36000 SD Service Manual 0203

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TABLE OF CONTENTS

1) Foreword

2) Safety precautions, cleaning and inspection

3) Technical specifications

- identification of the unit

- weight, oil capacity

- pressure and temperature specifications

4) Maintenance

- oil specification

- maintenance intervals

- servicing machine after components overhaul

5) Installation details

- converter drive coupling

- components to engine installation

- external plumbing

6) Operation of the unit - hydraulic diagram

- power flows

- electrical wiring

7) Troubleshooting - stall procedure

- check points - See page 5-3

8) Sectional views and parts identification

9) Assembly instructions

10) Disassembly and Reassembly of units

FOREWORD

This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER CLARK-HURTH OFF-HIGHWAY COMPONENTS DIVISION product.

Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service.

In order to become familiar with the various parts of the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations.

Whenever repair or replacement of component parts is required, only Spicer Clark-Hurth Components-approved parts as listed in the applicable parts manual should be used. Use of "will-fit" or nonapproved parts may endanger proper operation and performance of the equipment. Spicer Clark-Hurth Components does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Spicer Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.

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 operation of the machine. If replacement parts are required the part must be replaced with one of the same part number or with an equivalent part. Do not use a replacement 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.

2-1

CLEANING AND INSPECTION

CLEANING

Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned.

CAUTION: Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapours

BEARINGS

Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.

HOUSINGS

Clean interior and exterior of housings, bearing caps, etc., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaners.

CAUTION: Care should be exercised to avoid inhalation of vapours and skin rashes when using

All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft, lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound.

INSPECTION

The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.

BEARINGS

Carefully inspect all rollers, cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed.

2-2

OIL SEALS, GASKETS, ETC.

Replacement of spring load oil seals, O-rings, metal sealing rings, gaskets, and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time. Further loss of 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 assembly of mating members. Lubricate all O-rings and seals with recommended type Automatic Transmission Fluid before assembly.

GEARS AND SHAFTS

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks, or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and that shafts are true.

HOUSING, COVERS, ETC.

Inspect housings, covers and bearing caps to be certain they are thoroughly clean and that mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures.

LEGEND SYMBOLS

['J Disassembly of assembly groups
~
[!J Reassemble to from assembly group
~t~ Remove obstruction parts
L .... .J
~..,~ Reinstall - remount parts which had
L:.t.J obstructed disassembly
£ Attention! Important notice
il Check - adjust e.g. torque, dimensions,
pressures etc.
s T = Special tool P = Page
-.::] Note direction of installation
----
~ Visual inspection
¢ Possibly still serviceable, renew if
necessary ~ Renew at each reassembly
• Unlock, lock e.g. split pin, locking plate,
etc.
~ Lock - adhere (liquid sealant)
!~ Guard against material damage, damage
to parts
8 Mark before disassembly, observe marks
when reassembling
0 Filling - topping up - refilling e.g. oil, cool-
ing water, etc.
-r Drain off oil, lubricant
EB Tighten - clamp; tightening a clamping
device
~ Apply pressure into hydraulic circuit
~ To clean 2-3

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

3-1

TRANSMISSION DRY WEIGHT - LB [Kg]

HR MODEL

FEATURES

LOCKUP

FWD & REV CLUTCH MODULATION

PUMP BI-DIRECTIONAL

DISC PTO

LB [Kg]

1540 [698.5]

50 [23]

40 [19]

25 [12]

20 [10]

3-2

TYPE OF OIL

CAPACITY

CHECK PERIOD

NORMAL' DRAIN PERIOD

LUBRICATION

RECOMMENDED LUBRICANTS FOR CLARK POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS

See Lube Chart.

Consult Operator's Manual on applicable machine model for system capacity. Torque Converter, Transmission and allied hydraulic system must be considered as a whole to determine capacity.

Check oil level DAILY with engine running at 500-600 RPM and oil at 1800 to 2000 F. 182.2 -93,30 CJ. Maintain oil level to FULL Mark.

Every 500 hours, change oil filter element. Every 1000 hours, drain and refill system as follows: Drain with oil at 1500 to 2000 F. 165,6 -93,30 Cl.

NOTE: It is recommended that filter elements be changed after 50 and 100 hours of operation on new and rebuilt or repaired units.

(a) Drain transmission and remove sump screen. Clean screen thoroughly and replace, using new gaskets.

(b) Drain oil filters, remove and discard filter elements. Clean filter shells and install new elements.

(c) Refilf transmission to LOW mark.

(d) Run engine at 500-600 RPM to prime converter and lines.

(e) Recheck level with engine running at 500-600 RPM and add oil to bring level to LOW mark. When oil temperature is hot (180-2000 F.l [82,2-93,3° C] make final oil level check. BRING OIL LEVEL TO FULL MARK.

Prevailing Ambient Temperature

150
140
130
120 t
110
100
"1" !IO
1"2" 8C
7U
60
"3" I 50
40
JO
20
10
r ----
-10
-20
"4" -JO
-40
"5" -511
t -60 ·Oexron is a registered trademark of General Motors Corporation.

60

Temperature Range

(a) C'2 Grade 30 (b) C'3 Grade 30

"'" (c) Engine Oil:-Grade 30 API·CD/SE or CDISF (d) MIL-L·2104C·Grade 30

lei MIL·L·2104D·Grade 30

lal MIL·L·2104C·Grade 10

(b) MIL-L'2104D'Grade 10

"2" (c) C'2 Grade 10 Idl C·3 Grade 10

lei Engtne Oil:-Grade 10 API'CD/SE or CDISF

(1) Ouintclubric 822·220 (Non Phosphate Ester Fire Resistant Fluid) "3" (a) -Dexron

(b) *Oexron liD· see Caution Below

Temperature Range

30

Temperature Range

10

Temperature (a) MIL-L-46167

Range "4" (b) MIL-L'46167 A

-10

Temperature "5" (a) Conoco Hiqh-Perforrnance Synthetic Motor Oil -

Range Spec. No. 6718

PREFERRED Oil VISCOSITY: Select highest oil viscosity compatible with prevailing ambient temperatures and oil application chart.

Temperature ranges "2" and "3" may be used to lower ambient temperatures when sump preheaters are used.

Temperature range "4" should be used only in ambient tsrnp ~

range shown.

MODULATED SHIFT TRANSMISSIONS: T12000. 18000. 2400, 28000 & 32000 series transmissions with modulated shift use only C-3 or lemperature range 3 items (a) & (b) 'Dexron or 'Dexron II D. SEE CAUTION BELOW. 3000. 4000. 5000. 6000. BOOO. 16000 & 34000 series transmissions with modulated shift use only C-3 or temperature range 3 item (a) only' Dexron. Do NOT use 'Dexron II D. SEE CAUTION BELOW.

CAUTION: 'Dexron II 0 is not compatible with graphitic clutch plate friction material UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS. 'Dexron II 0 cannot be used in the 3000, 4000, 5000, 6000, 8000, '6000 or 34000 series power shift transmissions, or the HR28000 & HR32000 series having converter lock-up. or the C270 series converter having lock-up UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS.

Any deviation from this chart must have written approval from the application department of the Clark-Hurth Components Engineering and Marketing Department.

-20

*Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions, Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination, For extreme conditions judgment must be used to determine the required change intervals.

4-1

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL

The transmission, torque converter, and its allied hydraulic system are important links in the drive line between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other; therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered completed.

After the 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 level check plugs are provided.

Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug.

Run engine two minutes at idle to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running

at idle.

Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole. Install oil level

plug or dipstick. Recheck with hot oil (180 - 200 degrees F) [82,2 - 93,3 degrees C]. See hydraulic checks for warm up procedure.

6. Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.

4-2

HR 36000 Series Transmission Converter Drive Plate INSTALLATION INSTRUCTIONS

Proper Identification by Bolt Circle Diameter Measure the "A" dimension (Bolt Circle diameter) and order Drive Plate Kit listed below

<"" , .

BOLTCIRC~LE~\ •

"1('\ QQ

, ,

, . ,

,. ,

~ '\",'

"-BACKING RING

INTERMEDIATE DRIVE PLATES (5)

INTERMEDIATE DRIVE PlATES (6)

"A" Dimension (8oIt Circle Diameter) 15,00" (381.000 mm] diameter

KIt No, 802587-1Omm

"A" Dimension (Bolt Circle Diameter)

16.00" [406.4OOmm] diameter Kit No. 802594 W/O Nuts

16.00" [406.400 mm] diameter KIt No. 802558-1Omm

16.00" [406.400 mm] diameter KIt No. 802590-7/16-20

16.875" [428.625 mm] diameter •• Kit No. 802609-7/16-20

17.00· [431.800 mm] diameter KIt No. 802593-1Omm

17.00" [431.800 mm] diameter Kit No. 802562-7/16-20

Each kit will include the following parts: 6 Intermediate Drive Plates

1 Backing Plate

14 Drive Plate Mounting Capscrews Instruction Sheet

Each kit will Include the following parts: 5 Intermediate Drive Plates

1 Drive Plate Assembly

1 Backing Plate

14 Drive Plate Mounting Capscrews Instruction Sheet

•• 1 pc. Drive Plate Mounting Spacer is Included In Kit No. 802609.

NOTE: Assembly of flexplates must be completed within a 15 minute period from start of screw installation. If the screw is removed for any reason it must be replaced. The adhesive left In the tapped holes must be removed with the proper tap and cleaned with solvent. Dry the hole thoroughly and use 'a new screw for reinstallation.

Position drive plate and weld nut assembly on Impeller cover with weld nuts toward cover. Align intermediate drive plate and backing ring with holes in impeller cover. NOTE: Two dimples 1800 apart in backing ring must be out (toward engine flywheel). Install capscrews. Tighten cap-

screws 52 - 57 ft-lbs torque [70A - 77.1 N·m].

5-1

TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

1. Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. Dry thoroughly.

2. Check engine flywheel and housing for conformance to standard SAE. #3 - S.A.E. J-927 and J-1033 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play.

3. Install two 3.50 [88,90 mm]long converter to flywheel housing 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.

4. Install a 4.00 [101,60 mm]long drive plate locating stud in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step No.3.

5. Locate converter on flywheel housing aligning drive plate to flywheel and converter to flywheel housing.

Install converter to flywheel housing screws. Tighten screws to specified torque. Remove converter to engine guide studs. Install remaining screws and tighten to specified torque.

6. Remove drive plate locating stud.

7. Install drive plate attaching screw. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. After all eight (8) screws are installed, tighten each capscrew to the following torque: M-10 capscrews 48 ft·lbs torque [60.65 N·m.] This will required rotating the engine flywheel until the full amount of eight (8) screws have been tightened.

8. Measure crankshaft end play after converter has been completely installed on engine flywheel. This value must be within .001 [0,025 mm] of the end play recorded in Step No.2.

5-2

f\\'WNEa.

Plates To Be Installed

- With Concave Side Toward Engine Aywheel.

HR 36000 6 SPEED FULL POWER SHIFT SHORT DROP - PLUMBING

Checkpoint "C-C" Heat Exchanger Outlet Temperature

,,- - - - - - _---- .--------~I--~

I I I I I I

I I I I I I

Checkpoint "B-B" Heat Exchanger Oulet Pressure

CD

Port "AR" Converter Inlet

Port "S"

Clutch Pressure

~----

,

I I I

I

I

Port "AQ"

: Converter I Outlet

I

Checkpoint "A-A" Port "H" Heat Exchanger

Oil Fill Inlet Pressure

Heat Exchanger

Port "F" <D Lube Pressure

FRONT VIEW

CD

CLUTCH PRESSURE FWD-2nd, 4th & Bth-6 speed

CD

CLUTCH PRESSURE

s-c-s speed

4th-4 speed

5th, em-s speed

CLUTCH PRESSURE FWD-3 speed CD FWD-4speed FWD-1st, 3rd, 5th

-6 speed

SIDE VIEW

PORT SIZE

CD- .4375-20 SAE "0" RING PORT

® - .5625-18 SAE ·0" RING PORT @-1.3125-12SAE"0"RINGPORT ® - 'h N.P.T.

Electric

CD

Port "R" Pressure Pickup Converter Outlet

Port "J" @ Temperature Pickup Converter Outlet

CLUTCH PRESSURE 1st-3 speed

1st-4 speed

1 st, 2nd-6 speed

CLUTCH PRESSURE <D 3rd-4 speed

REAR VIEW

5-3

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 temperature and stabilize Converter Outlet Oil Temperature at 180° - 200°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 PSI [482,6 kPa] outlet pressure with engine at

no load governed speed.

Ports "R", "J", "S" and "AR" are used for field ''Trouble Shooting" or Production Tests.

Clutch Pressure

Recommend that the clutch pressure be monitored by a gauge having an indicator dial range of 0-400 [0,2758 kPa]. Gauge is to be located in the operators compartment. Clutch pressure range 240-310 PSI [1655-2137 kPa].

PORT CHART

FROM TO
PORT PORT REMARKS
AD AC PUMP TO FILTER
AS AH FILTER TO
REGULATIVE VALVE
HEAT CONVERTER OUT TO
AQ EXCHANGE HEAT EXCHANGER
HEAT AH HEAT EXCHANGER TO
EXCHANGE TRANSMISSION LUBE FILTER PART NO.
CARTRIDGE 234777
SPIN-ON 246787 OIL TEMPERATURE GAUGE SPECIFICATIONS

1. Normal Operating Temp. Range: 180° to 250°F [82,2° to 121,1 0c]

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 [3657,6] 234033
48.00 [1219,2] 234034 ~port "J" R~f-.~:"::':::::-i 1--- "X" Dim.

5-4

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 control cover for actuating the direction and speed clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. This regulator valve consists of a hardened valve spool operating in a closely fitting bore. The valve spool is spring loaded to hold the valve in a closed position. When a specific pressure is achieved, the valve spool works against the spring until port is exposed along the side of the bore. This sequence of events provides the proper system pressure.

After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to 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 element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter.

The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid 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 change its direction to allow correct entry for recirculation into the impeller element.

The torque converter will multiply engine torque to its designated maximum multiplication ratio when the output shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing.

The shift control valve assembly consists of a valve body with spool type solenoid cartridge valves which are controlled electronically.

6-1

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 oil, 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 of a drum with internal splines and a bore to receive a hydraulically actuated piston. the piston is "oil tight" by the use of sealing rings. A steel disc with external splines is inserted into the drum and rests against the piston. 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 0.0. 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 back-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 to 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.

6-2

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6-3 36000

SIX SPEED TRANSMISSION

BASIC DESIGN

6-4

36000 POWER FLOW

SIX SPEED TRANSMISSION

II

Forward 1st

Forward 2nd - - - - - - -

Direction & Speed Engage Clutch
ACDEFG
Forward 1st • •
Forward 2nd • • 6-5

36000 POWER FLOW

SIX SPEED TRANSMISSION

~

Forward 3rd --- _

Forward 4th - - - - - - -

Direction & Speed Engage Clutch
ACDEFG
Forward 3rd • •
Forward 4th • • 6-6

36000 POWER FLOW

SIX SPEED TRANSMISSION

Forward 5th

Forward 6th - - - - - - -

Direction & Speed Engage Clutch
ACDEFG
Forward 5th • •
Forward 6th • • 6-7

36000 POWER FLOW

SIX SPEED TRANSMISSION

. Reverse 1 st

Reverse 2nd - - - - - Reverse 3rd - - - -

Direction & Speed Engage Clutch
ACDEFG
Reverse 1st • •
Reverse 2nd • •
Reverse 3rd • • 6-8

36000

FOUR SPEED TRANSMISSION

6-9

36000 POWER FLOW

FOUR SPEED TRANSMISSION

Forward 3rd -------Forward 4th - - - - - - -

Direction & Speed Engage Clutch
ABCDEF
Forward 3rd • •
Forward 4th • • 6-10

36000 POWER FLOW

FOUR SPEED TRANSMISSION

Forward 1st

Direction & Speed Engage Clutch
ABCDEF
Forward 1st • •
Forward 2nd • • Forward 2nd - - - - - - -

6-11

36000 POWER FLOW

FOUR SPEED TRANSMISSION

Reverse 1st

Direction & Speed Engage Clutch
ABCDEF
Reverse 1st • • 6-12

36000

THREE SPEED TRANSMISSION

6-13

36000 POWER FLOW

THREE SPEED TRANSMISSION

Forward 1st

Forward 2nd - - - - - Forward 3rd - - - -

Direction & Speed Engage Clutch
ACDEF
Forward 1st • •
Forward 2nd • •
Forward 3rd • • 6-14

36000 POWER FLOW

THREE SPEED TRANSMISSION

Reverse 1st

Reverse 2nd - - - - - Reverse 3rd - - - -

Direction & Speed Engage Clutch
ACDEFG
Reverse 1st • •
Reverse 2nd • •
Reverse 3rd • • 6-15

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36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE

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36000 SERIES TRANSMISSION ELECTRIC SHIFT CONTROL VALVE

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6·30

TROUBLESHOOTING GUIDE FOR THE HR36000 TRANSMISSION

The following information is presented as an aid to isolating 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 central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine, as a complete system.

By analyzing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system.

HR36000 TRANSMISSION

HR36000 (power shift with torque converter 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. It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and lubricate the working components.

TROUBLESHOOTING PROCEDURES

Stall Test:

Use a stall test to identify transmission, converter, or engine problems.

Transmission Pressure Checks:

Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction 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 mechanical and electrical checks should be make:

• Check the parking brake for correct adjustment.

• Be sure all lever linkage is properly 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 and transmission. Air clean the radiator, if necessary.

• The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications.

7-1

Hydraulic Check:

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check.

Check oil level in the transmission. The transmission fluid must the at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. See NOTE below.

NOTE: The transmission fluid must be at operating temperature of 82 - 93' C (180 - 200' F) to

obtain correct fluid level and pressure readings.

To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at "stall". (Refer to converter stall procedure.)

CAUTION: Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall R.P.M.

A. CONVERTER STALL PROCEDURE

1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels.

2. Put the directional control lever in FORWARD (or REVERSE, as applicable).

3. Select the highest speed.

With the engine running, slowly increase engine speed to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range.

CAUTION: Do not operate the converter at stall condition longer than 30 seconds at one time, 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 to the transmission clutches, fluid, converter, and seals.

7-2

HR36000 CONVERTER GROUP

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8-1

HR36000 CONVERTER GROUP

ITEM DESCRIPTION OTY ITEM DESCRIPTION OTY
Bearing Support Screw 6 29 Impeller Hub
2 Bearing Support Lockwasher 6 30 Impeller Hub to Impeller "0" Ring
3 Drive Gear Snap Ring 3 31 Impeller
4 Pump Drive Gear Bearing 3 32 Hub Screw Backing Ring
5 Pump Drive Gear Bearing Support 3 33 Impeller Hub Screw
6 Pump Drive Gear 34 Oil Baffle Retaining Ring
7 Converter Housing 35 Oil Baffle
8 Charging Pump and Pressure Regulator Valve 36 Oil Baffle Seal Ring 11
9 Turbine Shaft Rear Bearing 37 Oil Baffle Oil Seal
10 Turbine Shaft 38 Impeller Hub Gear
11 Front Bearing 39 Impeller Hub Gear Snap Ring
12 Bearing Washer 40 Turbine
13 Bearing Retaining Snap Ring 41 Turbine Hub Screw Lock Tab 5
14 Turbine Shaft Oil Sealing Ring 42 Turbine Hub Screw 10
15 Converter Inlet Tube 43 Impeller Cover to Impeller "0" Ring
16 Stator Support 44 Impeller Cover
17 Stator Support Sealing Ring 45 Impeller Cover Bearing
18 Turbine Shaft Bearing Locating Ring 46 Impeller Cover Bearing Cap "0" Ring
19 Stator Support Screw Lockwasher 7 47 Impeller Cover Bearing Washer
20 Stator Support Screw 7 48 Impeller Cover Bearing Washer Snap Ring
21 Turbine Hub 49 Turbine Hub to Turbine Shaft Retaining Ring
22 Turbine Locating Ring 50 Impeller Cover Bearing Cap
23 Reaction Member Retaining Ring 51 Drive Plate Assembly
24 Reaction Member 52 Drive Plate 5
25 Reaction Member Spacer Dowel 53 Drive Plate Backing Ring
26 Reaction Member Spacer 54 Drive Plate Mounting Capscrew 14
27 Impeller Hub Bearing Retaining Ring 55 Impeller Cover to Impeller Screw 24
28 Impeller Hub Bearing 56 Screw Lockwasher 24 8-2

TRANSMISSION CASE & CONVERTER HOUSING ASSEMBLY

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8-3

TRANSMISSION CASE & CONVERTER HOUSING ASSEMBLY
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 Modulator Bypass Tube 1 62 Oil Lube Return Plug "0" Ring
2 Tube Retaining Screw 2 63 Cap Plug Gasket
3 Tube Retaining Screw Lockwasher 2 64 Cap Plug
4 Tube Clip 2 65 Tube Sleeve "0" Ring
5 4th Speed Pressure Tube 1 66 Tube Sleeve
6 Tube "0" Ring 1 67 Tube Sleeve "0" Ring
7 3rd Speed Pressure Tube 68 Tube Sleeve 1
8 Tube Retaining Screw 69 Plug 1
9 Tube Retaining Screw Lockwasher 70 Plug 1
10 Tube Clip 71 3rd Speed Pressure Tube 1
11 Forward Pressure Tube 72 Converter Housing to Transmission Case Screw 14
12 Tube "0" Ring Lockwasher
13 Valve Oil Supply Tube 73 Converter Housing to Transmission Case Screw 14
14 Port Plug 74 Converter Housing to Transmission Case Gasket 1
15 Port Plug "0" Ring 75 Converter Housing to Transmission Dowel Pin 2
16 Port Plug 76 Lockup Sleeve Retainer Screw 1
17 Port Plug "0" Ring 77 Lockup Sleeve Retainer Screw Washer 1
18 Speed Sensor Bushing Plug 78 Lockup Sleeve Retainer 1
19 Speed Sensor bushing Shim AR 79 Lockup Sleeve 1
20 Speed Sensor Bushing 1 80 Speed Sensor Bushing Plug 1
21 Bushing "0" Ring 1 81 Speed Sensor Bushing Shim AR
22 Converter Housing 1 82 Speed Sensor Bushing 1
23 Reducing Bushing 1 83 Speed Sensor Bushing "0" Ring 1
24 Breather 1 84 Lockup Hole Plug 1
25 Filler Plug 1 85 Transmission Case 1
26 Not Used 86 Transmission Case to Converter Housing Screw 9
27 Not Used Washer
28 Tube Sleeve 2 87 Transmission Case to Converter Housing Screw 9
29 Safety Valve Seat 1 88 Rear Cover to Case Dowel 2
30 Safety Valve Seat Retainer 1 89 Rear Cover to Case Gasket 1
31 Pressure Relief Valve Plunger 1 90 Rear Cover Plug 1
32 Pressure Relief Valve Spring 1 91 Rear Cover 1
33 Washer 1 92 Rear Cover Screw Lockwasher 3
34 Washer Retaining Ring 1 93 Rear Cover Screw 3
35 Converter Housing Sleeve Forward Shaft 1 94 Rear Cover Screw Lockwasher 5
36 Converter Housing Sleeve Lock 1 95 Rear Cover Screw 5
37 Converter Housing Sleeve Screw Lockwasher 1 96 Rear Cover Screw Lockwasher 16
38 Converter Housing Sleeve Screw 1 97 Rear Cover Screw 16
39 Converter Housing Sleeve Reverse & 2nd Shaft 1 98 Screen Assembly 1
40 Converter Housing Sleeve Lock 1 99 Screen Assembly Plug 1
41 Converter Housing Sleeve Screw Lockwasher 1 100 Clutch Pressure & Lube Tube "0" Ring 2
42 Converter Housing Sleeve Screw 1 101 Clutch Pressure & Lube Transfer Tube 2
43 ··Idler Gear Retainer Plate Screw 3 102 Clutch Pressure & Lube Tube "0" Ring 2
44 ··Idler Gear Retainer Plate 103 Rear Cover Plug 1
45 ··Idler Gear 104 Case to Rear Cover Stud Nut 4
46 ··Idler Gear Bearing Assembly 105 Case to Rear Cover Stud Nut Washer 4
47 ··Idler Gear Shaft Retainer Plate Screw 106 Pressure Tube Sleeve "0" Ring 1
48 ··Idler Gear Shaft Retainer Plate Screw 107 Pressure Tube Sleeve 1
Lockwasher 108 Case to Rear Cover Stud 4
49 ··Idler Gear Shaft Retainer Plate 109 Drain Plug 1
50 ··Idler Gear Shaft 110 1st Speed Clutch Pressure Tube 1
51 Converter Housing Sleeve Screw 111 1 st Speed Shaft Rear Bearing Lube Tube 1
52 Converter Housing Sleeve Screw Lockwasher 112 Oil Level Plug 2
53 Converter Housing Sleeve Lock 113 Dipstick Hole Plug 1
54 Converter Housing Sleeve 4th Shaft 114 Tube Sleeve 2
55 Port Plug 115 Tube Sleeve "0" Ring 2
56 Port Plug "0" Ring NI Suction Tube 1
57 Port Plug "0" Ring NI "0" Ring 1
58 Port Plug NI Bolt 2
59 Port Plug NI Lockwasher 2
60 Port Plug "0" Ring NI Oil Baffle 1
61 Oil Lube Return Plug NI Oil Baffle Screw 3
**6 Speed Transmission Only A.R. As Required N.I. Not Illustrated
8-4 36000

CLUTCH GEAR GROUP 3,4& 6 SPEED-SHORT DROP

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PRESSURE R36000 EGULAT

& CHARGING OR VALVE PUMP

1

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8-7

36000

PRESSURE REGULATOR VALVE & CHARGING PUMP

ITEM DESCRIPTION QTY ITEM
DESCRIPTION
Thrust Plate & Bearing Assembly 2 20 Valve Spring - Inner
2 Pump Driven Shaft Assembly 21 Regulator Valve Spool
3 Thrust Plate & Bearing Assembly 2 22 Clutch Pressure Supply "0" Ring
4 Wave Spring 2 23 Valve to Converter Housing Screw
5 Pump Shaft Seal 2 Lockwasher
6 Pump Drive Shaft Assembly 24 Valve to Converter Housing Screw
7 Charging Pump Housing 25 Regulator Valve Plug
8 Pump Suction Adaptor "0" Ring 26 Regulator Valve Plug
9 Pump Suction Adaptor Fitting 27 Pressure Regulator Valve
10 Charging Pump Suction Tube Coupling 28 Safety Valve Piston
11 Charging Pump Suction Tube Retainer 29 Safety Valve Piston Spring
12 Charging Pump Suction Tube Gasket 30 Piston Spring Retainer
13 Charging Pump Suction Tube Sleeve 31 Spring Retainer Snap Ring
14 Rear Cover Suction Flange 32 Pump Shaft Oil Seal
15 Rear Cover Suction Flange "0" Ring 33 Valve Body to Pump Gasket
16 Regulator Valve Pilot "0" Ring 34 Valve to Pump Screw Lockwasher
17 Spring Retainer Snap Ring 35 Valve to Pump Screw
18 Valve Spring Retainer Cup 36 Valve to Pump Screw Lockwasher
19 Valve Spring - Outer 37 Valve to Pump Screw QTY

2 2

2 2 2 2

8-8

36000

ELECTRIC CONTROL VALVE

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8-9

36000
ELECTRIC CONTROL VALVE ASSEMBLY
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
Plug 46 Not Used
2 Plug "0" Ring 47 Dust Cover
3 Directional Spool 48 Dust Cover Stud Washer 3
4 Directional Spool Spring 49 Dust Cover Stud Nut 3
5 Directional Spool 50 Nut 5
6 Control Valve to Converter Housing Gasket 51 Coil to Nut "0" Ring 5
7 Air Actuator 52 Solenoid Coil 5
8 Piston Housing Stop Plug 53 Connector Clip 5
9 Piston Housing Plug "0" Ring 54 Coil to Cartridge "0" Ring 5
10 Piston "0" Ring 55 Solenoid Cartridge 5
11 Glyd Ring 56 "0" Ring 5
12 Piston 57 "0" Ring 5
13 Piston Housing 58 "0" Ring 5
14 "0" Ring 59 Control Cover to Control Valve Screw 4
15 Declutch Spool 60 Control Cover to Converter Housing Screw 2
16 Plug 61 Control Cover to Converter Housing Screw 5
17 Declutch Spool Spring 62 Housing Plug 8
18 Control Valve Housing 1 63 Housing Plug "0" Ring 8
19 Range Spool Spring 3 64 Control Cover to Control Valve Screw
20 Range Spool 65 Control Cover to Control Valve Screw Lockwasher 12
21 Spool Plug "0" Ring 3 66 Plug 2
22 Spool Plug 3 67 Valve Stop "0" Ring
23 Range Spool 2 68 Valve Stop
24 Declutch Spool Stop 1 69 Regulator Spool Ball
25 Control Valve to Converter Housing Screw 2 70 Regulator Spool
26 Seal Plate Gasket 71 Regulator Spring
27 Seal Plate 72 Valve Stop
28 Seal Plate Gasket 73 Regulator Spring
29 Pipe Plug 74 Regulator Spool
30 Pipe Plug "0" Ring 75 Regulator Spool Ball
31 Spool Stop Pin 76 Pipe Plug "0" Ring
32 Accumulator Spring - Outer 77 Pipe Plug
33 Accumulator Spring - Middle 78 Regulator Spool Roll Pin
34 Accumulator Spring - Inner 79 Regulator Spool Roll Pin
35 Accumulator Spool 80 Pipe Plug
36 Cover Plate Screw 4 81 Plug "0" Ring
37 Cover Plate 82 Spool Stop Pin
38 Roll Pin 2 83 Accumulator Spring - Outer
39 Plug 2 84 Accumulator Spring - Middle
40 Control Cover to Control Valve Screw Lockwasher 85 Accumulator Spring - Inner
41 Control Cover to Control Valve Screw 86 Accumulator Spool
42 Plug 2 87 Control Cover
43 Plug 88 Plug 4
44 Wire Clip Attachment Plate 1 89 Not Used On This Model
45 Dust Cover Stud 3 8-10

LHR Model

ASSEMBLY INSTRUCTIONS

ELASTIC STOP NUT TORQUE

THREAD SIZE LB.;FT. [N-m)
1"·20 150·200 [203,4 • 271,1)
1 1/4" - 18 200 -250 [271,2 • 338,9)
1 1/2" - 18 350-350 [406,8·474,5)
1 1/4"·12 400 -450 [542,4·610,1) All lead in chamfers for oil seals, piston rings and "0" rings must be smooth and free from burrs.

Prelube before assembly. all piston ring grooves and "0" rings, with Multi-purpose grease Grade 2.

Apply thin coat of Loctite 638 (color green) to outside diameter of all oil seals, bore plugs and bores they are to be installed into, before assembly. Use extreme care not to allow sealant to come into contact with seal lip material.

Apply thin coat of Loctite 270 (color red) to all thru hole stud threads which do not have preapplied sealant.

If grease required for positioning gasket during assembly, use Multipurpose grease Grade 2.

After assembly of parts using Loctite, there must not be any free or excess material which might enter the oil circuit. Only use Loctite where specified.

General Bearing Installation Procedure

If a thermal assembly aid is used, (expanding by heating 275'F ± 25'F [135' ± 14'] a check must be made after mating parts have reached the same temperature within 20'F [II'C] or ambient, to be sure the bearings are positioned solidly against their respective shoulders.

A Low (1st) clutch taper bearing adjustment (See Special ~ Instruction).

A Low shaft rear bearing cap must be assembled as shown on ~RearView.

£ See Elastic Stop Nut Torque Chart.

A Special turbine shaft bearing 314MG loading notches must ~ be on same side as retaining ring.

A Cast iron piston rings in outer piston ring location and Viton ~ Rings at inner piston ring location. All speed versions, all

clutches.

A Alternate assembly of clutch plates, starting with Inner ~ Friction Plate on modulated clutches and Outer Steel Plate on non-modulated clutches.

A Place bolts to be used at these locations - Requires Special ~ Torque.

PLACE BOLT TORQUE FT'LBS [N'm]
.4375 52 - 57 [71 - 77]
.3750 33 - 36 [45 - 49] A Bend lock tabs at assembly, after tightening cap screws to ~ proper torque. Tabs must be bent against screw head flats or around corners as shown below.

A Clutch piston return spring:

~ Concave side of first Belleville spring must be assembled toward clutch piston. Alternate remaining springs.

A All dowel pins must be installed in transmission case before ~ assembly of mating parts.

A Tighten oil screen assembly 10 to 15 ft·lbs. [13-20 N'm] all ~models.

A Pack oil sealing ring grooves with grease. Install sealing ~ rings and center rings in ring grooves.

A Must be loose internal fit bearings with a NO.3 etched on ~ the bearing.

i} Oil Pump Sleeve and Coupling Assembly. Torque clamp bolt ~7.5 to 9 tt-lbs [10 -12 N·m].

A Bearing shield must face OUT on Low & 3rd clutch. Bearing ~ shield must face IN on Forward & Reverse clutches.

A Impeller hub and turbine hub assembly with backing ring ~ and special self-locking screws.

1. Clean hub mounting surface and tapped holes with solvent. Dry thoroughly, being certain tapped holes are clean and dry.

2. Install backing ring and special self-locking screws.

Tighten screws to 90-99 ttlbs [79-87 Nrn] for turbine and 58-64 ft-lbs [79-87 Nrn] for impeller.

Note: Assembly of hub must be completed within a fifteen minute period from start of screw installation. The special screw is to be used for one installation only. If the screw is removed for any reason, it must be replaced. The epoxy left in the hub holes must be removed with the proper tap and cleaned with solvent. Dry hole thoroughly and use a new screw for reinstallation.

£ Clutch Plates - Qty

Modulated Standard
12 Inner FWD 6 Inner
11 Outer 6 Outer
12 Inner REV 6 Inner
11 Outer 6 Outer
10 Inner 1st 10 Inner
10 Outer 10 Outer
6 Inner 2nd 6 Inner
6 Outer 6 Outer
12 Inner 3rd 12 Inner
12 outer 12 outer
6 Inner 4th 6 Inner
6 Outer 6 Outer
Grade 8 @
\ Grade 5 ED

Torque Specification for Lubricated or Plated Screw Threads

NOM. FINE THREAD COURSE THREAD FINE THREAD COURSE THREAD
SIZE LB-FT [N.m] LB-FT [N.m] LB-FT [N.m] LB-FT [N.m]
.7500 223 - 245 [302 - 332] 200 - 220 [271 - 298] 315 - 347 [427 - 470] 282 - 310 [382 - 420]
.6250 128 - 141 [174 - 191] 113-124 [153 - 168] 180 - 198 [244 - 268] 159 - 175 [216 - 237]
.5625 91 - 100 [123,4 - 135,5] 82 - 90 [111,2 - 122,0] 238 - 141 [173,6 - 191,1] 115 - 127 [156,0 - 172,2]
.5000 64 - 70 [86,8 - 94,9] 57 - 63 [77,3 - 85,4 90 - 99 [122,1 - 134,2] 80 - 88 [108,5 - 119,3
.4375 41 - 45 [55,5 - 61,0 ] 37 - 41 [50,2 - 55,5 ] 58 - 64 [78,7 - 86,7 ] 52 - 57 [70,6 - 77,2 ]
.3750 26 - 29 [35,3 - 39,3 ] 23 - 25 [31,2 - 33,8] 37 - 41 [50,2 - 55,5 ] 33 - 36 [44,8 - 48,8 ]
.3125 16 - 20 [21,7 - 27,1] 12 - 16 [16,3 - 21,6] 28 - 32 [38,0 - 433,] 26 - 30 [35,3 - 40,6]
.2500 9 - 11 [13,3 - 14,9] 8 - 10 [10,9 - 13,5] 11 - 13 [15,0 - 17,6] 9 - 11 [12,3 - 14,9] 9-2

13

i-

A

A

Items 1, 2, 3, 4 & 5 are Hex. Head Capscrews % - 16 X 4'/4"

Items 12, 13 & 14 are Hex. Head Capscrews %-16x 1"

Items 6 & 7 are flanged 12 point Head capscrews % -16 x 3"

Items 8, 9, 10 & 11 are flanged 12 point Head capscrews % -16 x 1'14"

Tighten in sequence as follows: 1-2-3-4-5-12-13 & 14

6-7-8-9-10 & 11.

VIEW A-A

CONTROL VALVE BOLT TIGHTENING SEQUENCE DIAGRAM

FRONT COVER OR CONVERTER HOUSING

PASSAGE MUST BE LEFT OPEN FOR INTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH.

PASSAGE MUST BE BLOCKED FOR EXTERNAL LUBE TUBE TRANSFER TO LOW CLUTCH. TIGHTEN PLUG

7-10 LBF·FT

[9.5-13.5 N·m]

LOW CLUTCH LUBE TRANSFER INSTRUCTIONS

9-3

SPEED SENSOR INSTALLATION

Regulator Valve and Charge Pump Ass'y.

Lift transmission using this hole

Rear view

9-4

1.060 ± .007 [26.9 ± .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 [54.2 Nm] torque.

MAINTENANCE AND SERVICE

The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would normally 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 HR36000 3,4 & 6 speed short drop transmission with many options. Assemblies may vary on specific models. The units are very similar to trouble shoot,

disassemble, repair, and reassemble.

CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism.

Drain as much oil as possible before disassembly.

See Figure 393 for LHR (Converter Lock-up) Disassembly and Reassembly. See Figure 509 for R-Model (Remote Mounted Transmission) Front Cover.

DISASSEMBLY

Figure 1

Side view HR36000 short drop transmission.

Figure 2

Remove drive plate mounting plate capscrews.

Figure 3 Remove drive plates and backing ring.

Figure 4

Remove impeller cover bearing cap and "0" ring.

10-1

Figure 5

Remove turbine shaft to turbine hub retainer ring. NOTE:

Retainer ring is thicker than the turbine hub locating ring.

NOTE: It is recommended an oil pan be available when removing the impeller cover to collect the oil remaining in the converter section. This oil cannot be drained when the unit is drained.

Figure 6 Remove impeller cover to impeller screws.

Figure 7

Using pry slots provided, remove impeller cover and turbine.

Figure 8

Turbine and impeller cover removed. Remove "0" Ring.

Figure 9

Remove turbine hub locating ring (see note in Figure 5).

Figure 10

Remove reaction member to stator support retainer ring.

10·2

Figure 11

Remove reaction member and spacer. Spacer is dowel pinned to reaction member and does not need to be taken apart unless replacement is necessary.

Figure 12 Remove oil baffle retainer ring.

Figure 13

An impeller removal tool, like the one shown, can be fabricated to facilitate the removal of the impeller and oil baffle.

Figure 14

Remove charging pump suction tube, tube adapter flange and "0" ring.

Figure 15

Remove charging pump and pressure regulating valve assembly.

Figure 16

Remove pump hole covers and pump adapters.

10-3

Figure 17 Remove solenoid dust cover.

Figure 18

Remove control cover assembly to converter housing screws and lockwashers. Remove control valve.

Figure 19

Remove seal plate and inner and outer gasket.

Figure 20

Remove control valve assembly. Remove valve to housing gasket.

Figure 21

Remove stator support to converter housing screws.

Figure 22

Turn support to align notch with pump drive gear and remove support.

10-4

Figure 23

Support converter housing with a chain hoist and strap. Remove converter housing to transmission case screws.

Figure 24

Separate the converter housing assembly from the transmission case. NOTE: The Reverse and 2nd and 4th speed clutches will be removed with the converter housing (see note in Figure 25).

Figure 25

Spread the 4th Clutch Front bearing snap ring out of the ring groove. Pry 4th clutch assembly from converter housing. NOTE: On a 3 speed transmission this will be the 3rd speed clutch, on a 6 speed transmission this will be Fwd-Hi and 3rd clutch. See figure 235 for 6 speed clutch.

Figure 26

Spread the reverse clutch front bearing snap ring out of the ring groove and pry the reverse and 2nd clutch assembly from housing.

Figure 27

Remove output shaft nut, washer and "0" ring. Remove output flange.

Figure 28

Remove output shaft rear bearing cap stud nuts and lockwashers.

10-5

Figure 29

Remove output shaft bearing cap and "0' ring.

Figure 30

Remove flange spacer.

Figure 31

Remove the 3rd shaft bearing cap stud nuts and lockwashers.

10-6

Figure 32

Remove the 3rd shaft bearing cap and "0" rings.

Figure 33

Remove the low (1 st) clutch shaft bearing cap stud nuts and lockwashers.

Figure 34

Remove the low (1 st) clutch shaft bearing cap and shims. Keep shims and cap together, if bearing cap, low (1 st) clutch, front and rear bearings, transmission case or rear cover are not replaced, the same shims will be used at reassembly.

Figure 35

Remove the low (1 st) clutch pressure and lube transfer tubes and "0" rings.

Figure 36

Remove the 3rd clutch rear bearing locating ring. (1 st speed drive shaft on a 3 or 6 speed transmission.)

Figure 37

Remove the output shaft rear bearing locating ring.

10-7

Figure 38

Remove the rear cover to case stud nuts, screws and lockwashers.

Figure 39

Remove oil screen assembly plug and screen.

Figure 40

Pry rear cover from case tapping on output shaft and clutch shaft to prevent binding. NOTE: The use of aligning studs will facilitate cover removal.

Figure 41 Remove rear cover and gasket.

Figure 42

Remove the 4th clutch disc hub retaining ring. NOTE: On a 3 speed transmission this will be the 3rd clutch disc hub.

Figure 43

Remove disc hub.

10-8

Figure 44

Remove the 2nd clutch disc hub retainer snap ring, ring retainer and disc hub retainer ring.

Figure 45

Remove disc hub.

Figure 46 Remove output shaft rear bearing.

-1:J

-01;

Figure 47

Remove the low (1 st) clutch and the output shaft together.

Figure 48 Remove the output shaft front bearing.

Figure 49

Remove the 3rd speed clutch assembly (on a 4 speed transmission only.) On a 3 and 6 speed transmission this will be the 1 st speed drive shaft.

Figure 50

Remove oil baffle screws with lockwashers.

Figure 51

Remove oil baffle.

Figure 52

Remove suction tube bolts and lockwashers.

10-9

Figure 53 Remove suction tube and "0" ring.

Figure 54

With the aid of an assistant, spread the forward clutch shaft rear bearing retaining snap ring. Tap on forward shaft to remove.

Figure 55

Remove forward clutch assembly.

10-10

Figure 56

Remove turbine shaft rear bearing outer race.

Figure 57

Remove the low (1 st) clutch shaft front taper bearing cup and spacer (oil baffle).

DISASSEMBLY AND REASSEMBLY OF SUB-ASSEMBLIES

OUTPUT SHAFT DISASSEMBLY

Figure 58 Remove front bearing inner race.

Figure 59 Remove output gear retaining ring.

Figure 60

Remove output gear.

Figure 61

If needed remove output gear inner retaining ring.

10-11

Figure 62 Install output gear inner retaining ring.

Figure 63

Position output gear on shaft with long hub of gear toward inner ring.

Figure 64 Install outer retainer ring.

Figure 65

Press or drive front bearing inner race on output shaft with shoulder on race down (toward gear).

Figure 66

Position outer race of bearing on inner race.

Figure 67

Position 4th clutch disc hub (3rd clutch of 3 speed) on shaft.

10-12

Figure 68 Install disc hub retaining ring.

4TH CLUTCH DISASSEMBLY (3rd Clutch on 3 Speed) (For the 6 speed transmission see Fwd-Hi and 3rd Clutch Figure 235)

Figure 69 Remove clutch shaft oil sealing rings.

Figure 70 Remove front bearing snap ring.

Figure 71

Remove front bearing.

Figure 72

Remove clutch disc backing plate snap ring.

Figure 73

Remove backing plate.

10-13

Figure 74 Remove the inner and outer clutch discs.

Figure 75

Compress piston return wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure.

Figure 76

Remove spring retainer snap ring and retainer.

Figure 77 Remove piston return wave spring.

Figure 78 Remove wave spring thrust washer.

Figure 79

Turn clutch over and tap shaft on a block of wood to remove clutch piston.

10-14

REASSEMBLY

(See cleaning and inspection page)

Figure 80

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 stabilize in ring groove.

Figure 81

Position piston in clutch drum. Use caution as not to damage sealing rings.

Figure 82

Position the wave spring thrust washer, wave spring, spring retainer and spring retainer snap ring on clutch shaft.

Figure 83

Compress wave spring and install spring retainer ring being certain ring is in full position in ring groove.

Figure 84

Install 1 st steel outer disc. (Teeth on the outer diameter.)

Figure 85

Install 1 st friction inner disc (teeth on the inner diameter). Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.

10-15

Figure 86

Position the backing plate on the clutch discs.

Figure 87 Install the backing plate snap ring.

Figure 88

Press the clutch shaft front bearing on shaft with snap ring groove in bearing down as shown.

Figure 89 Install front bearing snap ring.

Figure 90

Pack ring grooves with grease and install clutch shaft sealing rings. Center rings in grooves before assembly into housing.

3RD SPEED CLUTCH DISASSEMBLY AND REASSEMBLY (4 Speed Transmission Only)

DISASSEMBLY

Figure 91 Remove clutch shaft sealing ring.

10-16

Figure 92 Remove rear bearing snap ring.

Figure 93

Remove rear bearing.

Figure 94

Remove the 3rd speed gear outer bearing retaining ring.

Figure 95

Tap 3rd gear and outer bearing from clutch drum.

Figure 96 Remove backing plate snap ring.

Figure 97

Remove backing plate.

10-17

Figure 98 Remove the 3rd speed gear inner bearing.

Figure 99 Remove inner and outer clutch discs.

Figure 100

Remove the 3rd gear inner bearing snap ring.

Figure 101

Compress the piston return wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure.

Figure 102

Remove snap ring.

Figure 103 Remove wave spring retainer.

10-18

Figure 104

Remove wave spring.

Figure 105 Remove clutch piston return spring retainer.

Figure 106

Remove clutch piston.

REASSEMBLY

(See cleaning and inspection page)

Figure 107

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 securely. Grease ring to stabilize in ring groove. Install piston in clutch drum. Use caution as not to damage sealing rings.

Figure 108

Position the piston return spring retainer, wave spring, wave spring retainer and retainer snap ring on clutch shaft.

Figure 109

Compress wave spring and install spring retainer ring being certain ring is in full position in ring groove.

10-19

Figure 110

Install the 3rd gear inner bearing snap ring.

Figure 111

Install the 1 st steel outer disc. Install the 1 st friction inner disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.

Figure 112 Position clutch disc backing plate on discs.

Figure 113 Install backing plate snap ring.

Figure 114

Install 3rd speed gear inner bearing. NOTE: This bearing does not have an oil shield in it.

Figure 115

Position the 3rd speed gear into clutch drum. Align splines on gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction disc.

10-20

Figure 116

Install 3rd gear outer bearing. NOTE: Outer bearing has an oil shield in it, this shield must be up.

Figure 117

Install the 3rd gear outer bearing retaining ring.

Figure 118

Install clutch shaft rear bearing. NOTE: Ring groove in bearing must be up as shown.

Figure 119 Install bearing snap ring.

Figure 120

Install clutch shaft rear oil sealing ring. Grease ring to stabilize in ring groove.

FORWARD CLUTCH DISASSEMBLY AND REASSEMBLY (Non-modulated. For modulated clutches see modulation section.)

DISASSEMBLY

Figure 121

Remove forward clutch shaft oil sealing rings.

10·21

Figure 122

Remove the front bearing inner race retaining ring.

Figure 123 Remove front bearing inner race.

Figure 124 Remove bearing spacer.

Figure 125 Remove clutch gear and outer bearing.

Figure 126

Remove clutch disc backing plate snap ring.

Figure 127

Remove backing plate.

10-22

Figure 128 Remove the inner and outer clutch discs.

Figure 129 Remove clutch gear inner bearing.

Figure 130

Compress the piston return wave spring retainer. Remove spring retainer snap ring from ring groove. Release spring pressure.

Figure 131

Remove wave spring retainer and retainer ring.

Figure 132

Remove wave spring.

Figure 133 Remove wave spring thrust washer.

10-23

Figure 134

Remove clutch piston.

Figure 135 Remove rear bearing snap ring.

Figure 136

Remove rear bearing.

REASSEMBLY

(See cleaning and inspection page)

Figure 137

Install clutch shaft rear bearing. NOTE: Snap ring groove in bearing must be up as shown.

Figure 138 Install rear bearing snap ring.

Figure 139

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 securely. Grease ring to stabilize in ring groove.

10-24

Figure 140

Position piston in clutch drum. Use caution as not to damage sealing rings.

Figure 141

Position wave spring thrust washer on clutch piston.

Figure 142 Position wave spring on thrust washer.

Figure 143

Position wave spring retainer on wave spring.

Figure 144

Compress wave spring and install spring retainer ring being certain ring is in full position in ring groove.

Figure 145

Install one steel disc. Install one friction disc. Alternate steel and friction discs until proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.

10-25

Figure 146 Position clutch disc backing plate on discs.

Figure 147 Install backing plate snap ring.

Figure 148

Install clutch gear inner bearing. NOTE: This bearing does not have an oil shield in it.

Figure 149

Install clutch driven gear into clutch drum. Align splines on clutch gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs. Install clutch gear outer bearing. NOTE: The outer bearing has an oil shield 10 II, this shield most be down. £

Figure 150 Position bearing spacer on clutch shaft.

Figure 151 Install clutch shaft front bearing.

10-26

Figure 152 Install front bearing retainer ring.

Figure 153

Pack sealing ring grooves with grease. Install clutch shaft sealing rings. Center rings in grooves.

REVERSE AND 2ND CLUTCH DISASSEMBLY AND REASSEMBLY

3 and 4 Speed Transmission

(For 6 speed see Figure 268)

DISASSEMBLY (Reverse Being Disassembled)

Figure 154 Remove clutch shaft sealing rings.

Figure 155 Remove front bearing retainer ring.

Figure 156

Remove front bearing.

Figure 157 Remove front bearing spacer.

10-27

Figure 158

Pry clutch gear up far enough to use a a gear puller.

Figure 159 Remove clutch gear and outer bearing.

Figure 160 Remove backing plate snap ring.

Figure 161

Remove backing plate.

Figure 162 Remove inner and outer clutch discs.

Figure 163 Remove clutch gear inner bearing.

10-28

Figure 164

Compress the piston return wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure. Remove snap ring.

Figure 165 Remove wave spring retainer.

Figure 166

Remove wave spring.

Figure 167 Remove wave spring thrust washer.

Figure 168 Remove clutch piston. Turn clutch over.

2ND CLUTCH DISASSEMBLY

Figure 169 Remove backing plate snap ring.

10-29

Figure 170 Remove backing plate.

Figure 171 Remove inner and outer clutch discs.

Figure 172

Compress the piston return wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure. Remove snap ring.

Figure 173 Remove wave spring retainer.

Figure 174

Remove wave spring.

Figure 175 Remove wave spring thrust washer.

10-30

Figure 176

Remove clutch piston.

REASSEMBLY OF 2ND SPEED CLUTCH (See Cleaning and Inspection Page)

Figure 177

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 securely. Grease ring to stabilize in ring groove.

Figure 178

Position piston in clutch drum. Use caution as not to damage sealing rings.

Figure 179

Position wave spring and thrust washer on clutch piston.

Figure 180 Position wave spring on thrust washer.

Figure 181

Position wave spring retainer on wave spring.

10-31

Figure 182

Compress wave spring and install spring retainer ring being certain ring is in full position in ring groove.

Figure 183

Install one steel disc. Install one friction disc. Alternate steel and friction discs until proper amount of discs are installed. First disc next to piston is steel, last disc installed is friction.

Figure 184 Position clutch disc backing plate on discs.

Figure 185

Install backing plate snap ring. Turn clutch over.

REASSEMBLY OF REVERSE CLUTCH

Figure 186

Make sure piston bleed valve is clean and free of foreign material. Install inner seal ring. Install piston outer seal ring. Lock piston ring joint securely. Grease ring to stabilize in ring groove.

Figure 187

Install piston in clutch drum. Use caution as not to damage

sealing rings. ! ~

10-32

Figure 188

Position wave spring thrust washer on clutch piston.

Figure 189 Position wave spring on thrust washer.

Figure 190

Position wave spring retainer on wave spring.

Figure 191

Compress wave spring and install spring retainer ring being certain ring is in full position in ring groove.

Figure 192

Install one steel disc. Install one friction disc. Alternate steel and friction discs until proper amount of discs are installed. First disc next to piston is steel, last disc installed is friction.

Figure 193 Position clutch disc backing plate on discs.

10-33

Figure 194 install backing plate snap ring.

Figure 195

Install clutch gear inner bearing. NOTE: This bearing does not have an oil shield in it.

Figure 196

Install clutch driven gear into clutch drum. Align splines on clutch gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.

Figure 197

Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be down. £

Figure 198

Position front bearing spacer on clutch shaft.

Figure 199

Install front bearing. NOTE: Snap ring groove in bearing outer race must be down. .&

10-34

Figure 200 Install front bearing retaining ring.

Figure 201

Pack sealing ring grooves with grease. Install clutch shaft sealing rings. Center rings in ring grooves.

LOW (1 st) CLUTCH DISASSEMBLY & REASSEMBLY

DISASSEMBLY

Figure 202 Remove rear clutch shaft sealing rings.

Figure 203

Pry rear bearing up far enough to use a bearing puller.

Figure 204 Remove rear taper bearing.

Figure 205 Remove bearing thrust washer.

10-35

Figure 206 Remove 1 st speed gear and outer bearing.

Figure 207 Remove backing plate snap ring.

Figure 208 Remove backing plate.

Figure 209 Remove inner and outer clutch discs.

Figure 210 Remove 1 st speed gear inner bearing.

Figure 211 Remove 1 st speed gear spacer.

10-36

Figure 212

Compress the piston return wave spring retainer. Remove spring retainer snap ring from groove. Release spring pressure. Remove snap ring.

Figure 213 Remove wave spring retainer.

Figure 214

Remove wave spring.

Figure 215 Remove wave spring retainer.

Figure 216

Remove clutch piston.

Figure 217

Remove the 3rd speed drive gear and front bearing. (Driven gear on 4 speed transmission only.)

10-37

REASSEMBLY

(See Cleaning and Inspection Page)

Figure 218

Position 3rd speed driven gear on clutch shaft with long hub of gear up. (4 speed transmission only.)

Figure 219

Position front taper bearing on clutch shaft with small diameter of taper up. Press bearing into position. NOTE:

If thermal assembly aid is used, (expanding by heating 275QF+/-25QF. [135QC+/-[14QC] a check must be made after mating parts have reached the same temperature within 20QF [11 QC] ambient, to be sure the bearings are positioned solidly against their respective shoulders before bearing adjustment can be made. Turn clutch over.

Figure 220

Install clutch piston inner seal ring. Install clutch piston outer seal ring. Lock piston ring joint securely. Grease ring to stabilize in ring groove. Install piston in clutch drum. Use caution as not to damage sealing rings. ! ;t]

Figure 221 Install piston return wave spring retainer.

Figure 222 Position wave spring in retainer.

Figure 223 Position clutch spring retainer on spring.

10-38

Figure 224

Compress spring and install retainer ring being sure ring is in full position in ring groove.

Figure 225

Install one steel disc. Install one friction disc. Alternate steel and friction discs until the proper amount of discs are installed. First disc next to the piston is steel, last disc installed is friction.

Figure 226 Position backing plate on clutch discs.

Figure 227 Install backing plate snap ring.

Figure 228 Install 1 st speed gear spacer.

Figure 229

Install 1st gear inner bearing. NOTE: This bearing does not have an oil shield in it. A

10-39

Figure 230

Install clutch gear into clutch drum. Align splines on clutch gear with internal teeth of friction discs. Tap gear into position. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.

Figure 231

Install clutch gear outer bearing. NOTE: Outer bearing has a shield in it, this shield must be up.

Figure 232 Install rear bearing thrust washer.