Service Manual
Contents
1. Figure 165 Using example 035 037 average 036 016 052 shim pack position shim pack and main drive gear bearing cap on main drive gear Lube oil groove in bearing cap MUST be at the top Figure 166 Install capscrews and tighten 15 20 ft lbs torque 20 4 27 1 N m Figure 167 Place transmission in vertical position with main drive gear pointing down Install transmission out put flange and torque the nut Roll main drive gear and mainshaft to seat front and rear taper bearings Position a dial indicator as shown Pry on output flange to get main Shaft end play End play must be between 002 008 0 05 0 02 Add shims for more end play or remove Shims for less end play NOTE Each time a change is made retorque stud nuts and roll mainshaft Apply Loc tite 510 to both sides of each shim Using the main drive gear bearing cap as an alignment guide install the clutch housing to the transmission housing Tighten stud nuts securely With new gasket in position and transmission in neutral position control cover over gears aligning shift forks in shift cover with gear shift hubs If control cover is in neu tral and transmission is in neutral transmission drive gear should turn without output shaft turning Figure 168 When installing control assembly install and tighten center rear screw first center front screw second and then remaining screws Tighten screws 20 25 ft lbs torque 27 1 33 8 N2. Figure 34 Remove reverse gear Use caution as NOT to lose needle rollers under reverse gear Figure 36 Remove 2nd gear split washer CAUTION NOT lose locating ball This is to prevent split washer from spinning Do Pr 5 a o Figure 37 Remove 2nd gear Use caution as NOT to lose needle rollers under 2nd gear See Cleaning and Inspection Section Page 24 MAINSHAFT REASSEMBLY Figure 38 With clutching teeth of 3rd gear down coat inside diameter of gear with a high quality heavy grease This will hold needle rollers in position while assembling Lay up first row of needle rollers NOTE Units built before serial number 045451YJ will not have needle rollers under 3rd amp 4th speed main shaft gears Figure 39 Position roller spacer on first row of rollers Figure 43 Using caution as NOT to catch the needle roll ers on the edge of a spline or snap ring groove install 3rd Figure 40 Lay up second row of needle rollers gear on mainshaft Figure 44 Install 3rd speed thrust washer lock ball washer and washer retainer ring Figure 41 Position outer roller spacer on second row of NOTE Thrust washer for units with needle bearings rollers Grease rollers to hold in place under 3rd gear is thicker than washer for units without needle bearings under 3rd gear 280 282 with nee dles 240 238 without needles Figure 42 Figure 45 Turn mainshaft over Install 3rd gear synchro ni
3. sealant are required tighten 20 to 25 Lb Ft 27 2 33 8 Nm OVERHAUL OF TRANSMISSION ASSEMBLY The instructions contained herein cover the disassembly CAUTION Cleanliness is of extreme importance and an and reassembly of the transmission in a sequence that absolute must in the repair and overhaul of this unit would normally be followed after the unit has been Before attempting any repairs the exterior of the unit removed from the machine and is to be completely over must be thoroughly cleaned to prevent the possibility of hauled dirt and foreign matter entering the mechanism DISASSEMBLY OF THE TRANSMISSION Figure 1 Remove shift lever control top o trol assembly Figure 4 Remove rear mainshaft bearing cap and speedometer drive gear Figure 2 Remove control cover capscrews and control cover Figure 5 Tap on main drive gear to move mainshaft to Figure 8 Remove main drive gear and hearing assem the rear about 14 6 35 mm Use pry bars as shown to bly remove rear bearing cup and locating ring Le e i A A eA ES Figure 9 Using a hoist if available and a heavy rope Figure 6 Remove main drive gear cap bolts lift mainshaft assembly from transmission case Main Shaft can be removed by hand but is quite difficult to handle Figure 7 Using a soft hammer tap on threaded end of mainshaft Move mainshaft toward main drive gear From front of transmission remove main dri
4. wi A CLARK 390V TRANSMISSION THE CLARK SYNCHRONIZER AND HOW IT WORKS FOR YOU The Clark split pin synchronizer prevents the clashing of the gears and increase the speed of shifting In a conventional transmission which does not have synchronizers the absence of gear clashing is dependent entirely on the skill of the truck driver By double clutching and split second timing of engine speeds with the gear shifting movement a driver can synchronize the speeds of the engaging gears and thereby prevent the damage to gears by clashing when a fast shift The splint pin sychronzier performs the same function with or without the double clutching operating even though the driver does not accurately time his gear shifting movements It also mechanically prevents the driver from completing the shift to the point of gear engagement until the engaging gears have reached the same or synchronous speeds This is known as the blocking action of the synchronizer and it is this action that makes the oper ation of shifting a transmission having synchronizers different from one which does not have synchronizers Upon shifting gears in these synchronized transmissions the first part of the gear shift lever movement brings the blockers into contact The blockers momentarily prevent further movement of the shift lever and the pressure exerted by the driver to complete the movement is transferred by the blockers to the synchronizer providing the force nec
5. Approx install clutch return spring clips as shown when required Shim here to obtain 002 008 0 06 0 20 endplay on main drive gear when mainshaft rear bearing cup assembly is tightly clamped to rear face ot case Coat both sides of each shim with Loctite 510 before final assembly Tighten P T O cover screws 6 each side Tighten 2 screws 10 to 15 Lb Ft 13 6 20 3 N m to maximum torgue of 5 Lb Ft 6 7 Nm Tighten 6250 11 bolts 80 to 100 Lb Ft 108 5 135 5 N m 4th and 5th shift hub sleeve Short teeth to front of transmission Large chamfered side of hub to be put on the shaft first E i Tighten 4 screws 35 to 45 Lb Ft 47 5 61 0 N m K I WW A d Ee E K i d E _ mg t Tighten flange nut 400 to 450 Lb Ft 542 610 N m Coat gaskets on both sides or coat both mating surfaces with Loctite 510 before assembly These screws must not be over tightened to avoid cover A gasket damage When installing control assembly insta l amp tighten center rear screw first center front screw second amp then remaining screws Smooth ground surface next to needle thrust bearing P T O cover gaskets to be installed dry Tighten drain and filler plug 30 to 40 Lb Ft 40 7 54 3 N m when plain plugs are used When plugs with pre applied
6. Install 1st gear on mainshaft Ist GEAR Figure 60 Position 1st and Reverse shift hub sleeve and hub on mainshaft NOTE Counterbore in shift hub sleeve Fi 63 must be up igure 11 St e notte oh Figure 64 Position 1st gear split washer in groove of Figure 67 With clutching teeth of 4th gear down coat mainshaft NOTE If a 1st gear thrust washer is used in inside diameter of gear with a high quality heavy grease place of the split washer position thrust washer on shaft This will hold need rollers in position while assembling and proceed with Figure 66 Lay up first row of needle rollers NOTE Units built before serial number 045451YJ will not have needle rollers under 3rd amp 4th speed main shaft gears Figure 65 washer Wr Figure 66 Using a suitable bearing driver and soft ham mer install mainshaft rear taper bearing Be certain bear Figure 69 Lay up second row of needle rollers ing race is tight against split washer 12 NEEDLE BEARING 4th GEAR N AN Figure 73 Install 4th amp 5th synchronizer assembly and Figure 70 5th speed synchronizer cup on shaft Figure 74 Grease thrust bearing and install bearing and bearing race on mainshaft Figure 71 Turn gear over and using caution as NOT to catch the needle rollers on the edge of shaft install 4th Speed gear eN AM Figure 75 Mainshaft assembly complete Figure 72 Position 4th gear synchronizer c
7. between the bearing cap and transmission housing The following procedure is recommended to achieve a proper taper bearing end play Figure 157 Remove transmission clutch housing With main drive gear needle rollers in place and greased position main drive gear in housing bore Alogn clutching teeth on main drive gear with teeth in 5th speed synchro nizer cup Figure 158 Coat O D of oil seal with Loctite 510 and install with lip of seal up in main drive gear bearing cap 21 Figure 159 Position main drive gear bearing cap on main drive gear Lube oil groove in cap at the top Figure 160 Install two capscrews 180 Degrees apart and torque screws to 15 inch Ibs 1 7 N M Figure 161 Turn main drive gear and mainshaft by hand back and forth to seat taper bearings Figure 162 Recheck bearing capscrews and tighten to 30 inch Ibs torque 3 4 N m Figure 163 Using a taper gauge ata capscrew as Shown record gap between bearing cap and housing Example 035 0 88mm l E KS Figure 164 Using taper gauge at other capscrew as Shown Record gap Example 037 0 93 mm average between one capscrew and the other would be 036 0 91mm Using 036 as the average gap between the bearing cap and housing add 016 0 40 mm Example 036 016 will give a shim pack of 052 1 32 mm This Shim pack example would give a mainshaft end play of 002 008 0 051 0 203 mm 28
8. m 29 Figure 169 With special shift lever control top gasket in position install control top or remote control assembly on control cover Tighten screws 20 25 ft Ibs torque 27 1 33 8 N m CLEANING AND INSPECTION CLEANING Cleaning all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in clean ing fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners 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 inhalation of vapors and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lintless absorbent wiping rages free of abrasive materials such as metal filings contaminated oi
9. position Install shaft lock and capscrew 26 Figure 151 Coat a new gasket on both sides with Loctite 510 Position gasket on countershaft bearing cap Install bearing cap and bolts Tighten bolts 20 25 ft lbs torque 27 2 33 8 N m Figure 152 Install mainshaft assembly into transmis sion case as shown Figure 153 Position mainshaft rear bearing cup in housing bore Figure 154 Using a soft hammer tap rear bearing cup until cup locating ring is against housing i ei Be A b Ap wl EEN bh a Y a P Figure 155 Coat O D of oil seal with Loctite 510 and press seal in mainshaft rear bearing cap with lip of seal down Coat a new gasket on both sides with Loctite 510 Position gasket on mainshaft rear bearing cap Use cau tion as not to cover oil return grooves in bearing cap Install bearing cap with oil grooves lined up with oil holes in case ae h z y a i Figure 156 Install bearing cap bolts Tighten bolts 35 45 ft lbs torque 47 5 61 0 N m MINSHAFT TAPER BEARING ADJUSTMENT The mainshaft rear taper bearing and main drive gear taper bearing must have a 002 to 008 0 051 0 203mm end play after assembly of transmission is complete The mainshaft rear taper bearing and bearing cup are not adjustable The main drive gear taper bearingcup is located in the main drive gear bearing cap The taper bearing end play is regulated by shim pack
10. 39 Tip rear of countershaft down and into transmission case Feed rear of countershaft through rear countershaft bearing bore Move countershaft forward and into pilot bearing CAUTION Do NOT disrupt coun tershaft needle bearing Figure 140 Position rear bearing oil baffle as shown and Start rear bearing Figure 141 Drive rear bearing on countershaft and into rear bearing bore NOTE Countershaft drive gear must be Supported on each side with a 14 6 35mm flat bar to prevent damage to countershaft pilot bearing 25 Figure 1 ring N PE Install countershaft rea 7 e e Figure 143 Use heavy grease on reverse idler thrust washers to hold in place Position tang of washer in groove in housing Figure 144 Coat inside diameter of reverse idler gear with high quality heavy grease This will hold needle roll ers in position while assembling Insert one roller spacer Figure 148 Position roller spacer on second row of roll Figure 145 Lay up first row of needle rollers in spacer ers Grease rollers to hold in place NEEDLE BEARING _ REVERSE IDLER Figure 149 Figure 150 Carefully position reverse idler gear in hous ing Use caution as NOT to disrupt needle rollers Insert Figure 147 Lav up second row of needle rollers idler shaft through case and idler gear needle rollers d NOTE Idler shaft lock groove MUST line up with lock screw hole Drive shaft into
11. 85 Remove 2nd amp 3rd shift fork and rail assem bly CAUTION Do NOT lose interlock cross pin Figure 86 Remove 1st amp Reverse shift fork rail and lug assembly Figure 87 Using a small magnet remove the 1st amp Reverse shift fork rod lock pin Figure 91 If the 2nd 3rd 4th or 5th shift fork bushing is A en CR to be replaced remove worn bushings from fork Install Figure 88 Remove 1st amp Reverse shift fork and rail new bushing and bend bushing tab over top and bottom assembly of fork u l A ke u an i l Figure 92 Remove reverse latch plunger pin and spring See Cleaning and Inspection Section page 30 REASSEMBLY p LE m i P Wl mg o gt Es H pt Figure 90 Remove mesh lock spring and lock ball 3 each Remove crossover interlock balls 4 each Di Figure 93 Install reverse latch plunger spring pin and plunger spring plug 16 Figure 94 Position crossover interlock balls in cover cross bores 2 balls in cover cross bore between Ist amp Reverse rail groove and 2nd amp 3rd rail groove and 2 balls in cover cross bore between 2nd amp 3rd rail groove and 4th amp 5th rail groove See Figure 94 A INTERLOCK AL LS 4 INTERLOCK CROSS PIN 1 EE BALLS ADDED FOR BACK UP SWITCH ONLY Figure 94 A Figura 95 Position the mech lock spring and ball 3 each in spring pockets See Figure 94 A 17
12. E T M Fuller Mid Range Transmissions Roadranger More time on the road Service Manual Fuller Mid Range Transmissions TRSMO197 October 2007 Caution 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 FOREWARD This manual has been prepared to provide the customer and the maintenance personnel with information and instruc tions on the maintenance and repair of the CLARK Transmission Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight out lay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the transmission its principle of operation troubleshooting and adjustments it is urged that the service person study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of components parts is required only Clark 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 The Clark Equipment Company does not warrant rep
13. ESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Roadranger ETN 20 07 Eaton Corporation All rights reserved Printed in USA For spec ing or service assistance National Institute for SERVICE EXCELLENCE call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 80 0 826 4357 for more time on the road Or visit our web site at www roadr anger com Eaton Corporation Truck Components Operations Roadranger Eaton Dana and other trusted partners providing the best products and services in the industry ensuring more time on the road PO Box 4013 Kalamaz oo MI 49003 U S A www roadranger Com
14. Figure 96 Position 1st amp Reverse rocker arm on pivot pin Figure 97 Install 1st A Reverse shift fork and rail assembly in control housing Install shift rail lock pin to position rail in control housing Install 1st amp Reverse shift lug rocker lug Figure 98 shift rail and spacers in rail groove over mesh lock ball and spring NOTE Position widest spacer between shift lug and front support 2 narrower spacers between the shift lug and center support Figure 99 Install interlock cross pin in 2nd amp 3rd shift rail Position 2nd amp 3rd shift rail and fork assembly in rail groove over mesh lock ball and spring Make certain torque 27 2 33 8 N m Test Cover for Double Shift Pry 4th amp 5th shift fork and rail out of neutral position Try to pry 1st amp Reverse shift fork and rail out of neutral position 1st A Reverse fork should NOT shift If it does interlock cross pin or interlock cross over balls were not assembled correctly Disassemble cover and correct cross over See Figure 94 A FABRICATED RAIL SHIFT CONTROL DISASSEMBLY Figure 100 Position the 4th 8 5th shift rail and fork assembly in rail groove over mesh lock ball and spring Figure 103 With control cover in neutral pry 4th amp oth shift fork to 4th speed position toward the rear of cover Figure 101 Position front rail support over shift rails and install capscrews Position rear support over rails and
15. air or replacement parts nor failures resulting from the use thereof which are not supplied by or approved by the Clark Equipment Company IMPORTANT Always furnish the Distributor with the transmission serial and model number when ordering parts CL550 SERIES TRANSMISSION The CL550 is a 5 speed forward 1 speed reverse transmission of advanced design offering you the most efficient torque capacity to weight ratio of any 5 speed transmission in its torque range Two basic ratios are available as shown in the table below The CL551 ratio is designed for use in trucks equipped with a 3 or 4 speed auxiliary transmission and the CL557 ration is designed for use with trucks equipped with a 2 speed rear axle MODELS Speed CL551 390V CL557 397V CL558 Ta Constant mesh in all gears including low and reverse is a CL550 feature as is helical gearing throughout including low and reverse The Clark split pin synchronizer is used in 2nd 3rd 4th and 5th gears Greater bearing capacity in the CL550 is achieved by the use of numerous needle roller bearings and two tapered roller bearings and one large straight roller bearing at the rear of the countershaft shift forks have replaceable bronze inserts The shift pattern is of the standard progression type with all shifts having the same throw at the lever Page B shows a cutaway drawing of the CL550 Page C shows a cutaway drawing of the 390V CLARK CL550 TRANSMISSION D r b i 15 Jit
16. amp Sth Shift Hub Bearing ocoocooconconconconconconcnnonncnncnnrnnos 1 40 4th 4 5th Shift Hub Bearing Hacg cece ceesecessseeesseeeeees 1 41 Name E 2 42 Name Pl te are een 1 43 Countershatft Gear Retainer RIN neeese 1 ITEM Description QTY 44 45 46 47 48 49 50 51 52 53 54 99 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 15 76 17 78 79 80 81 82 83 84 85 86 87 Countershaft Drive Aa ee 1 CONAM e dao e 1 Countershaft Gear Key ooooooncccccccccocncooccoocnnoonconnncnonononanonnnonnns 2 CAU do 1 ODM E 1 Countershaft Rear Bearing oo oncnnnnnnininnnninanaranininaracinn caos 1 Countershaft Rear Bearing Outer Retainer Ring 1 Countershaft Rear Bearing Retainer Himg essccscccceccnrcn 1 Countershaft Rear Bearing Cap Gasket o 1 Countershaft Rear Bearing Lan 1 Kockwasher ee rer en 4 Rear Bearing CapSCreW geet a daa 4 Mainshaft Rear Bearing Cup amp Snap Ring 1 Speedometer Drive Gal o oonnncconnnnonicncnoninirarncinarananara canon 1 Mainshaft Rear Bearing Cap Gacket 1 Mainshaft Rear Bearing Lan 1 A O A 3 Mainshaft Rear Bearing C pgCreuw 3 Mainshaft Rear Bearing Cap Oil Seal 1 Mainshaft Flange Mut 1 Speedometer Tube Nut o onnocononncncnoncconnncnnnnncranicinanacino caos 1 Speedometer Driven Gear 1 Mainshaft Rear Bearing C pgCreuw 1 LOCK WAS INC ae ee a 1 Reverse Idler LOCKkSCreW ne
17. amp eReverse SOME Mall aaa eek 1 20 MIER BUSTING Aussen 2 21 SEET tee 2 22 4th amp 5th Shift EE 1 230 Rear Rail SUD DOR EEN 1 24 Rail Support ScreW nneeseeseeeseessssennnsnnnnnnnnnnnnnnnnnnnnnnennnnnnnen 6 GER Gei RAN OUD DOM sun era 1 26 2nd amp 3rd Shit codi 1 27 INterEock Gross Planas 1 28 1st Gear Shift Stop Space Wide ooocconcnnccocnncncicncccnconncnnos 1 29 TSEC Gear SHU LUO WEE 1 30 1st Gear Shift Stop Spacer o ooooonocononcccnncccnoncnononaninnanonnononnos 1 ITEM Description QTY A a EN En 1 32 Mesh amp Inter Lock Bali a 10 Ja Mesh Lock SPRING Seelen 3 34 Back up Switch Hole Plug Gasket 1 35 Back up Switch Hole Piug ness 1 36 1st amp Reverse Latch Plunger Springer Plug 1 37 1st amp Reverse Latch Plunger Plug Gacket 1 38 1st amp Reverse Latch Plunger Stop 1 39 1st amp Reverse Latch Plunger Spring cecene 1 40 1st amp Reverse Latch Plunger ceiien 1 AA erh 4 42 Screw Lockwasher CLARK CL550 SERIES TRANSMISSION ITEM DESCRIPTION QTY 1 Control Gover Basket anne 1 Ce TT E 14 3 Control GOVE EE ci ee 14 4 Control Cover Assembly sciis 1 5 Mainshaft Reverse Gear Bearing Spacer oconcccnncccnincnnnnnnos 1 6 Mainshaft Reverse Gear Roller Bearino 48 7 Mainshaft Reverse Gear Bearing Spacer oiccen 1 8 Mainshaft Reverse Gear Roller Bearino 48 9 Mainsha
18. bri cant 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 30 1 TROUBLESHOOTER S TRANSMISSION CHECKLIST NOISE ARISING IN NEUTRAL Misalignment of transmission Worn transmission bearings scuffed gear tooth contact surfaces on gears Worn mainshaft gear bushings Worn or rough reverse idler gear Sprung or work countershaft Excessive backlash in constant mesh gear Work mainshaft pilot bearing Incorrect lubricant Low lubricant level Noisy main drive gear bearing NOISE ARISING IN GEAR Worn or rough mainshaft rear bearing Excessive end play on mainshaft gears Noisy speedometer gears See Conditions under 1 NOISE ARISING OUTSIDE Out of balance fan Defective torsional dampener Out of balance crankshaft Out of balance flywheel Out of balance clutch assembly Loose engine mountings Worn universal joints U joints improperly installed Out of phase Misaligned or sprung driveshaft Incorrect driveshaft assembly Out of balance driveshaft Out of balance parking brake drum DIFFICULT SHIFTING Improperly operating clutch Does not release properly Shift hubs tight on Shift hub sleeve splines Damaged pointing on clutching teeth Misaligned mainshaft Damaged or worn synchronizer assembly Improper linkage adjustm
19. ent Worn or sprung shift fork 31 9 STICKING IN GEAR Improperly operating clutch Shift hubs tight on shift hub splines Misaligned mainshaft Improper linkage adjustment SLIPPING OUT OF DIRECT Misaligned of transmission on engine Worn drive gear teeth Worn clutching teeth on shift hub or drive gear Insufficient tension on detent balls Improper linkage adjustment Excessive shift lever whip action Worn torque lock on shift hub sleeve SLIPPING OUT OF OTHER SPEEDS Excessive clearance between mainshaft gear and mainshaft or worn needle bearings Excessive end play of mainshaft gear on mainshaft Worn clutching teeth Weak detent ball springs Improper linkage adjustment Worn torque lock on shift hub sleeve LOSS OF LUBRICANT Lubricant level too high Damaged gaskets Damaged or worn oil seals Cracked transmission housing Use of incorrect lubricant Oil return holes under bearing caps plugged BEARING FAILURES Use of incorrect lubricants Improper bearing adjustment Improper reassembly in unit overhaul Lack of cleanliness in unit overhaul Foreign particles in transmission Copyright Eaton and Dana Corporation 2007 EATON AND DANA CORPORA TION hereby grants its customer s vendor s or distributor s permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR R
20. es sary to synchronize the gears being engaged When the engaging gears have reached the same speed the blockers automatically disengage permitting the gear shift lever movement to be completed Therefore to properly shift a syn chronized transmission a steady and continuous pressure must be applied by the driver to the shift lever until the shift is completed Under normal conditions this action is instantaneous sometimes difficulty is experienced in shifting a synchronizer when the vehicle is standing still This is caused by the fact that the disengagement of the blockers requires relative rotation and with the vehicle at rest and with the engine clutch released there may be at times no relative rotation of the engaging gears Under these conditions the same con tinuous pressure should be applied to the shift lever and at the same time the clutch should be engaged slightly This will give sufficient rotation to unblock the synchronizer and allow the shift to be completed without difficulty RECOMMENDED LUBRICANTS FOR CLARK MANUALLY SHIFTED TRANSMISSIONS Mil L 2105C Extreme Pressure Lubricant or API classification GL 5 of the SAE viscosity recommended in the chart at the right is preferred All lubricants should be backed by the reputation of a well know sup ai T plier It is important to specify EP lubricants of the MIL L 2105C type only or of a API classification GL 5 Prevailing Ambient Temperatura ON a m d Do not u
21. ft Pilot BearinQ oooocconococonocanonccanonnonananono nos 1 103 Clutch Housing to Case Gud 2 104 Pedal Shaft Grease Fitting kA 2 105 Pedal Shaft Bushumg ccc ecccesccesscesseecsseeccsseeesseecenesenaess 1 106 Clutch Housing Lover 1 107 Clutch Housing Cover Screw Lockwasher 2 108 Clutch Housing Cover ScreW ooococccccocccconccononononinononcnonananinn anos 2 A TO 1 WO BUSMN A 1 111 Clutch Housing To Case Stud Nut 6 112 Clutch Housing To Case Stud Lockwasher 22 22200 2 0 6 MS BM cia ada ad 1 1 14 GIUIEHHOUSIT an co 1 115 Clutch Housing To Case Gud 4 116 PR UAG Ad dd 6 117 IA 1 118 O NOAA EE 1 1 19 Magnetic Drain Pl aaa io asi 1 120 Filler PIUGK see 1 Not used on all models AR As Required CLARK CL550 SERIES CONTROL PARTS GROUP ITEM Description QTY 1 Gear Shift Lever Dust Cover 1 2 Gear ome ro Maca 2 SO Elo CM re EE 1 4 Eug Eee 1 5 Gear Shift Lever Support Wacher 1 A ue EE 1 7 Control Top or Remote Control Gasket oo ocoocccnooo 1 8 EXPANSION Plena 1 A ee 1 10 1st amp Reverse Rocker Lug onncccnnnnnnnnnnnnnnncnanicinnnnacin nacos 1 11 Shift Fork LOCK Pm 4 12 et Reverse Rocker AM Asia 1 13 Mhie STONE 1 14 EE ee 1 15 Mesh Eock Ball nennen aan 1 16 1st amp Reverse Mesh Lock Gpmmng 1 17 1st amp Reverse Shift Fork eesenseseensennennennnensenneennennennnenen 1 18 1st amp Reverse Shift Fork Rail Lock Pm 1 19 ISE
22. ft Reverse Gear 1 10 st amp Reverse Shift Hub Sleeve 1 11 Shift Hub Sleeve Retainer RiNQ ooooccnccccnonccnnoncnonanaroncnonos 1 12 SES Reverse Shit EE 1 13 Mainshaft 1st Gear Bearing Spacer 1 14 Mainshaft 1st Gear Roller Bearing scce 44 15 Mainshaft 1st Gear Bearing Gpnacgr 1 16 Mainshaft 1st Gear Roller Bearing nennen 44 17 Mainshaft 1st Gear 1 18 Mainshaft Rear Bearing Thrust or Split Washer Retainer Ring 1 18A Mainshaft Split Washer nnen 1 19 Mainshaft Rear Bearing Long 1 CDN UE 1 21 Split Washer Retainer RINQ oooococnccccnoncccnoncnonacinoncnonananonnnoss 1 22 Mainshaft 2nd amp Reverse Gear Split Washer 2 23 Mainshall 2nd Bear 5 rd e 1 24 Mainshaft 2nd Gear Bearing Gparcer 1 25 Mainshaft 2nd Gear Roller Bearing 0 48 26 Mainshaft 2nd Gear Bearing Gparcer 1 27 Mainshaft 2nd Gear Roller Bearing 00 48 A een 1 29 2nd amp 3rd Synchronizer Assembly ocoocccccnocnciccncccncconncnnnos 1 30 3rd Gear Synchronizer Cup 1 sl Mainshalt grd Gear zustehen 1 32 Mainshaft 3rd Gear Locating Wacher seeren 1 33 Mainshaft 3rd Gear Retainer mg 1 34 Mainshaft 4th Gear sical cc tama eis Eee 1 35 4th amp Sth Shift Hub Sleeve ooooconconconconconconconcncnnconcnnons 1 36 4th 5th Synchronizer Cup 1 37 4th oth Synchronizer Assembly 1 38 4th Sth Synchronizer Cup 1 39 4th
23. g Clutch Housing Gover E Cover Beie Te COWEN SOO EEN Bushing Bushing Clutch Housing To Case Stud Mut Clutch Housing To Case Stud Lockwacher cscs Bushing Guten o eine BEE Clutch Housing To Gase Gd P T O Cover Plate crew K RE GOVE PIC A P T O Cover Plate Gasket suste Serie enee Eed Magnetic Drain Plig us u Filler Plug CLARK 390V SERIES CONTROL PARTS GROUP ITEM Description QTY 1 Gear Shift Lever Dust Loyer 1 2 Gear Shift Lever Pivot Pm 2 3 SGOMMON TOD sa aaa 1 A GBA SD EEVA een 1 5 Gear Shift Lever Support Wacher 1 6 Clesse 1 7 Control Top or Remote Control Gasket ooocoocccoo 1 6 Een ge Er TEE 1 S Ast amp ReverseRocker AN denne a 1 10 1st amp Reverse Shift Fork A Rail Assembly 1 A RallSUBPOkl nennen 1 12 Rear Rail Support Capscrew Lockwasher nessen 2 13 Rear Rail Support CapScrew ooocooonncccnocccnioancconcnononanonananonanonos 4 14 Front Rail Support Gapscrew ooccccnncccnocccnnonnncnnncnonnnonancnnnnnnnnns 4 15 Front Rail Support Capscrew Lockwasher scce 4 16 Front TI e E 1 17 2nd amp 3rd 4th amp Sth Shift Fork Bushing o 4 18 4th oth Shift Fork amp Rail Ass y Includes Item 17 1 19 2nd 3rd Shift Fork amp Rail Ass y Includes Item 17 1 20 Interlock Cross Pin acer 1 21 Interlock Tapered Pin Gupport 2 GT del A EI CNN 2 23 SES Re
24. ing Spacer oconcccnncccnincnnnnnnos 1 6 Mainshaft Reverse Gear Roller Bearino 48 7 Mainshaft Reverse Gear Bearing Spacer oiccen 1 8 Mainshaft Reverse Gear Roller Bearino 48 9 Mainshaft Reverse Gear 1 10 st amp Reverse Shift Hub Sleeve 1 11 Shift Hub Sleeve Retainer RiNQ ooooccnccccnonccnnoncnonanaroncnonos 1 12 SES Reverse Shit EE 1 13 Mainshaft 1st Gear Bearing Spacer 1 14 Mainshaft 1st Gear Roller Bearing scce 44 15 Mainshaft 1st Gear Bearing Gpnacgr 1 16 Mainshaft 1st Gear Roller Bearing ooooooccnoccccoonncnnoo 44 17 Mainshaft 1st Gear 1 18 Split Washer Retainer Ring cc eccccesceesseeessseeesseeeesneens 1 18A Mainshaft Rear Bearing Split Washer 1 19 Mainshatt Rear Bearing Long 1 A ee Sant 1 21 Split Washer Retainer RINQ oooococnccccnoncccnoncnonacinoncnonananonnnoss 1 22 Mainshaft 2nd amp Reverse Gear Split Washer 2 23 Mainshall 2nd Bear 5 rd e 1 24 Mainshaft 2nd Gear Bearing Gparcer 1 25 Mainshaft 2nd Gear Roller Bearing 0 48 26 Mainshaft 2nd Gear Bearing Gparcer 1 27 Mainshaft 2nd Gear Roller Bearing 00 48 A een 1 29 2nd amp 3rd Synchronizer Assembly ocoocccccnocnciccncccncconncnnnos 1 30 3rd Gear Synchronizer Cup 1 31 Mainshaft 3rd Gear Roller Beamng 48 32 Mainshaft 3rd Gea
25. install capscrews 18 Figure 107 Note position of interlock tapered pins for reassembly Figure 106 Remove interlock tapered pin supports Figure 109 Remove rear rail support 19 Figure 110 a Remove 1st amp Reverse shift fork and rail assembly Figure 111 Remove 4th 5th 2nd amp 3rd shift fork and rail assembly See caution in Figure 112 Figure 115 Remove poppet springs quantity 4 SI Figure 112 Use caution as NOT to lose interlock cross pin interlock tapered pins or mesh lock poppet balls 20 Figure 118 Remove reverse latch plunger spring and plunger 21 Figure 119 If fork bushings are worn secure fork in a vise equipped with soft jaws and remove worn bushings with a drift Install new bushings in fork Turn fork over on anvil of vise and secure bushing in fork using a prick punch and upsetting bushing metal on outside of fork Figure 120 Position 1st amp Reverse rocker arm on pivot pin as shown G Mm ze I o Tom N Wi Figure 121 Install reverse latch plunger spring and retaining plug Tighten plug securely e UU a Ce Figure 122 Install poppet springs quantity 4 Figure 123 Install mesh lock poppet balls quantity 4 Note 1st amp Reverse shift fork rail poppet ball in pocket 22 Figure 124 Align one tapered pop cross pin with hole in 1st amp Reverse shift rail Position rail on poppet ball with rail in neutral
26. l 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 Gears and Shafts If magno 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 to make cer tain they are not sprung bent or splines twisted and that shaft are true Housing Covers Etc Inspect housings covers and bearing caps to be cer tain they are thoroughly cleaned and that mating sur faces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condi tion which would cause subsequent oil leaks or failures Bearings Carefully inspect all rollers and balls for wear chipping or nicks to determine if any abnormal conditions exist Causes of abnormal wear must be corrected before transmission is returned to service Discard bearings Oil Seals Gaskets Etc Replacement of spring load oil seals O 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 lu
27. le rollers under gear NOTE Units built before serial number 045451YJ will not have needle rollers under 3rd amp 4th speed main shaft gears Figure 26 Remove 3rd gear synchronizer cup and syn chronizer assembly NOTE There is a variation in the mainshaft 1st gear retention One version has a split washer and a split washer retainer ring Using a three legged puller as shown in Figure 27 pull against split washer retainer ring to remove rear bearing Figure 27 Remove mainshaft rear bearing as shown See Note after Figure 26 The other version mainshaft 1st gear retention is a thrust washer between 1st gear and the rear bearing In this ver Sion there is not enough room to get a puller behind the thrust washer and it will be necessary to pull on the 1st gear as shown in Figure 28 Figure 28 Remove rear mainshaft bearing and 1st gear as shown Use caution as NOT to lose needle rollers under 1st gear See Note after Figure 26 A IN dr j um N i Figure 31 Remove 1st gear Use caution as NOT to lose needle rollers under 1st gear Ist gear was removed in Figure 28 for thrust washer retention Further disassem bly of the mainshaft will be identical in both versions Figure 29 Remove rear bearing and split washer retainer ring Figure 32 Remove 1st amp Reverse shift hub sleeve retainer ring Figure 30 Remove 1st gear split washer Figure 33 Remove shift hub and sleeve
28. nennenenennsnnennsnnsnnnsnnsnnnrnsrrsrsennn 1 Reverse eege 1 Reverse leon ico dls 1 Reverse Idler Thrust Washer ooooocccncnncccocncoccconononcononnnonnos 1 Reverse Idler Gear Bearing Gpnarcer 1 Reverse Idler Gear Bearing ooncconnnnnninncninininanicianocarnanoss 26 Reverse lr it pat 1 Reverse Idler Gear Bearing Gpnarcer 1 Reverse Idler Gear Bearing ooonncconnnnininncncnininanicinnccara nacos 26 Reverse Idler Gear Bearing Gpnarcer 1 Reverse Idler Thrust Wacher 1 Mainshaft Spigot Bearing Washer Retainer Ring 1 Mainshaft Roller Bearing Wacher nn 1 Mainshaft Roller Bearmng 14 Maim Drive GEAT eege 1 Main Drive Gear Bearing Cone oocooccccnoccniocccconnccooncnonananonnnnnns 1 Main Drive Gear Bearing Cup 1 Main Drive Gear Bearing Ghum rnrn AR Main Drive Gear Bearing Cap Oil Seal 2 220u022000 1 Main Drive Gear Bearing Lan 1 ITEM Description QTY 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 Bearing Capscrew Lockwasher oooocccccccocicaccnonacononanonananonanonos Bearing GAD AA Pl ONGOVEr Plate E P T O Cover Plate cc cececsecsecsecssecessseesseceessesseeseeseeeney K A TEE EE Transmission HOUSING oocccccncococinocaninccononanononanonanononanononononoos Countershaft Pilot Bearing ness Clutch Housing to Case Stud onccconnnicnninninnnninanininanacinnaaos Grease Ftmng E Bushin
29. position Figure 125 Note position of tapered interlock cross pin in relation to rail Figure 126 Install interlock cross pin in 2nd amp 3rd shift rail Figure 130 Slightly ra raise rear of Ath amp 8 5th shift rail and 3 align 2nd interlock tapered pin with cross hole in 4th amp Figure 127 Position 2nd amp 3rd shift rail on poppet railin Sth shift rail neutral position with interlock pin aligned with 1st inter lock tapered pin US Figure 1 131 Note position of Ener interlock pins and Shift rails Figure 128 Install ond interlock tapered pin Align pin with interlock cross pin hole Figure 132 Install 1st amp Reverse shift fork and rail assembly on poppet ball in a neutral position Align 1st amp Figure 129 Position 4th amp 5th shift fork and rail on pop Reverse rocker arm in notch at rear of rail as shown pet ball in neutral 23 E Figure 137 Tighten front and rear support capscrews 20 25 ft Ibs torque 27 1 33 8 N m Tap 4th amp oth shift fork and rail assembly forward to a neutral position Figure 134 Install rail support capscrews and washers Tighten capscrews slightly Figure 138 Coat countershaft pilot bearing needle roll ers with heavy grease to hold in place until countershaft is installed Figure 135 Install interlock tapered pin supports Tap 4th A oth shift fork to the rear 4th speed position 24 Figure 1
30. r Bearing Spacer 7 1 33 Mainshaft 3rd Gear Roller Beamng 48 34 Mainshaft 3rd Gear Bearing Spacer esseere 1 39 MANS Gpares a tea 1 E EE 1 37 Mainshaft 3rd Gear Locating WaSher oeenn 1 38 Mainshaft 3rd Gear Retainer mg 1 39 Mainshaft 4th Gear Roller Bearing oscene 34 40 Mainshaft 4th Gear Bearing Spacer sesser 1 41 Mainshaft 4th Gear Roller Bearing 00 34 42 Mainshaft 4th Gear 1 43 4th amp Sth Shift Hub Sleeve 1 ITEM Description QTY 44 4th A oth Synchronizer up 1 45 4th amp oth Synchronizer Assembly 1 46 4th A oth Synchronizer up 1 47 4th amp Sth Shift Hub Bearing oooocoonocccnccnconconcononcnnonarinonaoos 1 48 4th amp 5th Shift Hub Bearing Hacg eee cceeseecssseeessseeeees 1 49 Name Plate SerEW ns catas 2 50 Name PIE acne a 1 51 Countershaft Gear Retainer Ring nessen 1 52 Gountersnalt Drive Gea ee 1 53 Countershaft 4th Dni a 1 54 Countershaft Gear Kou 2 992 COUMers EE 1 AAA PPP 1 57 Countershaft Rear Bearing nooo 1 58 Countershaft Rear Bearing Outer Retainer RINng o ae 1 59 Countershaft Rear Bearing Retainer RINg escsccscncrecrnn 1 60 Countershaft Rear Bearing Cap Gasket u0 00nnnnn 1 61 Countershaft Rear Bearing Can 1 02 Lock Was os 4 63 Rear Bearing CapSCreW eesssssesieerireiserirerrrrrrrerrrrrrrrerrrnrreen 4 64 Mainshaft Rear Bearing Cup amp Snap Ring 2 1 65 Speedometer Drive Gear 1 66 Main
31. se extreme pressure lubricants other than MIL L 2105C or wbd of a API classification GL 5 E J m Many EP lubricants contain highly active chemical compounds that Fy have been formulated to perform satisfactorily in specific types of ar eil e sAm MIL L 2105C applications Severe corrosion residual deposits and inadequate m Grade 80 0 lubrication may result from improper application Use of EP lubricants a jor of a API other that MIL L 2105C or of a API classification GL 5 may result in El ana ag failure and or impaired operation u H DRAINING ECONOMY The object in draining the transmission oil t EA periodically is to eliminate possible bearing surface abrasion and is EB MILLA FUERA attendant wear Minute particles of metal the product of normal wear in service are deposited in and circulate with the transmission oil The oil changes chemically due to its repeated heating and cooling also the terrific churning it undergoes in the presence of air It is desirable Prion to drain out this used oil after the first 1 000 miles 1609 0 Km of ser Parera Cal vice regardless of type of service Subsequent drains should be made every 24 000 miles 38616 0 Km or six 6 months whichever comes first for highway service and every 8 000 to 10 000 miles 12872 0 16090 0 Km or six 6 months whichever comes first on off highway and pick up and delivery types of service Do this only when the transmission is thor oughl
32. shaft Rear Bearing Cap Gasket 1 67 Mainshaft Rear Bearing Can 1 A II 3 69 Mainshaft Rear Bearing CapSCrew sieer 3 70 Mainshaft Rear Bearing Cap Oil Gen 1 71 Mainshaft Flange Nur 1 72 Speedometer Tube Nut sccsssssesssssssseessseesesseeevsees 1 73 Speedometer Driven Gear onnnnnnninnnninninicninanicinrnccananarnnos 1 74 Mainshaft Rear Bearing CapSCrew oiccen 1 ES A EE 1 78 Reverseddler LOCKSCTEW nee ee 1 T7 Reverse Idler Shaft Lock une 1 TO Reverse ldlershalt secret 1 79 Reverse Idler Thrust Washer sn 1 80 Reverse Idler Gear Bearing Gpacer 1 81 Reverse Idler Gear Bearing oocnonnninnnnccninnnocncncranacinoss 26 82 el EE 1 83 Reverse Idler Gear Bearing Gpacer 1 84 Reverse Idler Gear Bearing oonoonnncnnnnccninnnocanncianacinos 26 85 Reverse Idler Gear Bearing Gpacer 1 86 Reverse Idler Thrust Waeher 1 87 Mainshaft Spigot Bearing Washer Retainer Ring 1 ITEM Description QTY 88 Mainshaft Spigot Bearing Wacher ssec 1 89 Mainshaft Spigot Beamg 14 90 Main Drive ear ua 1 91 Main Drive Gear Bearing Long 1 92 Main Drive Gear Bearing Cup 1 93 Main Drive Gear Bearing Gm AR 94 Main Drive Gear Bearing Cap Oil Gen 1 95 Main Drive Gear Bearing Can 1 96 EE eessen eet gedeien 4 97 Bearng Bet 4 98 PAO Cover Plate SCI OW eeneg eebe 6 99 PALO Ee E eaten tained a 1 100 P T O Cover Plate Gasket uns anne a ae 1 101 Transmission Laser 1 102 Countersha
33. up on clutch ing teeth of 4th gear NOTE Chamfer on I D of 4th amp 5th shift hub sleeve must go down Install shift hub sleeve on Shaft 13 Figure 76 If main drive gear taper bearing is to be removed split puller shown in Figure 76 is recom mended Figure 80 If the countershaft drive gear or 4th gear is to be replaced Figure 80 shows direction of drive gear and 4th gear hubs Figure 77 Remove pilot bearing washer retainer ring Remove bearing washer Use caution as NOT to lose pb Y roller bearings a Kapen a MAIN DRIVE GEAR REASSEMBLY Figure 81 If countershaft front bearing is to be replaced remove clutch housing and drive front bearing from transmission case Apply a light coat of Loctite 510 on the outer diameter of the new bearing Install in transmis Sion case as shown with end of bearing 001 007 below the face of case Clutch housing is reassembled tempo rarily on transmission case to facilitate reassembly of transmission but will be removed again later on to set mainshaft taper bearing end play Figure 78 Press new taper bearing on drive gear Turn gear over Using a high quality heavy grease coat roller bearing surface Place rollers in grease as shown 14 ROUND RAIL SHIFT CONTROL DISASSEMBLY WS ei Figure 82 Remove front and rear rail support cap Screws Figure 84 Remove the 4th amp 5th shift fork and rail assembly 15 Figure
34. ve gear bearing cap and shims Figure 10 Remove reverse idler lock and countershaft rear bearing cap bolts Shaft il i S Figure 13 Remove reverse idler gear and thrust wash ers NOTE Idler gear has loose needle rollers in it Do NOT lose these rollers we Figure 14 Remove countershaft rear bearing retainer ring E am E Figure 15 Pry countershaft to the rear Using a suitable puller remove countershaft bearing Figure 16 Countershaft rear bearing removed Note oil baffle position Remove oil baffle Figure 17 Remove countershaft assembly from trans mission case Countershaft front pilot bearing has lose needle rollers Use caution as NOT to lose these rollers Figure18 Position mainshaft in a Suitable stand A vise may be used if soft jaw are utilized Figure 19 Remove oth speed synchronizer cup and 4th amp 5th speed synchronizer assembly Figure 20 Remove shift hub thrust bearing and bearing race Jp Figure 21 Remove 4th amp 5th shift hub sleeve and 4th speed synchronizer cup Figure 22 Remove 4th speed gear Use caution as NOT to lose needle rollers under gear NOTE Units built before serial number 045451YJ will not have needle rollers under 3rd amp 4th speed main shaft gears A Figure 24 Remove 3rd gear thrust washer Use caution as NOT to lose lock ball Figure 25 Remove 3rd speed gear Use caution as NOT to lose need
35. verse SMIN Rall EN 1 24 Mesh Lock Poppet Ralls oooonononccnnnncccnnnncninonocaoo 4 25 Poppet lt EE 4 26 Reverse Latch biunger 1 22 Tat ed EE 1 28 Plunger Spring Retaining PIU eneee 1 29 Control Top or Remote Control Lapgcrgou 4 CLARK 390V CL550 SERIES ASSEMBLY INSTRUCTIONS Minimum endplay on mainshaft gears mainshaft first gear 010 0 25 all others 006 0 15 Unless otherwise specified Tighten all capscrews 20 to 25 Lb Ft 27 2 33 8 N m Hand spin idle gear and countershaft assemblies after each is installed on their bearings in transmission case Both must spin freely and smoothly Apply a thin coat of Loctite 510 to the O D of all oil seals before assembly Use Grade 2 Multi Purpose Grease to retain needle rollers Check all mainshaft constant mesh in gear bores during assembly gears to make sure they rotate freely on mainshaft Use MIL L 21260B oil to spigot bearing rollers after assembly in gear pocket These gaskets installed dry Rotate both tapered bearings with forward and rear pressure to seat brg cones before checking endplay When screws with pre applied thread locking compound are removed after and apply Loctite 262 Thread Lock before re instailation initial assembly clean threads thoroughly Tighten 5625 18 thd nut and studs 60 to 80 Lb Ft 81 4 108 4 N m Tighten 15 to 20 Lb Ft 20 4 27 1 N m 4 screws 30
36. y warm e pl E i rr H 5 EEE RW NM ZH E FLUSHING After draining flushing is desirable Replace the drain plug and fill the transmission to the proper level with a light flushing oil Drive the transmission for a short period at fast idle in such a manner that the gears in the transmis sion are rotating without load This washes out the old oil clinging to the interior of the gear case covers and shifter rails BE SURE TO DRAIN OUT ALL of the flushing oil before attempting to refill with new oil This flushing procedure is most important after first drain REFILL First removal all dirt around the filler plug Then refill with new oil of a grade recommended for the existing season and prevailing service Fill to the bottom of the level testing plug positioned on the side of the transmission DO NOT OVERFILL as the excess quantity will serve no useful purpose If the oil level is too high it will cause excessive oil churning and high oil temperature and possible leakage INSPECTION Oil level inspection should be made every 6 000 miles 9654 0 Km which usually coincides with the vehicle manufacturers chassis lube procedure Always clean around filler plug before inspection Add sufficient oil to maintain correct level CLARK CapscrewCL590 SERIES TRANSMISSION ITEM DESCRIPTION QTY 1 Control Cover Gaser ia tilda 1 Ce TT 14 3 Control GOVE EE ci ee 14 4 Control Cover Assembly sciis 1 5 Mainshaft Reverse Gear Bear
37. zer cup and 2nd amp 3rd synchronizer assembly Figure 46 With clutching teeth of 2nd gear down coat inside diameter of gear with a high quality heavy grease Figure 49 Position outer roller spacer on second row of This will hold needle rollers in position while assembling rollers Grease rollers to hold in place Lay up first row of needle rollers Figure 51 Using caution as NOT to catch the needle roll ers on the edge of a spine or snap ring groove install 2nd gear on mainshaft Figure 48 Lay up second row of needle rollers Figure 52 Position 2nd gear split washer locating ball in Shaft Install split washer in washer groove with ends of washer together at locating ball Figure 53 Install split washer retainer ring over split Figure 56 Position roller spacer on first row of rollers washer _ Figure 57 Lay up second row of needle rollers Grease Figure 54 With clutching teeth of Reverse gear up coat rollers to hold in place inside diameter of gear with a high quality heavy grease This will hold needle rollers in position while assembling Insert one roller spacer 10 REVERSE Figure 58 Figure 59 Using caution as NOT to catch the needle roll ers on the edge of a spline or snap ring groove install Reverse gear on mainshaft Figure 62 With clutching teeth of 1st gear down follow same procedure used in Figures 54 thru Figure 57 to install needle rollers and spacers
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