clutch piston in clutch drum Use caution as not to Install end plate damage seal rings 4 Figure 196 Figure 193 Install one friction disc Alternate steel and friction discs Position return spring and spring retainer on clutch shaft until the proper amount of discs are installed First disc next to the piston is steel last disc installed is friction
43. f the hydrau lic system the engine cannot be started by pushing or towing CONVERTER OUT PRESSURE CONTROLS CLUTCH TYPE CLUTCH INNER DISC CLUTCH OUTER DISC TYPE OF OIL CAPACITY CHECK PERIOD NORMAL DRAIN PERIOD SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER Converter outlet oil temp 180 200 F 82 3 93 3 C Transmission in NEUTRAL Operating specifications 25 P S I 172 4 kPa minimum pressure at 2000 R P M engine speed AND a maximum of 70 P S I 1482 6 kPa outlet pressure with engine operating at no load governed speed Forward and Reverse Manual Speed Selection Manual Multiple discs hydraulically actuated adjustment All clutches oil cooled and lubricated Friction Steel spring released automatic wear compensation and no OIL FILTRATION CLUTCH PRESSURE LUBRICATION Full flow oil filter safety by pass also strainer screen in sump at bottom of transmission case 240 280 psi 1654 8 1930 5 kPa With parking brake set see note oil temperature 180 200 F 82 2 93 3 C engine at idle 400 to 600 RPM shift thru direction and speed clutches All clutch pressure must be equal within 5 psi 34 5 kPa If clutch pressure varies in any one clutch more than 5 psi 34 5 kPa repair clutch NOTE Never use service brakes while making clutch pressure checks Units having brake actuated declutching in forward
44. f used remove auxiliary pump drive gear cover and gasket Remove the charging pump drive gear support bolts 14 Figure 81 Remove drive gear and support assembly Figure 82 Remove the auxiliary pump drive gear support bolts Figure 83 Remove auxiliary pump drive gear Figure 84 If stator support is to be replaced remove support screws and tap support from housing See Figure 333 for oil sealing ring sleeve removal 1st CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 85 Remove front bearing Figure 86 Remove bearing spacer 16 Figure 87 Figure 90 Remove low gear and outer bearing Remove inner and outer clutch discs Figure 88 Figure 91 Remove clutch disc end plate retainer ring Remove inner and outer bearing spacer DIY Figure 89 Figure 92 Remove end plate Remove low gear inner bearing 16 Figure 93 Remove piston return spring Belleville washer retainer ring retainer ae f Figure 94 Remove return spring retainer ring Figure 95 Remove return springs Belleville washers NOTE Belle ville washers in the 1st clutch are different than washers in the forward and reverse clutch 1st clutch washers have 4 four holes in them for identification only Do not mix 1st clutch washers with forward and reverse washers S Figure 96 Remove piston spacer Figure 97 Turn clut
45. g retainer ring Figure 118 Figure 121 Remove front bearing Remove reverse gear and bearing spacer 21 Figure 122 Remove clutch end plate retainer ring Figure 123 Remove end plate Figure 124 Remove inner and outer clutch discs E Figure 125 Remove inner reverse gear taper bearing Figure 126 Compress piston return springs Belleville washers Remove return spring retainer ring and ring retainer Figure 127 Remove piston return springs Belleville washers 22 Figure 128 Figure 131 Remove piston spacer Remove end plate lt lt Figure 129 Remove clutch piston Figure 132 Remove inner and outer clutch discs DISASSEMBLY OF 2nd SPEED CLUTCH Figure 133 Figure 130 Compress piston return spring retainer Remove retainer Remove end plate retainer ring ring Figure 134 Remove spring retainer and return spring Figure 135 Remove clutch piston See cleaning and inspection page 2nd CLUTCH REASSEMBLY Figure 136 Install clutch piston outer and inner seal rings Size rings as explained in Figure 98 OE Figure 7 Install clutch piston in clutch drum Use caution as not to damage seal rings E Figure 138 Position piston return spring and spring retainer on clutch shaft o Figure 139 Compress spring and install retainer ring Figure 140 Figure 143 Install one steel disc Install end plate retainer ri
46. h Figure 298 Figure 295 With new O ring on shaft position idler shaft in housing Position outer spacer on shaft Align groove in shaft with notch in housing Install lock ball Gi Figure 299 Tap shaft into position use caution as not to lose lock ball Figure 300 Install idler shaft spacer Figure 301 Install idler gear inner taper bearing on shaft with large diameter of taper down Position bearing spacer on shaft 52 Figure 302 Spread ears on reverse clutch front bearing locating ring Tap reverse and 2nd clutch assembly into converter 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 ring groove 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 and the 4th clutch assembly must be installed in the converter housing at the same time as the idler gear must be positioned between the clutch front bearing and the clutch drum Install the idler outer taper bearing with small diameter of taper down Make sure locating ring is in full position in ring groove Figure 305 Repeat procedures shown in Figures 295 thru 297 Figure 306 Position pilot bearings on 2nd and 3rd clutch shafts a light coat of grease will hold pilot bearings in place Figure 307
47. he low clutch friction disc has a yellow mark of nonsoluble paint on the outer diameter for permanent identification Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last PISTON disc installed is friction Figure 105 A Cross section of 1st clutch Figure 108 Install clutch disc end plate Figure 106 Figure 109 Install one steel disc Install end plate retainer ring u Figure 110 Install clutch gear inner bearing NOTE This bearing does not have shield in it Figure 113 Install clutch gear outer bearing NOTE Outer bearing has a shield in it this shield must be up Figure 111 Position bearing spacer on clutch shaft Figure 114 Position front 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 be in full position with internal teeth of all Figure 115 friction discs Install front bearing REVERSE AND 2nd CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY Reverse being disassembled Figure 119 Remove clutch gear bearing retainer ring Figure 116 Remove clutch shaft oil sealing rings Figure 120 Pry reverse gear from clutch assembly far enough to use a gear puller A Figure 117 Remove front bearin
48. isassembled Figure 153 Remove end plate retainer ring Figure 154 Remove end plate Figure 157 Install front bearing retainer ring Figure 160 Remove front bearing retainer ring Ss Figure 158 Install clutch shaft oil sealing rings Grease rings to facilitate reassembly into front housing 3rd AND 4th SPEED CLUTCH DISASSEMBLY AND REASSEMBLY Figure 161 Remove front bearing DISASSEMBLY 4th being disassembled Figure 159 Figure 162 Remove clutch shaft oil sealing rings Remove gear front thrust washer 28 Figure 163 Remove thrust washer lock ball Figure 164 Remove clutch gear and disc hub Figure 165 Remove clutch gear outer bearing Figure 166 Remove bearing spacer Figure 167 Remove inner bearing Figure 168 Remove gear rear thrust washer Figure 169 Remove thrust washer lock ball Figure 172 Remove end plate Figure 170 Remove thrust washer locating ring Figure 171 Remove clutch disc end plate retainer ring Figure 173 Remove inner and outer clutch discs Figure 174 Remove clutch disc return spring retainer ring 30 Figure 175 Figure 178 Remove spring retainer and spring Remove end plate Figure 176 Remove clutch piston Figure 179 Remove inner and outer clutch discs DISASSEMBLY OF 3rd SPEED CLUTCH Figure 177 Figure 180 Remove end plate retainer ring Remove r
49. litate Install 1st clutch rear bearing spacer alignment of rear cover to housing Figure 258 Install 1st clutch rear bearing NOTE Bearing locating ring Figure 261 groove must be out Position lock ball in idler rear bearing Figure 262 Align lock ball in idler shaft rear bearing with notch in rear transmission cover Tap cover in place and secure with Install bearing retainer ring bolts and washers Remove aligning studs Figure 259 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 O ring in position install bearing cap aps Figure 266 Install bolts and washars and tighten to specified torque See torque chart Figure 267 From the front tap the idler shaft to the rear until the rear bearing locating ring groove is exposed Install locating ring Figure 268 From the front tap the 1st clutch to the rear until the rear bearing locating ring groove is exposed Install locating ring OUTPUT SHAFT ROLLING TORQUE PROCEDURE Bearing Preload Figure 269 Position new O ring and gasket on 1st clutch rear bearing Figure 272 cap Tap output shaft front
50. nd 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 SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Desi EE Fig A Converter and Transmission Case Group Fig B Converter Gro pia d uus sam en Soe ee RD AIMER a ere Fig E Four Speed Clutch and Gear Group Fig D Clutch Groups lt Les X Reap COE ee Ve oso wets al m Fig E Control Valve Assembly Fig F Charging Pump and Regulating Valve Group Fig G External Plumbing and Pressure Check Points Fig H Assembly Instructions Fig HR24000 Typical Cross Section Fig J 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 powershlft 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
51. ner friction plates Alternately assemble starting with outer steel plate 12 outer steel plates 12 inner friction plates Alternately assemble starting with outer steel plate Special bearing loading notches opposite snap ring Bend lock tabs after tightening cap screws to proper torque Tighten oil screen assy 10 to 15 Lbs Ft 13 6 20 3 N m Low Forward and Reverse Clutch Springs Concave side of first Belleville spring to be placed against clutch piston Remaining six springs of each clutch to be stacked alternately reversed as shown Shim output shaft bearings to produce 6 to 8 Lbs in 0 68 0 90 N m pre load Clean mounting surfaces and tapped holes with solvent Dry thoroughly being certain tapped holes are dry and clean See text for proper installation Tighten 200 250 Lbs Ft 271 2 338 9 and stake nut securely into shaft notch Stator support screw assembly View S 1 Clean stator support mounting surface and tapped holes with solvent Dry thoroughly being certain tapped holes are clean and dry 2 Install 6 special stator support screws Tighten screws 12 to 16 Lbs Ft 16 3 21 6 N m torque See Caution Torque Specification for Lubricated Caution HR24000 4 Speed LD Notes All lead in chamfers for oil seals piston rings and O rings must be smooth and free from burrs Inspect at assembly Lubricate all piston ring grooves and O
52. ng REVERSE CLUTCH REASSEMBLY Figure 141 Install one friction disc Alternate steel and friction discs until 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 as explained in Figure 98 Figure 145 Figure 142 Install clutch piston in clutch drum Use caution as not to Install clutch disc end plate damage seal rings Figure 146 Figure 149 Install one steel disc Install end plate retainer ring Figure 147 Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next Figure 150 to the piston is steel last disc installed is friction Position piston return spacer over clutch shaft Figure 151 Install Belleville washers First washer with large diameter Figure 148 toward spacer Alternate seven 7 washers See Figure Install clutch disc end plate 152 A EL Figure 149 Install clutch disc end plate Figure 150 Install end plate retainer ring Figure 151 Install new piston ring expander springs per instructions on page 50 27 b 1111 Siilil ME Figure 152 Install piston rings on clutch shaft per instructions on page 50 3 each on standard converter 4 each with lock up converter REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY DISASSEMBLY 2nd clutch being d
53. ng on engine NOTE if Loctite 747 Primer T is not used allow 24 hours for the threadlocker to cure before installing on engine Position drive plate and weld nut assembly on impeller cover studs with weld nuts toward cover Align intermediate drive plate and backing ring with studs in impeller cover NOTE Two dimples 180 apart in backing ring must be out toward engine flywheel Install washers and stud nuts With a calibrated torque wrench tighten nuts 26 to 29 ft Ibs torque 35 3 39 3 N m Over for TRANSMISSION TO ENGINE INSTALLATION PROCEDURE CLARK TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 1 Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface with solvent 2 Check engine flywheel and housing for conform ance to standard S A E 3 S A E J 927 tolerance specifications for pilot bore size pilot bore runout and mounting face flatness Measure and record engine crankshaft end play 3 Install two 2 50 163 50 mm long transmission to flywheel housing guide studs in the engine fly wheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole 4 Install a 4 00 1101 60 mm long drive plate locat ing 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 posi tioned in step No 3 5 Locate transmission on flywhe
54. otal 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 This 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 a closed position When a specific pressure is achieved the valve spool works against the spring until a port is exposed along the side of the bore This sequence of events provides the proper system pressure After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support The oil then flows out of the converter to the oil cooler After leaving the cooler the oil is directed to a lubricating fitting on the transmission and through a series of tubes and passages lubricates the transmission bearings and clutches The oil then gravity drains to the transmission sump The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to
55. pproved 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 All 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 amp Service manual HR24000 4 Speed LD TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design is ues mey an Gee Wee eas s saa as qlin Fig A Converter and Transmission Case Group Fig B Converter Groupen oeiee 77 Fig C Four Speed Clutch and Gear Group Fig D Clutch 0105000000 Fig E Control Valve Assembly Fig F Charging Pump and Regulating Valve Group Fig G External Plumbing and Pressure Check Points Fig H
56. ptor EES 10 Pump Mounting Stud Lockvvasher 11 Pump Mounting Stud Nut 12 bilter Assembly 13 Valve to Pump Capscrevv 14 Valve to Pump Capscrew Lockvvasher 15 Valve to Pump Capscrew 16 Valve to Pump Screw Lockwasher 17 Valve to Pump Gasket 18 Thrust Plate amp Bearing Assembiy 19 Pump Driven Shaft Assembly 20 Thrust Plate amp Bearing Assembly Z1 Wave ODEN nce oS bbs ITEM DESCRIPTION QTY Plete SEES 23 Pump Drive Shaft Assembly 24 Pipe EE 25 Pump Mounting Stud 26 Pump Drive Gear Oil Seal 27 Pump Mounting Screw Lockvvasher 28 Pump Mounting Screw 29 Safety Valve Spacer 30 Safety Valve Poppet 31 Safsiy Valve Seat eue sssi 32 Safety Valve Spring 33 Safety Valve Retainer 34 Pump Assembly to Converter Housing Gaskets raz eR 35 P mpB dy Lente 36 Valve Mounting Screw 37 Valve Mounting Screw Lockwasher 38 High Clutch Pressure O Ring 39 Valve to Converter Housing Gasket 40 Control Valve Assembly 41 Valve Mounting Screw Lockwasher 42 Valve Mounting Screw Date Apr 2000 Maintenance amp Service manual CONVERTER LOCK UP OPTION Port 0 Heat Exchanger Charge Pump HR24000 4 Sp
57. r on shaft with long hub of gear Align clutch oil sealing ring sleeve with notch in case Tap down sleeve into position Figure 246 Figure 248 A 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 shaft Install idler shaft front bearing D Figure 248 Position forward shaft gear on rear of clutch shaft with long hub of gear toward bearing Install gear retaining ring See Figure 250 figure 248 A Install 1st clutch assembly in case pan Figure 254 Install bearing cap capscrews and washers tighten to specified torque See torque chart Figure 251 Install idler shaft assembly into front bearing Figure 252 Figure 255 Install output shaft front bearing taper bearing cup with Position oil baffle in transmission sump large diameter of taper in Figure 253 Coat outer diameter of oil seal with Permatex 2 and press p seal 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 oil seal 44 Figure 260 Position a new gasket and O ring on rear of housing A Figure 257 light coat of chassis grease will hold the gasket in place g Install two aligning studs in housing this will faci
58. re 17 Remove turbine hub to impeller cover bearing retainer ring Figure 18 Tap turbine and hub from impeller cover Figure 19 Remove impeller cover bearing IMPELLER COVER AND TURBINE REASSEMBLY See cleaning and inspection page Figure 20 Install impeller cover bearing in cover with bearing locating ring up H the turbine or turbine hub was replaced or dis assembled this procedure must be used for reassembly TURBINE HUB ASSEMBLY WITH BACKING RING AND SPECIAL SELF LOCKING 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 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 N m NOTE Assembly of turbine hub must be completed within a fifteen minute period from start of screw installation 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 special screw is to be used for one installation only If the screw is removed 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 use a new screw for reinstallation Figure 21 Position turbine as
59. re 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 discs 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 or bleed orifices depending upon the model in the clutch piston which allow quick escape for oil when the pressure to the piston is released H mo EI ES FWD Kap j A dak E 3 okey ey ee Fi WW Ext ant Eie t TW Di WS 5 E Es Sech m REV 2nd Ist n 1 d x k ji 1 T Yara _ MH 6 5 o ce Sl Pore I Sma NA 1 ia X E qan n 3 j SCH A uz m k Failte sox x FAT T ar tp nde 1 H 1 A E m pua I P Fi x 17 7 M sy 5 3 FIGURE A Date Apr 2000 HR24000 4 Speed LD Maintenance amp Service manual Figure B Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD CONVERTER AND TRANSMISSION CASE GROUP ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY l Pips Pl ge Sie restent demandant 2 33 Clutch Pressure Tube O Ring 1 2 Air Breather 1 34 Tube Sleeve
60. s value must be within 001 0 025mm of the end play recorded in step No 2 K Does not apply to units having 3 intermediate drive plates See Fig 4 HD
61. sembly in impeller cover 2 Be Figure 25 Figure 22 Remove reaction member NOTE Some units will have a Install turbine hub to impeller cover bearing retainer ring fixed reaction member and some units will have a free wheeling reaction member The fixed is a one piece and the freewheeling is an assembly Remove as an assembly Figure 23 Figure 26 Remove turbine locating ring from turbine shaft Remove reaction member spacer Figure 24 Figure 27 Remove reaction member retainer ring Remove impeller and hub assembly Figure 31 Figure 28 Seperate converter housing from transmission case Remove oil baffle retainer ring assembly NOTE Reverse second third and fourth clutches will remain in the converter housing Figure 29 Figure 32 Pry oil baffle from housing NOTE A resistance will be Remove 3rd speed clutch disc hub snap ring retainer outer noted because of the heavy oil sealing ring ring and retainer Figure 30 Support converter housing with a chain hoist Remove Figure 33 converter housing to transmission case bolts Remove disc hub retainer ring and disc hub Figure 34 Remove 2nd speed clutch disc hub snap ring retainer outer ring and retainer Figure 35 Remove disc hub retainer ring and disc hub Figure 36 Using an impact wrench if available if not a flange retainer bar must be used to hold the companion flange from turning loosen output flange nut Remove nut washer
62. shaft See Fig A for basic design silhouette The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover or remote mounted and connected to the transmission by means of flexible hoses The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch A provision is made on certain models to neutralize the transmission when the brakes are applied This is accomplished through use of a brake actuated shutoff valve The speed and direction clutch assem blies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft The purpose of the speed or directional clutches is to direct the power flow through the 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 Date Apr 2000 Maintenance amp Service manual HR24000 4 Speed LD With the engine running the converter charging pump draws oil from the transmission sump through the removable oil suction screen and directs it through the oil filter and the pressure regulating valve The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc tion and speed clutches This requires a small portion of the t
63. steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes On remote mounted torque converters remove drain plug from torque converter and inspect interior of converter housing gears etc If presence of considerable foreign material is noted it will be necessary that converter be re moved disassembled and cleaned thoroughly t is realized this entails extra labor however such labor is a minor cost compared to cost of difficulties which can result from presence of such foreign material in the system Reassemble all components and use only type oil recommended in lubrication section Fill transmission through filler opening until fluid comes up to LOW mark on transmission dipstick Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines Re check level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to LOW mark on dipstick Recheck with hot oil 180 200 F 82 2 93 3 C Bring oil level to FULL mark on dipstick Recheck all drain plugs lines connections etc for leaks and tighten where necessary TOWING OR PUSH STARTING Before towing the vehicle be sure to lift the rear wheels off the ground or dis connect the driveline to avoid damage to the transmission during towing 80 NOTE If the transmission has 4 wheel drive disconnect both front and rear drive lines Because of the design o
64. t the filter cartridge be changed after 50 and 100 hours Position the impeller cover bearing cap on bearing of operation on new and rebuilt or repaired units Figure 327 To install the control valve assembly it is recommended two Figure 324 aligning studs be used Position new modulator valve to See special section on page 69 for drive plate installation housing gasket on housing Install valve assembly Figure 325 With a new gasket in place install the charging pump Figure 328 assembly on mounting studs Install washers nuts and Position a new modulator to control valve gasket and install capscrews Tighten to specified torque See torque chart control valve assembly 2 Figure 332 Figure 329 If the auxiliary pump drive is not used position a new gasket Position new shuttle valve gasket on control valve Install and cover on opening Install bolts and washers and tighten shuttle valve assembly on control valve to specified torque See torque chart OIL SEALING RING SLEEVE REMOVAL NOTE The following photos are not of the HR Converter Housing but the sleeve removal procedure is identical Figure 330 Connect the pressure line from the shuttle valve to the control valve Connect the wires from the control valve to the shuttle valve solenoid Figure 333 Remove clutch front bearing retaining ring Figure 331 Install control valve to housing screws and lockwashers Figure 334 NOTE Use Loctite 2
65. to trouble shoot disassemble repair and reassemble CAUTION Cleanliness is of extreme importence and an absolute must in the repair and overhaul of this 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 Side view of the HR24000 4 speed transmission with electric control valve and modulation Figure 2 Remove oii titer element It is recommended a small pan be used to catch remaining oil in element Figure 3 Remove pressure regulating valve and charging pump Screws stud nuts and washers Figure 4 Remove regulating valve and pump assembly Figure 5 Figure 8 Disconnect shuttle valve cross over tube Remove shuttle valve assembly Figure 6 Remove two valve to converter housing cap screws Install Figure 9 two aligning studs Remove remaining cap screws Remove control valve assembly Figure 7 Figure 10 Remove shuttle valve solenoid wires Remove modulator valve assembly Figure 11 Remove drive plate attaching cap screws Some units will have stud nuts and washers Figure 12 Remove drive plate and backing ring Figure 13 Remove impeller cover bearing cap Figure 14 Remove turbine hub to turbine shaft retainer ring Figure 15 Remove impeller cover to impeller cap screws Figure 16 Remove impeller cover and turbine as an assembly Figu
66. ully for evidence of cracks or condition which would cause subsequent oil leaks or failures 59 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the drive line between the engine and the wheels The proper oper ation of either unit depends greatly on the condition and operation of the other therefore whenever repair or 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 installed in the machine the oil cooler and con necting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a de gree of judgment must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain engine system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter elements cleaning out filter cases thoroughly 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been 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
67. ure 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 TIT Figure 233 See cleaning and inspection page Position output gear on shaft with long hub of gear up 40 25 Figure 237 Remove small idler gear NOTE Soma special ratio units will have only one idler gear Install output shaft rear taper bearing large diameter of taper down IDLER SHAFT DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 238 Figure 235 Remove large idler gear Remove idler shaft bearing retainer nut Pry idler shaft rear bearing up far enough to use a bearing puller gt Am Figure 236 Figure 239 Remove rear bearing Remove gear spacer See cleaning and inspection page 4 pe IDLER SHAFT REASSEMBLY Figure 243 Install idler shaft rear bearing outer locating ring groove up Install bearing retainer nut tighten nut 200 to 250 ft Ibs torque 271 2 338 9 N m Figure 240 See cleaning and inspection page Position gear spacer on shaft REASSEMBLY OF TRANSMISSION Figure 241 Position large idler gear on shaft with long hub on gear down Figure 244 Install forward clutch rear bearing with bearing locating ring toward front of transmission case Figure 242 Figure 245 Position small idler gea
68. ward clutch assembly Remove forward clutch rear bearing Figure 59 Figure 62 Remove sealing ring sleeve retainer ring Remove output shaft front bearing cap bolts and washers Figure 63 Figure 66 Remove bearing cap and shims Unclinch lock nut by straightening upset metal in notch in idler shaft Remove shaft nut Figure 64 Remove output shaft front taper bearing cup Figure 67 Repeat procedure in Figure 66 for reverse idler shaft CONVERTER HOUSING DISASSEMBLY Figure 65 Spread reverse clutch front bearing locating ring Pry clutch Figure 68 assembly from housing Remove bearing spacers Figure 69 Remove reverse idler gear and outer taper bearing Figure 70 With the help of an assistant spread the 4th speed clutch front bearing locating ring and pry clutch from converter housing while the assistant removes the idler gear and outer taper bearing Figure 71 Jsing a soft bar drive reverse idler shaft from taper bearing d A 1 3 Figure 72 Remove taper bearing and thrust plate Remove shaft Use caution as not to lose lock ball Figure 73 Repeat procedures in Figures 71 and 72 for idler shaft removal Figure 74 Spread the turbine shaft bearing locating ring Figure 75 Figure 78 Holding ring open tap turbine shaft from stator support Remove pump idler gear retainer ring Figure 76 Figure 79 Remove turbine shaft Remove idler gear Figure 77 Figure 80

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