Maintenance and Service Manual 28000 Powershift I Transmission I R & HR MODEL 3 & 6 SPEED I LONG DROP WITH RANGE SHIFT CLARI-HURTE> COMPONENTS | SM RHR 283810 (Rev. 7.95)Service Publications 1293 Glenway Drive Statesville, NC 28677 TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive, rear wheels off the ground or disconnect the disconnect both front and rear drivelines, driveline to avoid damage to the trans- Because of the design of the hydraulic mission during towing. system, the engine cannot be started by pushing or towing. ‘©Copyright Clark Equipment Company, 1998 ‘Unpubished mater! {mites Oaibution No par ofthis work may be reprecuced in any orm under ny means winout rect witton permsscn ot Clark Equpment CompanyFOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Clark- Hurth Components-approved parts as listed in the applicable parts inanual should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repair or replacement ‘parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Silhouette... 2002... eee eee cee Fig. A Converter Assembly . . Fig. B Converter and Transmission Case Group ................ Fig. C 3 Speed Clutch and Gear Group 2.00.0... cece eee eens Fig. D Clutch Group 2... eee eee ee eee eeeeeeeeeeeeee Fig. E Regulating Valve, Charging Pump and Filter Group ........ Fig. F Control Valve Assembly... 0.0... cece cece eee eee » Fig. G Axle Disconnect and Mechanical Parking Brake .......... Fig. H Assembly Instruction Drawing .......6.2. 0622 00cceceee DISASSEMBLY OF TRANSMISSION CLEANING AND INSPECTION ..............00.0004 114 REASSEMBLY OF TRANSMISSION ............. 15 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL . 29 SPECIFICATION AND SERVICE DATA . 30 LUBRICATION ...............2.. - 30 TROUBLE SHOOTING GUIDE .... HR MODEL EXTERNAL PLUMBING DIAGRAM . HR MODEL TYPICAL THREE SPEED POWER FLOW ............. 33 CLUTCH AND GEAR ARRANGEMENT . SHIELDED BEARING INSTALLATION RING GEAR INSTALLATION . ‘SPEED SENSOR INSTALLATION 6 SPEED SECTION R-MODEL SECTION . DRIVE PLATE INSTALLATION ......200......0..00005 e+. 64-65 NOTE: Metric Dimensions Shown in Brackets [ _].NOTESTRANSMISSION ASSEMBLY The transmission and hydraulic torque portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate. The-transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation. To supplement the text below, and for reference use therewith, the following illustrations are provided: Basic Design Silhouette Converter Assembly Converter and Transmission Case Group Three Speed Clutch and Gear Group Cluteh Group Regulating Valve, Charging Pump and Filter Group Control Valve ‘Axle Disconnect and Mechanical Parking Brake Typical 28000 Cross Section External Plumbing Diagram Typical Three-Speed Power Flow Clutch and Gear Arrangement Ring Gear Installation Shielded Bea 9 Install The R, HR, and MHR Model Transmissions are of three basic designs. The R Model consists of a separate torque converter, mounted to the engine with the powershift trans- mission remotely mounted and connected to the torque converter with a drive shaft. The HR Model consists of a torque converter and powershifted transmission in one package mounted directly to the engine. The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by means of a drive shaft. (See Fig. A for basic design silhouette. The shift control valve assembly may be mounted directly on the side of the converter housing or front n cover, oF remote mounted and connected to the transmission by means of flexible hoses. The function of the control valve assembly is to direct oil under pressure to the desired directional and speed made on certain models to neutralize the transmission when the brakes are applied. red through use of a brake actuated shutoff valve, The speed and direction clutch assem- are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. ‘An axle disconnect is optional and is located on the output shaft. The drive to the front or rear axle can be disconnected or connected by manual shifting.HOW THE UNITS OPERATE With the engine running, the converter charging pump draws oil from the transmission sump through the ing valve and oil filter. removable oil suction screen and directs it through the pressure regul. ‘The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc- tion and speed clutches. This requires @ small portion of the total volume of oil used in the system, The remaining: volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. Thi regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in @ closed position, When a specific pressure is achieved, the valve spool works against the spring until @ port is exposed along the side of the bore. This sequence of events provides the proper system pressure. After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to Then through a series of tubes and passages lubricates the transmission be: gravity drains to the transmission sump. ing on the transmission. ings and clutches. The oil then The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary com- ponent which starts the oil flowing to the other components which results in torque multiplication. This el- ‘ement can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer meter. The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the ischarges at its center. Fluid directed n of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. torque converter. This element receives fluid at its outer diameter and by the impeller out into the particular do: The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and turbine elements. Its function is to take the fluid which ‘exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplication ratio when the out- put shaft is at zero RPM. Therefore, we can say that as the output shaft multiplication is increasing. is decreasing in speed the torque The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector spool provides one position for each speed range. A detent ball and spring in the direction spool provides three positions, one each for forward, neutral and reverse. With the engine running and the directional control lever in neutral position, oil pressure from the regulat- ing valve is blocked at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct oil, under pressure to either the forward or reverse direction clutch as desired.When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector spool. The same procedure is used in the speed selector. The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hy- dravlically actuated piston. The piston is “oil tight” by the use of sealing rings. A steel disc with external splines is “inserted into the drum and rests against the piston. Noxt, a friction dise with splines at the inner diameter ié inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with @ snap ring. A Hub with ©.D. splines is inserted into the splines of dises with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direc- tion as long as no pressure is present in that specific clutch. To engage the clutch, as previously stated, the control valve is placed oil under pressure to flow from the control valve, through @ tube, to a chosen clutch shaft. This shaft has the desired position. This allows a drilled passageway for oil under pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft. These rings direct oil under pressure to a desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against dises with teeth on the inner diameter, enables the hub and clutch shaft to be locked together and allows them to drive as a unit. There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released, R-28000 HR-28000 ‘MHR-28000 FIG. A¥ \TEM ONVOnKONH ~ n 12 13 14 15 16 7 18 19 20 21 22 23 24 25 26 27 28 29 30 HR 28000 CONVERTER GROUP (See page 56 for R Model Front Cover Group) DESCRIPTION Bearing Support Screw.... Bearing Support Screw Lockwasher.. Driving Gear Snap Ring...... Drive Gear Bearing, Drive Gear Bearing Support .. Drive Gear .... Snap Ring (Internal—See item 8. Drive Gear Hub Sleeve and Snap Ring Assembly — Ine. items 7 and 9. Snap Ring (External) — See mB... Valve Body to Converter Housing Gasket ....... Valve Body to Converter Housing MOM RING enn eee Valve Body to Converter Housin; “O" Ring, Valve Body to Converter Housing O” Ring... -1 Regulator Valve, Charging Pump and Filter Assembly ..... Oil Seal. Impeller Hub Gear Impeller Hub Gear Snap Ring Stator Support Oil Sealing Ring Sealing Ring Expander Spring «2... Stator Support Turbine Shaft .. Turbine Shaft Gear Turbine Shaft Gear Retainer Ring . Converter Housing and Tube Assembly Turbine Shaft Bearing. Turbine Shaft Oil Sealing Ring. Stator Support Screw Lockwasher...... Stator Support Sere Hub to Impeller Serew .. Hub to Impeller Screw Washer eaooerr eww TEM 31 32 33 34 35 36 37 38 39 40 Al 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 DESCRIPTION Impeller Hub Bearing Impeller Hub .. Impeller Hub “O” Ring Impeller .. Baffle Retainer Oil Baffle oe Oil Baffle Seal Ring Detent Spring .. Detent Ball . Valve to Converter Gasket. Control Valve Housing Assembly. Valve to Converter Housing Screw Lockwasher Valve to Converter Housing Scres Turbine Hub Screw Washer Hub Screw .. Ring Gear Screw . Ring Gear Screw Plain Washer . Flywheel Ring Gear Impeller Cover Sleeve Impeller Cover to Impeller Screw and Lockwasher .. Impeller Cover Impeller Cover “O” Ring ... Turbine Retainer Ring .. Turbine Turbine Hub Turbine Locating Ring .. Reaction Member Retainer ing .. Rea Member cnn Reaction Member Spacer Impeller Hub Bearing Retainer Ring...HR 28000 CONVERTER AND TRANSMISSION CASE GROUP Item DESCRIPTION 1° Suction Tube Assembly 2 Converter Housing and Tube Assembly 3 Tube Sleeve 4 Tube Sieove 5 Converter Housing Sleeve 6 Converter Housing Sleeve Lock 7 Converter Housing Sleeve Screw Lockwasher 8 Converter Housing Sleeve Screw 9 Converter Housing Sleeve Screw 10 Converter Housing Sleove Screw Lockwasher 11 Converter Housing Sleove Lock 12 Converter Housing Sleove 13° Breather 14 Sweet EI 18 Reducing Bushing 16 Tube Sleeve 17 Pipe Plug 18 Converter Housing to Transmission Housing Screw Lockwasher 19 Converter Housing to Transmission Housing Sciew. 20 Converter Housing to Transmission Housing Lockwasher 21 Converter Housing to Transmission Housing Screw. 22 Lube Tube Retaining Screw 23 Lube Tube Retaining Screw Lockwasher 24 Valve Oil Supply Tube 25 3rd Speed Tube "0" Ring 26 34d Speed Tube Assembly 27 Tube Clip 28 Tube Clip Lockwasher 29° Tube Clip Screw 30 Lube Tube Assembly 31 Lube Tube Retainer Screw Lockwasher 32 Lube Tube Retainer Soxew 33 Reverse Tube "0" Ring 34 Reverse Tube Assembly . 38 Tube Clip 36 Tube Clip Screw Lockwasher 37 Tube Clip Screw aty. item DESCRIPTION 38 Suction Tube "0" Ring . 39 Suction Tube Spacer Ring 40 Suction Tube Retainer Lockwasher 41 Suction Tube Retainer Screw 42 Tube Sleeve 48 Pressure Tube "0" Ring 44 Suction Lina Tube Clip Rivet 45. Conveter Housing to Transmission Case Gasket 46 Converter Housing to Transmission Case Dowel Pin 47 Low Speed Clutch Pressure Tube 48 Transmission Case to Converter Housing Screw Lockwasher 49 Transmission Case to Converter Housing Screw 50 Transmission Case Assembly 51 Transmission Case to Rear Cover Dowel Pin 52 Transmission Case to Rear Cover Gasket 53 Transmission Case Rear Cover 4 Rear Cover to Case Screw Lockwasher 55 Rear Cover to Case Screw 56 Roar Cover Pipe Plug 57 Rear Cover to Transmission Case Stud Nut 58 Rear Cover to Transmission Case Lockwasher 59 Tube Sleeve “O" Ring 60 Tube Sleeve 61 Transmission Case to Rear Cover Stud 2 Drain Plug 63 OilLevel Plug 64 Screen Assembly Gasket 65 Screen Assembly 66 Suction Tube Assembly 67 Suction Tube Cip Washer 68 Suction Tupe Clip 69 Pipe Plug 7 Suction Tube “O" Ring 71 Suction Tube Retainer Washer 72 Suction Tube Retainer Washer Screw 73 Oil Baffle(6 speed only) ty.28000 THREE SPEED CASE AND CLUTCH GROUP ITeM DESCRIPTION 1 1A BISSRISALLGSVSSSSS HRS Reverse and 3rd Clutch Shalt Piston Ring Piston Ring Expander S Reverse and 3rd Shatt Front Bearing Reverse and 3rd Shaft Front Bearing Front Beating Retainer Ring...» Clutch Driven Gear Bearing ‘Guutch Driven Gear Bearing Snap Ring ‘Guuteh Driven Gea CCluteh Hub Oi Baie Ring ‘Glutch Driven Gear Bearing Shap Ring (Clutch Driven Gear Bearing Retum Spring Retainer Snap Ring ‘Snap Ring Retainer Spring Retainer Piston Return Spring Spring Retainer Reverse and 3rd Clutch Shaft and Dram Spring Retainec Piston Retin Spring Spring Retainer Shap Ring Retainer Retuen Spring Retainer Snap Ring. 31d Gear Bearing ‘3d Gear Bearing Shap Ring Clutch Hub Oil Battie Ring 3rd Gear 31d Gear Bearing Spacer ‘3d Gear Bearing Shap Ring 31d Gear Beating Reverse and 3rd Shalt Rear Bearing 2nd Gear Clutch Hub Oi Battie Ring 2nd Gear Retainer Ring Return Spring Retainer Snap Ring Snap Ring Retainer Spring Retainer . Piston Return Spring ‘Spring Retainer Forward and 2nd lich Sha and Oram ‘Spring Retainer Piston Return Spring ‘Spring Retainor ‘Snap Ring Retainer Return Spring Retainer Snap hing ‘Clutch Driven Gear Bearing ‘Clutch Driven Gear Bearing Snap Ring ‘Clutch Hub Oil Baffle Ring CCluteh Driven Gear. ‘Clutch Driven Gear Bearing Snap Ring (Clutch Driven Gear Bearing Front Bearing Retainer Ring Front Bearing Locating Ring Forward and 2nd Shaft Front Bearing Front Bearing Retainer Ring Forward and 2nd Shaft Piston Ring Piston Ring Expander Springs ‘Low Spoed Clutch Shaft Pilot Bearing 2nd Gear Bearing Low Gear Bearing Retainer Fing Low Gear Bearing Low Gear Bearing Locating Ring Low Gear Low Gear Oi Bate Ring Low Geer Bearing Locating Ring arty ITEM DESCRIPTION ary 63 64 65 Low Gear Bearing Low Gear Bearing Retainer Ring Roturn Spring Retainer Snap Ring ‘Snap Ring Retainer Return Spring R Return Spring Return Spring Retainer Low Speed Clutch Shatt and Drum Bearing Cap Scrow Beating Cap Screw Lockwasher Drive Gear Retainer Ring Low Speed Drive Gear Idler Shaft Gear Low Shatt Rear Bearing ‘Low Shaft Rear Beating Retainer Ring ‘Low Shatt Piston Ring Low Shaft Piston Ring Rear Bearing Cap Gasket fear Bearing Cap "0" Ring ‘Low Shaft Rear Bearing Cap Low Shaft Rear Beating Cap Plug Idler Shaft Bearing Cap Screw Idler Shaft Bearing Cap Screw Lockwasher Ider Shaft Rear Bearing Lock Ball Idler Shaft Rear Bearing Rear Beating Locating Ring Idler Shatt Nut Idler Shaft Bearing Cap Gasket Idle Shaft Bearing Cap Rear Beating Cap Oi Seal Rear Bearing Cap "0" Ring Rear Beating Cap Screw Rear Beating Cap Serew Lockwasher Output Shaft Rear Bearing Cap Bearing Cap "0" Ring Rear Bearing Cup Rear Bearing Cone Output Shaft Gear - Output Gear Output Shatt Gear Spacer Output Shaft Bearing Cone Output Shaft Bearing Cup Front Bearing Cap "0" Ring Front Bearing Cap Shim a Front Bearing Cap. Front Bearing Cap Screw Lockwasher Front Besting Cap Screw Flange Nut Flange Nut Washer Flange Nut "O" Ring ‘Output Flange Front Bearing Cap Oil Seal Bearing Retaining Ring Idler Shatt Front Bearing Ialer Shatt Idler Shatt Gear Locating Ring Flange Nut Flange Nut Washer Flange Nut “O” Ring ‘Companion Flango ‘Output Shaft (Used with Disconnect oniy) Bushing (Used with Disconnect only Disconnect (OptionalTEM TEM ITEM LOW CLUTCH GROUP DESCRIPTION TEM DESCRIPTION ary, End Plate Retainer Ring 1 5 Clutch Piston... End Plate see T 6 Clutch Piston Outer Seal Ring Clutch Inner Dise coe 9 7 Clutch Piston Inner Seal Ring, Clutch Outer Disc 8 Low Speed Clutch Drum and Shaft...... 1 REVERSE AND 3rd CLUTCH GROUP DESCRIPTION ary. tem DESCRIPTION ary. End Plate Retainer Ring .. 2 5 Clutch Piston End Plate ..... -2 6 — Clutch Piston Outer Seal Ring... Clutch Inner Disc 7 Clutch Piston Inner Seal Ring. Clutch Outer Dise 8 Reverse and 3rd Clutch Drum and Shaft FORWARD AND 2nd CLUTCH GROUP DESCRIPTION ary. TEM DESCRIPTION End Plate Retainer Ring .2 5 Clutch Piston .. End Plate .. 2 6 Clutch Piston Outer Seal Ring... Clutch Inner Dise 7 Clutch Piston Inner Seal Ring... Clutch Outer Disc ..... 8 Forward and 2nd Clutch Drum and ShaftITEM DESCRIPTION ary. 1 2 3 4 5 6 7 8 9 10 "1 12 13 14 15 16 7 18 19 20 21 22 23 24 25 PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP Charging Pump Drive Sleeve......... Pump Sleeve Snap Ring ... Valve to Housing Gasket....... Valve Body “O” Ring... Valve Body “0” Ring Pipe Plug...... Safety Valve Seat... Safety Valve Spacer............ 05 : Safety Valve Plunger Safety Valve Spring Valve Stop "0" Ring . Valve Stop... ...e.eeeeee eee Valve Stop Roll Pin ..... Valve Stop Roll Pin ..... Valve Stop..........++ Valve Stop “O" Ring ...... Valve Piston .. Valve Spring - Inner......... : Valve Spring - Outer ...... Valve to Converter Housing Stud Valve Body to Pump Gasket Pump Body Snap Ring. . Thrust Plate & Bearing Assembly Pump Driven Shaft Assembly ........ Charging Pump Housing . . ITEM DESCRIPTION ary. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4 42 43 44 45 46 a7 48 49 50 Valve to Housing Stud Lockwasher Valve to Housing Stud Nut . Thrust Plate & Bearing Assembly Wave Spring Pump Shaft Seal.....0.....00ee2 eee Pump to Filter Adaptor Screw Lockwasher............. Pump to Filter Adaptor Screw. Pump Drive Shaft Assembly Pump Drive Shaft Oil Seal Pressure Regulator Valve............ Valve Body Roll Pin. . Valve Body “O” Ring Pump to Filter Gasket Filter Adaptor ....... Filter Adaptor Plug... By-Pass Filter Disc Spring......... By-Pass Filter Disc............ By-Pass Filter Disc Seat Filter Seat Retainer Ring...... Filter Housing "O" Ring....... Oil Filter Element Assembly ..... Oil Filter Element Spring... Filter Housing Pipe Plug........ Optional Adaptor for Remote Filter ... RN RARoccuuten oceturew ron ase ro " oecwren nevense ony mewn 2»—@ te x8 “Te 9 r—e a—@ ae | i : I s—8 eS | HYDRAULICALLY OPERATED CONTROL VALVE Figure 6TEM eNaunnroena nu 12 13 14 15 16 7 18 19 20 21 38 39 40 41 42 43 CONTROL VALVE ASSEMBLY DESCRIPTION ary. Valve Spool Oil Seal ...... Valve Spool Oil Seal Retainer Ring Valve Spool Oil Seal Washer Forward and Reverse Valve Spool ... - . Control Valve Assembly — Incl. items 1 thru 9, 15, 16 and 18 thru 20... Neutral Switch Detent Ball Neutral Switch ... Valve Housing Plug Valve Housing Plug “O” Ring .. Overshift Spacer Detent Spring Plug Detent Spring Plug Washer Detent Spring .....--.-- Detent Ball... Speed Selector Spool Speed Selector Overshift Spacer... Valve Spool Oil Seal Washer .. Valve Spool Oil Seal Retainer Ring ... Valve Spool Oil Seal Hydraulic Piston Housing Assembly NOTE: Items 22 thru 25, 32, 33 and 37 are various declutch options. Adaptor to Converter Housing Screw .. Adaptor to Converter Housing Screw Lockwasher..... Valve Adaptor Housing Converter Housing to Valve Adaptor Housing Gasket . Adaptor Housing to Converter Housing Screw .. Adaptor Housing to Adaptor Plate Gasket... Valve Adaptor Plate .. = soso neITEM ITEM AXLE DISCONNECT DESCRIPTION ary. Disconnect Housing Capscrew .. 4 Disconnect Housing Capscrew Lockwasher cscs 4 Disconnect Housing 1 ‘onnect Housing Plug coe Shift Hub ...... ee Shift Fork ....... 1 Shift Fork Lockscrew .. ITEM 8 9 10 W 12 13 14 15 DESCRIPTION ary. Disconnect Shaft ce 1 Detent Ball - od Detent Spring ... a 1 Shift Rail Shift Rail Oil Seal Bearing Retainer Ring... Bearing... Bearing Retainer Ring MECHANICAL PARKING BRAKE DESCRIPTION Backing Plate Assembly... Actuating Lever Brake Flange Brake Drum Brake Drum to Flange Screw Lockwasher Brake Drum to Flange Screw... 6 TEM 10 u 12 13 DESCRIPTION Return Spring... Brake Shoe (see item 3). Brake Lining .... Rivet Backing Plate Screw .. Backing Plate Screw Lockwasher ..MAINTENANCE AND SERVICE ‘The instructions comained herein cover tho disassembly and reassembly of the transmission in a sequence that would normaly be followod after the unt has been removed trom the machine and is to be complatoly overhauled. It must aloo be Understood that this a basic 28000 twersmission wath many ‘options, Companion flanges and output shafts with ana without ‘sconnect assemblies may vary on specific models, The urits are vory similar 10 trouble shoot disassemble, repair, and reassemble, CAUTION: Cieaniiness is of extreme importance and en absolute must in the ropalr and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be ‘thoroughly cleaned to provant he possibilty of dt and fereign matter entering the mechanism. NOTE: For A-Model (remote mounted) front cover removal, service and installation on transmission see page 59 Figure 1 DISASSEMBLY Remeve filter housing and filter element. NOTE: See lubrication section fer filler cartridge change interval. Figure 3 raging pump to regulating valve stud nuts, Remove pump and filter adapter. Figure 4 Remove pressure regulating valve assembly.Figure 5 Figure 8 Remove pump drive sleeves. Install two bolts in threaded holes 180° apart to remove cover from impaller. NOTE: Some units may have pry slots Insteed of threaded heles. Figure 6 Remove control valve bolts and washers. Remove Figure 9 control valve. Use eaution as not to lose detent springs and balls, Figure 10 Figure 7 If impeller cover bearing is to be replaced remove Remove Impeller cover bolts. retainer ring. Pry bearing from pocket. -2-Figure 14 Figure 14 Remove turbine retaining ring, Romove reaction member releiner ring Figuro 15 Remove turbine and hub assembly. NOTE: For special turbine Remove reaction member and spacer, 1 hub assembly see page 40. Figure 13 Figure 16 Remove turbine locating ring. Remove oil baffle retainer ring.Figure 20 Using pry slots in converter housing, pry oil baffle Remove bolts securing converter housing fo trans: ‘ond impeller fram housing. NOTE: Impeller, cil baffle mission housing. and impeller hub gear are removed as an assembly. Figure 21 Figure 18 Suppor converter housing with 9 chain fal Using Zemove stator support to houting bolts reading type snap ring pliers, spread ears on for- x "ator support 10 housing bolts ward eluteh front bearing retaining ring. Holding snap ring open tap converter housing from transmission housing. Figure 19 Figure 22 Remove stator support. NOTE: Support must be Converter housing removed. Note front bearing turned to clear pump drive gear. ing ring relieved of front bearing,z 2 Figure 26 Figure 23 Remove center pump drive gear. Remove pump drive gear bearing support bolts Figure 27 Figure 24 Remove turbine shaft gear retainer ring and gear. Move center gear toward the roar of converter housing. Remove pump drive gear on the right, Figure 28 From rear of converter housing tap turbine shaft Remove pump drive gear on the left. and bearing frem housing,Figure 29 - Figure 32 Remove impeller hub goar retainer ring. Remove impeller to hub bolts. Figure 33 Remove impeller hub "O" ring. Figure 34 Figuro 31 1 forwerd and 2nd clutch essembly remained in transmission Lift oil baffle and oil seal assembly from impeller. case, remove from caseFigure 35 Rear view of trensmission utilizing a mechanical parking brake option Figure 36 Remove output flange nut, washer and “O” ring. Figure 39 IF parking brake is not used, remove companion flange Remove brake shoes. and proceed to Figure 42. Figure 37 Remove parking brake drum and flange. Figure 40 Remove brake actuator armFigure 44 Figure 41 Remove brake backing plate belts. Figure 45 Remove low clutch rear bearing locating ring. igure 42 Remove idler shaft bearing cap bolts, bearing cap and idler shaft nut Figure 46 Remove rear cover bolts. Using pry slots provided, pry cover from transmission housing tapping an low clutch and idler shaft to allow caver to be removed Remove idler shaft rear bearing locating ring. without shaft binding, aFigure 47 Figure 50 Remove low eluich reat bearing retaining ring. Remove low speed drive gear retainer ving end NOTE: See page 42 for disassembly of low clutch utilizing a drive gear. ‘82: double taper beating (helical gears) Figure 48 . Romove low clutch roar bearing. Figure 5 Remove 2nd gear retaining ring. Figure 49 HW wansmission is a 6 speed sae page 51 figure 49A for idler Figure 52 shaft and output shaft removal. Tap idler shaft from housing, Remove 2nd gear. NOTE: Do not iose roar bearing lock bal,- Figure 56 Figure $3 Remove front output flange nut, washer, "O" ring Romove reverse and 3rd clutch assembly. and companion flange. Foe Be Figure 57 output shat removal Remove output shaft front bearing cap bolts and cap. Figure 58 Figure 55 Block output gear. Push output shaft from rear Remove rear output shaft bearing cap bolts end cap. through bearing and gear. —10-Cluich Disassembly NOTE: Two clutches are shown being disassembled. The low clutch, and the forward and second. All clutches are disassombled in a similar manner. The quantity of clutch discs will differ between the low clutch and the forward, reverse, second and third. Do. not mix the friction discs in the low clutch with the {riclion dises of any of the other clutches. (See note, Figure 92). Low Clutch Disassembly NOTE: See page 44 fr disassembly of low clutch utlizing taper Desrings in the low cluteh ge. Figure 59 Remove low clutch shaft rear bearing, Figure 62 Figure 6 Remove clutch end plate and inner and outer clutch Remove low speed gear retainer ring. discs. neRemove clutch piston return spring. A sleeve ' portion removed is recommended for removing 1 lutch piston return spring, washer, and retainer ring. Sleeve’ shown is a common pipe, with a 1-1/2 x 1 [39,0x26,0mml opening, The pipe is 6 x3-1/4x23/4 1155,0x85,0x78,0mm]. Compress spring rotainer wash- cer. Through opening remeve spring retainer snap rin: Release tension on spring retainer. Remove sprin finer and pring. Tuen cluieh over and tap clutch fon @ block of woed te remove clutch piston. Forward and 2nd Clutch Disassembly Figure Remove clutch shaft pision rings and expender springs. Instal piston rings and expander springs por instructions on page €€. — Figure 67 ~ Remove front bearing retainer ring Figure 68 Remove front bearing. Remove front bearing locating ring.: Figure 71 Compress return spring retainer. Remove retsiner Remove inner bearing. en Pring ring from groove, Figure 75 Relieve spring compression. Remove retainer ring, Figure 72 Remove end plate retainer ring. retainer and spring.Figure 76 Remove inner and outer clutch dises, Turn clutch ‘over and tsp clutch shait on 2 block of wood to re- move clutch piston. CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent ing fluid. If ie rocammended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and paris are thoroughly cleaned. CAUTION: Care should be exercised to avoid skin rashes, fire Razerds and inhalation of vapors when Using Selvent type cleaners. Bearings Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubrieont. Immerse again in cleaning fivid 0 Flush ‘out particles, Repeat ebove operation until bearings are thoroughly ciean. Dry bearings using moisture- free compressed air. Be careful to diroet sir stroam acrose bearing 10 avoid spinning. Do not spin bearings ihen drying. Bearings may be rotated slowly by hand {0 facilitate drying process Housings Clean interior and exterior of housing, bearing caps ere, moroughy., Cau pars may bo cleaned. In hot SSin aks wih a sel selon providing these ovis do not have ground or polished surfaces” Pars routd remain in scloven lng enough to be oroughe iy deaned and Rested. This wil sid the evaporation of the'eleaning solution and rinse water Pare cleaned im soluron fenke must bo thoroughly rinsed with loan rater fo remove til aces of kal. Cost part may Sco be ceaned with soom eleanor. CAUTION: Care should be exorsiiad 10. avoid in Falatfon of vapors tnd skin reshen wien using. alka Sener. ~ue All ports cleaned must be thoroughly dried imme ately by using moisture-free compressed sir or soft, Tintiess ebsorben! wiping rags free of abrasive materi als such a= metal filings, contaminated oil or lapping compound. INSPECTION The impertance of careful and thorough inspection of all parts cannot be oversiressed. Replacement of All pans showing Indication of wear or sires will alim= inate costly and avoidable failures at 2 later date, Bearings Carefully inspect all rollers, eagos and cups for weer, chipping or nicks to determine fitness of bearings for further use. De not replace 2 beering cone oF cup. individually without replacing the mating eup or cone al the same time. After inspection, dip bearings ‘Automatic Transmission Fluid and wrap in clean lint less cloth or paper fo protect them until installed. Oil Seals, Gaskets, Ete Replacement of spring load cil seals, "O" rings, metal sealing rings, gaskets and snap rings is more economical when unit is disassembled than premature: ‘overhaul to repiaee these parts at a furure time. Fur- ther loss of lubricant through a worn seal may result in failure of other more expensive parts of the assom- bly. Sealing members should be handled careful particularly when being installed. Cutting, seratehing, or curling under of lip of seal seriously impairs its efficiency. Apply a thin coat of Permatex No. 2 on the outer diameter of the oil seal to assure an oll tight fir into the retainer. When assembling new metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all SO" rings and seals with recommended type Automatic Transmission Fluid before assembly. Gears and Shafts If magna-flux process is available, use process to check parts. Examine teeth on ail gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear feet show spots where cata hardening is warn through oF eracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and thot shafts are true. Housing, Covers, ete. Inspect housings, covers end bearing caps to be certain they are thoroughly cloaned and that mating surfaces, bearing bores, ete., are free from nicks oF burrs. Check all parte carefuily for evidence of cracks cor condition which would cause subsequent cil leaks or failures.REASSEMBLY Forward and 2nd Clutch Reassembly (See page 46 for modulated clutch cross section! discs until the proper amount of dises are Firat disc noxt 19 the piston it steal, lat dine imtaled Figure 77 Install new clutch piston inner and outer sealing rings. Figure 78 yn in clutch drum. Use caution as Figure 79 . Install clutch piston return spring, spring retainer Figure 82 and rotsiner snap ring. Insert ono steel dias. Install end plate reteiner sing. --Figure 83 Figure 86 Install cluttk driven gear inner bearing. Insllduth div gear Ilo ich dum Align splines on clutch geet wil internal teeth of fletion igure 87 Fina tep gear inte postion. De no! force this oper tion. Gear splines must be in full position wiht ine Install front bearing. NOTE: Snap ring groove in ternal teeth of all friction dises. front bearing must be down. Figure 85 Install diven goar outer beating. Bearing shila must face in SEE PAGE 35 FOR PROPER SHIELDED BEARING INSTALLATION 16Figure 89 Install clutch shaft oll sealing rings and expandor springs por instnictions on page 66, Low Clutch Reassembly and outer sealing ring. Insert piston into clutch drum using caution ae not to damoge seals Position piston return spring, spring retainer and retainer sop ‘ing. Compress spring and rotanor and install snap ing. NOTE: For assembly of low clutch uthizig tapar bearings in the iow clutch guar see page 44, Figure 91 Install low gear inner bearing Figure 92 Install one friction dies. NOTE: The friction discs in the low clutch has higher co-efficient rating than the {tition dacs In tho othor clutches, therefore the dl ‘must nol be mixed, The low clutch inner dise can bo Hlentifed by'an°X" stamped on one side of the inner tet The iw ch aera ho fs Sip non soluble yellow paint sprayed on the outer edge of tho dine. ‘Alternate steel and fiction dive until he proper amoun’ of lacs are Insaled. Fire dise next {fo the piston Is steal, ast csc instaled Is fiction. Figure 94 Install end plate and retainer cing.Figure 95 Install low gear into cluteh drum, Align splines on low gear with intornal teoth of friction dises. Top gear into position. Do not force this operation, Gear spi rust bo in full pasition with internal tecth of ail friction discs. Figure 96 Insiall low gear outer bearing. NOTE: When in- tailing the Srd gear in the 3rd speed clutch a bearing spacer is used between the inner and outor 3rd gear bearing. Figure 97 Install low gear retainer ring. Figure 98 Install low clutch shaft rear bearing. Reassembly of the Output Shaft For 6 speed transmission see page 52 Fig. 5. View of eutput shaft as it would be positioned in transmission eace. Note front cone bearing shouldered fon shaft with large diameter of bearing in. Figure 100 ition output gear in transmission case with pro- truding hub toward front of ente. See Fig. 99. ‘output shaft, gear spacer end taper beering from front of case and through output gear. Insiall front taper bearing cup. Block output shaft and install rear tapor bearing with large diameter in. a18—Using new O" rings install rear output bearing csp and taper bearing eup on transmission «ase, Lube Figure 104 ‘opening in bearing cap must be sligned with lube 16 0" ring, Tighton bearing cap bolts te speci- ‘washer and flange nut, Block output gear. See elastic stop nut torque chart) torquo chart. Figure 102 Install front bearing cap and shims. Tighten bolts to specified torque. Tap output shaft front and rear Jo seat taper boarings. Loosen front baring caps bolts Figure 105 From the rear of the transmission case install the low clutch assembly. Using an inch ib. terque wrench, deteie the roling torque ofthe output shat end recor. Tighten rant basing cap bolts to pected torque. Check ong argue with bots tt. Torgue must be 6 to 8 inh tbs. (0.68 = 080 Num more than wen 7 Bening cap bolts were foes. Ad! ot omit shins on the front From the front of e208, vat oh a cap to ‘the proper preioad. reverse and 3rd clutch assembly. ~19-Figure 110 Install icler shaft and bearing assembly. NOTE: The 6 speed nit will have te gears and @ heavier front bearing, Figure 107 Install 2nd speed gear on low clutch shaft, ; Figure 11 Figure 108 Install low clutch reer bearing with bearing ring groove to the Install 2nd speed gear retainer ring. soa, NOTE: Fo oassmbly of ow et ing ear SOU taper bearings see page 42, Figure & Figure 109 Figure 112 Install low speed drive gear and retainer ring. Install low clutch rear bearing retainer ring. =20—sls = ~ Figure 113 Figure 116 Position 2 new gasket on rear transmission case. Install low clutch shaft piston sings, Install new Align lock ball in idler shaft rear bearing with natch gasket and “O" ring on low shaft bearing cap. in rear transmission cover. Tap cover in place and secure with bolts and lockwaehers. Figure 117 Figure 114 Install bearing cap and secure with lockwashers and Torque rear cover bolts to specified torque. bolts, Tighten to specified torque. Figure 115 From front of transmission ense tap low clutch ene idler shaft 10 rear. This will allow clearance to install Figure 18 reor bearing snap ring, Install idler shaft rear bearing locating ring. 2Figure 118 Install idler shaft nut, Block idler cea, tighten nut. See elastic stop nut torque chart. With a new gasket in position instal idler Figure 122 shaft besring eap. Tightan boits to specified torque. Locate brake shoes. If a mechanical parking brake is not used proceed to figure 125. Figure 120 Figure 123 Install brake backing plate assembly. Tighten bolts Install upper and lower brake shoe return springs. to specified torque. Figure 124 Install brake drum and flange assembly.Secure flange with @ new "0" ring, washer and flange mt Figure 128 Block output shaft and tighten nut. See elastic stop nut torque Apply a light coat of Permatex No. 2 on tho outer cohort, ply a lie 2 on thi diameter of the oil baffle sesl, Press seal in oil baffle down. Figure 126 Position low speed clutch shaft front pilot bearing on 2nd ‘clutch she, alight cost of groasa will hold beating in position, From the front of the wansmission ease install the forward Figure 129 land 2nd clutch sssembly. Use caution as not to damage pilot bearing, NOTE: For R Mode! front end s00 page 60, Fig. 9 Install ¢ new oil baffle seal ring Figuro 127 NOTE: See page 40 for 13 inch spacial impeller hub bear. ing and 12 boit assembly instructions. Insta now "0" ring on impeller hub. Align holes in impale hub with holes in impeller. Install bolts and tightan to spoitiod torave. Lockwaite in pats to prevent loosenine Figure 130 Install oil baffle on impeller assombly. 23J ZO GEAR RETAINER RING TURBINE SHAFT NOTE: LONG HUB OF DRIVE GEAR TOWARD RETAINER RING Figure 194 Figure 191 Tap turbine shaft and bearing assembly into convert Install impeller hub gear fr housing from frent. At the rear of the convertor Housing install turbine sheft gear and retainer ring #6 shown. Figure 132 Secure impeller hub gear with retainer ring. Figure 135 Position center pump drive gear. Figure 133 Install new turbine shaft piston ring. Figure 136 Install loft pump drive gear. = 24Figure 137 Install ight pump drive gear Align holes in pump crive gear bearing supports with holes in eorvertor housing, Install ats and washers and tighten to specified torque Figure 188 Position new gasket and "0 ings on housing, light coat of ‘grease wil hold gasket and “0” rings in place, install alignment ‘studs in transmission housing to facilitate converter housing t9 ‘ranemission housing assembly. Figure 139 Support converter housing with a chain fall, Spread forward lurch front bearing retainer ring. | Position converter housing to transmission case astombly. Tap housing into place using caution as not to damage any of the clutch shaft pisten rings Figure 140 Secure converter housing to transmission case with bolls and washers, Tighten fo specified torque, Figure 141 Install new sealing ring expander spring and oil sealing ring on support. NOTE: Expander spring gap to be 180 from sealing ring hook joint.” Position support on turbine shaft to cloar pump drive gear Align support holes with converter housing. igure 142 Install stator support belts and tighten to specified torque.Grease stator support piston ring, cil baffle oil seal Figure 146 and seal ring to focitete reassembly. Install impeller Install rection member retainer ring and oil baffle essembly In converter housing. in housing, Secure with oil baffle Figure 147 re ring is in full position in ring Install turbine locating ring on tu Figure 145 Insta reaction member spacer with tang of spacer out Install reaction member. NOTE: Casted keiob on reaction member must be positioned batwion the 3 & 8 o'clock lation on sup Figur 148 port, preferably betwoan 4 & 8 o'clock Install turbine, =26—Align holos in impeller cover with holes in impel- ler. Instell bolls and washers and tighten to specified torque. Figuro 150 If impeller caver bearing was removed, press bear Figure 153, Ing in position and secure with retainer ring. Locate detent balls and springs in control valve Position new gasket. Secure valve with bolts and washers. Tighten to specified torque, Figure 151 Install a new impeller cover “O" ring and greate Figure 154 lightly to facilitore reassembly. Install pump drive sleeves. 27 ~igure 155 Figure 157 Potition new gasket and YO" rings on pressure reg Install new 0" ring in fitor adaptor housing. Instalt iter vlator valve, Install valve on studs. cloment and housing. Tighten fiter housing 20 to 25 ft. Ibs. torque [27,2 - 33,8 Nm Figure 156 With new valve body to pump gasket in position insert pump drive shaft through valve body. Use caus tion as not to damage valve body oil soal. It may be necessary fo turn impeller one align pump shaft with drive sleSERVICING MACHINE AFTER TRANSMISSION OVERHAUL hydraulic tystem are important links in the drive line between the engine and the wheels. The proper oper- ation of either unit depends greatly on the con and operation of the other; therefore, whenever repai for overhaul of one unit is performed, the balance of the system’must be considered before the job can be considered completed. ‘After the overhauled or repaired transmission has been instlled in the machine, the oll cooler, and con- necting hydraulic system must be thoroughly cleaned. This can be accomplished in soveral manners and a ‘gree of judgment must be exercised as to the method employed. ‘The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from 3. Replace cil filter elements, cleaning out filter cates thoroughly. 4. The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” ‘compressed removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If neces- sary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT vse flushing compounds for cleaning purposes. 7 Recheck all dr: smote mounted torque converters remove plug from torque converter and inspect interior of converter housing, gears, etc. If presence of considerable foreign material i noted, it will be necessary that converter be re- moved, disassembled end cleaned thoroughly. It is realized this entails exira labor; however, such labor is a minor cost compared to cost of di which can result from presence of such foreign material in the system. . Reassemble all components and use only type cll recommended in lubrication section, ill fransmiation through filer opening. until laid ‘ipo LOW mark on transmission dipstick, NOTE: If the dipstick is not accessible oil level check pluge sre provided. Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug. Run engine two minutes at 500-600 RPM to prime torque converter and hydraulic lines. Re- check level of fluid in transmission with engine running at i Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER cil level check plug hole. Install oil level plug or dipstick. ‘Recheck with hot oil (180-260""F) (82, 2.98, 3° Cl. Bring oil level to FULL mark on dipstick or cuns freely from UPPER cil level plug. plugs, lines, connections, ete., for leaks and tighten where necessary. TORQUE IN (LBS.—FT.) BOLTS, CAPSCREWS, STUDS AND NUTS Grade 5 Identification, 3 Radial Dashes 120° Apart on Head of Bolt erase 5 @ Torque Specifeation for Lubieates ‘or Patod Screw Threads Grade 8 Identification, 6 Radial Dashes 60° Apart on Head of Bolt Grade 8 zi] 3 ~~ SOARSE THREAD NE WREXD | CORRE THREAD See) wet ny wat wen wor ea wer fo) SE | Sios[ ae ao | pany eral [ies te | [98a lf as we Pp 0 30 [1353.08] seo] ea | [saw | oa | ja. oe if or P12 ee |e ah soe[ateas | [seeeia [a= a1 | [soe sg. || see [17 ean | so. sy | [ms- ral Scoot “se yo Lees oaa_[ sree | [778 ene || o-oo | tion tony | — 00. s8 | (ons 1103) Sexe] otioo"[ iss tass) [ee oo | irre veng) || vas ver [irae wonsy | vista | sso wraay “Seso| Tae at [ [as org | Tastee | isda tees] || 00 too | Laas 268) | isos | ers0-227 | Heol eessees [foes osea | eww aod | teria zona |[_ats-ae7 | pors-aos} | 200-310 | (825-209) -29-SPECIFICATIONS AND SERVICE DATA—POWER SHIFT TRANSMISSION ‘AND TORQUE CONVERTER aescune wea 933°C. 2SPSI INTRA Kol mie precise a 000, [e828 Mol ute prem wh engine opting Sooo Seetion — Manual uo dacs eaten a Seat cuten ouTeR oc LUBRICATION Ful ow ft ste bys, ho star sre 260-0 ps E48 20604 KPa} Wah ping 1s22°" 985°C eng ate 0010 60 AP Prosi mutta egest ve © px 45 Pa It fan epee cha, TYPE OF OL See tube cher Const Operator Manes teuchine del for system capac Converter Trenumistion a sed yeas Bocmiee epscty ccecx PERIOD Wr 1608 we 00" {2 98,3" €)" Maintain oi level Fut NORMAL very 500 hows, change all fer lament Evry 1000 hours dna and veil natn at Fhe Bint with oi at 150" 10 200° (esre"99,3" ch itor 30 and 100 hows oF ope sand abut or ropes on © Dian tanaminion and move sump ® ° efi tanamison to 1OW mach fun angine at 500.600 RPM. to prime Soverar and Fos. (0) Racha level with eng 1300" 600 BPH ond ‘aaa ier fo LOW marks When oil tra tore thot 180200" F) [882.933 C] inaks final il lye cheks BRING OL eva To uu nae. ‘Normal deain Severe or sustained high op temperatures or very dusty atm: ‘ted deterioration and contamination. For extreme conditions ju: required change intervals. —30- 1d filer change intervals are for average environmental and duty. rorpheric conditions yment must be used to determine theTROUBLE SHOOTING GUIDE For The R and HR Model, 28000 Transmission The following data is presented as an aid to locating the others. By studying the principles of oper the source of difficulty in a malfunctioning unit. I is together with data in this section, if mey be possible necessary to consider the torque converter charging 10 correct any molfunction which may occur in the pump. transmission, oil cooler, and connecting lines sys¥er. 26 2 complete system shen running down the source TROUBLE SHOOTING PROCEDURE BASICALLY CON. of trouble since the proper operation of any unit here- _SISTS OF TWO CLASSIFICATIONS. MECHANICAL AND in depends greatly on the condition and operations of | HYDRAULIC. MECHANICAL CHECKS Prior to checking any part of the system from @ 2. Chock shift levers and rods for bindling or resirie hydraulic standpoint, the following mechanical checks tions in travel that would prevent full engagement. should be made: Shift levers by hand at control valve, if full engage- 1. A check should be made to be sure all control ment cannot be obtained, difficulty may be in control lever linkage is properly connected and adjusted at all cover and valve assembly. connecting points. HYDRAULIC CHECKS Before checking on the torque converter, transmis- the converter. Where the former means is impractical, sion, and allied hydraulic system for pressures and the latter means should be employed as fellows: rate of oil flow, it is estential that the following pro- Engage shift levers in forward and high speed and liminary checks be made: apply brakes, Accelerate engine half to three-quarter Check oil level in transmission. This should be done throttle. with oil temperatures of 180 to 200° F. [82,2-93,4° C] Hold stall until desired converter outlet temperature DO NOT ATTEMPT THESE CHECKS WITH COLD OL is reached. CAUTION: FULL THROTTLE STALL SPEEDS To bring the oil temperature to this specification it FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT is necessary to either work the machine or “stall” out THE CONVERTER. LOW CLUTCH PRESSURE Caure Remedy 1. Low oil level 1. Fill to proper level 2. Clutch pressure regulating velve spool stuck open. 2. Clean valve spool and housing. 3. Faulty charging pump, 3. Replace pump, 4. Broken or worn clutch shaft or piston sealing rings 4. Replace sealing rings. 5. Clutch’ piston bleed valve stuck open, 5. Cloan bleed valves thoroughly. LOW CONVERTER CHARGING PUMP OUTPUT 1. Low oil level 1. Fill to proper level 2. Suction screen plugged. 2, Clean suction sereen. 3. Air leaks at pump intake hose and connections or 3, Tighten all connections or replace hore if necessary. collapsed hose. (R-28000 only) 4. Defective oil pump. 4. Replace pump, OVERHEATING 1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem: bly. 2. Wern oil pump. 2. Replace. 3. Low oil level. 3. Fill to proper level. 4. Pump suction line taking air. (R-28000 only) 4. Check oil line connections and tighten securely. NOISY CONVERTER 1. Worn coupling gears 1. Replace, 2. Wern oil pump. 2. Replace. 3. Worn or damaged bearings 3. A complete disassembly will be necessary to deter- mine what bearing is faulty. LACK OF POWER 1. Low engine RPM at converter stall. 1. Tune engine check governor. 2. See “Overheating” and make same checks, 2. Make corrections as explained in “Overheating.” =31-