34000 Powershift Z Transmission — R-HR LHR & MHR 4 SPEED LONG DROP CLARICHURTE> g OMPONENTS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 @ 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 manual should be used. Use of “willfit” 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.( eneTABLE OF CONTENTS HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Basic Design Sithouette Converter Group Converter Housing and Transmission Case Group... ++ Reverse and 2nd, Low & Output Group Forward, 4th, 3rd & Idler Group Regulating Valve and Charging Pump Group Control Valve Assembly Electric Control Valve (Non-Modulated) Axle Disconnect and Mechanical Parking Brake Assembly Instruction Illustration DISASSEMBLY OF TRANSMISSION REASSEMBLY OF TRANSMISSION CLEANING AND INSPECTION SERVICING MACHINE AFTER TRANSMISSION OVERHAUL SPECIFICATION AND SERVICE DATA LUBRICATION TROUBLE SHOOTING GUIDE RING GEAR INSTALLATION ee TYPICAL FOUR SPEED POWER FLOW ELECTRIC CONTROL WIRING DIAGRAM EXTERNAL PLUMBING DIAGRAM R-MODEL SECTION CONVERTER LOCK-UP SECTION MID-MOUNT CONVERTER SECTION (MHA) MODULATION SECTION .. NOTE: Metric Dimensions Shown in Brackets { 1 » Fig. A Fig. 8 Fig. C Fig. D Fig. E Fig. F Fig. G . Fig. H Fig. | Fig. J 36 - 50 . 51 . 54 . 55 56 57.58 59 6 63 81 97 107TRANSMISSION ASSEMBLY The transmission and hydraulic torque portion of the power train enacts an important role in transmitling 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 commen hydraulie 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 Sithouette Converter Group Converter and Transmission Case Group - Reverse and 2nd, Low & Output Group Forward-4th, 3rd & Idler Group Regulating Valve & Charging Pump Group Control Valve Assembly Electric Control Valve ‘Axle Disconnect and Mechanical Assembly Instruction External Plumbing Ring Gear Installation Four Speed Power Flow rking Brake The R, HR, and MHR Model Transmissions are of three basic designs. The R Model consists of a sepa 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 @ torque converter and powershifted transmission in one package mounted direclly 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 azzembly may be mounted directly on the side of the converter housing or front transmission cover, or remote mounted and connected to the transmission by means of flexible hoses, The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutch, A provision is made on certain models 10 neutralize the iansmission when the brakes are applied This is accomplished through use of a brake actuated shutoff vaive. The speed and direction clutch assem- blies are mounted inside the transmission case and are connected to the output shaft of the converter either by direct gearing or drive shaft, The purpose of the speed or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction. An axle disconnect is optional and is located on the output shaft, The drive to the front or rear axle can bbe 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 removable oil suction screen and direct through the pressure regulating valve and oil filter. The pressure regulating valve maintains pressure to the transmission control cover for actuating the direc tion and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed through the torque converter citevit to the oil cooler and returns to the transmission for positive lubrication, This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in a closed petition, When 2 specific pressure is achieved, the valve spool works against the spring until a port is exposed along the side of the bore. This sequence of events provides the proper system pressure. ‘After entering the converter housing the oll is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support, The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a fitting on the transmission. Then through a series of tubes and passages lubricates the transmission bearings and clutches. The oil then gravity drains to the transmission sump. The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover, This element is the pump portion of the hydraulic torque converter and is the primary com: ponent which starts the oil flowing to the other components which results in torque multiplication. This el- fement can be compared to 2 centrifugal pump in that it picks up fluid at its center and discharges a outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the ovtput shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque. The reaction member of the torque converter is located between and at the center or inner diameters of the Impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. The torque converter will multiply engine torque to its designed maximum multiplicetion ratio when the out- put shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque mult lication is increasing. The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector spool provides one position for each speed range. A detent ball and spring in the direction spool provides three positions, one each for forward, neutral and reverse. With the engine running and the directional control lever in neutral position, oil pressure from the 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 at 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- ight” by the use of sealing rings. A steel disc with external deaulically actuated piston. The piston is“ splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted, Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A Hub with ©.D. splines is inserted into the splines of dises with eeth 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 in the desired position. This allows cil under pressure te flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has 4 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 dises against the heavy back-up plate. The discs, with teeth on the outer diameter, clamping against ddisce 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. 34000 MHR34000 HR34000 FIG. AFIG. BITEM DESCRIPTION Bearing Support Screw Bearing Support Screw Lockwasher Drive Gear Snap Ring... Pump Drive Gear Bearing Pump Drive Bearing Support Pump Drive Gear Conwerter Housing Charging Pump & Regulating Valve Assembly... é Turbine Sheft Turbine Shaft Bearing Turbine Shaft Bearing Wesher Turbine Shaft Bearing Snap Ring “Turbine Shaft Piston Ring Converter inlet Tube Stator Support Piston Ring Piston Ring Expander Spring Stator Support Screw Stator Support Screw Lockwesher Turbine Hub Turbine Hub Snap Ring Reaction Member Snap Ring Reaction Member. Reaction Member Spacer Bearing Snap Ring Impeller Hub Bearing Impetier Hub Impeller Hub “O" Ring HR 34000 CONVERTER GROUP. FOR R-MODEL (REMOTE MOUNTED CONVERTER) SEE PAGE 63 ary 6 6 3 3 3 3 ITEM DESCRIPTION 29° impeller 30 Impeller to Hub Screw Backing Ring 31 Hub to Impeller Screw 32 Oil Baffle Retainer Ring 33° OilBafite.. 34 Oil Battle Seal Ring 35 OilBaffle Oil Seat 36 Impeller Hub Geer 37 Impeller Hub Gear Snap Ring 38 Turbine 39 Turbine Hub Screw Lock Tab 40 Turbine Hub Screw 41 Impeller to Cover “O” Ring 42 Impeller Cover 43. Turbine Hub Bearing 44 Impeller Cover Hub “0” Ring 45 Bearing Spacer 46 Bearing Snap Ring 47. Turbine Hub Snep Ring 48 Impeller Cover Hub 49 Ring Gear Backing Plate 50 Flywheel Ring Gear « 51 ling Gear Stud 52 Aing Gear Stud Belleville Washer 53. Ring Gear Stud Nut 54 Impeller Cover Hub Screw 55 _ Impeller to impeller Cover Screw 56 Impeller to Impeller Cover Seren Lockwasher ary 24 72 24 24 24a THR. OPTION FIG. c34000 CONVERTER HOUSING &TRANSMISSION CASE GROUP ‘SEE PAGE 64 FOR R-MODEL CASE GROUP ITEM DESCRIPTION ITEM DESCRIPTION 1 Tube Cip Screw 2 Tube Cip Scrow Lackwasher 3 Tube Cip 44th Speed Pressure Tube 5 th Speed Pressure Tube “O" Ring 33rd Speed Pressure Tube 7 Tube Clip Screw... 3 Tube Clip Scrow Lockwasher 9. Tubectp 10 Forward Pressure Tube Assembly 11 Forward Tube "0" Ring . 12 Valve Ol! Supply Tube 13. dth Lube Pressure Plug Cap 1 Sth Lube Pressure Plog 15 Converter Housing Adaptor (Not used on all modes) 18 Lube Prossure Port Plug 17 Port Plug “O" Ring 18 Speed Sensor Fug 19 Speed Sensor Plug “O" Ring 20 Speed Sensor Adjuster Bushing 21 Converter Housing. 22 Reducing Bushing 23 Breather 24 Confer Housing to Front Cover Stud 25 Converter Housing to Front Cover Stud Lackwasher 28 Converter Housing to Front Gover Stud Nut 27 Canvertr Housing t Front Covet Screw 28 Convert Housing 1 Frat Cover Screw Lockwasher 2 30 31 Safety Valve Seat 32 Valve Seat Retaine 32 Pressure elie! Valve Plunger 34 Retaining Ring 3 Washer. 35 Pressure Reliel Spring 37 Converter Housing Seeve. 38 Converter Housing Sigeve Lack 33 Steove Lock Serew Lockwasher 4D Sleeve Lock Screw - Converter Housing Sieve 42 Converter Housing Sleeve Lock 43. Sleove Lock Screw Lockwasher 4% Sieave Lock Screw 45 Steeve Lock Screw 438 Sleeve Lock Serow Lockwasher 47 Converter Housing Sleove Lock 48 Convertor Housing Sleove 83. Plug or External Lube for Low Beating 50 Port Plug "0" Ring ‘St Forward Clutch Pressure Port Plug 52 Por Plug "0" Ring. 53 Port Plug, Bi Port Pug. 55 Pom Plug "0" Aing 55 sth Cluteh Pressure Port Pug 57 Por Plug "0" Ring 53 Cop Gasket 53 Cop 52 Plug 81 Plug 52 Port Pug "0" Ring. 83 Lube By-Pass Port Pug 5% Converter Housing 1 Case Serow Lockwasher 85 Converter Housing to Transmission Case Seraw 5 Converter Housing to Transmission Case Scrow Lockwasner 87 Converter Housing 1a Transmission Case Seraw 158 Converter Housing a Transmission Gasket 52 Converter Housing o Transmission Case Dowel Fin 70 Tube Sleeve "0" Ring 7 Tube Siewve 72 Rane Seren 73 Retainer Screw Lockwasher 7 Outer Roce Retainer ‘Outer Roce - used with lock-up only 7 n BSSSRESS2SSSSERERRISue 128 nt ey 1B 1m 135 138 cr 133 3 130 uy 132 149 145 148 137 133 18 150 Speed Sensor Hole Plug Speed Sensor Plug "O" Ang Speed Sensor Adjuster Bushing ‘Adjusting Bushing Shin Plug "0" Ring Lock-Up Supply Hole Plug ‘Tranemiesion Case ‘Transmission Case o Roar Cover Dowel Pin Dipstick Tubs Clip . ‘i Dipstck Housing Dipstck Dipstck Housing "0" Ring Dipstck Tube Dipstck Tube Ci Lockwasher- Dipstck Tube Clip Serew Tube Sleeve Tube Sleeve Suction Tube Suction Tubs "0" Ring Suction Tube Flange “Transmission Case to Rear Cover Gasket “Transmission Case Feat Cover Sd Clutch Supply Passage Pug Fear Cover Cave Serow Lockwasher Fear Covert Case Scrow Rear Covert Case Screw Lociwasher Rear Cover to Case Screw Screen Aasembiy Gasket Screen Assombiy ‘st Speed Sleave “O" Ring 4st Speed Clutch Pressure Sloove jet Speed Sleove "0" Ring... Rear Cover Supply Poa. Plug "0" Ring eat Covert Cave Stud Nut Rear Cover to Case Stud Lockwesher Rear Cover to Gase Stud . Rear Covert Case Stud 2.0.20 Suction Tube Reiner Washer Serew Suction Tube Retainer Washer. Tube Sleeve = ing ‘Tube Sleeve Suction Tube Clip Serew Suction Tube Clip Suction Tube Clip Screw Lockwasher Battle Mouncing Plate Assembly "Mounting Plate to Case Screw Washer Mounting Piste to Case Screw ‘laa to Case Screw... Oj Bate to Case Scrow Lockwasher |. Oi Battle to Mounting Plate Washer (i Battle to Mounting Plate Screw. Oi Batte ‘st Speed Clutch Prascure Tube» Low Shaft Fear Soaring Lube Tube 2rd Spoed Clutch Pressure Tube. Oiteevel Pug Drain Pug "0" Ring Drain Plug... Auxiliary Orin Pug “O” Ring ‘auxiliary Orin Pug Drain Back Plug rain Back Plug "0" Ring Tube Sieeve "0" Fing Tube Stee Taps Steeve "0" Rog o Siewe Fror Cover Ol Seal Canvartor Housing Front Cove Sorvarter Housing Front Cover Gasket Hosa Fitting Hose Assomoly Hose Fting aryFig. D fITEM DESCRIPTION 1 Reverse & 2nd Clutch Shaft Piston Ring 2. Piston Ring Expander Spring 3. Front Bearing Retainer Ring 4 Front Bearing Snap Ring 5 Reverse & 2nd Shaft Front Bearing 8 7 a 1 Reverse & 2nd Shaft Front Bearing Spacer . Clutch Driven Gear Bearing (Glutch Driven Gear Locating Ring * Clutch Driven Gear Beating Spacer 19 Clutch Driven Gear Locating Ring 11 Clutch Driven Gear Beating 12 Clutch Driven Gear. . 13 Clutch Hub Oil Battle Ring 14 Spring Retainer Snap Ring 18. Shap.fing Retainer 18 Spring Retainer 17 Piston Retutn Spring 18 Spring Retainer 19° Backing Plate Retainer Ring 20 Backing Plate-Reverse Clutch 21 Clutch Inner Dise-Reverse Clutch 22 Clutch Outer Dise-Reverse Clutch 23. Clutch Piston Assembly Reverse Clutch 24 Clutch Piston Outer Seal 25 Clutch Piston Inner Seal 26 Reverse & 2nd Clutch Drurn 27 Cluteh Piston Inner Seal 28 Clutch Piston Outer Seal 29° Clutch Piston-2nd Clutch 30 Clutch inner Dise-2nd Clutch 31 Clutch Outer Disc-2nd Clutch 2 Backing Piate-2nd Clutch 38 Backing Plate Retaining Ring 34 Spring Retainer 35 Piston Retuen Spring 36 Spring Retainer ... 37 Shap Ring Retainer - 38 Spring Retainer Snap Ring... 39 2nd Clutch Dise Hub Retainer Snap Ring 40 2nd Clutch Hub Retainer Ring Retainer 41 2nd Clutch Disc Hub Retainer Ring 42 Clutch Hub Oil Baffle Ring 43 2nd Clutch Disc Hub 44 Front Béaring Cap Oil Seal 45. Front Bearing Cap 48 Bearing Cap Shim 47, Front Bearing Cap “0” Ring 48. Front Bearing Cup 49. Front Bearing Cone 50 Output Shaft 51 Front Bearing Cap Screw 52 Front Bearing Cap Screw Lockwasher 53 Output Shaft Gear Spacer 4 Thrust Washer AR-AS Required “Not used on all modols 34000 REVERSE & 2ND, LOW & OUTPUT GROUP ary ITEM BANANA SSRISRLBRIVSSISH DESCRIPTION Rear Bearing Cone Rear Bearing Cup Rear Bearing Cap “0” fing - Rear Bearing Cap "0" Ring Rear Bearing Cap Screw Lockwasher Rear Beating Cap Screw Rear Bearing Cap Oil Seal Rear Bering Cap Screw Rear Bearing Cap Screw Lockwasher Rear Beating Cap ‘Output Shaft Gear Rear Bearing Cap Stud Rear Bearing Cap “O" Ring Bearing Cap Shim ...... Rear Bearing Cap Stud Lockwasher Rear Bearing Cap Stud Nut Rear Bearing Cap Plug Rear Bearing Cap a Clutch Shaft Piston fing {st Speed Clutch Shaft & Drum id Speed Driven Gear 4st Speed Clutch Front Bearing Assembly (Cup and Conel ‘at Spead Clutch Shaft Bearing Spacer Ist Speed Clutch Shaft Retainer Ring {seSpeud Cth Saft Plot Bearing. Cluteh Piston Inner Seal Clutch Piston Outer Seal CGutch Piston Clutch Inner Dise Clutch Outer Disc. - Giuteh Dise Backing Plate Backing Plate Snap Ring CCluteh Hub Oit Baffle Ring Piston to Dise Spring Washer Spacor Dise Springs: Fi Spring Retainer Ring 1st Speed Gear Bearing Spacer 1st Speed Gear Bearing 1st Gear Bearing Snap Ring 1st Speed Gear ‘st Speed Gear Bearing ‘Thrust Washer Lock Ball - 1st Speed Gear Bearing Thrust Washer jst Speed Clutch Shaft Rear Bearing Assembly (Cup and Cone) Bore Plug Oil Seat ‘Output Flange Output Flange "0" Ring Output Flange Washer Output Flange Nut ary.FIG. E i ein hor” 100: 93 per 98 937 2 7 e “teITEM 1 Forward & 2nd Shaft Piston Ring 2. Piston Ring Expander Spring 3 Front Bearing Retainer Ring 4 Forward Shaft Front Bearing 5 Forward Shaft Front Spacer: 6 a 3 9 0 DESCRIPTION Chath Oven Gear Bearing uth riven Gar Locating fing “Shieh Diven Gea Bearing Spacer Guth Grivn Gear Locating ing Guach Dven Gear Bearing 11 Forward Guch riven Goat 12 Guten tub Ol ete ing 12 Spring Petaner Sap Ring 14 Shap ng Rosner 15 Sping Retaner 18 Peton Retun Sing 17 Spring Retainer 12 Backing Pate Snap ing 13. Cun bee Ssoking Pte 20 Ghtch Outer Dee 21 Ghrch ona Disc 22 Guten Paton Assembly 23 Ghtch ston Outer Sea! 24 Chtch ton ner Sol 25 Forward Sat @ Cuteh Dram 26 Forward Shalt Rear Bering 27 Forward Shaft Bearing Wother 28 Forward Shaft Rear Seating Washer Faia ing 9. Forward Shah fear Soting Tt Washer JO Bearing Tut Washer Retainer fing 31 Spring Roane 32 Plton Ratu Spting 3 Sping Retainer BA Spring Retainer Sap Ring 3S th cluch Dis Hub Reating Ring 36 Cich Hob Oi Batting Sr ainchiah ie Hub 38 Backing late Snap Ring 33 Gch Dis Bacting Plate 49° Gutch Ouer Oe. 41 Guten ner Ose 2 Cutch Peon 5 Guten Fton Outer Sea! {SE Gutch Petan ner Sol 413 SinSpeed Sha Cute Grom 38 Pont eatng Locating ing 47 StnSpeed Shaft Front Bemtng 42 Front Bearing Retainer ing 25. dinSpwed Shaft Paton ing 52 Peron Ring Expander Spring 51 SyeSpand Roar Bearng + not used on all models 34000 FORWARD, 4TH, 3RD & IDLER GROUP. ITEM SSSISaras 101 102 103 DESCRIPTION Bearing Thrust Washor ‘1d Speed Shaft Rear Bearing Retainer Ring Rear Searing Cap Stud... Rear Bearing Cap "O" Ring «. Rear Searing Cap Plug Rear Searing Cap Lockwasher Rear Bearing Cap Nut Rear Bearing Cap Rear Bearing Cap “O" Ring 3rd Speed Shatt Piston Ring Idler Shstt Bearing Cap Stud Nut Idler Shaft Bearing Cap Stud Lockwasher.. Idler Shaft Rear Bearing Cap lier Shaft Bearing Cap Gasket Idler Shaft Bearing Cap Stud Rear Bearing Washer Retainer Ring Inler Shaft Rear Bearing Washer Idler Shaft Rear Bearing 3rd Speed Bearing Retaining Ring 3re Speed Gear Beating Bearing Retainer Ring 3rd Speed Gear Bearing 31d Speed Gear CCluteh Hub Oi Baffle Ring 3rd Speed Bearing Retaining Ring ‘Spring Retainer Snap Ring ‘Spring & Snap Ring Retainer Piston Return Spring ‘Spring Retainer... Backing Plate Snap Ring Backing Plate ‘Clutch Outer Disc Clurch Inner Disc. = ‘Clutch Piston Assembly Clutch Piston Outer Seat Clutch Piston Inner Seal... 31d Speed Clutch Shaft & Oru Idler Shaft & Gear Idler Shaft Front Bearing Idler Shaft Plot Bearing Speedo Drive Gear Lockball ‘Speedo Drive Gear ‘Speedo Gear Retaining Ring Rear Bearing Cap Bearing Cap Seraw Lockwasher Bearing Cap Screw: Rear Bearing Cap Screw Fear Bearing Cap Screw Lockwasher Speede Driven Gear Speedo Tube Nut "O” Ring Speedo Tube Nut Speedo Tube Nut Oil Seal ary.e ut at34000 PRESSURE REGULATOR VALVE & CHARGING PUMP ‘TEM DESCRIPTION ary. ITEM DESCRIPTION ary. 1 Thrust Plate & Bearing Assembly....... 2 19 Valve Spring - Outer 1 2 Pump Driven Shaft Assembly 1 20 Valve Spring = Inner.....-.s0028+ 1 3. Thrust Plate & Bearing Assembly.....-. 2 21 Regulator Valve Spool . 1 4 Wave Spring 2 22 Clutch Pressure Supply “O" Ring....... 1 5 Pump Shaft Seal. . 2 23 Valve to Converter Housing Screw 6 Pump Drive Shaft Assembly 1 Seer a Soria acme 24 Valve to Converter Housing Screw 2 8 Pump Suction Adaptor “O” Ring sss. 1 25 Regulator Valve Plug.....-- al ee ee 4 26 Regulator Valve Plug.....00ecccccccre T 10 Charging Pump Suction Tube Coupling ... 1 Moe ee ea 1 Charging Pump Suction Tube Retainer... 1 28 Safety Valve Piston .-...-.00000se00s t 2 Charging Pump Suction Tube Gasket... 1 28) Safety Valve) Piston Spring i 13 Charging Pump Suction Tube Sleeve... 1 30 Piston Spring Retainer. . ! 14 feat Cover Suction Flange... ‘i 31 Spring Retainer Snap Ring .........+0+ 1 18 Reer Cover Suction Flange “O" 1 32 Pump Shaft Olt Seal... .- u 16 Regoleter Valve Pilot “O” Ring 1 33 Valve Body to Pump Gasket .. ad ee 4 34 Valve to Purp Screw Lockwasher 2 18 Valve Spring Retainer Cup .....eeeee00 1 Bene oe ear Bt 36 Valve to Pump Screw Lockwasher....-. 2 37 Valve to Pump Screw. 2rss. FORWARD REVERSE i || Fwo a REV en Less DEctuICH eo 2 ‘CONTROL VALVE ASsEMaLy tamoecuuter FIG. G int kcal ea aS Y34000 CONTROL VALVE ASSEMBLY 4 SPEED WITH AIR DECLUTCH FORWARD & REVERSE ITEM DESCRIPTION ary. ITEM DESCRIPTION ary. 1 Air Actuator Assembly..........00000 1 23 Valve to Adaptor Housing Screw Piston Housing Stop Plug wd Lockwasher: cere 9 Piston Housing Plug “0” Ring . 1 24 Control Valve Housing.........0ss222+ 1 25 Neutral Switch Actuating Pin seed 4 Piston "O" Ring........0.e0 ced 5 Giyd RAG... eee cence 1 26 Neutral Switch .........4 1 6 Piston ceed 27 Valve Spool Stop 1 7 Piston Housing 1 28 Spool Stop 1 BORING. eee T CET! vee ‘ 9 Speed Selector Spool .. 1 30 Forward & Reverse Valve Spool 1 10 Plug. 1 31 Valve Spool - Figure “C” 1 11 Oil Seal. 1 32 Control Valve Spring - Figure "C" ...... 1 12 Detent Ball . 1 33 Not Used On This Option 13 Detent Spring...........0005 i 34 Seal Plate to Adaptor Plate Screw...... 4 *4 Detent Spring 1 35 Seal Plate to Adaptor Plate Screw 15 Detent Ball .. 1 One 16 Pipe Plug. e 36 Control Valve Seal Plate Fees ; 37 Adaptor Housing to Converter Housing 18 Detent Spring... ......ceeeeeeee eens 7 Boyes mate enereniecing 19 Detent Spring Pin. cess 1 Screw Lockwasher.. a 20 Detent Spring Plug Washer. 1 39 Converter Housing to Valve Adaptor Screw 6 21 Detent Spring Plug...........00eeeeee T 40 Valve Adaptor Plate . 1 22 Valve to Adaptor Housing Screw . a2 41 Converter Housing to Valve Adaptor Plate Gasket .....0..eeeee00 vd 42 Seal Plate to Adaptor Plate Gasket ..... 1 43 Control Valve to Seal Plate Gasket ..... 1Mo. [cove [SOLENOID] MRE SOR NUMBER OF] | WIRE 4 a 1st) YELLOW 1 14.00 [355.6] 8 F F321&R|F PINK |1(SConnectors)| 17.80 [452,0)| 6 E FWO. BLUE, i 9.00 [228,64] 7 A REV. BROWN, i 17.25 438.2) 5 8 2nd GREEN 1 12.00 Bo46) 9 o 3rd ORANGE 1 10.75 [273.0] ELECTRIC CONTROL VALVE ASSEMBLY ITEM DESCRIPTION ary. ITEM DESCRIPTION 1 Control Valve Housing. ceed 14 Housing Screw 2 Plug 1 15 Housing Screw Receptacle Screws....... cere 4 16 Housing Screw.... 4 6 Pin Receptacle & Wire Assembly... 1 17 Housing Plug ... 8 Housing Plug ............. 0. 2 18 Housing Screw....... 6 Housing Plug ....-...ceceeeeeeeeeee 19 Housing Plug 7 Housing Screw Washer........ 14 20 Solenoid Assembly. 8 Housing Screw 2 21 Solenoid “O" Ring. . 9 Solenoid Cover Stud ..........0. 3 22 Solenoid “0” Ring 10 Solenoid Dust Cover : 1 23 Solenoid “0” Ring 11 Cover Stud Washer 3 24 Solenoid Coil (12 or 24 Volt Cover Stud Nut 3 25 Solenoid “O" Ring. 13 Dust Cover Seal . at See page 59 for wiring diagram. ary.MECHANICAL PARKING BRAKEeM 1 2 TEM AXLE DISCONNECT DESCRIPTION avy. TEM DESCRIPTION ary. Disconnect Housing Capscrew 4 8 Disconnect Shaft ..eecenu Disconnect Housing Capscrew 9 Detent Ball .... ceceneeeeceeeee T Lockwasher ce 4 TO Detent Spring cree on Disconnect Housing = 1 11 Shift Rail oo 1 Disconnect Housing Plug... coe I 12 Shift Rail Oil Seal 1 Shift HUB eee - wl 13. Bearing Retainer Ring .. i Shift Fork... - 1 14 Bearing a Shift Fork Lockscrew ooo. 1 15 Bearing Retainer Ring : 1 MECHANICAL PARKING BRAKE DESCRIPTION ary. ITEM DESCRIPTION av. Backing Plate Assembly... 8 Return Spring nn 2 Actuating Lever ... = 9 Brake Shoe (see item 3)... Brake Shoe and Lining ......-- TO Brake Lining enero 2 Brake Flange -1 11 Rivet. Brake Drum ..... al 12 Backing Plate Screw Brake Drum to Flange Screw 13 Backing Plate Screw Lockwasher ..... 4 Lockwasher ..... Brake Drum to Flange Screw... 6> ]| “y y BaF ey \ FIG. JAlt igad in chamfors foro seas, piston ings and "9" singe must be smooth and eee Wom buts Inspect as assembled Pralube betore assembly. Al piston ing grooves ‘nd "3" rings, with Multi-purpose greage Grace 2 ‘Apply thin coat af Locte 638 (color green) 10 futeide diameter of al ol seals, ore plugs and bores tnay are 1 be instaled ilo, belore Sssembly Use sxlfeme care not to alow sealant 10 ome into conte! wih coal ip mate ‘Apply thin coat of Loctite 270 (eo! green to al {iru hole stud tiveads whch do nat Nave pro ‘spp sestant ‘opty thin coat of Loctite Vibra Seal 516 [color ‘Burt orange to all pipe ead tings which Go fot nave pre-applied sealant, It grease required for positioning gasket during {ezombly, cee Mull;purpove grease Grade 2 Aller assembly of part using Loci, there must ‘at be any rep or oxcoss mate whica might ler ge i ecu Oniy use Loctite whore Specified General Bearing instalation Procedure a thermal assembly ad i used. (expancing by heating 275°" 25°F (195° = 380°C] a check ‘must be mace after mating pats have reached the ‘sume temperature thin 20°F [87°C] ot ambient {o be sure ihe bearings are postioned solialy gains! Ina respective shoulders ‘Low (1 elute taper bearing adjustment (See Special Insructions) A. teat wa eating cap must be stsemblag at ‘Shim output shalt bearings to produce 4:10. I. LSE eo Nm prolad rling ivan As Ay S0esial sting shat bearing 914M lasing olchas must be on same sice as retaining tng. Elathie Stop Nut Torque Chart 2X 02s iton piston rings in owe piston cng acation ‘ane Viton Rings at nae piston rng locaton. All Speed versions, al clutenes. Aa Sauter sie! plates, 6 ner hton plates, Siarnately sezemole, staring wih outer sie! plate Ax B ower seal plates 9 inner tion plate Stamately assemble, sarang wll outer sieel pate Mocuited Forward and Raves tones. 1 outer (Dy Hos pes, 1 nner Heton pte, sheet sri staring wise tn pte NO Hovulod Ponrard avd Pavers utes se tema 24 Pace wots tobe used at these eaters -Raques Special Torque Pace BOLT _[_ToRGUE Tes [~wml_] 5 S257 ro 0 sas] Bana ok tbs at asemby, ae ating am Ssrena fo proper torque. Tabs must be bant against Screw hood lst or around corners as shown ca AxSbieh piston return spring: Concave side of fret Bellevite spring must be fseembled toward eich piston. Allernata Femaining springs [Al dowel pine must be installed in transmission tase belre nsvembly of mating parts. Tigo ol screen assembly 101 15 Fi, tbs. 11820 Wim at modes fs Wen nstatiog euch support piston ring, hooking ‘nde must be 100" Wom expander spring opening Aas be lose internat bearings wih 8 No. 3 Sched on the beating AX OF Puma Sleeve and Coupling Assembiy. Torque ‘lama bolt 73 9 9 FL Lbs (10-12 Nm] Ax Bearing shied must face OUT an Low & 3rd clutch. Bearing shield rust face IM 90 Forward & Reverse clutches. Axle hates in converte auppart (048-089 [1.17 424] ameter) must be checked pris to assembly inust be lee ol eit and burs Impotie hub and turbine hu assembly with ‘packing cng and special selltocking strews. 7 Clean uo mounting surlace and tapped holes win sven Ory thoroughly, boing cenain ‘aoped hales are clean and ary. 2. Inatal nacking ring and special seltlocking Screws. Tighten soraws to 9099 FL. Lbs (122-194 Nm] for toroine and 58.64 Ft Lbs. [79.7 avy or impel. Nola: Assembly of hub must bo completed within 2 liteen minute parod trom stat of screw instal lation, The speett screw isto DB used for one Instllaton ony, tho evaw is removed for any ‘ason, t must be replaced. The apory let in Ine hob holes must be removed wi the propar Tap fd clesnaa wi aalvent Dry Note thoroughly and tse a new raw ior veinstatation cues @ a Sea caus & a) eS |S Tae | i eee ee] a oe ae sooo [1.70 | jase samy | L753 35.4) 2. i 983-1193 | See eerner tee bo Pee eee [Tarso [aes 29 | 353° 39a 132 | 3308 ws. | 2 zy tas [pes aa) [ae a eat saree a ome onl eeo eta] | 4Regulator Valve and Charge Pump Ass'y [— Lift transmission using this hole Assemble Speed Sensor Bushin ig in housing to specified dimension with Loctite 262 and stake (Q) three places. (ON ‘ ! ko Ci Y) Acasa ‘a Stake 3 places approx equally spaced. pi Ss | 1,060 +007 (26.9 +18] % i 4 Alter curing of Loctite, speed sensor bushing Must be secure with 40 Ft, Ub. [54.2 N-m] torque O Ground driven emergency Steering pump drive—option wispeedo drive | Parking brake (10 x3) L-% 19 brake (10%3) Direction of rotation with \ Oy) Forward clutch engaged REAR VIEW HR, LHR & MHR 34000 4 SPEED FIG. KMAINTENANCE AND SERVICE “The instructions contained herein cover the disassembly and reassembly of the transmission in @ sequence that would nor: rmally be followed after the unit has been removed from the machine and is to be completely overhauled. it must also be ‘understood that this is a basic HR 94000 4 Speed transmission with many options. Companion flanges and output shafts with ‘and without disconnect assemblies may vary on specific ‘models. The units are very similar to trouble shoot, disassemble, tepait, and reassemble, CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit, Before ‘attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibilty of drt and foreign ‘matter entering the mechanism. Drain as much ail as possible before disassembly. See page 81 for LHR (Converter Lock-up) Disassembly and Reassembiy. ‘See page 63 for R-Model (Remote mounted) transmission front Cover section, Sea age 98 for MHR (Mid-mount) (see Figure A for basic design sithouette) DISASSEMBLY Figure 1 Side view with manual control valve. flow clutch has external lube, remove tube as shown in Figures B and 9 on page 70. See ‘page 75 for low clutch lube transfer information. Figure 2 view with electric control valve. NOTE: Valve shown is 3 sm speed valve-see Fig. H for the four speed valve. Remove pump suction tube, tube adaptor, flange and “O” ring. Figure 3 Figure 4 Remove charging pump and pressure regulating valve assembly,Figure 8 Remove impeller cover to impeller bolts, Figure 6 Remove control valve bolts and washers, Remove control Figure 9 valve. Use caution as not to lose detent springs and balls inariat eave caer Remove turbine shaft outer retainer ring. Figure 7 Figure 10 Remove impeller cover bearing cap bolts. Remove bearing Using pry slots provided, pry impeller cover and turbine cap. from turbine shaftFigure 11 Remove imfiéller cover and tFigure 18 Remove stator support bolts. Figure 19 Turn support to clear pump drive gear. Remove suppor, shoe Figure 21 Remove converter housing and clutch assemblies from transmission housing. 5 ‘Spread 4th clutch inner bea assembly from housing. retainer ring and tap clutchFigure 29 Figure 32 Remove bearing cap. Remove low (1st) clutch bearing cap and shims igure 30 Figure 33 Remove outer bearing locating ring. Remove low (1st) speed clutch pressure sleeve, Figur 31 Remove tow (tst) clutch bearing cap stud nuts and ro 34. washers. Remove idler shaft bearing cap stud nuts and washers.Figure 35 Remove béaring cap and gasket. ry slats provided, pry cover from tre tapping on idler shaft and 3rd clutch to al Figure 36 Remove outer bearing locating ring. Figure 37 Remove rear cover bolts and washers. ingand disc hubFigure 41 Figure 44 Remove disc hub retainer ring. Loosen low (1st) clutch, Figure 42 Figure 45 = Remove 2nd clutch dise hub, Remove low (Ist) clutch end idler shaft together from housing. Figure 43 - 3 Tap idler shaft toward rear of housing, NOTE: Idler shaft Figure 46 and low (Ist) clutch must be removed together, Remove 3rd speed clutch assembly. ( —a—Figure 47 Figure 50 Remove fofivard clutch inner beating retainer ring and Remove low (st) clutch inner bearing cup locating cing and thrust washer. spacer (oil baffle). Figure 48 Figure 51 Tap forward clutch assembly to the rear far enough to Tap inner bearing cup from housing, remove inner bearing outer locating ring Figu: Figure 49, Block output shaft to prevent turning, Remove output flange nut, washer and “O" ring, Aamove flange, Remove forward clutch assembly —9-Figure 53 Figure 56 Romove front bearing cap and shims. Remove the 4th speed clutch disc hub retainerring and disc hub from idler shaft, Figure 54 Figure 57 Remove rear bearing cap, Remove idler shaft inner bearing, this should be a slip ft. Figure 85 Block output gear. Push output shaft through bearing and (gear from the rear, Remove idler shaft outer bearing retainer ring, Figure 58 exFigure 59 Figure 62 Remove idler shaft outer bearing, Install inner bearing on bearing race. Position 4th speed - clutch dise hub on idler shaft. install disc hub retainer ring IDLER SHAFT REASSEMBLY (Sesfeleantiaiend inseecasyeese) 4th SPEED CLUTCH DISASSEMBLY Figure 60 Figure 63, Install idler shaft outer bearing. NOTE: Bearing outer Remove clutch shaft oil sealing rings (piston rings). See page retainer ring groove must be up. 119 for sealing ring and expander spring installation Figure 61 Figure 64 | shaft 10 bearing retainer ring, Remove bearing to shalt retainer ring —Wwe—Remove clutch bearing, Remove end plate retai Remove end plate. Figure 65 Figure 66 iner ing, Figuro 67 ae eal Figure 68 Compress return spring retainer. Remove return spring retainer ring, Figure 69, Remove piston return spring and inner and outer spring retainers. Figure 70 Remove inner and outer clutch dises.Figure 71 Juin clutch over and tap on a block of wood to remove the clutch piston, Figure 74 ome Position the inner spring retainer, the ston return spring, the = outer spring retainer, and retainer ring in clutch drum, REASSEMBLY OF 4th SPEED CLUTCH {See cleaning and inspection page) 7 Figure 72 Make sure clutch piston bleed valve is clean and free of foreign Figure 75 ‘material Install piston inner seal rng, Install clutch piston cure Compress return spring instal sping retainer rng, piston ting. Leck piston ring joint secutely. Grosse ring. to stabilize in ting groove. Figure 73 lutch drum, use caution as net to damage the Figure 76 ston seal cings, Install 1st steel aise ceeFigure 77 Install 1st friction disc, Install next steel dis. Alternate friction and steel discs until the proper amount of dises are installed, Fist diec next to the piston is steel, last die installed is friction, Figure 80 Install clutch shaft front bearing with bearing outer locating ‘ing groove down. Install bearing to clutch shaft retainer ring Figure 81 Install clutch shaft oil sealing rings and expandgt springs per instructions on page 118. Figure 78 Install clutch dise end plate, 3rd SPEED CLUTCH DISASSEMBLY Figure 79 Install end plate retsiner ring. Figure 82 Remove clutch shaft rear oil sealing ring, 14 oFiguro 86 Remove cluten shaft to rear bearing retsiner ring, Tap gear and outer bearing from clutch. Le Figure 84 Figure 87 ig Remove rear bearing. Pry inner bearing up enough to install a bearing puller Figure 85 Figure 88 Turn clucch over and remove clutch gear retainer ring. Remove inner bearing. —15—Figure 89 Figure 92 Remove inner bearing locating ring. Compress return spring retainer. Remove retum spring retainer ring. ( Figure 90 Figure 93, Remove end plate retainer ring. Remove piston return spring and inner and outer spring Figure 91 Figure 94 Remove end plate Remove inner and outer clutch discs. —16—Remove elyich piston. 3rd SPEED CLUTCH REASSEMBLY (See cleaning and inspection page) Figure 96 ‘Make sure clutch piston bleed valve is clean and free of foreign ‘mateo. Install piston inner seat ring. Install clutch piston outer piston ring, Lock piston ting securely. Grease ring to stabilize in ring groove Figure 97 Position piston in clutch drum, use caution as not to damage the inner and outer piston seal rings. -—7e— Figure 98 Position the inner spring retainer, the piston retucn spring the outer spring retainer and retainer ring in clutch drum. Figure 99, Compress return spring, Install spring retainer ring Instait clutch gear inner bearing locating ring.igure 101 Install 1etstee! disc. Install 1stfriction disc. Alternate steel and friction dises until the proper amount of discs are installed. First dise next to the piston is steel, last dise installed fs friction. Figure 102 Install cluteh disc end plate. Figure 103 Install end plate retainer ring. Figure 104 Install clutch gear inner bearing. NOTE:This bearing does not have a shield in it, Figure 105 Install clutch driven gear and hub into clutch drum. Align splines on clutch hub with internal teeth of feion discs, Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction dises. Figure 106 Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be up. =18— !Figure 107 Install outer bearing retainer ring. Figure 108 Install clutch shaft rear bearing. NOTE: Bearing outer ratainer ring groove must be up. Figure 110 Install clutch shaft oil sealing ring FORWARD CLUTCH DISASSEMBLY For Modulated Clutch See Page 108 Figure 111 Remove clutch shaft front oil sealing rings (piston rings). See page 118 for sealing ring and expander spring installation Figure 109 Install ¢2ar bearing retainer ring Figuro 112 Remove front bearing retaining ring, —19—Figure 113 Figure 116 Pry front bearing up far enough to install @ bearing puller. Pry clutch gear up far enough to installa gear puller. - = a | Figure 117 Remove clutch gear and outer bearing. Figure 115 Remove front beating spacer. Remove bearing spacer. Not used on all models, —20—igure 119 Remove clutch dise end plate retainer ring. Remove inner besring Figure 120 Figure 123, Remove end plate, Compress piston retuin spring. Remove spring retainer ring, re tainer wesher, spring retainer washer, return spring and spring 7 a, =. Figure 121 Figure 124 Remove the inner and outer clutch discs. Remove clutch piston. oyFigure 125 Remove clutch shaft rear bearing retainer ring. yy Figure 126 Remove rear bearing FORWARD CLUTCH REASSEMBLY (See cleaning and inspection page) For Modulated Clutch see page 110 Install clutch shaft rear bearing. NOTE: Bearing outer locating ring groove must be up. encsleaaaat Figure 128 Install bearing retsiner ring, Figure 123 Make sure clutch piston bleed valve is clean and fre of foreign ‘material. Install piston inner seal ring. Install piston outer piston fing. Lock piston ring joint securely. Grease ring % stabilize in fing groove, Figure 130 Position piston in clutch drum, use caution as not to damage the inner and outer piston seal rings, —22— \Figure 131 Install the clutch piston return spring as explained in figures 98 ‘and 99, Install the clutch dises as explained in figure 101 NOTE: The forward clutch has an outer spring retainer washer that is installed between the return spring and spring retainer Fing retainer washer. Figure 132 Install clutch dise end plate. Figure 133, Install anu plate retainer ring, Figure 134 Install the clutch gear inner bearing, NOTE: This bearing does not have a shield in it. Figure 136 Position beating spacer on clutch shaft. Not used on all models. Figure 136 {ch gear and hub into clutch drum. Align splines fon clutch hub with intemal teeth of friction dises. Tap gear ‘nto position. Do not force this operation. Gear splines must be in full position with intenal teeth of all friction discs.Figure 137 Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be down. Figure 138 Position front bearing spacer on clutch shaft, Figure 139 Install clutch shaft front bearing, —24— S Install clutch shaft oil sealing rings and expander springs per instructions on page 119. - REVERSE & 2nd CLUTCH DISASSEMBLY (Reverse being disassembled) For Modulated Clutch see page 113 ene Figure 142 Remove clutch shaft oil sealing rings (piston rings). See page 113 for seating ring and expander spring installation,. Figure 143 Figure 146 Remove fedhit bearing retainer ring Remove front bearing spacer. Figure 144 Figure 147 Pry front bearing up far enough to install a bearing puller Pry clutch gear far enough to install a gear puller. . Figure 145 Figure 148 Remove the clutch gear and outer bearing, Remove front bearing. —25—