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1. HR 24000 6 SPEED TRANSMISSION FIGURE A Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual FIGURE B Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD CONVERTER AND TRANSMISSION CASE GROUP ITEM DESCRIPTION QTY T Wipe Plugins se He are 2 2 Air Breather 1 3 Pipe lg cc ee had ee ees 1 4 Pipe Blue pn eu ou beets PIG 2 5 Converter Housing Sleeve 1 B CT awk s dre RP he tpe Rana 1 7 Clip Screw Lockwasher 1 8 attert iu nme rue REPERI 1 9 Glip SCFew song amp LES wu eer AG 1 10 Clip Screw Lockwasher 1 TECH euer da BUNGA NANANA eed ed 1 12 Converter Housing Sleeve 1 13 Pipe Plug iss ies eh E Seb leiden 2 14 Converter Housing to Transmission Case Screw Lockwasher 17 15 Converter to Transmission Case Screw 17 16 Pipe let Ae ee er 2 TZ PUNA NG Waa paa 1 18 Hole Plug Gasket 1 19 Case Assembly Hole Plug 1 20 Converter Housing 1 21 Screen Assembly Gasket 1 22 Screen Assembly 1 23 Converter Housing to Transmission Case Gasket ii ka pa see wien na 1 24 Converter Housing to Case Dowel Pin 1 25 Clutch Pressure Tube O Ring 1 26 Lube Tube Sleeve 1 27 Tube Sleeve
2. 1 30 Soleni d zn een bad bee een et hed ERES en 5 31 Solenoid Coll sch urn HT Dr GE 5 32 Solenoid O Ring 5 33 Solenoid O Ring 5 34 Solenoid OMRING dr Henn Er 5 35 Control Valve Housing 1 36 Valve Spool Stop 1 37 Ground Wire Harness 1 38 Receptacle Mounting Screw 4 39 Receptacle amp Wire Assembly 1 40 Dust Cover Mounting Stud Lockwasher 2 41 Dust Cover Mounting Stud Nut 2 42 SGrOMIME Tess fou aa eher 1 43 DustiCov r un ANG ie nae ne RAR ABA ANG 1 44 DustCover Seal u a ee ren ee ot 1 45 Dust Cover Mounting Stud 2 Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual FIGURE G Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD CHARGING PUMP amp VALVE ASSEMBLY GROUP ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Valve Stop Roll Pini sab dee 1 22 Tit Plate Seal ses 2 4 Wake top iin 1 23 Pump Drive Shaft Assembly 1 X BERNER IR 1 BE Big A RAS PEN E nenn 1 keen tee RO a EC 1 25 Pump Mounting Stud 2 5 Valve Stop GO Ring wessen 1 26 Pump Drive Gear Oil Seal 1 6 Valve Piston soe eo EE
3. 1 3 Spring Retainer 1 4 Piston Return Spring 7 5 Piston Return Spring Spacer 1 6 Forward Shaft Drum amp Plug Assembly 1 7 Piston Ring Expander Spring 3 8 Forward Shaft Piston Ring 3 9 Piston Ring Sleeve Retaining Ring 1 10 Piston Ring Sleeve 1 11 Forward Shaft Rear Bearing 1 12 Reverse Shaft Piston Ring 3 12A Piston Ring Expander Spring 3 13 Front Bearing Retaining Ring 1 14 Front Bearing Snap Ring 1 15 Reverse Shaft Front Bearing 1 16 Front Bearing Retaining Ring 1 17 Clutch Driven Gear Bearing Assembly 1 18 Reverse Clutch Gear amp Hub Assembly 1 19 Baffle Ring ir sen ALY een area 1 20 Spring Retaining Snap Ring 1 21 Spring Retainer 1 22 Piston Return Spring Belleville Washer 7 23 Piston Return Spring Spacer 1 24 Reverse and 3rd amp 4th Clutch Drum and Plug Assembly 1 25 Piston Return Spring
4. 1 28 Clutch Pressure Tube O Ring 1 29 Tube Sleeve 1 30 Clutch Pressure Tube O Ring 1 31 Tube Sleeve 1 32 Clutch Pressure Tube O Ring 1 ITEM DESCRIPTION QTY 33 Clutch Pressure Tube O Ring 1 34 Tube Sleeve 1 35 Clutch Pressure Tube O Ring 1 36 Tube Sleeve 1 37 Clutch Pressure Tube O Ring 1 38 Transmission Case Assembly 1 39 Tube Sleeve 1 40 Clutch Pressure Tube O Ring 1 41 Rear Cover to Transmission Case Gasket 1 42 Transmission Case to Rear Cover Dowel Pit 222129kx AERIS 1 43 Rear Cover Pipe Plug 1 44 Rear Cover 1 45 Rear Cover to Case Screw 20 46 Rear Cover to Case Screw Lockwasher 20 47 Transmission Case to Rear Cover Dowel Pins es vaste ane 1 48 Pipe Plug 1 49 Pipe Plug naa BA PDA aan ne ts 1 50 Magnetic Drain Plug 2 51 Oil Battle ess oss engere 1 52 Tube Clip 2 53 Clip Screw Lockwasher 1 BA Clip SEW ose co pee eR 1 55 Suction Line Assembly O Ring 1 56 Suction Tube Assembly 1 57 Screw Lockwasher 2 58 Suction Line Screw 2 59 Clutch Lube Tube 1 60 3rd Speed Tube
5. 1 26 Spring Retainer 1 27 Spring Retainer Snap Ring 1 28 3rd amp 4th Clutch Shaft Pilot Bearing 1 29 Retainer Locating Ring 1 30 Retaining Ring Retainer 1 31 Clutch Disc Hub Retaining Ring 1 32 Battle RE uote eur ea sate Sesto TU Se ed HEE 1 33 lge D se Hub 22 zt Creme eR pare Hal 1 34 Piston Return Spring 1 35 Spring Retainer 1 36 Spring Retainer Ring 1 37 5th amp 6th Clutch Shaft Pilot Bearing 1 38 Retainer Snap Ring 1 39 Retaining Ring Retainer 1 40 Clutch Disc Hub Retaining Ring 1 41 Baffle RING seit sarin aan 1 42 Cl tch Disc Hub v e PNG rene NAA naka had 1 43 Spring Retainer bing 1 44 Spring Retainer 1 45 Piston Return Spring Belleville Washer 7 46 Piston Return Spring Spacer 1 47 Forward High and 5th amp 6th Clutch Drum amp Plug Assembly 1 48 Forward High Shaft Piston Ring 3 48A Piston Ring Expander Spring 3 49 Front Bearing Retaining Ring
6. 1 Bo JEIDOW ee nn Dean daa pe ons es 1 4 Valve Pl g s ce ESPERE ONU RS VE Rep ena 1 5 Forward amp Reverse Shift Spool 1 6 Spool Position Spring 1 7 Forward amp Reverse Shift Spool 1 8 Valve Housing Plug 1 9 o Valve Spool ceana ure eub Rv wae E E RE 1 10 Control Valve Spring 1 11 Valve Housing Spool Bore Piug ronn 1 12 Spool Position Spring 1 T3 SHIT SO cts ess cene um ee te ebbe dide dad 1 14 Spool Srop ieri n aD einen R A a E e RE E a Ri 1 15 iRoll BPib se ena tee o ee a AG Ka EO Ae 1 RE Idee NEE en Gow e Ee GANAN e u 1 17 1st Speed Shift Spool 1 187 Pipe Bled EEN Rie Pa ee ae rk 2 19 Shuttle Valve to Electric Contro Gasket 1 20 gt Port Plugs sens Sega ea DL EEE A es 1 21 SpoOLlStoD cn es ess aie fat ade amor N ae Ener ams 1 22 High Low Shuttle Spool 1 23 Shuttle Spool Spring 1 24 Shuttle Valve Body 1 25 Pipe Plug sat ara Aa mee a ae ER US DN 7 26 Valve Mounting Screw Lockwasher 2 27 Valve Mounting Screw 2 28 Valve Mounting Screw Lockwasher 1 29 Valve Mounting Screw
7. 1 25 Turbine Sh ft eng cius sn Bra NG 1 26 Baffle RING 2344 Lie eee ren 1 27 Stator Support Screw 6 28 Auxiliary Pump Drive Bearing Support 1 29 Bearing Retaining Ring 1 30 Pump Drive Gear Bearing 1 31 Bearing Locating Ring 1 32 Auxiliary Pump Drive Gear 1 33 Pump Mounting Cover Gasket 1 34 Pump Mounting Cover 1 35 Pump Mounting CoverCapscrew Lockwasher 4 36 Pump Mounting Cover Capscrew 4 37 Idler Shaft Lockball 38 Reverse Idler Gear Bearing Thrust Plate HR24000 6 Speed LD CONVERTER AND PUMP DRIVE GROUP ITEM DESCRIPTION QTY 39 Reverse Idler Gear Bearing Assembly 2 40 Reverse Idler Gear Lower Shaft 1 41 Reverse Idler Gear Upper Shaft 1 42 Reverse Idler Gear Bearing Thrust Plate 2 43 Bearing Retaining Plate Nut 2 44 Impeller to Cover O Ring 1 45 Impeller Cover 1 46 Turbine Hub Bearing 1 47 Impeller Cover to Bearing Cap O Ring 1 48 Turbine Hub Bearing Retaining Ring 1 49 Turbine Retaining Ring 1 50 Impeller Cover Bearing Cap 1 51 Drive Plate Assembly 1 52 Drive Plate iios Bea ae 3 53 Drive Pla
8. 1 50 Front Bearing Snap Ring 1 51 Forward High Shaft Front Bearing 1 52 Front Bearing Retaining Ring 1 53 Clutch Driven Gear Bearing 1 54 Clutch Gear Bearing Retaining Ring 1 55 Clutch Driven Gear Bearing Spacer 1 56 Forward High Clutch Gear amp Hub Assembly 1 57 Gil Batfle Ring rS anne EE at ees are re 1 58 Clutch Gear Bearing Retaining Ring 1 59 Clutch Driven Gear Bearing 1 60 Front Bearing Cap Screw Lockwasher 4 61 Front Bearing Cap Screw 4 62 Flatige Nut sn ausleben ng 1 63 Flange Washer mna sa een an 1 ITEM DESCRIPTION QTY 64 Flange O Ring 1 65 Front Output Flange 1 66 Front Bearing Cap Oil Seal 1 67 Front Bearing Cap 1 68 Bearing Cap Shim 1 69 Front Bearing Cap O Ring AR 70 Front Bearing Cup 1 71 FrontBearing Cone 1 72 Forward Shaft Gear 1 73 Gear Retaining Ring cece eee 1 74 st amp 2nd Clutch Shaft Front Bearing 1 75 Front Bearing Spacer 1 76 1st 2nd Clutch G
9. 1 61 High Speed Clutch Pressure Tube 1 62 Low Speed Clutch Pressure Tube 1 63 Dipstick Tube Assembly 1 64 Dipstick irr eer Rm Ren 1 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD FN D ONG B 53 FIGURE C Apr 2000 Maintenance amp Service Manual ITEM DESCRIPTION QTY 1 Bearing Support Screw amp Lockwasher 2 Bearing Support Screw D Lockwasher 3 Idler Gear Bearing Locating Ring 1 4 idler Gear Bearing Retaining Ring 1 5 Pump Drive Idler Gear 1 6 idler Stub Shaft Bearing 1 7 Bearing Retaining Ring 1 8 Bearing Locating Ring 1 9 Bearing Locating Ring 1 10 Pump Drive Bearing Support 1 11 Bearing Retaining Ring 1 12 Pump Drive Gear Bearing 1 13 Bearing Locating Ring 1 14 Pump Drive Gear 1 15 Idler Gear Stub Shatt asoan 1 16 Stub Shaft Lock Ball 1 17 Piston Ring Expander Spring 1 18 PISTON RING netic ee ia Hal 1 19 Stator Support 1 20 Bearing Snap Ring 1 21 Piston RINO manna euer dade 1 22 Bearing Retaining Ring 1 23 Bearing Locating Washer 1 24 Turbine Shaft Bearing
10. Figure 2 Loosen filter assembly It is recommended a small pan be used to catch the oil left in the filter element Remove filter element Figure 3 Remove pressure regulating valve stud nuts bolts and washers Figure 4 Remove pressure regulating valve and charging pump assembly Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 5 Figure 8 Disconnect shuttle valve to control valve cross Over tube Remove shuttle valve assembly from aligning studs Figure 6 connect shuttle valve solenoid wires Disconnect shuttle valve solenoid Figure 9 Remove control valve assembly Figure 7 Remove two valve to converter housing cap screws Install Figure 10 two aligning studs to facilitate valve removal Remove Remove drive plate cap Screws and washers Some units remaining cap screws will have stud nuts and washers Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD e o Figure 14 igure Remove impeller cover bolts NOTE It is recommended a Remove drive plate and backing ring container be available to catch remaining oil in wheel section Figure 12 Figure 15 Remove impeller cover bearing cap Remove turbine hub to turbine shaft retaining ring Figure 13 Figure 16 Remove bearing cap O ring Remove impeller cover and turbine as an assembly Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 17 Figure 20 Remove turbine to turbine shaft locating ring R
11. vel 12 Gluteh Outer DISC tatas ttn re ec e co ed d 6 6 Clutch Piston Seal Outer 1 13 Cl tch Inner DISC eit ooo en 6 7 Clutch Piston Seal Inner 1 14 Clutch Disc Backing Plate 1 15 Backing Plate Retaining Ring CLUTCH ASSEMBLY REVERSE 3rd amp 4th ITEM DESCRIPTION QTY 1 Backing Plate Retaining Ring 1 2 Clutch Disc Backing Plate 1 3 Clutch Inner Disease sehn 12 4 Clutch Outer Disc m12 5 Clutch Piston Reverse c ccesseeseeeseceeeeeeeeeeeseeeeseesaeeeeeeaes 1 6 Clutch Piston Seal Outer wl 7 Clutch Piston Seal Inner ee 1 ITEM DESCRIPTION QTY 8 Reverse amp 3rd 4th Clutch Drum Assembly 1 9 Clutch Piston Seal Inner 1 10 Clutch Piston Seal Outer nennen 1 11 Clutchbtsion 28 A 1 126lutchOuterDISC s aeree eere rere eto 6 T3ClutchlnnerDisC censeret etre nn treni 6 14Clutch Disc Backing Plate 1 15 Backing Plate Retaining Ring 1 1 1 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD FIGURE F Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD ELECTRIC CONTROL VALVE ASSEMBLY 6 SPEED FULL POWER SHIFT LESS DECLUTCH ITEM DESCRIPTION OTY 1 EIDOW 2 be uo EE satin die eae eh eae 1 2 Forward Pressure Tube Assembly
12. Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 56 Remove rear bear ng spacer Remove 1st and 2nd clutch assembly Figure 54 Figure 57 Remove output shaft assembly Remove idler shaft front bearing Figure 55 Figure 58 Remove dler shaft assembly Remove oil sump oil baffle 10 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 59 Remove forward clutch shaft drive gear retainer ring and drive gear See Figure 59A Figure 61 Remove forward clutch oil sealing ring sleeve retainer ring Ng WS mu moi m Li EPIS un EX Ki 1 K SAE IN 4 kho N c LE Sa 4 m 1 x ka Se KIN N NET WA Figure 62 Remove sealing ring sleeve Figure 59 A Figure 63 Figure 60 Remove forward clutch shaft rear bearing retainer ring and From the front remove the forward clutch assembly bear ng a gt FE Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 64 Figure 67 Remove front output shaft bearing cap bolts and washers Spread reverse clutch front bearing locating ring Pry clutch Remove bearing cap and shims from housing mia Figure 65 Figure 68 Remove output shaft front taper bearing cup Remove reverse and 3rd and 4th clutch assembly Figure 69 Figuro 66 Spread forward high clutch front bearing locating ring Pry Remove clutch shaft pilot bearings clutch from housing Apr 2000
13. 115 127 156 0 172 2 128 141 173 5 191 2 113 124 153 2 168 1 180 198 224 0 268 5 159 175 215 8 237 3 7500 223 245 200 220 271 2 298 3 315 347 4271 470 5 282 310 382 3 420 3 FIGURE Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Due to mounting clearance Tighten lockscrew and use grade 5 stud as shown lockwire as shown Lockscrew and wire shown 90 out of position KANA EUR ad p Vs S ES SECTION A A THROUGH PUMP DRIVE in section B B Thd Length Min Max oo O O i 131 1 44 os Engine flywheel 33 3 36 6 FRONT VIEW housing face No capscrew used MEA in this mounting hole CA due to clearance AAS UNE Thd 3750 16 UNC Thd SECTION B B o f O r A o 5 A SECTION S S Apply Loctite No 262 Auxiliary Pump Drive to this boit eu petore Auxiliary Pump Mounting installing Assemble speed sensor bushing See View R in housing to specified dimension with Loctite 262 and stake 3 places 1 397 35 48 1 383 35 13 N VIEW R See View R After curing of Loctite speed sensor bushing must be secure with 40 Ft Lb 54 2 N m torque Stake 3 places approx equally spaced orientation not critical o VIEW W W Typical 3 Places Parking Brake ELECTRIC SOLENOID CONTROL REAR VIEW FIGURE Apr 2000 Ground
14. It is recommended that clutch pressure be monitored by a gauge having an indicator diai 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 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Charge Pump amp Filter Shielded Bearing I rt Emergency Steering LI Pump Drive Option MECHANICAL DISCONNECT Front Shown Rear Available MECHANICAL DISCONNECT WITH SPEEDO Rear Shown FIGURE Apr 2000 Maintenance amp Service Manual Assemble oil filter and tighten 20 to 25 Lbs Ft 27 2 33 8 N m Teflon seals must be sized prior to ass y 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 inner friction plates Alternately assemble starting with outer steel plate gt BBBB 12 outer steel plates 12 inner friction plates Alternately assemble starting with outer steel plate gt A Tighten 200 to 250 Lbs Ft 271 2 338 9 N m Special
15. Maintenance amp Service Manual HR24000 6 Speed LD Ng Figure 70 Figure 73 Remove forward high and 5th and 6th clutch assembly Remove idler gear taper bearing outer thrust plate Figure 71 Figure 74 Unclinch lock nut by straightening upset metal in notch of Remove idler gear and outer taper bearing idler shaft Figure 75 Figure 72 Using a soft hammer tap idler shaft from housing to remove Remove locknut inner taper bearing 2 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 79 Repeat figures 71 thru 78 to remove forward high idler shaft Figure 76 Remove inner taper bearing Figure 77 Figure 80 Remove inner bearing thrust plate Remove pump idler gear retainer ring 7 Figure 78 Remove idler shaft Use caution as not to lose shaft Figure 81 lockball Remove idler gear and bearing assembly D d ES Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 82 Figure 85 Remove charging pump gear support screws and lock Remove auxiliary pump gear beanng and support washers Figure 86 Remove pump gear bearing and support Spread the turbine shaft bearing locating ring Figure 84 Remove auxiliary pump gear support screws and lock Figure 87 washers Holding ring open tap turbine shaft from stator support Hi Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 88 Remove stator support screws and support Figure 9
16. 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 Figure 253 Position support in coverter housing aligning holes in support with holes in housing Tap support into position 43 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 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 penod 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 257 Install reverse idler shaft spacer Figure 254 With new O ring on shaft position reverse idler shaft and lock ball in converter housing T Figure 258 Install idler gear inner taper bearing on shaft with large diameter of taper down Figure 255 With new O nng on shaft position idler shaft and lock ball in converter housing Tap both shafts into position Figure 256 Figure 259 Note lock
17. 1 27 Pump Mounting Screw Lockwasher 3 7 Valve Spring Inner 1 6 1 28 Pump Mounting Screw 3 8 Valve Spring Outer 1 29 Safety Valve Spacer 1 9 Regulating Valve amp Filter Adaptor 30 Safety Valve Poppet 1 een baisers een 1 31 Safety Valve Seat sapo sum 1 10 Pump Mounting Stud Lockwasher 2 32 Safety Valve Spring seau 1 Vi Pamp Mounting Stud NUE sense 33 Safety Valve Retainer 1 TA Filter Asssmbly a ae 1 34 Pump Assembly to Converter Housing 13 Valve to Pump Capscrew 2 GREEN 1 14 Valve to Pump Capscrew Lockwasher 2 38 Pump Body ese ESR PRA REA 1 15 Valve to Pump Capscrew 1 36 Valve Mounting Screw 4 16 Valve to Pump Screw Lockwasher 1 37 Valve Mounting Screw Lockwasher 4 17 Valve to Pump Gasket 1 38 High Clutch Pressure O Ring 1 18 Thrust Plate amp Bearing Assembly 2 39 Valve to Converter Housing Gasket 1 19 Pump Driven Shaft Assembly 1 40 Control Valve Assembly 1 20 Thrust Plate amp Bearing Assembly 2 41 Valve Mounting Screw Lockwasher 5 21 Wave Spring 42 Valve Mounting Screw 5 Apr 2000 Maintenance amp Service Manual CONVERTER LOCK UP OPTION Heat Exchanger Check Point AAT Heat Exchanger Outlet Temperature Port A HR MODEL l Out
18. TRANSMISSION 1 CLUTCH DISASSEMBLY nn afc een 16 REASSEMBLY OF TRANSMISSION 48 CLEANING AND INSPECTION 65 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL 66 TOWING OR PUSH STARTING 66 SPECIFICATION AND SERVICE DATA 67 LUBRICATION Es rog ptus A AE Ee A 67 TROUBLE SHOOTING GUIDE 68 CLUTCH AND GEAR ARRANGEMENT 69 POWERFLOW 1c US a a E HE 70 ELECTRIC SOLENOID CONTROL 73 CONTROL WIRING DIAGRAM 74 DRIVE PLATE INSTALLATION 75 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 76 PLUMBING DIAGRAM WITH LOCK UP 79 NOTE Metric Dimensions Shown in Brackets Apr 2000 Maintenance amp Service Manual HR24000 6 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 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 follo
19. at bottom of transmission case 240 300 psi 1654 8 brake set see note oil temperature 180 2068 4 kPa With parking 200 of 182 2 93 3 C engine at idle 1400 to 600 RPM shift thru direction and speed clutches All clutch pressure must be equal within 5 psi 134 5 kPa If clutch pressure varies inanv one clutch more than 5 psi 134 5 kPal repairclutch NOTE Never use service brakes while making clutch pressure checks Units having brake actuated declutching in forward and or reverse will not give a true reading ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS RECOMMENDED LUBRICANTS FOR CLARK HURTH COMPONENTS POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS Prevailing Ambient Temperature Fahrenheit Dexron is a registered trademark of General Motors Corporation Celsius Temperature Range Temperature Range Temperature Range Temperature Range al C2 Grade 30 b C3 Grade 30 c Engine Oil Grade 30 APICDISE or CDISF dl MILL2104CGrade 30 9 MIL L2104DGrade 30 al MIL L2104CGrade 10 b MIL L2104DGrade 10 C2 Grade 10 2 di C3 Grade 10 el Engine Oil Grade 10 APICDISE or CDISF Il Ouintolubric 822220 Non Phosphate Ester Fire 5 a Conoco High Performance Synthetic Motor Oil Spec No 6718 PREFERRED OIL VISCOSITY Select highest oil viscosity compatible with prevailing ambient temperatures and oil application chart Temperature ranges 2 and 3 may be used
20. ball in position in both shafts Position bearing spacer on shaft 44 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 260 Figure 263 Position idler gear on bearing with hub of gear up Install retainer nut on shaft Figure 261 Figure 264 Install idler gear outer taper bearing on shaft with large Tighten nut 200 to 250 ft Ibs torque 271 2 338 8 N m diameter of taper up Figure 262 Figure 265 Position outer spacer on shaft Stake nut securely into shaft notch ENT aca Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 266 4 bearing was removed press turbine shaft bearing into position Install bearing washer and retainer ring Install new turbine shaft oil sealing ring Figure 267 Spread ears on turbine shaft bearing retainer ring located in reaction member support Tap turbine shaft and bearing into position being certain bearing snap mng is in full position in snap ring groove Figure 268 Position auxiliary pump drive gear bearing and support in housing Figure 269 Align holes in bearing support with holes in housing Install support screws and lockwashers tighten 23 to 25 ft Ibs torque 31 2 33 8 N m Figure 270 Position charging pump drive gear bearing and support in housing 45 Figure 271 Install support screws and tighten 23 to 25 ft 31 2 33 8 Nm ibs torque Apr 2000 Maintenance amp Service Manual HR2400
21. 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 individually 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 HR24000 6 Speed LD Oil Seals Gaskets and Retaining Rings Replacement of spring load oil seals 0 rings metal sealing 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 tight fit 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 member
22. disassemble and rebuild converter assembly 2 Replace 3 Fill to proper level 4 Check oil line connections and tighten securely NOISY CONVERTER 1 Worn oil pump 2 Worn or damaged bearings 1 Replace 2 A complete disassembly will be necessary to determine what bearing is faulty LACK OF POWER 1 Low engine RPM at converter stall 2 See Overheating and make same checks 1 Tune engine check governor 2 Make corrections as explained in Overheating Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual 24000 SERIES 6 SPEED FULL POWERSHIFT CLUTCH AND GEAR ARRANGEMENT 69 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Clutch Pressurized Engaged 1st FWD amp 1st 2nd FWD HI amp 2nd 3rd FWD amp 3rd FORWARD 1st 2nd wes e um 3rd DR Cp tar AZUR HR 24000 6 SPEED TRANSMISSION 70 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD IDLER sp eg om ee o o m Le n u amp INPUT gt ALI Sch EXER e i e FWD Li Q gt lt lt E pen ER REV 1 3rd 1st sA 1 amp 4t
23. discs Do not groove up force this operation Gear splines must be in full position with internal teeth of all friction discs 1 Figure 164 Install bearing retainer ring Figure 161 Install outer taper bearing large diameter of taper up B gf Figure 165 Figure 162 Install clutch shaft piston rings and expander springs per Install bearing retainer ring instructions on Page 78 28 Apr 2000 Maintenance amp Service Manual DISASSEMBLY OF FORWARD HIGH AND 5th AND 6th CLUTCH Forward High being disassembled See page 77 for special ratio cross section Figure 166 Remove clutch shaft od sealing rings and expander springs Figure 167 Remove front bearing retainer ring MU Figure 168 Remove front bearing HR24000 6 Speed LD Figure 169 Remove clutch gear bearing retainer ring Figure 170 Remove clutch gear and outer bearing u 2 y D Figure 171 Remove bearing spacer Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 172 Remove end plate retainer ring Figure 173 Remove end plate Figure 174 Remove inner and outer clutch disc Figure 175 Remove clutch gear inner bearing D Figure 176 Compress piston return disc springs Remove spring retainer ring and ring retainer gt Figure 177 Remove piston return disc springs N Apr 2000 Maintenance amp Service Manual Figure 178 R
24. has been completely installed on engine fly wheel This value must be within 001 0 025mm of the end play recorded in step No 2 Does not apply to units having 3 intermediate drive plates See Fig 4 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD FORWARD HIGH CLUTCH WITH SPECIAL RATIO NOTE The disc spring packs are to be used as within this assembly Failure to replace all complete assemblies and care should be taken piston return springs can result in unequal not to intermix the individual disc springs with deflection within the spring pack The result of disc springs in another clutch or disc spring this imbalance may adversely affect overall life pack of springs Each disc spring assembly is made up of Service replacement assemblies are banded selected springs to precisely match each part together and must be replaced as assembly 79 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 24000 PLUMBING DIAGRAM WITH LOCK UP PROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS NOTE NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS 1 Fill the oil sealing ring grooves with a good grade of grease this will help stabilize the teflon ring and expander spring in the ring groove for installation 2 Position the expander spring in the inner groove of the new piston ring with the expander spring gap 180 from the hook joint gap of the piston rin
25. on stator support Figure 331 For a fixed reaction member install reaction member with thick side of blades out For freawheel reaction member see Figure 333 HR24000 6 Speed LD Figure 332 Install reaction member retainer ring Proceed to Figure 337 FREEWHEEL REASSEMBLY NOTE The freewheel assembly cannot be serviced If the treewheel is damaged it must be replaced as an assembly Figure 333 Install outer race and sprag assembly in reaction member NOTE Undercut shoulder of race must go toward the rear of the reaction member Figure 334 Install outer race to reaction member retainer ring BA Apr 2000 Maintenance amp Service Manual VIEWED FROM THIS DIRECTION OUTER RACE FREEWHEELS CLOCKWISE Figure 335 MUST FREEWHEEL IN CLOCKWISE ENGINE ROTATION Figure 336 Position reaction member to impeller hub gear spacer on reaction member support Install reaction member on support Check rotation of fraewheeling reaction member to be sure of proper freewheel assembly Install reaction member retaining ring Figure 337 Install turbine locating ring HR24000 6 Speed LD Figure 338 With a new impeller cover to impeller O ring in place install turbine and impeller cover assembly on turbine shaft Figure 339 Install turbine hub to turbine shaft retainer ring Figure 340 Install impeller cover to impeller screws and lockwashers Tighten to specified torque See torqu
26. 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 may be cleaned in hot solution tanks 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 skirn 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
27. shaft rear taper bearing large diameter of taper down taper down BT E Apr 2000 Maintenance amp Service Manual IDLER SHAFT DISASSEMBLY Figure 236 Pry idler shaft rear bearing up far enough to use a bearing puller Figure 237 Remove rear bearing Figure 238 Remove small idler gear d Zeg HR24000 6 Speed LD Figure 239 Remove large idler gear Figure 240 Remove gear spacer See cleaning and inspection page IDLER SHAFT REASSEMBLY aT Figure 241 Position gear spacer on idler shaft Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 242 Position large idler gear on shaft with long hub on gear down Figure 246 Tap turbine and hub from bearing add Figure 243 Position small idler gear on shaft with long hub of gear down Figure 247 Tap impeller cover bearing from cover See cleaning and inspection page IMPELLER COVER AND TURBINE REASSEMBLY Figure 244 b t Install idler shaft rear bearing with bearing outer locating fing groove up DISASSEMBLY OF IMPELLER COVER bo Figure 248 Install impeller cover bearing in cover with bearing locating ring up H the turbine or turbine hub was replaced or disassem bled this procedure must be used for reassembly Figure 245 Remove turbine hub to impeller cover bearing retainer ring SAT Apr 2000 Maintenance amp Service Manual TURBINE HUB ASSEMBLY WITH BACK
28. 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 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 EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER LOW CLUTCH PRESSURE Cause 1 Low oil level 2 Clutch pressure regulating valve spool stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings 5 Clutch piston bleed valve stuck open Remedy 1 Fill to proper level 2 Clean valve spool and housing 3 Replace pump 4 Replace sealing rings 5 Clean bleed valves thoroughly LOW CONVERTER CHARGING PUMP OUTPUT TEN Low oil level N Suction screen plugged w Air leaks at pump intake hose and connections or collapsed hose R24000 only Defective oil pump 1 Fill to proper level 2 Clean suction screen 3 Tighten all connections or replace hose if necessary 4 Replace pump OVERHEATING 1 Worn oil sealing rings 2 Worn oil pump 3 Low oil level 4 Pump suction line taking air R24000 only 1 Remove
29. 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 friction discs Figure 206 Install clutch gear bearing spacer un Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 207 Install clutch gear outer bearing NOTE Outer bearing has a Figure 210 shield in it This shield must be up Install bearing retainer ring A Figure 211 Figure 208 Install clutch shaft piston rings and expander springs per Install bearing retainer ring instructions on page 78 FORWARD CLUTCH DISASSEMBLY Y M Figure 209 Install clutch shaft front bearing NOTE Bearing outer Figure 212 diameter locating ring groove must be up Remove clutch disc end plate retainer ring Gan LA Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 213 Figure 216 Remove end plate Remove piston return disc springs Figure 214 Figure 217 Remove inner and outer clutch discs Remove piston spacer Figure 218 Figure 215 Remove clutch piston Compress piston return disc springs Remove retum spring retainer ring and ring retainer See cleaning and inspection page dl T roo Maintenance amp Service Manual FORWARD CLUTCH REASSEMBLY Figure 219 Install clutch piston outer and inner seal rings Size as explained in Figure 103 Figure 220 Install clutch piston in clutch drum Use caution as n
30. to lower ambient temperatures when sumppreheaters are used Temperature range 4 should be used only in ambient temperature range shown MODULATED SHIFT TRANSMISSIONS 112000 18000 24000 28000 amp 32000 series transmissions with modulated shift use only C3 or temperature range 3 items a amp b Dexron or Dexron Il D SEE CAUTION BELOW 3000 4000 5000 6000 8000 16000 amp 34000 series transmissiOns with modulated shift use only C3 or temperature range 3ilem a only Dexron Do NOT use Dexron Il D SEE CAUTION BELOW CAUTION Dexron II D is not compatible with graphitic clutch plate friction material UNLESS IT MEETS THE APPROVED C 3 SPECIFICATIONS Dexron II D cannot be used in the 3000 4000 5000 6000 8000 16000 or 34000 series power shift transmissions or the HR28000 amp HR32000 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 Hurth Components 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 accelerated deterioration and contamination For extreme conditions judgment must be used to determine the required change intervals Apr 2000 Maintenance amp Service Manual HR24000 6 Speed
31. with bearing snap ring toward front of housing Figure 280 Install retainer nut on shaft and tighten 200 to 250 ft Ibs torque 271 2 338 9 N m Stake nut securely into shaft notch Figure 283 Align forward clutch shaft piston ring sleeve with groove In housing Tap sleeve into position and secure with sleeve retainer ring Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual Figure 284 Position forward clutch assembly into transmission housing Use caution as not to damage forward shaft piston rings Tap clutch into position Figure 287 Install bearing capscrews and washers and tighten to specified torque Figure 285 Install output shaft front taper bearing cup Figure 288 Position forward gear on forward clutch shaft with long hub of gear toward bearing Install gear retainer ring di j z e IN T d Se Hi NG Ml L N II N N d Ng L Figure 286 N Cm Coat outer diameter of oil seal with Permatex 2 and press A seal in bearing cap with lip of seal in Remove any excess A sealant Install new O ring on bearing cap Install front Figure 288 A bearing cap and shims A a Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 289 Figure 292 Install idler shaft front bearing Position rear bearing spacer on clutch shaft Figure 290 Figure 293 Position 1st and 2nd speed clutch in front bearing bore and install 1st and 2nd clutch rear bear
32. 0 6 Speed LD Figure 272 Figure 275 Position pump drive idler gear and bearing on idler gear Install idler gear inner taper bearing on shaft with large stub shaft diameter of taper dawn Figure 273 Figure 276 Install idler gear to stub shaft retainer ring Position bearing spacer on shaft Figure 274 Figure 277 Install idler shaft spacer Position idler gear on bearing with hub of gear up Apr 2000 Maintenance amp Service Manual Figure 278 Spread ears on forward high clutch front bearing locating ring NOTE The idler gear and taper bearing cup assembly and the forward high clutch assembly must be installed in the converter housing at the same time as the idler gear must be positioned between the forward 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 HR24000 6 Speed LD Figure 281 Spread ears on reverse clutch front beanng locating nng Tap reverse and 3rd and 4th 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 See cleaning and inspection page SEE FIGURE FOR SPEED SENSOR BUSHING INSTALLATION REASSEMBLY OF TRANSMISSION Figure 279 Position outer spacer on shaft Figure 282 Install forward clutch shaft rear bearing into bearing bore
33. 1 Remove low gear 1st AND 2nd CLUTCH DISASSEMBLY Figure 92 Figure 89 Low gear removed Remove front bearing ww Figure 90 Figure 93 Remove front bearing spacer Remove inner and outer bearing spacer 16 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 94 Figure 97 Remove end plate retainer ring Remove clutch inner bearing Figure 98 Figure 95 Remove piston rerum disc spring retainer ring retainer Remove end plate Figure 96 Figure 99 Remove inner and outer clutch discs Remove return spring retainer ring 17 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 1st AND 2nd CLUTCH REASSEMBLY Figure 100 Remove piston return disc springs NOTE Do not mix disc springs with any other disc springs as they are matched Figure 103 spring packs See note Page 77 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 101 Remove piston spacer Figure 104 Install clutch piston inner seal and size as explained in figure 103 Figure 102 Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston Figure 105 Position piston in low clutch drum as shown Use caution as See cleaning and inspe
34. 400 PS I 0 2757 kPa Gauge DR ere between Port F and Port P Should read 240 300 P S I 1654 8 2068 4 kPa when Engine is running PORT W 1 0000 11 5 5625 18 O RING Install O to 400 PS I 0 2757 kPa Gauge between Port B and Port AB Should have zero pressure when solenoid is NOT ENERGIZED Should read 240 300 PS l 1654 8 2068 4 kPa when solenoid IS ENERGIZED PORT U 7500 14 NPTF Apr 2000
35. Driven Emergency Steerir Pump Drive Optior Maintenance amp Service Manual HR24000 6 Speed LD amp NI a x ES roy i 3rd 1st amp 4th amp 2nd Fx 5th h LI mI hd E HR 24000 6 SPEED TRANSMISSION TYPICAL CROSS SECTION FIGURE J Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD MAINTENANCE AND SERVICE The instructions contained herein cover the dis assembly and reassembly of the transmission in a sequence that would normally be followed after the unit has been removed from the machine end is to be completely overhauled It must be understood that this is a basic HR24000 6 speed full power shift transmission with many options All HR24000 6 speed full power shift transmis sions ore very similar to trouble shoot disassemble repair and reassemble CAUTION Cleanliness is of extreme importance 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 Drain unit thoroughly before disassembly DISASSEMBLY Figure 1 Side view HR24000 6 speed full power shift transmission Electric Control Valve
36. Highway IMPORTANT Always furnish the Distributor with the 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 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic DESIGN papaka ind nee ses Fig A Converter and Transmission Case Group Fig B Converter Group SUR nn te a Fig C Six Speed Clutch and Gear Group Fig D Clutch Group Fig E Control Valve Assembly n on aaaea aaa aaau 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 DISASSEMBLY OF
37. ING 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 stan of screw installa tion 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 insuf ficient 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 salvent Dry hole thoroughly and use a new screw for reinstallation Figure 249 Position turbine assembly in impeller cover ua N ke Figure 250 Install turbine hub to impeller cover bearing retainer ring HR24000 6 Speed LD Figure 251 Remove impeller hub bearing from stator support as shown Remove support oil sealing ring and sealing ring expander spring Sea cleaning and inspection page SEE FIGURE FOR SPEED SENSOR BUSHING INSTALLATION CONVERTER HOUSING REASSEMBLY Figure 252 Install new sealing ring expander spring and oil sealing nng
38. LD TROUBLE SHOOTING GUIDE For The R amp H R 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 therein 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 CONSISTS OF TWO CLASSIFICATIONS MECHANICAL AND HYDRAULIC MECHANICAL CHECKS Prior to checking any part of the system from a hydraulic 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 restrictions in travel that would prevent full engagement Shift levers by hand at control valve if full engagement cannot be obtained difficulty may be in control cover and valve assembly HYDRAULIC CHECKS Before checking on the torque converter transmission and allied hydraulic system for pressures and rate of oil flow it is essential that the following preliminary checks be made Check oil level in transmission This
39. OTES 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 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 as Apply a light coat of Loctite No 592 to all uncoated plugs 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 Entarged view of stator support piston ring amp expander es Note Expander gap to be approx 180 from ring hook joint to aid assembly See Caution VIEW S Torque Specification for Lubricated Grade 5 co or Plated Screw Threads Grado 8 NOM FINE THREAD COARSE THREAD FINE THREAD COARSE THREAD SIZE LB FT N m N m LB FT N m LB FT N m 8 10 150 17 6 9 11 12 3 14 9 12 16 26 30 35 3 40 6 23 25 31 2 338 50 2 555 33 36 448 48 8 37 41 50 2 55 5 78 7 86 7 52 57 70 8 772 57 63 5 80 88 108 5 119 3 91 100 123 4 135 5 82 90 111 2 122 0 128 141 173 6 191 1
40. S 1 DRIVE PLATE AND BOLT CIRCLE DIA 4 INTERMEDIATE 3 INTERMEDIATE BOLT CIRCLE DIA 3 DRIVE PLATES DRIVE PLATES N BACKING RING BACKING RING Ei N 32 2985 IMPELLER A Dimension Bolt Circle Diameter COVER A Dimension Bolt Circle Diameter 11 38 2881900 mmj Diameter A 13 50 342 900 mm Diameter Kit No 802215 Kit No 802217 13 125 333 375 mm Diameter Kit No 802263 13 125 333 375 mm Diameter Kit No 802216 13 50 342 900 mm Diameter 5 Each kit will include the following parts Kit No 802214 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 AN 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 installing on engine NOTE If Loctite 747 Primer T is not used allow 24
41. Service Manual lt pana gt SPICER Off Highway Products Powershift Transmission 24000 HR 6 Speed Long Drop TSM 0066 April 2000 Maintenance amp Service Manual HR24000 6 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 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 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 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 Spicer Off
42. UTCH REASSEMBLY QS Figure 152 install piston retum springs First spring with large diameter toward spacer Alternate seven 7 springs See note in Figure 100 Figure 149 Install clutch piston outer and inner seal rings Size s explained in Figure 103 Figure 153 Install piston return spring retainer ring retainer and retainer ring on clutch shaft Compress return springs and install retainer ring Be sure ring is in ful position in Figure 150 Install clutch piston in clutch drum Use caution as not to damage seal nngs retainer PISTON FWD HI Figure 151 Position piston return spring spacer over clutch shaft Figure 153 A aa 2 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 154 Figure 157 Install one steel disc Install end plate retainer ring Figure 155 Install one friction disc Alternate steel and friction discs Figure 158 untilthe proper amount of discs are installed First disc next Install clutch gear inner taper bearing small diameter of to the piston is steel last disc installed is friction taper up Figure 156 Figure 159 install clutch disc end plate Position taper bearing spacer on shaft eJ Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 160 Figure 163 Install reverse gear Into clutch drum Align splines on Install clutch shaft front bearing with bearing locating ring reverse gear with internal teeth of friction
43. aft 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 arid 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 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 turb
44. and pump drive disconnect Although the converter housing shown is different than the 6 speed full power shift converter housing the disassembly and reassembly procedure is the same DISASSEMBLY Figure 350 Remove auxiliary pump drive idler gear support bolts Li Figure 351 Remove idler gear pump drive gear bearing and support as an assembly Figure 352 Remove pump drive gear bolts Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 353 Figure 356 Remove gear bearing and support Idier shaft and gear removed Figure 354 Figure 357 Remove idler shaft retsining ring Remove disconnect shift hub Figure 355 Figure 358 Using a hammer puller as shown remove idler shaft NOTE Remove lock wire from shift fork lock screw loosen lock Use caution as not 10 lose shaft lock ball screw and remove shift fork GI Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 361 Position pump drive gear bearings and support in housing Align holes in bearing support with holes in housing Install a flat washer on each support bolt Install a sealing washer on each support bolt Install bolts and washers thru the housing and into bearing support Figure 359 Remove pump drive gear support bolts Figure 362 Tighten bearing support bolts 23 to 25 ft Ibs torque 31 2 33 8 Nom Figure 360 Remove pump dnve gear support and bearing assembly Remove shift rail detent
45. bearing loading notches IN 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 disc spring to be placed against clutch piston Remaining six springs of each cluth 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 N m 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 VI REVERSE IDLER W T 1ST Low Caution 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 HR24000 6 Speed LD N
46. c system must be thoroughly cleaned This can be accomplished in several manners and a degree 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 steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes 5 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 removed disassembled and cleaned thoroughly It 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 6 Reassemble all components and use only type oil recommended in lubrication section Fill transmission through filler opening unt
47. cation 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 Port G Forward Clutch Pressure Port H Reverse Clutch Pressure Modulated Reverse Clutch Pressure Port on Modulator Valve Oil Temperature Gauge Specifications 1 Normal Operating Temperature 180 250 F 2 Red Lined Temperature 250 F 121 C 1 4 NPT Clutch Pressure Check Ports 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 B F K L and M These ports can be used for field Trouble Shooting or vehicle Production Line tests Ports F L and M These ports are to be used as check points for normal vehicle Production Line test Port F Clutch Pressure
48. cedure in Figure 301 for idler shaft output oil seal Press seal in bearing cap with lip of seal in With new O ring in position install bearing cap Figure 303 Figure 306 Install idler shaft rear bearing retainer nut Tighten nut 200 Install bolts and lockwashers and tighten to specified to 250 ft Ibs torque 271 2 338 9 N m torque See torque chart B Bi Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD OUTPUT SHAFT ROLLING TORQUE PROCEDURE Bearing Preload Tsp output shaft front and rear to seat taper bearings Loosen front bearing cap bolts Using an inch Ib torque wrench determine the rolling torque of the output shaft and record Tighten front bearing cap bolts to specified torque Check rolling torque with bolts tight Torque must be 6 to 8 inch Ibs 0 68 0 90 N m more than when bearing cap bolts were loose Add or omit shims on the front bearing cap 10 achieve the proper preload Figure 307 Position new O ring and gasket on 1 stand 2nd clutch rear bearing cap Figure 310 Position parking brake backing plate on output rear bearing cap Install bolts and lockwashers tighten to specified Figure 308 torque See torque chart Position bearing cap on clutch shaft Install bolts and lockwashers tighten to specified torque See torque chart Figure 309 Position new gasket on idler shaft bearing cap Install bearing cap bolts and lockwashers tighten to specified Figure 311 torqu
49. ction page not to damage inner and outer piston sealing r ngs 18 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 106 Figure 109 Position piston return spnng spacer over clutch shaft Using a sleeve with the proper inner diameter drive the spring retainer ring into position NOTE Be certain retainer ring is in full position in ring groove Figure 107 Install piston return disc spring See note Page 77 First spring with large diameter toward spacer Alternate seven 7 springs See Figure 110 A Figure 110 Position ring retainer washer over retainer ring 2 PISTON a A A Figure 108 Install piston return spring retainer nng on clutch shaft Figure 110 A NG oe Apr 2000 Maintenance amp Service Manual Figure 111 Install one steel disc Figure 112 Install one friction disc NOTE The friction discs n 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 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 disc installed is friction Figure 113 install clutch end plate HR24000 6 Speed LD Figure 114 Install end plate retainer ring Figure 115 Install clutch g
50. dy tL NOTE USE RELAY WHERE STARTER SOLENOID DRAW IS MORE THAN GAMPS RELAY NO u DELCO REMY 1114238DR I2VDC OR EQUIV i n DELCO REMY 1114239DR 24VDC OR EQUIV ef Pen Kp VENE CH CAB CONTROL IS SUPPLIED WITH 36INCHES mo OF LEAD WIRE BLANK ENDS eu p Cal CD 2 WIRE SIZE BATX p START fe NO 18 AW G CAB CONTROL ENERGIZED WIRES WIRE NO COLOR CODE 1 4 5 6 i WHITE a G F2 1 4 5 6 10 2 BLACK F3 1 5 6 3 RED CAB Tuan E CONTROL le o F4 5 6 i 1 5 6 10 4 YELLOW ASSY L F5 1 6 5 GREEN pm 1 F6 1 6 10 6 BLUE F3 Fa G N 7 BROWN ka 3f STARTING Wes ENGINE 8 BLACK i ra ka da RI jer d ORANGE R2 lo PINK R3 _ CONTROL u SYSTEM VALVE VOLTAGE ASS Y 12 VDC AND SEE MODEL 24 VDC PARTS LIST E SOLENOID CAPACITY 240212 12 VDC 240224 24VDC a 6 SPD TRANSMISSION ELECTRIC SOLENOID CONTROL WIRING DIAGRAM 1 2VDC AND 24VDC jenueyy 221A18S 9 22UEUSJUIEN aq paads 9 000t2HH Maintenance amp Service Manual HR24000 6 Speed LD DRIVE PLATE INSTALLATION Measure the A dimension Bolt Circle diameter and order Drive Plate Kit listed below Note four 4 kits have three 3 intermediate drive plates and one 1 drive plate and weld nut assembly Two 2 kits with four intermediate drive plates f ALIGNMENT HOLE
51. e See torque chart Position brake actuating arm 3 Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual Figure 315 Position 3rd and 4th speed clutch disc hub on 1st and 2nd clutch shaft Figure 312 Locate brake shoes and linings on backing plate Install upper and lower brake shoe return springs Install brake drum and output flange Figure 316 Figure 313 Install disc hub retainer nng Install output flange O ring washer and nut Figure 314 Tighten output flange nut 200 to 250 ft Ibs torque 271 2 338 9 N m Figure 317 Install disc hub retainer ring retainer M Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 318 Figure 321 Install ring retainer retainer ring Install disc hub retainer ring retainer Figure 319 Figure 322 Position 5th and 6th speed clutch disc hub on the idler install ring retainer retainer ring shaft pug Figuro 323 Install the front output flange O ring washer and nut Figure 320 Tighten flange nut 200 to 250 ft Ibs torque 271 2 338 9 Install disc hub retainer ring N m paa Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 324 Install forward clutch pilot bearing Figure 327 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 ss to alig
52. e chart Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 344 Figure 341 To install the control valve assembly it is recommended two Position a new Q ring over impeller cover bearing aligning studs be used Position new control valve to housing gasket on housing Install control valve assembly Figure 345 Figure 342 Position new shuttle valve gasket on control valve Install Position the impeller cover bearing cap on bearing shuttle valve assembly on control valve Figure 346 Install control valve to housing screws and lockwashers Figure 343 NOTE Use Loctite 262 on upper right hand screw See special section on page 75 for drive plate installation Tighten screws to specified torque See torque chart Apr 2000 Maintenance amp Service Manual 4 Figure 347 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 348 Using a new gasket position charging pump assembly on mounting studs Install washers nuts and capscrews Tighten nuts and capscrews to proper torque See torque chart Figure 349 Install new oil filter cartridge NOTE It is recommended that the filter cartridge be changed after 50 and 100 hours of operation on new and rebuilt or repaired units 60 HR24000 6 Speed LD The following is the disassembly and reassembly of the auxiliary pump drive
53. ear Bearing 1 77 Bearing Locating Ring 1 78 Bearing Spacer ce eee es 1 79 1st amp 2nd Clutch Gear 1 80 BalfleRIng se Baa foe eta PURO CRI E Ee Nan 1 81 Bearing Locating Ring 1 82 1st amp 2nd Clutch Bearing 1 83 Belleville Washer Retainer 1 84 Spring Retainer Ring 1 85 Belleville Washer Fi 86 Belleville Washer Spacer 1 87 1st amp 2nd Clutch Drum amp Bleed Valve Assembly 1 88 Bearing to Shaft Spacer 1 89 Clutch Shaft Rear Bearing 1 90 Bearing Retainer Ring 1 91 1st amp 2nd Shaft Piston Ring 1 92 Bearing Cap Gasket 1 93 Bearing Cap O Ring rennen 1 94 Bearing Cap Plug EE aaa NANA tale 1 95 Rear Bearing Cap 1 96 Bearing Cap Screw Lockwasher 4 97 Bearing Cap Screw eee 4 98 Idler Shaft Front Bearing 1 KT EE alias 1 100 Idler Shaft Rear Bearing 1 101 Idler Shaft Rear Bearing Lock Ball 1 102 Rear Bearing Loca
54. ear inner bearing NOTE This bearing does not have shield in it Figure 116 Position bearing spacer on clutch shaft Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 120 install front bearing Figure 117 9 Install low clutch driven gear and hub into clutch drum REVERSE 3rd AND 4th Align splines on clutch hub with internal teeth of all friction g CLUTCH DISASSEMBLY Reverse being disassembled discs Figure 118 install clutch gear outer bearing NOTE Outer bearing has a Figure 121 shield in it this shield must be up Remove clutch shaft oil sealing nngs and expander spnngs i co Figure 119 Figure 122 Position front bearing spacer on clutch shaft Remove front bearing retainer ring BI Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 123 Figure 126 Remove front bearing Remove reverse gear Figure 124 Figure 127 Remove clutch gear bearing retainer ring Remove end plate retainer ring V Figure 125 Pry reverse gear from clutch assembly far enough to use a Figure 128 gear puller Remove end plate ao DT Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD MP s Figure 132 Figure 129 Compress piston return disc springs Remove return spring Remove inner and outer clutch discs retainer ring and ring retainer Figure 130 Figure 133 Remove taper bear ng spacer Remove piston return disc springs Figure 131 F
55. earing 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 Apr 2000 Maintenance amp Service Manual HR24000 6 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 direction and speed clutches This requires a 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 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 sh
56. emove piston spacer Figure 179 Remove piston DISASSEMBLY OF 5th AND 6th CLUTCH Figure 180 Remove end plate retainer ring HR24000 6 Speed LD nt Figure 181 Remove end plate D BR f Figure 182 Remove inner and outer clutch discs Figure 183 Compress piston return spring retainer Remove retainer nng Apr 2000 Maintenance amp Service Manual Figure 184 Remove spring retainer and return spring Figure 185 Remove clutch piston See cleaning and inspection page 5th AND 6th CLUTCH REASSEMBLY Figure 186 Install clutch piston inner and outer seal rings Size as explained in figure 103 X xS HR24000 6 Speed LD gt o P Figure 187 Install clutch piston in clutch drum Use caution as not to damage seal rings a Figure 188 Position piston retum spring and spring retainer on clutch shaft En a a Figure 189 Compress return spring and install spring retainer ring Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 190 Install one steel disc Figure 193 Install end plate retainer ring FORWARD HIGH CLUTCH REASSEMBLY Figure 191 Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next Figure 194 to the piston is steel last disc installed 1s friction Install Install clutch piston outer seal rings Size as explained in end plate and
57. emove reaction member spacer Figure 18 Remove reaction member retaining ring Figure 21 Figure 19 Remove reaction member NOTE Some units will have a fixed reaction member and some units will have a free wheeling reaction member The fixed is a one piece and the Figure 22 freewheeling is an assembly Remove as an assembly Remove oil baffle retaining ring Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 23 Pry oil baffle from housing NOTE A resistance will be Figure 26 noted because of the heavy oil sealing ring Remove forwerd clutch front pilot bearing Figure 24 Support converter housing with a chain hoist Remove converter housing to transmission casa bolts Figure 27 Remove 3rd and 4th clutch disc hub snap ring retainer outer ring Figure 25 Separate converter housing from transmission case assembly NOTE Reverse and 3rd and 4th and Forward High and 5th and 6th clutches will remain in the converter Figure 28 housing Remove snap ring retainer Bia Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 29 Figure 32 Remove disc hub retainer ring Using an impact wrench if available if not a flange retainer j bar must be used to hold the companion flange from turning loosen output flange nut Remove nut washer O ring and flange Figure 30 Remove clutch disc hub Figure 33 Remove parking brake drum flange nut washer and O ring F
58. ew Lockwasher 1 Apr 2000 Maintenance amp Service Manual FIGURE E Maintenance amp Service Manual HR24000 6 Speed LD CLUTCH ASSEMBLY 1st amp 2nd ITEM DESCRIPTION QTY 1 Backing Plate Retaining Ring 1 2 Clutch Disc Backing Plate 1 8 Clutch Inner Disc eee iain oh ieee 10 gelieft 10 ITEM DESCRIPTION QTY 5 Clutchi PISTON xo c ana an 1 6 Clutch Piston Seal Outer eee 1 7 Clutch Piston Seal Inner an 1 8 1st amp 2nd Clutch Drum Assembly 1 CLUTCH ASSEMBLY FORWARD ITEM DESCRIPTION QTY 1 Backing Plate Retaining Ring 1 2 Clutch Disc Backing Plate 1 3 Clutch Inner Disc 12 4 Clutch Outer Disc erre ner herren 12 ITEM DESCRIPTION QTY 5 iGluteli PISTON riesen ie RE PEERS e RSEN 1 6 Clutch Piston Seal Outer see 1 7 Clutch Piston Seal Inner 1 8 Forward Clutch Drum Assembly 1 CLUTCH ASSEMBLY FORWARD HIGH amp 5th 6th ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Backing Plate Retaining Ring 1 8 Forward High amp 5th 6th Clutch Drum Assembly 1 2 Clutch Disc Backing Plate 1 9Clutch Piston Seal Anne 1 3 Clutch Inner Disc 12 10Clutch Piston Seal Outer sss 1 4 Clutch Outer DISG ccrte ette 12 11 Clutch Piston 5th amp 6th cccccccccceccsscsesecsscsesscsesecsesseesseeeens 1 5 Clutch Piston High
59. g 8 Carefully position the piston ring and expander spring on the clutch shaft in the inner most ring groove Hook the piston piston ring joint 4 Repeat steps 1 2 and 3 for the remaining ring or rings making certain all hook joints are fastened securely 5 Apply a heavy coat of grease to the outer diameter of the rings and clutch shaft Center the piston ring s in the ring groove 6 Before installing the clutch assembly in the front cover or converter housing it is recommended a piston ring sleeve PIN s 241309 237576 or 234265 be used to center all of the piston rings in their respective ring grooves Use extreme caution to not damage piston rings when installing the clutch shaft in the front transmission cover or converter housing USED FOR POSITIONING PISTON RING PISTON RING OF PISTON RINGS SLEEVE 234265 SLEEVE 241309 lt 237576 De g Ze eem N ly H 5 CLUTCH SHAFT CLUTCH SHAFT BEARING PISTON RINGS h PISTON RINGS Be sure that lead in chamfer and intersection of lead in chamfer to piston fing bore is free of burrs and nicks PISTON mg a 248424 P TK Piston Ring 5 Am C i A i BN WA RING GAP NN W f NA l j Y ni LI 248425 YJ NA SPRING fd Expander Ring X N GAP E p kh P tia m SPRING y SPRING GAP AND RING GAP d GAP ARE 180 APART FL 78 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 24000 PLUMBING DIAGRAM WITH LOCK UP PORT P 5625 18 O RING Instai O to
60. h amp 2nd 4M Fwo Hi v it S t amp 6th Ji 2 V EI LI Clutch Pressurized Engaged 4th FWD HI amp 4th 5th FWD amp 5th 6th FWD HI 6th FORWARD 4th HR 24000 6 SPEED TRANSMISSION 71 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 2 mm gt OUTPUT Semen T Wi 3 m a Clutch Pressurized Engaged Fir rec rou RT 1st REV amp 1st d SE 2nd REV amp 3rd c SR 3rd REV amp 5th E A Ll REVERSE ee JE 1 1st Pa L Zo 2nd en e wn e o wm e e e 3rd wem o nn C _ HR 24000 6 SPEED TRANSMISSION 72 Apr 2000 0003 Jdy EI 6 SPEED TRANSMISSION ELECTRIC SOLENOID CONTROL Pilot Pressure Vent ENERGIZED DIRECTION amp SPEED Forward ist Forward 2nd DE ENERGIZED SOLENOIDS ENERGIZED CLUTCHES PRESSURIZED Forward amp 1st Fwd High amp 1st Forward 3rd Forward 4th Forward 5th Fwd amp 2nd Fwd High amp 2nd Fwd amp 3rd Forward 6th Reverse 1st Reverse 2nd Reverse 3rd PILOT amp CLUTCH PRESSURE CHECK POINTS 1P 1st Pilot 2P 2nd Pilot 2C 2nd Clutch FHP Fwd High Pilot R P Reverse Pilot R C Reverse Clutch Fwd High amp 3rd Rev amp 1st Rev amp 2nd Rev amp 3rd jenueyy 2211195 33 a2urud uley aq paads 9 0004ZHH 0003 J
61. 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 anc backing ring with studs in impeller cover NOTE Two dimples 180 apart in backing ring must be out foward engine flywheel Instal 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 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 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 conformance 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 ENGINE crankshaft end play FLYWHEEL 3 Install two 2 50 63 50 mm long transmission to flywheel housing BORE guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole FLYWHEEL 4 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 5 Locate tra
62. iameter 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 direction as long as no pressure is present in that specific clutch Apr 2000 Maintenance amp Service Manual HR24000 6 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 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 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
63. igure 134 Remove inner taper bearing Remove piston spacer os Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD mo Figure 135 Remove clutch piston Figure 138 Remove inner and outer clutch discs DISASSEMBLY OF 3rd AND 4th CLUTCH Compress return spring retainer and remove retainer ring gt ol Figure 136 Figure 139 Remove end plate retainer ring Remove spring retainer and return spring Figure 140 Figure 137 Remove clutch piston Remove end plate See cleaning and inspection page X Apr 2000 Maintenance amp Service Manual 3rd AND 4th CLUTCH REASSEMBLY Figure 141 Install clutch piston outer and inner seal rings Size as explained in figure 103 SS Se Figure 142 Install clutch piston in clutch drum Use caution as not to damage seal rings GH Figure 143 Position piston return spring and spring retainer on clutch shaft un LLL Figure 144 Compress return spring and install retainer ring HR24000 6 Speed LD Figure 145 Install one steel disc Figure 146 Install one friction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next to the piston is steel last disc installed is friction Figure 147 Install clutch disc end plate Figure 148 Install end plate retainer ring 25 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD REVERSE CL
64. igure 31 For 5th and 6th speed clutch disc hub removal repeat Figure 34 figures 27 thru 30 Remove brake drum Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 35 Figure 38 Remove brake shoe return spring Remove brake backing plate attaching bolts and washers Figure 36 Figure 39 Remove brake shoe and lining Remove backing plate Figure 37 Figure 40 Remove brake actuator lever Remove output shaft rear bearing cap bolts and washers Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 41 Figure 44 Remove rear beanng cap Remove low clutch shaft rear bearing cap bolts and washers Remove bearing cap Figure 42 Figure 45 Remove output flange spacer Remove idler shaft rear bearing retainer nut CA Figure 43 Remove idler shaft bearing cap bolts and washers Remove Figure 46 bearing cap Remove idler shaft rear bearing locating ring Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 47 Figure 50 Remove 1st and 2nd clutch rear bearing locating ring Remove rear cover Figure 48 Remove rear cover to Case screws Figure 51 Remove 1st clutch rear bearing to clutch shaft retainer ring Figure 49 The use of aligning studs wil facilitate the rear cover removal Using pry slots provided pry cover from trans mission case Using a soft hammertap on the 1st clutch and Figure 52 idler shaft to prevent cover from binding Remove rear bearing
65. il fluid comes up to LOW mark on transmission dipstick Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines Recheck 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 7 Recheck all drain plugs lines connections etc for leaks and tighten where necessary TOWING OR PUSH ST ARTING 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 66 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 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD CONVERTER OUT PRESSURE CONTROLS CLUTCHTYPE 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 182 3 933 C Transmission in NEUTRAL Operating specifications 25 PS 1172 4 kPal minimum pressure at 2000 RPM engine speed AND a maximum of 70 PSI 482 6 kPa outlet pressure with engine operating at no load governed speed Forward a
66. ine and change its direction to allow correct entry forrecirculation 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 folr 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 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 tlight 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 d
67. ing on clutch shaft tap into place NOTE Bearing locating ring groove must be out Figure 291 Figure 294 install idler shaft assembly into front bearing Install bearing retainer ring 50 Apr 2000 Maintenance amp Service Manual Figure 295 Position oil baffle in transmission sump Figure 296 Position output shaft assembly in front bearing bore use caution ss not to damage front oil seal Figure 297 Position a new gasket and O ring on rear of housing A light coat of chassis grease will hold the gasket in place Install two aligning studs in housing this will facilitate alignment of rear cover to housing Position lock ball in idler rear bearing u B4 ao HR24000 6 Speed LD Figure 298 Align lock ball in idler shaft rear bearing with notch in rear transmission Cover Figure 299 Tap cover in place and secure with bolts and lockwashers Remove sligning studs Figure 300 Tighten cover bolts to specified torque See torque chart Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 301 Figure 304 From the front tap the Ist and 2nd clutch to the rear until Position speedometer gear on output shaft Optional not the rear bearing locating ring groove is exposed Install used on all models locating ring Figure 305 With rear taper bearing cup in rear bearing cap apply a very Figure 302 light coat of Permatex 2 to the outer diameter of the rear Repeat pro
68. n 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 325 Position new O rings and gasket on front of transmission housing A light coat of chassis grease will hold O rings and gasket in place Figure 328 Apply a light coat of Permatex 2 to the outer diameter of Figure 326 the oil baffle oil seal Press seal in baffle with lip of seal Position pilot bearings on the 3rd and 4th amp 5th amp 6th toward impeller hub bearing Position new oil baffle sealing clutch shafts a light coat of grease will hold pilot bearings ring on oil baffle Position oil baffle in housing and install in place retaining ring Be sure ring is in full position in ring groove Apr 2000 Maintenance amp Service Manual Figure 329 Install impeller and hub assembly using caution as not to damage the oil baffle oil ssal NOTE Use extreme caution as not to cut break or unhook the oil sealing ring on the support Figure 330 Position impeller hub bearing spacer
69. nd Reverse Manual Speed Selection Manual Multiple discs hydraulically actuated spring released automatic wear compensation and no adjustment All clutches oil cooled and lubricated Friction Steel OIL FIL TRA TION CLUTCH PRESSURE LUBRICATION 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 DAIL Y with engine running at 500600 RPM and oil at 180 to 200 F 182 2 93 3 CI 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 operation on new and rebuilt or repaired units a Drain transmission and remove sump screen Clean screen thoroughly and replace using new gaskets Drain oil filters remove and discard filter elements Clean filter shells and install new elements Refill transmission to LOW mark Run engine at 500 600 RPM to prime converter and lines Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 1180 200 F 82 2 93 3 C make final oil level check BRING OIL LEVEL TO F lll MARK Full flow oil filter safety by pass also strainer screen in sump
70. nsmission on flywheel 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 transmission to engine guide studs Install remaining screws and tighten to specified torque 6 Remove drive plate locating stud SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER 7 Install drive plate attaching screw and washer Snug screw but do not tighten NOTE Fig 4 installation install drive plate attaching washers and nuts Tighten each nut 28 to 30 ft Ibs torque 38 0 40 6 N m 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 flywheel 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 After all eight 8 screws are installed torque each one 25 to 30 ft Ibs Torque 33 9 40 6 N m This will require torquing each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened FLY WHEEL HOUSING 8 Measure engine crankshaft end play after transmission
71. ot to damage seal rings Figure 221 Position piston return spring spacer over clutch shaft HR24000 6 Speed LD Figure 222 Install piston return springs First spring with large diameter toward spacer Alternate seven 7 springs See note in Figure 100 and Figure 223 A Figure 223 piston return spring retainer ring retainer and retainer ring on clutch shaft Compress return springs and install retainer ring Be sure ring is in full position in retainer Install PISTON FWD HI Figure 223 A cis D cen Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 224 Figure 227 install one steel dise Install end plate retainer ring OUTPUT SHAFT DISASSEMBLY Figure 225 install one fnction disc Alternate steel and friction discs until the proper amount of discs are installed First disc next Figure 228 to the piston is steel last disc installed is friction Remove rear bearing Figure 226 Figure 229 Install clutch disc end plate Remove output gear 39 Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD R Figure 230 Figure 233 SMOOVE gesr Spacer Position gear spacer on output shaft Figure 231 Remove front beanng Figure 234 See cleaning and inspection 8 9 P peg Position output gear on shaft with long hub of gear up OUTPUT SHAFT REASSEMBLY Figure 232 Figure 235 install output shaft front taper bearing large diameter of install output
72. plug washer spring and ball Remove shift rail and shift rail oil seal See cleaning and inspection page REASSEMBLY Apply a light coat of permatex 2 to the outer diameter of the pump disconnect shift rail oil seal install seal in Figure 363 housing with lip of seal n Position shift fork on shift rail with long hub of fork toward Install shift rail in housing NOTE Notches in shift rail pump opening Tighten fork to rail lockscrew securely and must line up with detent hole on top of housing lockwire to prevent loosening ie Apr 2000 Maintenance amp Service Manual Figure 364 Position shift hub in shift fork with hub gear teeth toward pump drive gear Shift hub into gear to hold hub in position Figure 365 Install a new OQ ring on the pump drive idler shaft Position lock ball in shaft NOTE A light coat of chassis grease will hold ball in shaft Figure 366 From the front side converter section install pump drive idler gear and bearing assembly Align idler shaft lock ball with notch in housing Tap idler shaft O ring and lock ball into housing and thru idler gear and bearing until idler shaft snap ring groove is exposed HR24000 6 Speed LD Figure 367 nstall idler shaft retainer ring Figure 368 Position pump drive idler gear drive gear and bearing assembly in housing Figure 369 Install a flat washer on each support bolt Install a sealing washer on each support bolt Align
73. pump drive bearing support holes with holes in housing Install bolts and washers thru the housing and into the bearing support Tighten 23 to 25 ft Ibs torque 31 2 33 8 Nm Apr 2000 Maintenance amp Service Manual Figure 370 Position pump drive gear support and bearing assembly in converter housing Figure 371 Align pump drive gear support holes with holes in converter housing install support screws and lockwashers Tighten 23 to 25 ft Ibs torque 31 2 33 8 N m Proceed with converter housing assembly OIL SEALING RING SLEEVE REMOVAL NOTE The following photos are not of the HR Converter Housing but the sieeve removal procedure is identical Figure 372 Remove clutch front bearing retaining ring oe HR24000 6 Speed LD Figure 373 Remove front oil sealing ring sleeve retainer screw and washer Remove sleeve lock Figure 374 Using a sleeve puller like the one shown remove sleeve Figure 375 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 sieeve is aligned with sleeve lock notch Apr 2000 Maintenance amp Service Manual CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
74. put Front Fi Auxiliary Pump Drive Breather SEE NOTE Port L SEE NOTE Port J Port J Check Point C C Heat Exchanger Inlet Temperature Check Point BB Heat Exchanger Outlet Pressure E Port A 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 Port M REAR VIEW HR24000 6 Speed LD Parking Brake Option Port K Converter Inlet Pressure Check Point Dipstick 1st Clutch Pressure Check Point 375 24 SAE O Ring Port Ground Driven Emergency Steering Pump Drive amp Mounting Option Port U Drain Plugs or Optional Vendor Dipstick Ports Apr 2000 Maintenance amp Service Manual Charge Pump for Remote Filter Option Check Point for Forward HR24000 6 Speed LD REMOTE FILTER OPTION Port F LA Regulator Valve Pressure 240 280 PSI 1655 1931 kPa Modulated Clutch 1 4 NPT x Oil Screen 7 FWD HI 3RD 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 pressure with 600 PSI 4137 kPaJ intermittent surges Ref SAE Spec No 4517 100R1 Hydraulic Hose Specifications 2 See Lubri
75. s Lubricate all 0 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 carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD 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 operation 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 connecting hydrauli
76. snap ring Figure 103 Figure 195 Figure 192 Install clutch piston inner seal rings Size as explained in Install clutch disc end plate Figure 103 33 Ve Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD Figure 199 Install piston return spring retainer ring retainer and Figure 196 ratainer ring on clutch shaft Compress return springs and Install clutch piston in clutch drum Use caution as not to install retainer nng Be sure ring is in full position in damage seal rings retainer 4 ki PISTON FWD HI Figure 197 Position piston return spring Spacer over clutch shaft Figure 199 A Figure 198 Install piston return springs First spring with large diameter E toward spacer Alternate seven 7 springs See note in Figure Figure 200 100 Install one steel disc TAM Dans Apr 2000 Maintenance amp Service Manual Figure 201 Install one friction disc Alternate steel and friction discs untilthe proper amount of discs are installed First disc next to the piston is steel last disc installed is friction Install end plate and snap ring Figure 202 Install clutch disc end plate Figure 203 Install end plate retainer ring HR24000 6 Speed LD 1 Figure 204 Install clutch gear inner bearing NOTE This bearing does not have a shield in it lt Figure 205 Instali clutch driven gear and hub into clutch drum Align splines on clutch hub with internal
77. te Backing Ring 1 54 Drive Plate Mounting Screw 10 55 Drive Plate Mounting Screw Lockwasher 10 56 Impeller to Cover Screw 24 57 Impeller to Cover Screw Lockwasher 24 58 Turbine Hub 1 59 T rbine n Pag yaa Nagka rete kang as 1 60 Turbine Hub Ring 1 61 Turbine to Hub Screw 12 62 Turbine Retaining Ring 1 63 Reaction Member Retaining Ring 1 64 Reaction Member 1 65 Impeller to Hub Bearing Spacer 1 66 Impeller to Hub Screw 8 67 Impeller to Hub Screw Lock Tab 4 68 Impeller 2 2 2 Sea en 1 69 Impeller Hub O Ring 1 70 impeller Hub Gear 1 71 Impeller Hub Gear Bearing 1 72 ldler Shaft O Ring 2 73 Reverse Idler Shaft 2 74 Oil Baffle Retaining Ring 1 75 Oil Baffle sad nee amet 1 76 OU Sealiid ut dee Mar Sh ee he ee 1 77 Oil Baffle Seal Ring 1 Apr 2000 HR24000 6 Speed LD Maintenance amp Service Manual FIGURE D Apr 2000 Maintenance amp Service Manual HR24000 6 Speed LD CLUTCH AND GEAR GROUP ITEM DESCRIPTION OTY 1 Forward Shaft Pilot Bearing 1 2 Spring Retainer Ring
78. ting Ring 1 103 Pump Drive Sleeve oe ys tese eer era me SERED 1 104 Idler Shaft N t zer nel Rate re 1 105 Jdl r G ar Spacer oem rerien dapis randina 1 106 Idler Shaft Gear 1 107 Idler Shaft Gear 1 108 idler Shaft Bearing Cap Gasket 1 109 idler Shaft Bearing Cap 1 110 Idier Shaft Bearing Cap Screw Lockwasher 4 111 Idler Shaft Bearing Cap Screw 4 112 Output Shaft 1 5 c ass NG Dace ler pe dad 1 113 Output Gear Spacer 1 TIA Opa TEE es Pan 1 115 Rear Bearing Cone 1 116 Rear Bearing Cup 1 117 Rear Bearing Cap O Ring 1 118 Rear Bearing Cap O Ring 1 119 Rear Bearing Cap 1 120 Rear Bearing Cap Screw Lockwasher 3 121 Rear Bearing Cap Screw 3 122 Rear Bearing Cap Oil Seal 1 123 Rear Output Flange 1 124 flange Q Ring iis ve b tette mme Res 1 125 Flange Washer 1 NEE EE 1 127 Rear Bearing Cap Screw 1 128 Rear Bearing Cap Scr
79. wing illustrations are provided SECTIONAL VIEWS AND PARTS IDENTIFICATION Basie Design xcu nn en ee ee en al nahen Fig A Converter and Transmission Case Group Fig B Converter Group kah oh sae eine een oe we as Fig C Six Speed Gear and Clutch Group Fig D tee ee EE Fig E Control Valve Assembly anann 0 0 00 eee eens 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 Model consists of a separate torque converter mounted to the engine with the powershift transmission remotely mounted and connected to the torque converter with a drive shaft The shift control valve assembly may be mounted directly on the 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 assemblies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct g

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