DANA 36000 Long Drop OHT-00611) 2) 3) 4) 5) 6) 7 8) 9) 10) TABLE OF CONTENTS Foreword Satety precautions, cleaning and inspection Technical specifications - identification of the unit ~ weight, oil capacity ~ pressure and temperature specifications Maintenance ~ oil specification - maintenance intervals - servicing machine a‘ter components overhaul Installation details ~ converter drive coupling = components to engine installation > extemal plumbing Operation of the unit ~ hydraulic diagram = power flows ~ electrical wiring Troubleshooting - stall procedure ~ check points - See page 5-3 Sectional views and parts identification Assembly instructions Disassembly and Reassembly of unitsSAFETY PRECAUTIONS To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable opevation of the machine. If replace- ment parts are required the part must be replaced with one of the same part number or with an equivalent part. Do not use a replace- ment part of lesser quality. The service procedures recommended in this manual are effective methods of performing service and repair. Some of these procedures require the use of tools specifically designed for the purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not recommended by Spicer Clark-Hurth Components, must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the replacement part, service procedure or tool selected. It is important to note that this manual contains various ‘Cautions’ and ‘Notices’ that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the unit or render it unsafe. It is also important to understand that these ‘Cautions’ and “Notices’ are not inclusive, because it is impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fuid. It is rocommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned. A CAUTION: Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapours BEARINGS Remove bearings from cleaning fluid and strike fiat aganst a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed ait. Be careful to direct alr stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process, HOUSINGS Clean interior and exterior of housings, bearing caps, étc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evap- oration of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaners. A CAUTION: Care should be exercised to avoid inhalation of vapours and skin rashes when using ‘Ali parts cleaned must be thoroughly dried immediately by using moisture-tree compressed air or soft, nt: less absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping ‘compound. INSPECTION Tho importance of careful and thorough inspection af al parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date. BEARINGS Carefully inspect al rollers, cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time, After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them unti installedOIL SEALS, GASKETS, ETC. Replacement of spring load oil seals, O-rings, metal sealing rings, gaskets, and snap rings is more eco- nomical when unit is disassembled than premature overhaul to replace these parts at a future time, Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. 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 assem- bly of mating members. Lubricate all O-rings and seals with recommended type Automatic Transmission Fluid before assembly. GEARS AND SHAFTS I magna-flux process is available, use process to che:k parts, Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true. HOUSING, COVERS, ETC. Inspect housings, covers and bearing caps to be certain they are thoroughly clean and that mating sur- faces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures. LEGEND SYMBOLS +. Ty | osssermit eens aos Panes wach reeenoty Unlock, lock e.g. split pin, locking plate, Reassemble to from assembly group uo Remove obstruction parts Lock » achere (liquid sealant) Reinstall - remount parts vbich had ‘Guard against material damage, damage obstiucted disassembly to pars Mark belore disassembly, observe marks ‘Attention! Important notice en Check - adjust @.g. torque. cimensions, Prossures otc. Filing - topping up - refiling &.g. ol, 20 ing water, et. DGC Do ak T= Special tool P= Page Drain off ol, lubricant Tighten - clamp; tightening a clamping device Note direction of installation Visual inspection Apply pressure into hydraulic siruit Possibly stil sorvicoablo, renew if necessary To clean BirTRANSMISSION IDENTIFICATION NAMEPLATE LOCATION ON REAR LEFT LOWER CORNER OF TRANSMISSION CASE A. IDENTIFICATION OF THE UNIT 1. Model and type of the unit 2. Serial number REAR VIEWTRANSMISSION DRY WEIGHT - LB [Kg] FEATURES FWD & REV CLUTCH PUMP — BIDIRECTIONAL LOCKUP = _MODULATION DISC PTO \B 1540 50 40 25 20 {Kg} [698.5] [23] (19) (2) [10]‘SPECIFICATIONS AND SERVICE DATE - POWER SHIFT TRANSMISSION AND TORQUE CONVERTER CONVERTER OUT — Converter outlet temp. 180- OIL FILTRATION Full flow oil fiter safety by- PRESSURE 200 degrees F. (82,3-03,3, pass, also strainer screen degrees C_] in sump at bottom of Operating Specifications: transmission case. 25 PSI. [172,4 kPa] minimum pressure at 2000 APM engine CLUTCH 240-310 PSI [1654,8- speed and a maximum of 70 PRESSURE 2137,4 kPa] with parking PSI [482,6 kPa) outlet pressure brake set (see Note), with engine operating at no- ‘engine at low idle, shitt load governed speed. thru directional and speed ciutches. All clutch CONTROLS Forward and Reverse - Electric pressure must be equal Speed Selection - Electric within 5 PSI [34,5 kPa} Ht clutch pressure varies in CLUTCH TYPE Muttiple discs, hydraulically any one clutch more than actuated, spring release, 5 PSI (34,5 kPa] repair automatic wear compensation clutch. ‘and no adjustment. All clutches «il cooled and lubricated NOTE: Never use service brakes while CLUTCH INNER DISC Friction making clutch pressure checks. Units having CLUTCH OUTER DISC. Steet brakes actuated declutching valves in DRY WEIGHT 1500 LBS. (680 kg} forward andlor reverse: will not give a true reading, ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS. BRAKE RELEASE PROCEDURE Consult equipment manufacturers manual for brake release and towing procedure. 38SPECIFICATIONS AND SERVICE DATA - POWER SHIFT TRANSMISSION AND TORQUE CONVERTER SQQURRTER COT Ge attlw. 2 LFAIRATEN tna marge ren SRE ert tanunarame, in CunoHPnEne 5 tes n-ne at omaeunes Bene oe amps seferauanaeen eat SAP U nr Age, So eteren i iieaaiee aagmonee Seeieee oe 5 commas) femted owas’ was = Speed Seecton - Manual ‘docluich reverse: nen wae ae CIUTOALTYPE le is sty ated aeserere ool Seen, ES aie CLUTCH INNER DISC Friction. CLUTCH QUTER DISC Stee LUBRICATION RECOMMENDED LUBRICANTS FOR SPICER CLARK-HURTH COMPONENTS POWER SHIFTED ‘TRANSMISSION AND TORQUE CONVERTERS. TYPE OF OL 00 Lube Chart ‘capacity ‘Consult Operator's Maru on appieabis rachis ‘yeaa tor fy forge Comer, ‘Tears anal yrs eyomrn ruc bo ‘3 unl to Solemn Capos CHECK PERIOD ec toe AL nth engine ning at EoD Sea Saat ite Boras Ba Gh aaa feves PUL ma Noma ey S20 nes. range tse DRAIN PERICO Every 1000 haus, eae veal [ene Oran wack st5" 0) Fae oa % BoC > BCFW 21000 FF - see note botom fist, Deron” ss agprved hemeve! ef ol carpet wt ore converts SSPE en aoe ENGINE OL OF GL OILS ARE NOT APPROVED. ine eae een Saute onan nea ae hee ants unre me IED Ol VISCOSITY - select ghost of vscotly compatle it the prev ipeatrs en fae oT asain cer shaw s SAME ESEAATENS pete namin fh min pein 9 ‘Shtosy vee bere tere Sa ae ear eyes $000 tees tor avenge, ‘Sirota arg dt jae contin, Saa or orang obeaintepaaye ‘egg arpa cn mil out aceiag or mene nest used Serine the eased cone Mere for exes nao result " Exietoa ot sordon ti hon using opr Sng ars ous serene cach Param by ‘anaerg tude and wera ot rm. eee Dei. Va Fh ‘Sanya Gn ros vans trmason bs 3 Vanemeaton shod nt be Pomoved ten ‘tly on is analyst aRzsneqelmsonetoey st cams micremiesan Bodrum cet am Steger se ee Tapers eer ser sens ‘hoa wes seperate spinel ne hs crernienraeertee ee orton te syoamrusatermgerste memstont et “Dostron ca opines tacoma of Genaral Motors Comp. “4 (0) ran tapaiesion and mone sma ower. Can screen enough fepiste. usa nom gusset Drain ci iar, remove and card toe ihrer Gan Wer tear ta new w Ft tranemision to LOW marke Fan engre at £0 £00 REM 1 prime arena sna int Fechack evel wi a Sco aoa cf ang tra LO Seether cere ot seo Bh OIL LEVEL TO FULL OAK @ ‘ « RECORIMENOED SAE Js00 viscOSITY GRADE [BASED ON PREVAILING AMBIENT TEMPERATURE AE MD | Tensor? 1 EOUVALENT i] ] | DE crus i 1 1 os a POWER SHIFT TRANSMISSION AND TORQUE ‘CONVERTER HYDRAULIC FLUIO ANALYSIS, see clam co icone at aan arial {Smping ota ower ahh ananisacr npr ert hut frien Ba sence wre boned oa apt re [5 sclatsh sna Soon Lge changes m sit mr ‘Eom ti nome evel ey Fees an sperma onan emt the ‘Saramtsien ot ts fyoache tad dey cancion ene of he ‘Yanariien acunl Conan, o action ike by fw eorarislon ‘erehenerrtng sping ene bw ropanalty The otowing part por miton AM aus epson oneal (Gucbines when may be uead torreon me a Rectal EM ‘eon re 2s PP Cepper Gu 30 PPM Sacen Sh "20 PPM Alerinem A spe Cosa > soppu Chromium Cr 3PMSERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other, therefore, whenever repair or overhaul of ‘one unit is performed, the balance of the system must be considered before the job can be considered completed. ‘Attor the overhaul or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement 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 machine for cleaning. 3, Replace oil filter elements, cleaning out filter cases thoroughly. 4, The oil cooler must be thoroughly cleaned. The cooler should be "back flushed’ with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil. compressed air and steam cleaner for that purpose. Do not use flushing compounds for cleaning purposes. 5. Reassemble all components and use only type oil recommended in lubrication section. Fill transmission through filter opening until fluid comes up to LOW mark on NOTE: If the dipstick is not accessible. Oil evel check plugs are provided. Remove LOWER check plug, fill until oll runs ‘rom LOWER oil hole. Replace filler and level plug. Run engine two minutes at idle to prime torque converter and hydraulic lines. Recheck evel of fluid in transmission with engine run- ing atidle. Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil evel plug or dipstick. Recheck with hot oil (180 - 200 degrees F) [82,2 - 93,3 degrees C]. See hydraulic checks for warm up procedure. 8. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.HR 36000 Series Transmission Converter Drive Plate INSTALLATION INSTRUCTIONS Proper Identification by Bolt Circle Diameter Measure the “A” cimension (Bolt Circle diameter) and order Drive Plate Kit listed below Dieansion (Bolt Cre Oferta) imension (Bolt Cecke Diameter) 15,00" [881,000 men diameter 16.00" [406,400 men] carnetor OU No, 002557-100m {ot No, 002504 WO Nu 16.00" [408,400 vn] Gamerer ‘Ri No, 802558-t0mm 116.00" (406,400 men] clamor Wet No, 002580-7/16-20 17.00" [481,800 mm) ctamnetor ‘dt No. 002589- 10mm 17.00" (631,800 men camer Each hit wil include the folowing parts ‘Giesermaciagn Orie Pines 1 Backing Pits Ka No. 602562-7/16-20 14 Drive Pato Mounting Capscrowe Instruction Sheet ‘Ech kit wil include the folowing parts: 'Statormeciato Orie Plates NOTE: Assombly of faxpiates must be complated 1 Deve Pat Assembly ‘wits a 15 minute period from star of seraw! 1 Backing Pate ‘naan. if te sorew bs romovod fr any reason 14 Drive Paole Mounting Capscrows must be replaced. The adhesive let the tapped Instuston Sheet ‘holes must be removed wah the proper tap ond ** tp Drive Pato Mounting Spacer is A ‘leaned with sotvent. Ory he hoie thoroughly and Inetucoc in Kt No, 8022608. [Use anew sexeMe fr reintaltin. Position drive plate and weld nut assembly or Impeller cover with weld nuts taward cover. Align intermediate drive plate and backing ring with holes in impeller cover. NOTE: Two dimples 180" apart in backing ring must be out (toward engine flywhee), Install capscrews, Tighten cap- screws 52 - 57 ftlbs torque [70.4 - 77.1 Nm 4TRANSMISSION TO ENGINE INSTALLATION PROCEDURE . Remove all burrs from fiywheel mounting face and nose pilot bore, Clean drive plate surface with solvent. Dry thoroughiy. . Check engine flywheel and housing for conformance to slandard SAE. #3 - SAE, J-927 and J-1033 tolerance specifications for pilot bore size, pilot bore runout and ‘mounting face flatness. Measure and record engine crank- shaft end play. . Install two 3.50 [88,90 mm) long converter to tlywheel hous- ing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole. . Install a 4,00 [101,60 mm| long drive plate locating stud in a ‘drive plate nul. Align the locating stuc in the drive plate with the tlywnee! crive plate mounting screw hole positioned in Step No. 3. Locate converter on tlywhneel housing aligning drive plate to flywheel and converter to flywheel housing Install converter to flywhee! housing screws. Tighten scrows to specified torque. Remove converter to engine guide studs, Install remaining screws and tighten to specttied torque. Remove drive plate locating stud. Install drive plate attaching screw. Snug screw but do not tighten. Some engine flywheel housings have a hole loca’- ‘ed on the flywhee! housing circumference in fine with the drive plate screw access hole. A screwclriver or pry bar used to hold the drive plate against the flywheel will faciitate instaltation of the drive plate screws. Rotate the engine fly- \wheel and install the remaining seven (7) flywhee! to drive plate attaching screws. Snug screws Dut do not tighten. After ll eight (@) screws ave installed, tighten each cap- screw to the following torque: M-10 capscrews 46 ftths torque [60.65 Nm] This will required rotating the engine ‘lywhee! until the full amount of eight (B) screws have been tightened, Measure crankshaft ond play after converter has been Ccomipiatoly installed on engine fiywhael. This valuo must bo within .004 [0,025 mm of the enc play recorded in Step No, 2HR 36000 FULL POWER SHIFT ‘SHORT & LONG DROP - PLUMBING Checkooint “Cc Hoat Exchanger Outer Temperature, {Checkpoint "&-8" @- 4975-20 SAE “v ING FORT rm “as os “AC” @- s02s-108A€-0° NG FORT @-1.9125:12 SAE “OrRING PORT @-uner @ on co ee A eons © @ Totpeinre Pekap Convert Out cuUTGH presume fat oped cuurcH sncssune © iataopecd Tee toeed 63Port “J” - Converter Outlet Temperature Port is to be used for Converter Outlet ‘Temperature Pick-up, Gauge is to be located in the Operator Compartment, See Oil Temperature Gauge Specification. Port “J'- Converter Outlet Pressure Test Conditions: Warm Transmission to normal operating temp- erature and stabilize Converter Outlet Oil Tomperature at 180" - 20°F [82,2 - 93,3°C), Operating Specifications: 25 PSI [172.4 kPa] minimum pressure at 2000 RPM engine speed and a maximum of 70 PS! [482,6 kPa} outlet pressure with engine at no load governed speed. Ports “A, ‘J’, “Sand “AR” are used for flold “Trouble Shooting’ or Production Tests, Clutch Pressure Recommend that the clutch pressure be monitored by a gauge having an indicator dial range of 0-00 [0.2756 kPa). Gauge is to be located in the operators compartment, Clutch pressure range 240-310 PSI [1655-2197 kPa}, PORT CHART FROM TO PORT PORT, REMARKS AD AC PUMP TO FILTER ES ae REGULATIVE VALUE HEAT ‘CONVERTER OUT TO AC. EXCHANGE HEAT EXCHANGER HEAT HEAT EXCHANGER TO EXCHANGE AD TRANSMISSION LUBE FILTER CARTRIDGE OIL TEMPERATURE GAUGE SPECIFICATIONS 1. Normal Operating Temp. Range: 180° to 260'F (62,2° to 121,1°C} 2. Red Lined Temp.: 250'F (121,1°CV) 3. Maximum Operating Temp. 300°F [148,9°C} 4. Chart - Oil Temp. Gauge: =x" DIM, PART NO. 144.00 [3857.6] 234033 48,00 [1219.2] 2s4034 i "a" Ro. Le. Dim.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 directs it through the pressure regulating valve and oil filter. ‘The pressure regulating valve maintains pressure to the transmission contro} cover for actuating the direction and speed clutches. This requires a small portion of the total volume of cil used in the system. The remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating in a closely fitting bore. The valve spoot is spring loaded to hold the valve in a closed position. When a specific pressure is achieved, the valve spool works against the spring until 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 ol cooler. After leaving the cooler, the oil is directed to a fitting on the transmission. 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 elements through the impeller cover. This elemen: is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication, This element can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the output shatt of the torque converter. This element receives fluid t Its outer diameter and discharges at its center, Fluid directed by the impeller out into the particular design of blading in the turbine and the 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 fluid which is exhausting from the inner portion of the turbine and charge its direction to allow correct entry for recirculation into the impelier element. The torque converter will multiply engine torque tc its designated maximum multiplication ratio when the output shaft is at zero RPM. Therefore, we can say that as the output shatt is decreasing in speed the torque multiplication is increasing. ‘The shift control valve assembly consists of a velve body with spool type solenoid cartridge valves which is are controlled electronically.With the engine running and the directional control lever in neutral position, oil pressure from the regulating valve is blocked at the control valve, and the transmission is in neutral. Selection of forward or reverse will direct ol, under pressure to either the forward or reverse directional clutch as desired. When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selectional spool. The same procedure is sued in the speed selector. the direction or speed clutch assembly consists cf a drum with internal splines and a bore to receive a hydraulically actuated piston. the piston is “oll tight" by the use of sealing rings. A steel! disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with O.D. splines is inserted into the splines of disc with teeth on the inner diameter. The disc and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in theat specific clutch. To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure to flow from the control valve, through a tubed, to the chosen clutch shaft. Oil pressure sealing rings located on the clutch shaft direct oil under pressure to pass thru a drilled passageway in the clutch shaft to enter the piston cavity. Pressure of the oil forces the piston and disc against the heavy bacc-up plate. The disc, with teeth on the outer diameter, clamping against disc with teeth on the inner diameter, enables the hub and clutch shaft fo be locked together and allows them to drive as a unit. There are bleed balls in some of the clutches which allow quick escape for oil when the pressure to the piston is released.ania aATVA + HLIM CaLVOIONI Nowwngon =—NOWWINGOW SW3LI AlddNS LON THM HEVID Gadd t - 0009€ INVYSVIC SIINVYGAH36000 SIX SPEED TRANSMISSION BASIC DESIGN36000 POWER FLOW SIX SPEED TRANSMISSION Direction & speed | Engage Clutch ACDEFG Forward 1st Froward 2nd -----------------------------= Forward 1st e| | lel | Forward 2nd e e36000 POWER FLOW SIX SPEED TRANSMISSION Forward 3rd Froward Ath ---++-:----2--sessssecceeneace A Forward 3rd e Direction & speed | Engage Clutch D Forward 4thForward 5th Froward 6th ----- 36000 POWER FLOW SIX SPEED TRANSMISSION Direction & speed Engage Clutch ac D EFG Forward 5th Forward 6th36000 POWER FLOW SIX SPEED TRANSMISSION = 7 Wet CT] FS L } [SRE J/ on /SES — — ~ = 1) gommnoS | | = NY i REVERSE! Low (0 a = c =~ er a | eG a8 5 \ Game fo {iI L i I v yf { J - . F G G f Direction & speed | Engage Clutch ACODEFG Reverse 1¢¢ Reverse 1st e Reverse 3rd ~ Eoveneans LT Reverse 3rd e oeFOUR SPEED TRANSMISSION BASIC DESIGN 6936000 POWER FLOW FOUR SPEED TRANSMISSION Forward 3rd Direction & speed | Engage Clutch Forward 4th -~ noe ABCODEF Forward 3rd ele |_| Forward 4th e e36000 POWER FLOW FOUR SPEED TRANSMISSION Forward 1st Direction & speed | Engage Clutch Forward 2nd =-------------+seeserennnnnen BEDEE @e> Forward ist e Forward 2nd36000 POWER FLOW FOUR SPEED TRANSMISSION —fle 3 A QB — (ONG N RRS = — oly Vi = A 7 eae eo eek ey —y QY ye. J 4 u— REVERSE | _ a | 7 c a Bw et 5 ( / sL if |. “Res PU Reverse ist Direction & speed armege Catan Reverse 1st ° e|THREE SPEED TRANSMISSION r rN Popewanp = an : Pd, || J TC > coe sow cay | an i +) A J | “a | ic IL BASIC DESIGN 61336000 POWER FLOW THREE SPEED TRANSMISSION Reverse 2nd--~ Reverse 3rd —-—- woes [Reverse 2nd | | jeje; | | Reverse 3rd e | ile Direction & speed | Engage Clutch ACODEFG Reverse 1st —————_— Reverse 1st e| lel |36000 POWER FLOW THREE SPEED TRANSMISSION Direction & speed | Engage Clutch CDEF Forward 1st ———— Forward 1st A Forward 2nd : ‘orward 2nd---~ Forward 2nd e| |e Forward 3rd Forward 3rd e eDOA FZ Puke DGAZL WVHOVIG ONIHIM TOHLNOD GION31OS 91d¥L9373 Pue NOISSINSNVEL aaads €BONVEO 8 NMOHE L ama 9 Na3uD s MOTIBA v aay € vows z SIH ‘ 3009 ¥O19 | ON 3uIM) GA $2 PUB DAAZL WVHOVIC ONINIM TOULNOD GION310S DINLOATA Pue NOISSINSNVYL daads t(aa3ds 9) JOULNOD GIONS10S 91410373OGAYZ PUP OGAZL - WYEOVIG ONILIM TOKLNOO oa GION310S D14L9373 NOISSINSNVUL ‘Ads 9 Myer *SaNa_WNYTB - 34K av 40 SaHoMI9g MAM OBIIadNS 51 TOULWOD GYD36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED FULL POWERSHIFT FORWARD LOW ENGAGED36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED FULL FOWERSHIFT 7 FORWARD Low O O OK O FORWARD 1 HIGH ‘SOLENOID ‘SUPPLY A O (ES prot pressure EES cuurcn pressure BBS venr FORWARD HIGH ENGAGED 62136000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION 4 SUPPLY REVERSE ——| S888 cuuren pressune BERRI pivot pressure 88888 ver 3RD SPEED REVERSE ENGAGED 62236000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION 2ND SPEED REVERSE ENGAGED ez 38888) cLuTen pressure 38882 puor pressure ‘888E vent36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE 6 SPEED VERSION ‘SBBcwWTCH Pressune QE PLOT PRESSURE RBEBvenr 1ST SPEED FORWARD ENGAGED oe36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT Rev. 4th zamill GLE: (fg bllba Oj Clutch Pressure Pilot Pressure36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT FWD 4th 4 Clutch Pressure 4 Pilot Pressure Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 3rd (4 SPEED) Lede ML ee Ze pee Clutch Pressure Pilot Pressure Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 2nd (4 SPEED) Clutch Pressure Pilot Pressure Vent36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 1st (4 SPEED) PAS YT LLM A LTTE: Vial Yi o 2 Ss a D o 2 a = 2 2 oO © £ 3 a a ® 2 a = 2 a Ee 8 E 5 s36000 SERIES ELECTRIC CONTROL VALVE HYD CIRCUIT NEUT. 3rd (3 SPEED) U Vilage ea Clutch Pressure VentTROUBLESHOOTING GUIDE FOR THE HR36000 TRANSMISSION ‘The following information is presented as an aid to isoleting and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only the ccantral unit of & group of related powertrain componen's. Proper aperation af the transmission depends ‘on the condition and correct functioning of the other components of the group. Therefore, to properly diag- nose a Suspected problem in the transmission, itis necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooley, fiter, connecting lines, and controls, including the engine, as a complete system. By analyzing the principles of operation together with the information in this section, «t should be possible 10 identify and correct any malfunction which may occur in the system. HR36000 TRANSMISSION HR36000 (power shit with torque convertar transmission) troubles fall into three general categories: ‘mechanical, hydraulic and electrical problems, In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important, Transmission fluid is the “life blood” of the transmission, M must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, 10 engage and told the clutches from slipping, and to cool and lubricate the working components. ‘TROUBLESHOOTING PROCEDURES Stall Tes Use a siall lest to identify transmission, converter, or ergine problems. ‘Transmission Pressure Checks: ‘Transmission problems can be isolalad by the use of pressure lests. When the stall lest indicates slipping clutches, then measure clutch pack pressure lo determing if the slippage is due fo low pressure or clutch plate trction material failure. In addition, converter charging pressure and transmission lubrication pressure may also be measured, ‘Mechanical and Electrical Checks: Prior to checking any part of the system for hydraulic function (pressure testing), the following mechani al and electrical chacks shoult be make: ‘* Check the parking brake for correct adjustment. * Be sure all lever linkage Is property connected and adjusted in each segment and at all connecting points. ‘The controls are actuated electrically. Check the wiring and electrical components, Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine anc transmission, Air clean the radiator, if necessary. ‘© The engine must be opersting correctly, Be sure thet itis correctly tuned and adjusted to the correct idle ‘and maximum no-load governed speed specifications, ”Hydraulic Check: ‘Also, before chacking the transmission clutches, torque sonverter, charging pump, and hydraulic circutt for Pressure and rate of oil flow, itis important to make the following transmission fluid check. Check oil Javel in the transmission. The transmission fluid must the at the correct (full lavel). All clutches and the converter and its fluid circuit lines must be fully charged (tiled) at all tmes. Sea NOTE below. A NOTE: The transmission fluid must be at operating temperature of &2 - 99° C (180 - 200" F) to ‘obtain correct fiuid level and pressure readings. ‘To raise the oil temperature to this specication it is necassary to either operate (work) the vehicle or run the engine with converter at “stall. (Reter to converter stall procedure.) A CAUTION: Be careful that the vehicle does rot move unexpactedly when operating the engine and converter at stall FLPMA, ‘A. CONVERTER STALL PROCEDURE 1. Put the vehicie against a solid barrier, such as a wall. andlor apply the parking brake and block the wheels, 2. Put the directional contro! lever in FORWARD (or REVERSE, as applicable). 3. Select the highest speed. With the engine running, siewly increase engine speed to approximately one-halt throttle and hold Until transmission (converter outlet) oil temperature reaches the operating range. RX curnon: cose oe om cnsen un van so nee ne ine ‘shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature (120° C) 250° F maximum) will cause damageHR36000 CONVERTER GROUPITEM 1” 12 13 14 15 16 Ta 18 19 20 at 22 23 2a 25 27 28 HR36000 CONVERTER GROUP DESCRIPTION Bearing Support Screw Bearing Support Lockwasher Drive Gear Snap Ring Pump Drive Gear Bearing Pump Drive Gear Bearing Support Pump Drive Gear Converter Housing Charging Pump and Pressure Regulator Valve ‘Turbine Shaft Rear Bearing Turbine Shaft Front Bearing Bearing Washer Bearing Retaining Snap Ring ‘Turbine Shaft Oil Sealing Fing Convertor Inlet Tube Stator Suppor Stator Suopon Sealing Ring ‘Turbine Shaft Bearing Locating Ring ‘Stator Support Screw Lockwasher Stator Suppor Screw Turbine Hub Turbine Locating Ring Reaction Member Retaining Ring Reaction Member Reaction Member Spacer Dowel Reaction Member Spacer Impeller Hub Searing Retaining Ring Impeller Hub Searing aTy Wee eee eee wae ‘TEM 29 30 31 BREBR g 7 88 Sere ee DESCRIPTION Impeller Hub Impetier Hud to Impeller “O” Ring Impeller Hub Screw Backing Ring Impeller Hub Screw Oil Battle Retaining Ring Oil Battle Oil Battle Seal Ring Oil Baffle Ol Seal Impeller Hub Gear Impeller Hub Gear Snap Ring Turbine Turbine Hub Screw Lock Tab Turbine Hub Screw Impetier Cover to Impelier “O" Fling Impetiar Cover Impetier Cover Bearing Impelier Cover Bearing Cap “O" Ring Impetier Cover Bearing Washer Impeller Cover Bearing Washer Snap Ring ‘Turbine Hub to Turbine Shaft Retaining Ring Impolier Cover Bearing Cap Drive Plate Assembly Drive Plate Drive Plate Backing Ring Drive Plate Mounting Capscrew Impetier Cover to impeller Screw ‘Screw Lockwasher aTy o 10 wane ene nnn 4 24TRANSMISSION CASE & CONVERTER HOUSING ASSEMBLYTRANSMISSION CASE & CONVERTER HOUSING ASSEMBLY eM DESCAIPTION qty 1 Modulator Bypass Tube 2 Tube Retaining Screw 3. Tube Retaining Screw Lockwasher 4 Tube Clip 5 ath Speed Preasure Tube 6 Tube "0" Ring 7. 31d Speed Pressure Tubs 8 Tube Retaining Screw 8. Tube Retaining Screw Lockwasher 10 Tube Clip 11. Forward Pressure Tube 12 Tube "0" Ring 43. Valve Oil Supply Tube 14 Pon Pg 15. Port Plug "O" Ring 16 Pont Plug 37 Pon Plug "0" Ring 4B Speed Sensor Bushing Plug 49. Speed Sensor bushing Shim 20 Speed Sensor Bushing 21. Bushing °O° Ring 22 Converter Housing 23 Reducing Bushing 24 Breather 25 Filer Pog 26 Not Used 27. Nol Used 28 Tube Sieve 29. Safety Valve Seat 30 Safety Valve Seat Retainer 31 Pressure Relie! Valve Plungor 32 Pressure Rellet Valve Spring 33 Washer 34 Washer Retaining Ring 35 Converter Housing Sieeve Forward Shaft 36 Converter Housing Sieeve Lock ‘37 Converter Housing Sleeve Screw Lockwasher 38 Converter Housing Sieeve Screw 39 Corwertor Housing Sleeve Reverse & 2nd Shaft 40 Convener Housing Sieeve Lock 41, Converter Housing Sleeve Screw Lockwasher 42 Converter Housing Sieeve Screw 43 “idler Gear Retainer Piate Screw 44 “ldler Gear Retainer Pate 45 “idler Gear idler Gear Bearing Assembiy idler Gear Shatt Retainer Plate Screw 48 “Idlor Gear Shatt Retainer Plate Screw 50 “idler Gear Shait 51 Converter Housing Sieve Screw 52 Converter Housing Sleeve Screw Lockwatshor 59. Convertor Housing Sieeve Lock 54 Convener Housing Sleeve 4tn Shaft 55 Por Plug 5B Port Plug "0" Ring 57 Pont Plug "0 Ring 5B Por Plug 59 Pon Plug 60. Port Plug "O" Ring 61 OF Lube Return Plug "6 Speed Transmssion Oniy AR As Required SSLSKLSKLSSKY SFLSSSSSsIsHFI NISISSASRLSR 100 Cich Pressure & Lube Tube °0° Ring 101 Clutch Pressure & Lube Transfer Tube 102 Clutch Pressure & Lube Tube “O" Ring 103. lear Cover Plug 104 Case to Rear Cover Stud Nut 105 Case to Rear Cover Stud Nut Washer 106. Pressure Tube Sleeve ‘O° Ring 107 Pressure Tube Sleeve 108 Case to Rear Cover Stud 109 Drain Plug 110. tst Speed Clutch Pressure Tube ‘11 1st Speed Shatt Rear Bearing Lube Tube 112 Ol Level Plug 113 Dipstick Hole Pag 114 Tube Sleeve 115: Tube Sloeve "0" Ring iTeM DESCRIPTION ary ll Lube Return Plug ‘O" Ring 1 Cap Plug Gasket 1 Cap Plug 1 Tube Sleeve "0" Ring 1 Tube Sleeve 1 ‘Tube Sleeve "0" Ring 1 Tube Sleeve 1 Plug 1 Plug 1 Sh Speed Pressure Tube 1 Converter Housing to Transmission Case Screw 14 Lockwasher Converter Housing to Transmission Case Screw 1 ‘Converter Housing to Transmission Case Gasket Converter Housing to Tranamission Dowel Pin Lockup Sloave Astainer Screw Lockup Sleeve Retainer Screw Washer Lockup Sleove Retainer Lockup Sleeve ‘Speed Sensor Bushing Plug ‘Speed Sensor Bushing Shim a ‘Spoad Sensor Bushing ‘Speed Sensor Bushing “O" Ring Lockup Hole Plug Transmission Case ‘Transmission Case to Converter Housing Screw ‘Washer ‘Transmission Case to Converter Housing Screw Rear Cover to Case Dowel Rear Cover to Case Gasket Rear Cover Plug Froat Cover Rear Cover Screw Lockwasher Rear Cover Screw Rear Cover Screw Lockwasher Rear Cover Screw Rear Cover Seren Lockwasher Rear Cover Screw ‘Screen Assembly ‘Soteen Assembly Plug NI Suction Tube NI ‘O° Ring NI Bott NI Lockwasher NI Oil Battie NI Gil Battie Screw ee eee eee ee Pee ae Peet Perret rr NA. Not MustatesCLUTCH GEAR GROUP 3, 4 & 6 SPEED - LONG DROPDESCRIPTION QTy ‘Tem Qty iTem DESCRIPTION DESCRIPTION ITEM 1, Chan Shat 08 Seating Fi ‘Retainer feng’ 2 Front Ring ing Rolaining Ring Locating Ring Rota’ ng > il 955 23338 philippe | Pe PELE eee a SESSSCSSSSRRE SES Py 8: Nut to Nut Lockwasher Rear Bearing Gear Outer Bearing Gear Inner Beareg 175 Gulch Sha Drum Assory 36000 CLUTCH & GEAR GROUP 3, 4 & 6 SPEED SHORT DROP 176 Clutch Piston inner Seat Spend on Rear ag 6 “Clutch Sha 3 oe Setar Ring Re if ‘Spring Assomt 23rd Clutch Disc Hub fh Disc Hue Ristanee Sn 2 Ang ing Retainer Plate late Srap Ring in Retain Spring Thrust Waser Berna 7 jp Retainer Sha Shing Retains 28 Backi £29 Back 30 Pao BS be36000 PRESSURE REGULATOR VALVE & CHARGING PUMP.ITEM 12 13 14 15 16 7 18 19 36000 PRESSURE REGULATOR VALVE & CHARGING PUMP DESCRIPTION Thrust Plate & Bearing Assembly Pump Driven Shaft Assembly Thrust Plate & Bearing Assembly Wave Spring Pump Shalt Seal Pump Drive Shaft Assembly Charging Pump Housing Pump Suction Adaptor “O" Ring Pump Suction Adaptor Fitting Charging Pump Suction Tube Coupling ‘Charging Pump Suction Tube Retainer Charging Pump Suction Tube Gasket Charging Pump Suction Tube Sieve Rear Cover Suction Flange Rear Cover Suction Flange *O" Ring Regulator Valve Pilot °O° Ring Spring Retainer Snap Ring Valve Spring Retainer Cup Valve Spring - Outer arty eee eee ees aw nwan Tem 24 23 24 25 or 28 Seseeeeess DESCRIPTION Valve Spring - Inner Regulator Valve Spool Clutch Pressure Supply 0” Ring Valve to Converter Housing Screw Lockwasher Valve to Converter Housing Screw Regulator Valve Plug Regulator Valve Plug Pressure Regulator Valve Safety Valve Piston Safety Valve Piston Spring Piston Spring Retainer ‘Spring Retainer Snap Ring Pump Shatt Oil Seal Valve Body to Pump Gasket Valve to Pump Screw Lockwasher Valve to Pump Screw Valve to Pump Screw Lockwasher Valve to Pump Screw aty Pero ro alee oll36000 ELECTRIC CONTROL VALVE ASSEMBLYTEM SSSLRELAERESBBSRRVIRVS DESCRIPTION Plug Plug “O° Ring Directional Spool Directional Spool Spring Directional Spoo! Control Valve to Converter Housing Gasket Air Actuator Piston Housing Stop Plug Piston Housing Plug "O" ing Piston “O° Ring Giya Ring Piston Piston Housing "O° Ring Decltch Spool Pig Declutch Spool Spring Control vaive Housing Fiange Spoo! Spring Range Spoo! Spool Plug O° Ring Spool Plug Flange Spoo! Deelutch Spool Stop Control Vaive to Converter Housing Screw Seal Plate Gasket Seal Plate Seal Plate Gasket Pipe Plug Pipe Plug “0” Ring Spo! Stop Pin ‘Accumulator Spring - Outer ‘Accumulator Spring - Middle ‘Accumulator Spring - Inner ‘Accumulator Spool Cover Piate Screw Cover Plate Rot Pin Pug Control Gover to Control Valve Screw Lockwasher Control Cover to Control Valve Screw Plug Plug Wire Clip Attachment Plate Dust Cover Stut 36000 ELECTRIC CONTROL VALVE ASSEMBLY QTY 210 Irem aé BERRRESRPSSASAAARARVASSILSALSRLSSSARRL BERLE DESCRIPTION Not Used Dust Cover Dust Cover Stud Washer Dust Cover Stud Nut Nut Col to Nut “0° Ring Solencid Coll Connector Cip ail to Cartidge 0" Ring Solenoid Carbide “0° Ring ‘0° Ring “Oo Ring Conttol Cover to Control Valve Screw Control Caver to Converter Housing Screw Control Gaver to Converter Housing Screw Housing Plug Housing Plug "O° Ring onto! Cover 9 Control Vatve Scrow Control Cover to Control Valve Scrow Lockwashor Pug Valo Stop “O° Ring Valve Stop Regulator Spoot Ball Regulator Spoot Fogulator Speng Vale Step Rogulator Speng Regulator Speot Regulator Spoot Bal Pipe Plug 0" Ring Poe Pug Regulator Spoot Rol Pin Regulator Spot Rt Pia Poe Pug Plug "0" Ring Spoo! Stop Pia ‘Accumulator Sping - Outer ‘Reoumulatoe ping - Nice ‘Accumulator Speing Innee Accumulator Spook Contioi Cover Pug Not Used On This Model QTy Bees ess sess sss essa sceansanaanansaeesASSEMBLY INSTRUCTIONS Oem (aoa -27) [2712-39691 (ea a7e8) 15124-6101)Alloa in charts for a seas, piston rxge anv “OT sngs must ba ‘noo ana fee ‘rom burs. Prelude haloes sesembly. al piston rag grooves ard O° rings, with Mult purpose grease Grade 2, Apply tin cost of Loctts 698 (oslr gran 1 outs dsmetar oft «il stale, bore plugs arc bores they are 1 be instaod inn, belore ‘assemby- Use exteme care not bo alow sealant fo com into con- {act with 5608 Ip ratoria Apo}, the coat of Loctite 270 (ool red toa eu hols stk theoade which do pot have proaepied sealer gree requred for positoring gasket coring assert, use Mah pumpoue grease Grade 2 Alter sesermbly ol parts using Loci, there must rot be ary ew of ‘excess material which might ener the of ccut. Only use Lotte tahoe specitind. General Bearing instataton Procedure a trecmnal asembly sid is used, (expanding by hasing 275°F = 25°F [135" » 1] a check must be made ater mating parts have ‘wach the same temperature witlin 20°F [11°C] cr ambi, 0 be ‘Sure tha basengs are posiioned sally agains! far respective routers, Low tt tn per beng assent (Se Spee! irene) ow shat ar ting op mus be assed 3 som on etl A sie waste 809 Ht Trae Ont Special turbine shaft baaring 314MG loacing notches rst 3¢-on seme 8ice as retaining rng. ‘Cast ron piston rings in ute piston ring Weation and Vion Figs at inner piston fing location. Al speed versions al ‘chiches ‘Anerate aasombly of lush sates, starting with Inner Friction Plate on madulsied clcnes and Outer Steel Pata cn non-moduated civiches, Place bots to be used a hase locations - Requires Special 92 ‘end lock tabe at ascembiy, aftr tightening cag sevens to ‘praetor, Tabs must be ent against screw aed Ra ‘or around comers as shown booW. 6—O ‘Clutch piston return spring Concave sid of fest Belevile spring rust be assembled toware cutch piston Allerate remaining sping, ‘Al dome! pins must be installd in tanemission case betore accamtiy of mating pars, ‘Tighten ol seeen assembly 1010 15 fis. (13-20 Ne all redets Pack alt seaing sing grooves with grease. insta satin Bo er ey ge Must be loote ints 8 bearings with & No.3 etched on 8 boarng. (1 Pump Sieve ard Counting Ascambly Torque camp Delt 7510.9 ibs [10-12 Nem, aring shield must face OUT on Low & 3rd clutch Baring shield mut face IN at Foraard & Peverse cutee, lenpolier sare tune hu assembly with backing ing and spacial sstiookg screws, 1 (Clase hub mounting sursos and tappsc holes wth sok vont. Dry thoroughly, being certain tapped heies are san and ay. 2 Install backing rng and spacial sotocking sorews “Tatton serous to 90-99 fis [79-87 Nem} for turbine and 15-44 fs [787 Ne} fora, ‘Note: Assembly ot rub rrust 26 completed within a igen ‘into potiod from start of xcrem nstlision. The special ‘oven i612 be used for one instalation ony the Soew ‘eneved for any reason, R must te rapaced. The epoxy let In the hu holes must be removed withthe prope tap sas ‘leaned with solvent. Dry hole thoroughly end use @ naw {er0n fot ronsiatston. AX clutch Plates - aty a Modulates Standard en ¥2 immer Fi enna nd 7 4 inna PLACE BOLT | ToRQUE FriLaS fmt # Soe sa Soar trmer 1S nar ars ad oem eae = aos We-an | Sour Our simmer dBi Bouter 2 ouor ‘Sinner an inrar 8 Our Some Torque Spectiaticn or Lubricated orades ‘oF Pltod Screw Threads orsdes ‘Nout FINE THREAD ‘COURSE THREAD FINE THREAD ‘COURSE THREAD Sewer (Nm Grr Nm ert Dm) ise Nn 7500) 223-245 | [ove-sie]_| 200-220 | [av -286|_ | -gi8- 87] er a70] | Bae 310 | ee = 40] 260) #98- 141) (074-19i] | tNa- tau” | 1988-160) |t0- 108 | [eae -aee) 158-175) ete 297] sees] 9¥-Y00 ana 196.5) | 2-90 [fina aah | caw- sai fr7ae- tai.) | 11S var [S80 VER] ‘5000, 64-70 ‘(688-849 | —ST-63—| «(773-854 90-00 | [va22.1- 1942] 0-88 oes T1993 As75) 41-48 | 1885-61.01 | 37-41 | ts02-555) sB-64 | (er-867] 82-5 | [oB- 772) 3750, 28-29 | 1989-908] | 25-25 | feia-sam_ [ara feo2- 888] | 99-38) eae a88| 3105, 16-20 | i727.) W218 | (63-216) | a. 2 | fag. a0] |S WO TA 2600, 9-1 /[taa-t48) |e 10 | (loa t9s| | tts) iso. a8] 9) ag 4 9TMUST a FOR INTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH. PASSAGE MUST BE BLOCKED FOR EXTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH. TIGHTEN PLUG. TAO LBRFT (8.5-13.5 Nm} LOW CLUTCH LUBE TRANSFER INSTRUCTIONSSPEED SENSOR INSTALLATION Regulator Valve and Charge Pump Ass'y. Rear view a4 Lift transmission using this hole 1.990 = .007 [95.3 = .18) SHIM TYPE BUSHING Assemble Speed Sensor Bushing with shims required to provide correct dimension. Clean thread on bushing and housing with Locktite cleaner. Use Locktite number 270 or number 262 on both bushing and housing. Tighten bushing to 45-50 LBF-FT [61-68Nm] torque. After curing of Locktite, ‘Speed Sensor Bushing must be secured with 40 LBF-FT [64.2 Nm] torque.MAINTENANCE AND SERVICE The nstructens contained herein caver the disassambly and disassemble, repair, and reassemble. reassembly of the transmission in a sequence that would CAUTION: Cloaniiness is of extrume importance and an normaly be followed alter the unit has been removed from the sbsolvie must the repsir and overheut of ths unit. Belore ‘machine and is to be completely overauled, it must also be attempting any repains, the exterior of the unit must be lunderstoad that this is @ basic HR3EQ00 3, 4 & 6 speed long thoroughly cleaned to prevent the possiblity of dit and foreign top tansmissicn wth many options. Assaméiies may vary on rater entering the mechanism, ‘specific models. The units are very similar to trouble shoot, Drain as rach cil as possi before csassarntiy ‘See Figutes 409 through 460 for LHR (Converter Lock-up} Disassembly and Reassembly See Figures $21 through 539 for F-Model (Remote Mounted Transmission) Front Cover. DISASSEMBLY Figure 1 Figures ‘Side view HF:36000 long drop transmission, Remave drive plates and backing ring, Figure 2 Figure 4 Remove drive plate mounting piste capscrews. Rlemove impeller cover bearing cap and “O° ring.Figure § . Figure 8 a Remove turbine shaft to turbine hub retainer ring. NOTE: futbine and impeller cover removed. Remove °O” Fling. Fetainer ring Wicker than the turbine hub locating Heng. removing the impelier cover to collect the oil remaining NOTE: It is recommended an oil pan be available when va il cannot be drained in the converter section. Thi when the unit is drained, Figure 9 Figure 7 Figure 10 Using pry sot provided, remove impeller cover and turbine Remove reaction momber to stalor support retainer tngFigure 11 Remove reaction member and spacer. Spacer is dowel Figure 14 pinned to reaction member and does not need to be taken Remove charcing pump suction tube, tube adapter flange ‘apart unless replacement is necessary. and “OF ring t- Figure 15 Figure 12 [LJ] Remove charging pump and pressure regulating valve Remove of ble reine tg F sentiy Figure 13 ‘An impeller removal tool, ike the one shown, can be fabri Figure 16 cated to facilitate the removal of the impeller and oil bate Remove pump hole covers and purre adaptersFigure 23 ‘Support converter housing with @ chain hoist and strap Remove converter housing te transmission case screws. Separate the converter housing assembly from the trans: mission case, NOTE: The Reverse and 2nd and 4th speed clutches wil be removed with the converter housing (sé note in Figure 25) Figure 25, ‘Spread the 4th Clutch Front bearing snap ring out of the ring ‘groove. Fry 4th clutch assembly tram converter housing. NOTE. On a3 speed transmission this will be the 9rd speed ‘chtch, on a 8 speed transmiesion this willbe Fwd-Hi andl Sid Ccltch. See figure 241 for 6 speed cutch, Figure 26 ‘Spread the reverse clutch front bearing snap ting out of the ting groove and pry the reverse and 2nd clutch assembly from housing. Figure 27. Remove idiar shaft rear bearing cap stud nuts. Figure 28 ormove bearing cap and "6" ringFigure 29 Remove the ard shat! bearing cap stud nuts and lockwashers Figure 30 Romove the Sr shaft bearing cap and"O" rings, Figure 31 Remove the low (st) clutch shalt bearing cap stud nuts and lockwasshers. Figure 32 Remove the low (st) clutch shaft bearing cap and shims Koop chims and cap together, i bearing cap, low (ist) clutch, front and rear bearings, transmission case or rear cover are not replaced, the same shims wil be used at roasserro) Figure 33, Remove the low (1st) clutch pressure and lube tranater tubes and *O" rings. g hk Figure 34 Remove the 3rd clutch rear bearing locating ring. (1st speed drive sha on a 3 oF 6 speed transmission.)Figure 38 Figure 35 Pry rear cover from case tapping on idler shat and clutch Remove the idler shaft rear bearing locating ring, to prevent binding. NOTE: The use of aligning studs taciitate cover removal. Figure 96 Figure 39 Remove the rear cover to case stud nuts, screws and Rleenove tear cover and gash. lockwashers, Figure 37 Figure 40 lernove oll sereen assembly phig and screen Flemnove idler shatt rear bearing retainer ring, 107+. + CJ Figure 47 Fomove tho idler shaft front bearing. Figure 48 Remove the 3rd speed clutch assembly trarsmission only.) On a 3 and 6 speed transmis be the 181 speed dive shaft Figure 50 Remove bearing cap stud nuts and washers Figure 49 Block output shatt to prevent turning. Rlamove Flange nut, washer abd *o" ring. Remove fiange, Figure $2 Remove rear bearing cap shims. Wire shims to bearing cap for reassembly.Figure 53 Figure 56 Remove front bearing cap capscraws and washers Romeve oil bate fo kansmission case Screws snd wash ee << 5, Figure 57 Remove oil bathe and mounting plate & Figure 55 — Block output ear gear. Push Output shaft through bearings Romove suction tube bots and lockwashors and gear from rear position. 1w.10Figure 62 Figure 59 Remave turbine shaft rear bearing outer race. Figure 63 uch shalt front taper bearing cup Remove the low (1st) ‘and spacer (all bat). Win thea ofan aust spond tha forward cich shaft DISASSEMBLY AND REASSEMBLY OF rear bearing retaining snap ring. Tap on forward shaft to ‘SUB-ASSEMBLIES IDLER SHAFT DISASSEMBLY Figure 61 Renoretorearscuchassemty. hha Remove front bearing inner race,Figure 74 Figure 71 Postion tront baring innor and outer race on idler shat with ‘nctal isc hub retaining rng. Shoulder on inner race down (loward gear) 47H CLUTCH DISASSEMBLY (3rd Clutch on 3 Speed) eh (For the 6 spoed transmission seo Fuxt-Hi and 3rd Clutch Figure 241) Figure 72 Figure 75 Remove clutch shalt of sealing rings Figure 73 Figure 76 Postion 4th clutch aisc hub (Src clutch of 8 spaed) on shat emove front bearing snap ring 1013Figure 77 Figure 80 Remove front bearing, Remove the inner and outer clutch discs, Figure 21 ree Compress piston return wave epting retainer. Remove Remove cltch disc backing plate snap ng. spring retainer snap ring ftom groove. Release speng ressve Figure 79 Figure 82 Remave backing plate. Remove sping retainer snap fing and eta 10-14REASSEMBLY (See cleaning and inspection page) Figure 83 Remove piston return wave spring, Figure 86 Make sure the piston bleed valve is clean and free of foreign ‘materials. Install the piston inner seal ring. install the piston outer seal ring. Lock ring joint securely. Grease ring to stabilze in ting groove, Figure 94 Remove wave spring thrust washer. Figure 87 Position piston in olutch drum. Use caution as not to damage sealing rings. Figure 85 Figure 88 Tum clutch over ang tap shaft on a block of wood to remove Position the wave spring thrust washer, wave spring, spring clutch pision. retainer and spring retainer snap ring on clutch shah 1015Figure 89 Figure 92 ‘Compress wave spring and install spring retainer ring being Position the backing plate on the clutch discs. ‘cerain ring sin full postion in sg groove, Figure 93 Figure 90 Install the backing plate snap ring. Install 1 stee! outer disc. (Teeth on the outer diameter) Figure 91 Install 1st friction inner disc (teeth on the inner ameter) Alternate steel and friction discs unt the proper amount of Figure 94 discs are installed. Fst disc nex! to the piston ie sleet, last Press the clutch shaft front bearing on shaft wth snap ring dise installed is fiction. ‘groove in bearing down as shown, 10-18Figure 95 Figure 98 Install front bearing snap ring ‘leenove rear bearing snap ting. Figure 96 Pack ring grooves with grease and Install clutch shatt sealing rings. Centar rings in grooves betore assembly into Figure 99 foweing Remove rear bearing, 3RD SPEED CLUTCH DISASSEMBLY AND REASSEMBLY i (4 Speed Transmission Only) DISASSEMBLY ¥ Figure 97 Figure 100 Remove clutch shaft sealing ring Remove the ard speed gear outer bearing retaining ring 1017Figure 101 ‘Tap Sed gear and outer bearing from clutch drum, Figure 102 Figure 105 Remove backing plate snap ting Remove inner and outer clutch discs, Figure 103 Figure 106 Remove backing plate. FRermove the ard gear inner bearing snap ring. 10-18Figure 107 Figure 110 ‘Compross the piston return wave spring retainer. Remove Remove wave spring. spring retainer snap ring from groove. Release spring pressure, Figure 111 Fermove clutch piston return spring retainer. Figure 109 Figure 112 Remove wave spring retainer. Remove clutch piston. 10-19REASSEMBLY (See cleaning and inspection page) Figure 113 ‘Make sure piston bleed valve is clean and free of foreign ‘materiale. Install clutch piston inner seal ring, Install clutch piston outer seal ring, Lock piston ring joint securly, Grease ring to stabilize in ring groove. Install peston in clutch drum. Use caution a8 not to damage sealing rings. Figure 114 Position the piston return spring retainer, wave sping, wave ‘spring retainar and retainar snap ring on clutch shart Figure 115 ‘Compress wave spring and instal spring retainer ring being certain ring isin full postion in ring groove. Figure 116 Instat the 2rd gear Inner bearing snap ring, atti Figure 117 Install the 1st steet outer disc. install the 1st fiction loner disc. Altemate steel and fiction discs until the proper amount of discs are installed. First disc noxt tothe piston is stool, last de installed i tition, Mis Figure 118 Position clutch disc backing plate on discs,Figure 119 Figure 122 Install backing plate snap ring. Instal 3rd gear outer bearing. NOTE: Outer bearing has an oll shield in this shield must be up. Figure 120 Install Std speed gear inner bearing. NOTE: This bearing Figu a a ie oe Install the Srd gear outer bearing retaining ring Figure 121 Position the Sid speed gear into clutch drum. Align splines fon gear with internal teeth of friction discs. Tap gear into Figure 124 position. Do not force this operation. Gear splines must be Install clutch shatt rear bearing. NOTE: Ring groove in boa In full postion with internal teeth ofall ction disc ing must be up as shown. 10-25le t Figure 125 Install bearing snap fing. Figure 126 Install clutch shalt rear ol sealing fing. Grease ring to stab ‘ize In ring groove, FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY (Non-modulated. For modulated clutches ‘see modulation section.) DISASSEMBLY Figure 127 Remove forward chatch shatt oil sealing rings 1022 Figure 128 Figure 129 Rermave front bearing inner race, Figure 130 Remove bearing spacer.Figuro 131 Figure 134 Remove cltch gear and ote beng Remove the loner and cute ch cs. ~ * wt | i ig Figure 132 Figuee 195 Remove clutch disc backing plate snap ring. Remove clutch gear inner bearing, ‘nave spring retainer, Remove rom ring groove. Release spxing Figure 133 Remove backing plate. 1020Figuro 137 Figure 140 Remove wave spring retainer and retainer ring. Flemove cstch piston. Figure 138 Figure 141 Remove wave spring, emove rear beating snap ring. Figure 139 Remove wave spring thrust washer. Remove rear bearing, 10-24REASSEMBLY (See cleaning and inspection pag Figure 146 Position piston in clutch drum. Use caution as not to Figure 143 damage sealing rings. Install clutch shaft rear bearing, NOTE: Snap ring groove in bearing must be up as shown. i Figure 144 Figure 147 Install rear bearing snap rng, Position wave spring thrust washer on clutch piston &e. pl Figure 145 4 ‘Make sure piston bleed vaWve 's clean and free of foreign ‘material. install clutch piston inner seal ring, Install clutch piston outer sual ring, Lock piston ring joint securoy, Grease Figure 148 ting to stabilize in ring groove. Position wave spring on thrust washer,Figure 149 Figure 152 Position wave spring relainer on wave spring Position clutch disc backing plate on discs, Figure 150 ‘Compress wave spring and insta spring retainer ring being Figure 153, ‘certain rng is intl postion in ring groove Figure 151 Install one stool disc. Install one friction disc, Altornate steel land frction discs unll proper amount of discs are installed. Figure 154 First disc next to the piston 1s steel, last disc installed is Install elutch gear inner bearing. NOTE: This bearing does frietion rot have an ol shield in ae AFigure 185 Install clutch driven gear into clutch drum. Align splines on ‘okatoh gear with internal leeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be ‘in full postion with intemal teeth of all friction discs. Install ‘cktch gear outer bearing. NOTE: The outer bearing has an oil shied init, this shield must be down. A Figure 156 Position bearing spacer on clutch shat. Figure 187 Install clutch shaft front bearing, Figure 158 Instal front bearing retainer ring. a Figure 159 Pack sealing ring grooves with grease, Install cltch shaft ‘sealing rings. Center nngs in grooves. REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY ‘3.and 4 Speed Transmission (For 6 speed see Figure 274) DISASSEMBLY (Reverse Being Disassembled) Figure 160 Remove ciutch shaft sealing ringsFigure 161 Remove front bearing retainer ring \s Figure 162 Remove tront bearing Figure 163 Remove front bearing spacer Figure 164 Pry clutch gear up far enough to use a a gear puller Figure 165, Remove clutch gar and outer bearing, Figure 166 Remove backing plate snap ring. 10.28Figure 167 Remove backing plate. Figure 168. Remove inner and outer cluich discs. Figure 169 emove clutch gear inner bearing. 1029 Figure 170 Compress the piston retum wave spring retainer. Reenave spring retsiner snap ring ftom groove. Ralease spring pressure. Remove snap rng. Figure 171 lemove wave spring retainer. Figure 172 Remove wave spring.Figure 173 Remove wave spring thrust washer. Figure 174 Remove clutch piston. Turn clutch over. 2ND CLUTCH DISASSEMBLY Figure 175 Remove backing plate snap ring. 10:90 Figuee 176 Remove backing plate. Figure 177 Remove inner and outer clutch discs, Figure 178 ‘Compress the piston retum wave spring retainer, Remove ‘spring retainer snap ring from groove. Release spang pressure, Remove snap rin.Figure 179 Remove wave spring retainer. Remove wave spring. Figure 181 Remove wave spring thrust washer. Figure 182 remove cin piston REASSEMBLY OF 2ND SPEED CLUTCH {See Cleaning and Inspection Page) Figure 183, Make sure piston bleed valve is clean and free of foreign materials. Install clutch piston inner seal ring. install clutch piston outer seal ring. Lock piston ring joint eecuraly, Grease ting to stablize In ring groove. Position piston in clutch drum. Use caution as not to damage sealing rings. 3 tosFiguro 185 Figure 188 Position wave spring and thrust washer on clutch piston, Compress wave spring and instal spring retainer ring being ‘cartain rg is in full pesition in ring groove. rn Isl one sta ds. Inston etion de. A ss Install one stost dsc Install on tition isc. Alternate stee a ee ed _and friction discs until proper amount of discs are installed, First dsc nox! to piston isto, ae cise insted sition Figure 187 Figure 190 Position wave spring retainer on wave spring Postion clutch ie backing plato on dics, 1082Figure 191 Install backing plate snap ring, Turn clutch aver, Figure 194 Position wave spring thrust washer on clutch péston, REASSEMBLY OF REVERSE CLUTCH For 6 Speed see Figure 295 Figure 192 Figure 195 Moke sure plton bled vale le clean and tree of foreign ‘materi. ital inner sealing. Ill piston ovter sea ng. Leck sion sng pit securely. Grease ring lo slate ning oore Figure 193 Install piston in clutch drum. Use caution as not to damage sealing rings. ! Position wave spring retainer on wave spring, q 1039Figure 197 Figu ‘Compress wave spring and install spring retainer ring being Install backing plate snap ting. ‘cerain ring sin full postion in sg groove, si Figure 198 Install one stael dsc. Install one friction disc. Aternate steel ‘and friction discs until proper amount of discs ae installed. First disc next to piston is stool, last disc installed Is Fiction. Figure 201 Install clutch gear inne bearing, NOTE: This bearing does ‘rot have an oil shield in it Fgure 202 Inca ctch ven get ath uy, An sla on th guar al nh of ben des Tp peur no Pgure 80 WD sosest bee tee recone, Gear spree bo Postion chach dec ba ten cs 2 ld utpeonon wt nl eel a ae Soc 1084Figure 206, Figure 203 Inetall front beacing retaining fing, Install clutch gear outer bearing. NOTE: Ovtor bearing has a shield in, this shield must be down. p Figure 207 Pack sealing ring grooves wit grease, Install clutch shaft Sealing rings. Center rings in rng grooves, Figure 208 LOW (1st) CLUTCH DISASSEMBLY & REASSEMBLY DISASSEMBLY Figure 205 Install front bearing. NOTE: Snap ring groove in bearing Figure 208 ‘outer race must be down, A Remove rear clitch shat sealing rings 10-95Figure 209 ry rear bearing up far enough to use a bearing puller Figure 210 Remove rear taper bearing. me) Figure 211 Remove bearing thrust washer Figure 212 Flemove 1st spaed gear and outer bearing. Figure 213, lemove backing plate snap ring Figure 214 Remove backing plat,“4 ae: ae Figure 215 Remove inner and outer clutch oscs VEE a eps Figure 216 Remove tst speed gear inner bearing. Figure 217 Remove 1st speed gear spacer, Figuee 218 Compress the piston retun wave spring retainer. Remove pong retainer snap ring ftom groove. Release spring pressure, Remove snap ring. Figure 219 lemove wave spring retainer. Ba Figure 220 Remove wave spring 100?REASSEMBLY (See Cleaning and inspection Page) Figure 221 Figure 224 Remove wave spring retainer. Position Se speed driven gear on catch shat with long bas ‘of gear up, (4 speed tranemission ony) Lem Figure 225 Position front taper bearing on clvich shalt with salt ameter of taper up, Press bearing into position. MOTE: 1 thermal assembly aid is used. (expanding by heating 275!F¥-259F. [135'Crh[14°C] a check must be made after mating parts have reached tne same temperature within 20°F [11°C] ambient, 10 be eute the bearings ate positioned —solialy against their respective Shoulders before bearing adjustment can be made, Turn clutch over. Figure Remove clutch piston. Install clutch piston inner seal ring. instal clutch piston outer Figur 223 seal ring. Lack piston ring joint securely. Grease ring 10 Remove the rd speed drive gear and front bearing, (Driven stabilze in ring groove. Install piston in clutch drum. Use ‘gear on 4 speed transmission only.) ‘caution as not to damage sealing rings. 03 1088Figure 227 Instal piston return wave spring retainer Figure 228, Position wave spring in retainer Figure 229 Position clutch spring ratainer on spring. Figure 230 Compress spring and install retainer ring being aure ring Is in fll postion in ring groove, i Figure 231 Install one steel disc, Install on® friction disc. Alternate stee! and friction discs unl the proper amount of discs are installed. Fist disc next to the piston is stool, last disc Installed is fiction. Figure 232 Position backing plate on clutch discs 10.99Figure 233 Figure 236 Install backing plate snap ring Install clutch gear into clutch drum, Align splines on chat gear with intemal teeth of friction ciece. Tap gear into Position. Do not force this operation. Gear splines must be ‘n fll postion with internal teeth of ai terion discs. M Figure 237 Install clutch gear outer bearing. NOTE: Outer bearing has Figure 234 a shield in it, this shield must be up. Install 1st speed gear spacer j\ Figure 235 Install 1st gear inner bearing. NOTE: This bearing docs Figure 238 ‘not have an oil shield in it. A Install ear bearing Uwrust washer 10-40Figure 238 stall clutch shatt rear taper bearing, laige cfameter of bearing down. NOTE: Hf thermal assembly aid Ie. used. (expanding by nealing 275° -25°F[135°C-i-14")0 a check ‘must be made ater mating parts have reached the same temperature wihin 20°F(11°C] of emolent, to be sure the Dealings ste postioned sotdly against thei respective shoulders belore bearing adjustments can be made. ii Figure 240 The tmo clutch shat oll sealing rings will be installed alter the low clutch taper bearings are adjusted. DISASSEMBLY AND REASSEMBLY ‘OF FORWARD HIGH AND SRD SPEED CLUTCH (6 Speed Transmission Only) FORWARD HIGH CLUTCH BEING DISASSEMBLED mS Figure 241 Remove clutch sha oil sealing rings. Figure 242 Femnave front beating retainer ring Figure 243, Remove front bearing. Figure 244 move ciutch gear outer bearing retainer ring. toaFigure 245 Figure 248 Remove clutch gear and outer bearing Flemove clutch dsc backing plate. se — she * . Figure 208 Figure 208 Remove inet and cuter shh dees. Femovecich gar ine Pating i ~ es , : a Figure 250 Conotss piston ren wave sprig. Remove eum spang Figure 267 ‘ent. noes days wore sing an epg Remove backing plate rstane ng rae 10-42Figure 261 Figure 254 Remove clutch piston Remove inner and outer chtch ccs DISASSEMBLY OF 3RD CLUTCH iii . \aet Figure 252 Figure 255 ‘Compress piston retum wave spring. Remove retum spen Tu dutch over and remove Si cuch dsc backing pate tearing. Remove rng retainer, wave peng end speng retainer ing, retainer Figure 253 Remove backing plate. ermowve clutch piston. 10.43REASSEMBLY OF FORWARD HIGH (6 SPEED ONLY) AND 3RD ‘SPEED CLUTCH ‘See cleaning and inspection page. REASSEMBLY OF 3RD CLUTCH Figure 260 Position pitan in clutch drum. Use caution as not to damage sealing rings. Figure 257 Make sure piston bleed vaive i clean and tree of foreign materiale. i Figure 261 Postion plan ratum epting retulne, wave. sping and fuser dg washer cach cn Onioree are Mong a tne etal pring relia’ fg bang ceria dng wn ht Install clutch piston inner seal ring. position in ring groove. igure 289 Install clutch piston outer piston fing. Lock piston ring joint ‘securely, Grease ring to stabilize in ring groove, Install one steel sc, 1048REASSEMBLY OF FORWARD HIGH CLUTCH (6 SPEED ONLY) Figure 263 Install one fiction disc. Akemate stool and fiction ses until the proper amount of dises are instated. First se next 10 the piston is steel, last disc installed is fection. Figure 266 Repeat procedures in Figures 251 thru 259, a Figure 264 Figure 267, install clutch diso backing pate ‘instal clutch gear inner bearing. NOTE: This bearing does not have a ahioldin it Figure 268 Install clutch driven gear into clutch drum, Align splines on ‘dutch gear with intemal testh of fiction disos. Tap gear into Figure 265 position. Do not force this operation. Gear splines must be Install backing plate retainer ring. in tll positon with internal teeth of al tition discs, 10-48Figure 269 Install utch goar outer bearing. NOTE: Outer bearing has 8 shield in it, this shield must be down. A Figure 270 Install ter basting retainer ring. Figure 271 Install clutch shatt front bearing, NOTE: Ox locating ting groove must be down. / bearing Ys Figure 272 Install bearing retainer ring. Figure 273, Pack oil sealing ring groves with grease. Install sealing rings and center rings in ring grooves. DISASSEMBLY AND REASSEMBLY OF REVERSE AND 2ND CLUTCH (6 Speed Only) DISASSEMBLY REVERSE CLUTCH BEING DISASSEMBLED (For Modulation see figure 479.) mS Figure 274 Remove front clutch shat oil sealing rings,Figure 275 Figure 278 Remove front bearing retainer ring Femove inner taper bearing. Remove clutch dise backing plate retainer ring, Figure 278 Figure 273 Using a gear puller remove front bearing, elutch gear and Remove backing plate ‘lutch gear outer taper bearing, Figure 280 Remove inner and outer clutch discs, 1047i Figure 281 Compress clutch piston return spring. Remove spring Figure 284 retainer ring, washer, spring and spring retainer. Remove backing plate. Figure 262 Remove clutch piston. Figure 285, DISASSEMBLY OF 2ND CLUTCH FRermave inner and outer clutch discs, Figure 286 Figure 283 Compress clutch piston return spring. Remove spring Remove clutch dise backing plate retainer ring fetainer ring, washer, spring and spring retainer. 1048Figure 287 Figure 290 Remove clutch piston. Install clutch piston outer soal ring. Lock piston ring joint securely, Grease sing to stabilize in ring groove. Insta piston in clutch drum, Use caution a8 nat to damage sealing REASSEMBLY OF 2ND AND REVERSE CLUTCHES mee ny See cleaning and inspection page. . 2ND CLUTCH BEING REASSEMBLED ba Figure 231 Psion piston return spring retaner, retum spring and Figure 208 fetainer ring washer in clutch drum Make sure piston bleed valve is clean and frne of foreign materia Win Figure 202 Figure 289 Gorpress totum spring and instal spring retainer ing being Install clutch piston inner seal rng. Certain ig i in ful position in ving groove 1049Figure 293 Install one stool dc. Install one friction disc. Atomate steel land friction discs until the proper amount of discs are Figure 296 Installed. First disc next to the piston is steel, last disc Install clutch gear inner taper bearing with large diameter of Inetalled is friction taper down. Figure 294 Install clutch dise backing plate. Install backing plate retainer ning, Figure 297 Position taper bearing spacer on clutch shaft. REASSEMBLY OF REVERSE CLUTCH For Modulation see Figure 509. Figure 298 Install elutch driven gear into clutch dum. Align splines on ‘dutch gear with intemal teeth of fiction discs. Do not force Figure 295 this operation. Gear spines must be in ful position with Repeat procedures in Figures 288 through 294 informal tooth of all riction discs.a Install clutch dfive gear outer taper bearing on clutch shaft ‘wh large ciameter of taper up . Figure 300, Install clutch shaft front Dearing, NOTE: Bearing outer retainer ring groove must be down. A Figure 301 Install bearing retainer ring. NOTE: Retainer ring is selected at assembly for proper thickness. A snap ring kit is available. Select the thickest of the rings in the kit thet can be fitted into snap ring groove to assure a taper bearing tight- ect ter te Figure 302 Pack oil sealing ring grooves with groase, Install sealing tings and center rings in ring grooves, TURBINE SHAFT. DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 303 Remove turbine chatt oil sealing ting. Figure 304 lemove the bearing snap ring. 1051Figure 308 Remove bearing washer. Figure 308 Position bearing washer on shatt rx ah. — Figure 306 Pry bearing up far enough fo press of pull bearing trom turbine shaft Figure 309 REASSEMBLY Antal bearing snap ring See cleaning and inspection page . 3 Figure 307 Figure 310 Press bearing on turbine chef wih outer diameter ing Pack a sealing ring groove with grease. Insta sting ng gro0ve up. and center ing in groove. 1052DISASSEMBLY AND REASSEMBLY OF IMPELLER AND OIL BAFFLE DISASSEMBLY Figure 311 Remove impeller hub gear snap ring. Figure 312 Remove impeller hub gear Figure 313 Remove oil ball, oil seal anc battle seal ring. Figure 314 Remove impetier to hub screws. Figure 315, Hlemove scren backing ring. Remove impeller trom hub. FRemave hub to impeter “O° ring. REASSEMBLY See cleaning and inspection page. Clean hub mounting surface and tapped holes with Solvent. Dry thoroughly, being certai tapped holes are clean end ary, Figure 316 {f removed, install impeller hub bearing in hub. install hub bearing snap ring. Position a new hub to impeller “O" ring on hub,Figure 317 ‘Align holes in impeller with impeller hub, Position ienpeller on nub using caution as not to diseupt “O” ing Figure 318 Install backing ring GR saseas Install special satf locking screws. Tighten screws $8-64 ‘L bs. [79-87 Nm]. NOTE: Assembly of hub rust be ‘completed within a Fiteen minute period from start of screw instalation. The special screw is to bo used for one Installation only. the serew Is removed for any reason it ‘must be replaced. The epoxy left in the hub holes must be removed wih the proper tap and cleaned with solvent. Dry hole thoroughly and use a new screw for reinstallation. Figure 320 Apply a light costo Loctite 63 to the outer diameter of the ‘il bafile cll seal, Press oil seal in of baie with lip of seal down. "3 Position oll batfie on impeller, use caution as nol to damage ‘i seal. Install new oll batfle sealing ting Figure 322 Position hub gear on impeller hub. Install gear to hub snap fing,DISASSEMBLY AND REASSEMBLY OF TURBINE AND IMPELLER COVER DISASSEMBLY Figure 323 ‘Block impeller cover as shown. Remove turbine hub to front bearing snap ring. Figure 324 Remove bearing spacer. irr Figure 325 ‘Tap turbine and hub trom impeier cover bearing, Figure 326 ‘Sraighten turbine hub bot lack tabs. Ramove turbine to au bolts. Remove turbine hub, REASSEMBLY See cleaning and inspection page A figure 927 ‘Align holes in turbine with holes in turbine hub. Position locke tabe and install turbine hub bolts. Tighten bolts to specifiod torque, (See torque chart). Bend a corner of the lock tab over a lat of the bolt heads. NOTE: On units with converter lock-up, special turbine to hub installation must be used, See Lock-up section. D> 1D Figure 328 Center impeller cover aver turbine and hub. Install impeller cover bearing in impeller cover and over turbine hub.Figure 329 Position bearing washer on turbine hub, ny ¥ recommended each gear be marked for its location for reassembly, Various gear ratios dictate proper gear location at reassembly. Figure 330 Insta turbine hub to bearing snap ring, CONVERTER HOUSING DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 333 Remove pump drive gear bearing support screws and lockwashers Figure 331 Figure 334 Remove turbine shaft Iroat beating locating snap tng, lemove pump drive gears and bearing assembliesFigure 335 | unit has a lube pressure relief valve, disassemble in order Figure 337 shown for eteaning and inspection Tighten pump drive gear bearing support screws to specified torque. OIL SEALING RING SLEEVE REMOVAL (Remove sleeves only if they are to be replaced.) 1 = Remove clutch shaft front bearing locating ring 2- Remove retainer plate screw, washer and plate. 3- Using a suitable puller, remove sieeve CONVERTER HOUSING REASSEMBLY (See Cleaning and Inspection Page) OIL SEALING RING SLEEVE INSTALLATION 1- When installing a new sleeve itis recommended a press or a ariver be used to prevent damage to the sieeve and be sure the notch in the RET.RING™ VALVE SEAT sleeve is aligned with sleeve lock notch. 2 - Postion sleeve lock. 3 - Install capscrew and washer, tighten to specified Figure 298 torque. Position clutch shaft front bearing if unit has lube pressure relief valve and was disassembled locating ring in ring groove. for clearing oF replacement, reassemble in ordet shown Figure 336 Pump drive gear instalation, See note aller fguie 326. Figure 239 Install the right end left gear in the proper locaton. Install Position turbine shaft and bearing in housing. Tap bearing the center charging pump drive gear. into postion far enough to install bearing snap ring. 1057Figure 341 Spread reverse clutch front bearing locating ring and tap reverse and 2nd clutch assembly into converter housing. Be Certain locating ring isin full postion in ring groove. Figure 342 Spraad 40h speed clutch ring locating ring. NOTE: (On a 6 speed transmission this will be the forward-ni and 3d clutch. Tap clutch assembly into position being Cerlain ring is in full position in ring groove. Figure 343 Install forward clutch shaft front bearing TRANSMISSION REASSEMBLY See cleaning and inspection page. NOTE: It @ new transmission housing or converter housing is needed for reassembly see assembly instruction page for speed sensor bushing installation. wmbly instruction page for screw and nut ~ Position the forward ch bore, Push duteh eb far enough to instl bly back in bearing bore unti ;ocating ning shoulders in bearing bore. Figure 345, Position a new “O ring on the suction tube and install tube In tranemission case,re Sanit” | Figure 346 Figure 349 Ins ion tube to case screws and washers, Tighlen to View of output shalt at # would be positioned in the tans jee Torque Chart) mission case. NOTE: Long hub of output gear toward the rear of transmission. Sy, “/ S. Roneoar Figure 350 Position il battle in case, Figure 348, and tighten to specified onan g on shalt with large space on shaft ff, spacer & bearing from lnstalt oll bat forque Chast)Figure 352 in position in front bearing 19g an cap With taper bearing inn cap, install new bearing cap “C instal tied torque. (See Torque Chart) q TIN FT é ‘a ou ; Figure 384 or & thrust wash From the rear position ouput shaft 1080 rear output shalt taper bearing on si diameter of taper toward thrust washer. Make sure bearing js tight against thrust washer Figure 356 Install new oll seal & "O" ring on race bearing cap. With rear taper bearing outer race in place In bearing cap peal bearing oap shims on studs & inctall bearing cap stud nut fockwahers & stud nutsSpacer (oil baffle) fearing cup Locating ring. a Figure 358 Figure 361 “Tap and rotate ouput shat to seal taper bearings. Loosen tear bearing cap bolts. Using an inch Ib. Torque wrench \Ughten rear bearing cap bolts 10 spscitied torque. Check rolling torque with bolts tight, Torque must be 4 to 10 inch tbs. 10,46 - 1,1 Nm] more than when bearing cap bos wore loose, Add or omit shims on the bearing cap to achieve the proper preload Figure 362 “The low clutch (18) and the ier shaft must be installed in the transmission case together. The help of an assistant or by placing the transmission case on the front face may faci Figure 359 itate this step. Be sure clutch and ier are in full postion in Install rd speed clutch assembly (on 2 4 speed only). On a rane 3 and 6 speed this will be low clutch drive shaft ww Figure 363 install idler shaft rear bearing, NOTE: Snap ring groove Figure 208 must be out, (To the rear.) With the locating ting in pesiion In the low clutch front bearing bore, install the spacer (oll afte) and front bearing cup. See figure 345. 10-81Figure fing inetall rear idler bearing oap on trane- Install ear beating to idler shalt retainer ring Using new *O" mission case.Figure 370 Figure 373 Install lockwashers and stud nuts, tighten to specitied Position new °O" rings on bearing cap, Install ap on studs torque. (See Torque Chart) Figure 374 Install lockwasher and stud nuts, tighten to specications, (See Torque Chart) Figure 371 ¥ Install output flange, *O" ring, washer and elas Block output flange to prevent turning and tighten tlange nut to specitied elastic stop nut torque. (See Torque Chart) Figure 375 Install of sump screen assembly and plug. Ti to 15 LBE-FT. [13-29 Nery]. REFER TO PAGE 10-93 FOR LOW (1ST) CLUTCH TAPER BEARING ADJUSTMENT, NOTE: After low (1st) clutch taper bearing adjustment and bearing cap and shims are installed and torqued, return transmission to an upright position, Figure 372 Install dutch shalt or drive shall rear bearing locating ring, Remove low clutch rear bearing cap and shims and proceed to Figure 376, 10-69Figure 376 I new “OT tings on the clutch pressure and fer tubes, postion tubes in rear cover, ‘Rg ones wih ress, sal seaig tos Figure 379 Position the 2nd speed clutch disc hub on the low ( hath. In he “ rolainer. Install ring retainer, retainer ring. See Figure 380. Low Cluteh Shatt E Retaines eng retainer 2nd Clutch Oige Hub Figure 37 Postion pre-selected shin pack on shuds, Figure 380 Figure 378 Install bearing cap, washers specifid torque, (See Torque Ci tud nuts, Tighten 10 Figure 361 install turbine shaft rear bearing outer raceInstall a new transmission housing to conv gasket and “0” rings on transmission housing. A light ‘grease wil hold gasket in position. Figure 363, Position the 2nd and rd clutch pilot bearings on o ‘shafts, a light coat of grease wall hold bearings in pos The use of alignment studs wil fa assembly. Install alignment studs and postion converter housing on studs. NOTE: Turn output shatt to align Clutch disc hub in clutch disc. tate housing to housing Figure 385 Instat converter housing to transmission housing bolls and lighfen to specified torque, NOTE: Bolts are not to be used to pull front cover to transmission housing Tighten bolts to specified torque Figure 388 ring groove on stator suppor with grease, Install seating ring. Install impeller hu bearing inner race ‘on stator support Position support on turbine shall, turn Jpport to clear pump dive gear, Align suppor holes with converter housing, Figure 287 Instal stator suppor sctews and tighten to spacstied torque. For Lock-up see lockup section starting with Figure 408, {See Torque Chart)jon a new impeller cover to Impeller "O" ring on impeller or cow ine assembly on turbine install trp 7 shaftFiguro 394 10 enpeller sere que, (See Torq Install impo tighten to speci lockwashers, Figure 396 Position a new “O" ring on the impeller cover beaving cap. Inatail cap on irmpetier. Figure 397 Install the drive plate and backing ring per instructions or dirve plate installation page Figure 398 Tighten drive plave screns per instructions, CONTROL VALVE INSTALLATION The use of alignment studs will facilitate valve installation. rworter housing gasket and ment stu,Install the two control valve to co Tighten to specified Te Figure 408 Position solenoid protection cover and install stud nut washers and stud nuts, Position one seat plate plate and outer seal plato gasket on studs against controt valve Figure 405 ighten stud nuts to specified torque. (See Torque Chan} yure 402 Position contra valve cover assembly on stu, 10-68Figure 406 Install a nee °O" ring on the pressure regulator valve housing. Position regulator valve and charging pump on converter housing. Figure 407 Install regulator to converter housing screws and lockwashers. Tighlen lo specied torque, Figure 408 Install charging pump suction tube, °O" ring, adapter fiting, adapter ange and tlange screws and lockwashers. Tighten ‘screws to specified torque, (See Torque Chart) 10-69HR36000 CONVERTER SECTION LOCK-UP DISASSEMBLY AND REASSEMBLY PROCEDURE. CONVERTER LOCK-UP PERMITS DIRECT ENGINE DRIVE FOR HIGH SPEED TRAVEL CYCLES. This lock-up section must be used In conjunction with the HR'36000 transmission maintenance and service section of this manual for complete disassembly and reassembly. MAINTENANCE AND SERVICE ‘The insrictions contained herein cover the disassembly and CAUTION: Clesnlinass ig of extreme impartance and an reassembly of the lock-up portion of the torque converter abeolute must in the repair end overhaul ofthis unt. Betore In sequence that would nosmally be followed after the unit atterrpting any repairs, the exterior of the unit must be has been removed fromm the machine and is to be completely sughiy cleaned to prevent the possibilty ot dirt and foreign overauied. NOTE: Some units wil have drive gears and same ‘mattor entering the mechanism: units will have flex plate drive. Disassembly and reassembly wil be the same DISASSEMBLY Figure 409 Figure 411 retaining fing Figure 412 Figure 410 Remove beating retainer ol sealing fing and ex Remove bearing cap and “O" ring. springFigure 413 Figure 416 Remove bearing rotainer Remove impeller cover to impeller “O° ring IMPELLER COVER AND LOCK-UP DISASSEMBLY AND REASSEMBLY DISASSEMBLY Figure 414 Remove impeller cover to impetier bots, Figure 417 ‘Support mpelier cover on blocks as shown, Tap turbine hub from impeller cover bearing, Figure 415 Using pry slots provided. pry impeller cover and lock-up assembly from impeter. CAUTION: When impeller cover i far enough from impeller. use 2 hook and hoist in ane of the Figure 418 bol holes to prevent assembly trom faling. Remove turbine and lock-up hub from impeller cover tortStraighten comers of turbine hub capscrew lockplates. Flemave backing plates. NOTE: Some lock-ups will have Femove turbine hub capscrens and lockplates. NOTE: A ‘one friction disc as shown in Figure 423 and some will ‘change has been made on the turbine to turbine lock-up have two frictions discs separated by a steal disc as bub retention. See assembly instruction page tor ‘shown in Figure 424 proper reassembly procedure. Figure 420 Figure 421 Figure 424 Remove lock-up backing plate to impeller cover self locking Rlemove two friction discs and one inner steel disc. capserons, (2 plate lock-up).Figuee 428 ‘Remove lock-up piston inner piston ring trom impeller cover. Figure 425 Remove lockup drive disc — Figure 429 Remove impeller cover beating. See cleaning and inspection section in the jintenance and service manual and Figure 42 complete transmission disassembly and reassembly. Remove lock-up piston. REASSEMBLY OF THE LOCK-UP, IMPELLER COVER AND TURBINE Figure 427 Figure 430 Remove lock-up piston outer piston ring and ring expander Install anew lock-up piston inner piston ring. Be sure ring spring, NOTE: Not all units will have an expander ring under lock joint is securely lastened. Grease ring to stabilize in the piston ring, fing groove.Figure 431 Position lock-up piston outer oil sealing rng expander spring in fing groove. Install oll sealing ring aver expander spring being sure lock joints securely fastened. Expander spring ‘gap to be 180° fram sealing rng haok jon. Grease ring 19 facilitate assembly into impeter cover, NOTE: Not all units will have an expander spring under the piston ring, Figure 432 Position lock-up piston in Impstir cover using caution as not to.damage the inner and ovter piston rings Figure 433 Postion drive disc in impeller cover, aligning holes in ove dis with holes in impeller cover. Install lock-up dis (tition). NOTE: Some units will have two (2) lock-up discs (friction) and one steel disc, if you have a two (2) lock-up discs, install one (1) friction disc (leeth on the inner diameter of disc). Install steel ise (teeth on the outer diameter). Install second friction disc. The steel dise separates the two friction discs. a Figure 435 ‘Some units will have only one (1) friction isc as shown in Figure 419 Install friction diseFigure 437 Install backing plate to impeller cover self locking eapaocens. Tighten to speciied torque. (See torque chart) Figure 438, ‘Align holes of lock-up hub with holes in turbine. Tap hub into place. Figure 439 stall capscrew backing ring, install turbine to lock-up hhub special capscrews, NOTE: SEE SPECIAL CAPSCREW INSTALLATION PROCEDURE ON ASSEMBLY INSTRUCTION PAGE. 1075 Figur Position turbine and fock-up hub in impeller cover assembly aligning lock-up hub teeth with drive dso (discs). Install turbine in cover, CAUTION: Do not force this operation, Tum impeller cover and turbine aver. NOTE: Do not let turbine lock-up hub slip out of lock-up disc (discs). Figuee 441 bine hub Irom under side and install impeller cover bearing. It inner turbine hub locating ing was removed, ‘nstall ring in turing hub. TRANSMISSION PORTION OF LOCK-UP Figure 442 ‘Aker converter housing has. been removed, check turbine shaft to transmission housing lock-up pressure sleeve. it sleeve is to be replaced. remove sleeve retainer capscrew.Figure 443 Remove retainer and sloove. Iv & Figure 447 Remove supply line from lock-up inlet elbow on transmission housing n Figure 434 Remove modulator lockup valve supply line tube nut tom modulator vane. Figur Remove modulator valve fro Proceed with transmission disassembly, clesning ‘and inspection and reassembly as explained in the Figure 445 appropriate maintenance and service manual up to Remove supply ine fom pressure reguator valve ‘iting. turbine and impeller cover installation. 1078Figure 449 Figure Position a new impellor cover to impeiier “0” ring on impellor Install new sealing ring expander spring and oll sealing ring over fon impeter cover beanng retainer Expander spring gap to bbe 180" from sealing fing hook joint. ~

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