Maintenance and Service Manual C2000 Torque Hf Converter Hf a CLARICHURTE> COMPONENTS SUN 2000 ev. 4-90)Service Publications 1-77 at I-40, Rt. 18, Box 38 Statesville, NC 28677 TOWING OR PUSH STARTING Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the trans- mission during towing. NOTE: If the transmission has 4 wheel drive, disconnect both front and rear drivelines. Because of the design of the hydraulic system, the engine cannot be started by pushing or towing. ‘©opwight Clark Equipment Company 1981, 1882, 1983, Upbeat Al ght eames nit Ditton No part ofthis work ay be reproduced any form unde ‘ny, means without deect writen permission of Cath Eauipment Compa,FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the mainten- ance and repair of the CLARK-HURTH COMPONENTS product. Extreme care has been exercised in the design, selection of materials and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service. In order to become familiar with the various parts of the product, its principle of operation, trouble shooting and adjustments, it is urged that the mechanic study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only Clark- Hurth Components-approved parts as listed in the applicable parts imanual should be used. Use of “‘will-fit’’ or non-approved parts may endanger proper operation and performance of the equipment. Clark- Hurth Components does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied by or approved by Clark-Hurth Components. IMPORTANT: Always furnish the Distributor with the serial and model number when ordering parts.TABLE OF CONTENTS HOW THE UNITS OPERATE. 0.0.0.0... - 002 0ce eee eee 1 TORQUE CONVERTER ASSEMBLY (CROSS SECTION) FIG.A............-. 2 INTERNAL OIL FLOW — FIG.B.. 2.6.0 s cece cece eee ee eee eee eee 3 TORQUE CONVERTER ASSEMBLY — EXPLODED VIEW — FIG. C ASSEMBLY INSTRUCTIONS — FIG.D.............02002005 DISASSEMBLY OF TORQUE CONVERTER... =. 22-22 - eee 7 CLEANING AND INSPECTION 14 REASSEMBLY OF TORQUE CONVERTER.............. 15 ASSEMBLY INSTRUCTIONS — FIG. E 2 PRESSURE AND LUBRICATION SPECIFICATIONS.............-.+ veces 25 IRREGULARITIES IN PERFORMANCE... 2. 0-0se0cceceeeeee ee . 26 CONVERTER TO ENGINE INSTALLATION........... coset tee ee eee eee 28 SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL............... 30 CHARGING PUMP PRIMING PROCEDURE. .... 2.2... 02-0200. 0c0eeeee ee - 30 SPEED SENSOR INSTALLATION..........02.0.00.000020 es - 13 NOTE: Metric Dimensions Shown in Brackets | 1.HOW THE UNITS OPERATE The torque converter portion of the power train enacts an importent role in di the driving wheels. In order to properly maintain and service these units their function and how they operate. livering engine power to important to first understand The torque converter and transmission function together and operate through » commen hydraulic system. To obtain maximum serviceability they have been designed and built at separate units, It is necessary, however, to consider both units in the study of their function and operation. To supplement the text herein, and for reference use therewith, the following illustrations are provided. Fig, A — Torque Converter Assembly — Cross Section B — Internal Oil Flow — Torque Converter |. C — Torque Converter Assembly — Exploded View D — Assembly Instructions The torque converter is composed of four members: The impeller which is the driving member, the drive disc or impeller cover, the turbine, which is the driven member and the reaction member. The reaction member option is splined to the converter support and does not rotate in either direction or can be free wheeling, de- pending on the application. The impeller and drive dise form the outer shell. The turbine runs within the outer shell and is connected to the output sheft. The oil is the only connection between the turbine and impeller member. Three pump drive gears are bearing mounted in the converter housing and meshed with » gear on the impeller hub. With the engine running the pump drive gears rotate at engine speed, The pumps are externally mounted on the converter housing and are connected to the pump shafts by a pump drive sleeve. With the engine running, the converter charging pump draws oil from the transmission sump and through oll filiers to the pressure regulating valve located on top of the converter. From the regulating valve It is then directed to the transmission clutches and into the converter. The pressure regulating valve remains closed until required pressure is delivered to the transmission for actuating the direction and speed clutches. This regulator valve consists of # hardened valve spool operating in a closely fitted bore. The valve spool is backed up by a spring to hold the valve spool against itt seat until the oil pressure overrides the spring force. The valve spool moves toward the spring until a port is exposed in the side of the bore. The oil can flow through this port Into a distributor which directs the oil through » pastage to the converter. After entering the converter, the oil is directed into the converter support through the impeller bearing and. to the convertor cavity. Three members of the torque converter aro composed of a series of blades. The blades are curved in such '@ manner 23 to force the cil to circulate from the impeller fo the turbine, through the reaction member and again into the impeller. This circulation causes the turbine to turn in the same direction as the impeller. Oil enters the inner diameter of the impeller and exits from the outer diameter into the outer diameter of the turbine, then exits from the inner diameter of the turbine and through the reaction member. The cil again enters the inner diameter of the impeller. The oil exits between the turbine shaft and reaction member support and through an oil distributor which directs the oil out of the converter, and to the cil cooler. After leaving the cooler the oil is directed to the lubri« cating oil inlet on the transmission and through a series of tubes to the transmission bearings, and clutches, The oil is internally returned to the transmission sump.The converter lube and leakage oil is returned to the transmission sump by a flexible hose installed in the lowest pipe tap hole in the converter housing. This line must have a continuous drop to allow by gravity flow, leakage oll to return to the transmission sump, A safety valve is built in the pressure regulating valve and will open to bypass oll only if an excessive pressure is built up due to a blocked passage. With the engine operating at any speed and the turbine and output shafts stationary, the converter is in a “stall” condition. Full power or wide open throtile “stalls” for more than 30 seconds at a time will ger excessive heat and may cause converter or transmission seal damage. FIG. A—Torque Converter Assembly — Cross Section2000 SERIES CONVERTER OIL FLOW DIAGRAM FROM FILTER To FILTER To ‘TRANSMISSION cuuTcH FROM TRANSMISSION ‘SUMP Bi His pressune aah [i tow pressure [J crawity a suction GRAVITY DRAIN TO. ‘TRANSMISSION SUMP Figure B€2000 CONVERTER WITH OFFSET OUTPUT ITEM DESCRIPTION aty Pump Gear Snap Ring : 3 Pump Drive Gear . 3 Broathor 1 Name Piato 1 Name Plate Screw : 2 Pressure Regulating Valve to Housing Gasket 7 Valve to Housing "0" Ring. & Safety Value Spxing 9 Safety Valve Plunger 10 Safety Valve Seat. ....-.. 11 Pressure Port Pipo Plugs 12 Valve Stop “0” Ring... 13° Valve Stop. 14 Roll Pin. 18 Regulating Vaive to Housing Screw Lockwasher 16 Regulating Vaive to Housing Seraw 17 Regulating Valve Assembly. 18 Fol Pin 19 Regulating Valve Spring (Outer. 20 Regulating Valve Spring tnner) 21 Regulating Valve Piston. Valve Stop “O" Ring Valve Stop Pump Drive Front Bearing Pump Shaft Spacer Pump Drive Rear Bearing Rear Boating Locating Ring Pump Driv Shaft......- Rear Bearing Retainer Ring Pump Shaft Retaining Washer Pump Shaft Retaining Ring Pump Drive Sleave Assembly Pump Gasket Charging Pump. Pump Mounting Scrow Pump Mounting Screw Lockwashor Fipe Plug Converter “Out” Temperature Port Oil Battle Serew Lockwasher Oil Bole Scxow. ... Output Shaft Oil Seal Output Bearing Retainer Lockwasher Output Bearing Retainer Screw Output Flange Nut Output Fiange Washer... Flange Washer “0 Ring. Output Flange....... Bearing Retainer Stud Nut. u Bearing Retainer Stud Nut Lockwashor. Output Bearing Retainer Output Bearing Retainer Stud. Output Beating Retainer “0 Ring Output Shaft Rear Bearing BRISSSASHLASLSSRYRRSSRYSBRYRRRBV ITEM DESCRIPTION ary Ba 55 58 BELRKLRSLSSRILSSLSRISAAY AA NARASSSISHRLSLISSS Rear Bearing Rotainer Ring... 2. Output Shaft Output Shaft Gest. . Outout Shatt Front Bearing Front Bearing Retainer Ring Converter Out Pressure Port Converter Housing Oil Baffle "O" Ring... Oil Battle Oil Baie Ol Seal Impeller Hub “0” Ring Impeller Hub Gear Impeller Hub Gear Bering. ‘Suppor Oil Sealing ‘Soaling Ring Expander Spring ‘Support Screw, . ‘Support Serew Lockwasher Reaction Member Support. Teskoe Sha Sag Fig Turbine Sha. Turbine Shaft Bearing. Beating Rotainor Ring Turbine Shatt Gear. Gear Retainer Ring Impeller Impl to Hub Screw Lock Tab Impollor to Hub Serew.... Reaction Memiber Spacer Reaction Member... Reaction Member Retainer Ring Turbino Locating Ring Turbine Hud... Turbine Turbine to Hub Serow Washer Turbine to Hub Serew Turbine Hub Bearing Locating Ring) Turbine Hub Bearing. Beating Retsiner Washer Irmpallor Cover "0" Ring Impeller Cover... .. Turbine Retaining Ring Bore Plug "0" Ring... Impeller Cover Bore Piug Bore Plug Retaining Ring... Flexplate Assembly Flexplate oe cee Flexplate Mounting Screw 10 Floxplate Mounting Sceew Lockwasher....2+......10 Backing ing 1 Impellor Cover to Impelloe Scrow 24 Impollor Cover to Impeller Screw Lockwasher 2 108 thru 136 are various optionsFIT BEARING. NO.'3" ETCHED ON BEARING. BEARING 10 BE ASSEMBLED WITH PART NO. FACING TOWARD THE “FRONT. USE BEARING WITH FULL INNER- RACE SHOULDER ONLY. DO NOT SEAL TOBE FLUSH WITH REAR SURFACE (OF BAFFLE, INSTALL SEAL FROM THIS SIDE. _—PEAMATEX 2 STUDS USED _—~ ON REAR BEARING CAP NOTE: METRIC DIMENSIONS. ‘SHOWN IN BRACKETS [ ASSEMBLE BEARING WITH BALL LOADING NOTCHES. AS SHOWN, USE BEARING WITH SEALOR senaai SHIELD GROOVES IN INNER RACE. Toraue Spectcaton for Luorcted Pea Sew Tene Grade 8 Toe CORRE THREAS. ie COARSE TRE, Sze weet mi weet tum | test ra 58 we] nna raf || aoe [as or | iis 27 [emote 00 ex] 773. eset || oo- | fren isem | wo. aw | fons ta as at [soa sea || se ee | | 97a | eo | | os. 7a ar asf aia a |r| oo oe | se fa | 2s se | (ves. ona) |] on se | [ano aaa | oe [sa soe) 00 so [ tres rast jf ras | dase are [aa 149) Figure D ’QUEINAUL INSYAIETIONS FOR TORQUE CONVERTER OF dirt and forsign matter entering the il mnachanism. CAUTION: Cloantiness & of extreme importance is unit. Sefore attempting any repelre, the exterlor Of the unit must be thoroughly deaned fe prevent the and an sbscluie must In the repair end averhaul of pani fe to be com. Tho following tnstrucitons will cover the disessam- fly and rasssumbly of the torque converter ia 8 se it ie removed frem the meshine sce quew:e hat would aeemelly be followed after the plaisly overhauled. DISASSEMALY GF THE TORQUE CONVERTER Be ae eh ‘ae r z z 2 og ge * z £ z E Remove flexplate mounting scrows pie eae Ws Figere 4 ing two small screw drivers es shown, remove bore plug. Remove flaxplats and backing ring.Figure 3 - ‘Through bore plug hele, remove turbine retaining ring. Bigure & See Figure 6. Remove impeller cover end bearing assembly. Remeve turbine. ° Figure 10 Figure 7 Romove reaction member retainer ring. Remave Impeller sever to Impeller boltsFigure igure 16 Remove reaction mainber snc spacer. Uf reaction Losan ot befits bolls (gly. 3). Tap lightly on exch member ix free wheeling remove as an assembly. bolt. This will locsen lf bafile from converter hour Gro Fig. 22 or feoewhoet diaearombly}. ing. SS Bane V8 Higure 18 Fear eo Eee ok ae oe Who befile is laces ramave bulla bole, Remave vil baffle from housing. Figuoe 13 Figues 146 Ramewa icnpetler. Remove impoiler huls from housing.Figure 2 Remave adaptors ¥ Figure Remove charging pump to sanvorinr housing bolts. Figure 30 Kamove pup shaft retaining ring. Pagure 18 Remove charging pump. Remove sccassory sump driva wdeptor bolts haf relaining washer. Remove punp ~10-igure 33 Remove pump drive gear eet Using an impsct wrench (if available) remove output ut lf impact wrench is not availabty a Flange retainer ber must be simed to huld Feng for ar ing while removing flange nur. ‘gue 27 Remove flange aut, washer, “O” rig and flange from uipurt shai. From rear of housing remove pump drive shaft end Remove output shaft bea bearing assombly. and washers. neigure 92 Remove support and turbine shaft assembly. From frant of housing drive output shaft assembly from converier pousines. NOTE: Hf converter housing has 2 bore plug in the rear center line, ramove plug. Remove turbine shaft ‘gear retainer ring. Remove support and turbine shaft astembly. Turbine sheft gear will remain in rear oF housing. This iz special ralio gear snd ie larger than the support bore, Figure 20 ‘Ovtput shaft, gear and bearing pressed from bearing retainer, See note shove, gure 36 Remove turbine shaft bearing retainer ring from sup- Remove raection member support bolls, peri. -neFigure 28 gure 26 |F support bearing is to be removed procedure shown with split puller % rocommanded, jemove presture regulaling valve fo housing screws fancl lockwethers, Figure BF Fayre 49 Remave support vil sealing ring and sealing ring @x- Remove pressure regulating valve, safety valve plung- pander spring. or snd spring. aeFigure 40 If pressure regulating #8 to be disassembled, compress valve spring stop. ‘Tap roll pin fom valve housing. CAUTIGR Spring stop 18 under spring pressure. Re- ove épring stop, Inner and utr spring and valve Piston. Figure 6% Remove freewheel assembly from the reaction mom- ber. MOTE The freewheel assembly cannot be serv lead. {F the froawheal fe damaged it cust be replaced at an assembly. aia CBANWNG AND INSPECTION READING Clean ait parts tharoughly using solvent type clean= ing fluid._ Ie roeammended thar paris be imraarsed in slashing luk snd moved sap wad dew alawiy unl sit old lubricant snd foreign material js dissolved ane parts sre thoroughly clsaiec. CAUTIOM: Cace should be exercised to avoid skin rashes, fire havards and ichalation of vapors when uting solvent type cleaners. Bearings Remove bearings from cleaning fluid and strike larger sles of cone fla? againet © diock af woos to dle- lodge solidified perticies of lubrizant, immerse again in lesning #uld'to flush our partielaz. Rapast abovn ‘peration until bearings are thoroughly clean. Dry BSearinge uilag raoisure fees woraprossad aie. Bs cate ful to dirsct air siveam across bearing to aveld spln- ning, Do not spin bearings when drying. Besrings may he rotated slowly by hand t0 facilitate deying proess. Freawhee! Amembly Clean the complete freewhoot assomily the same <6 sleoning bearings. MOTE Do no: disassemble tree whee! assembly. if fraawheel assermbly. ix it mux! be replsces with a enzeplove sttecaly. After elyaning and drying freewheel assembly dip complete essembly in automatic ransmission ful and wrap ina loan lntlee cloth or peper to proiaer until Sssambled, Houslage Clean interior and exterior of housings, bearing caps, not sole ‘ote, thoroughly. Cast parte may be cleaned tion tanks with enild alkali solu paris de nol have ground or polished urfaces. Parte should remain in solution long enough to be tharough- ly cleaned and hasted. This will aid the evaporation of the sleaniag solution andl rice wares, Parts cleaned in solution tanks must be thorsughiy riagud with closn wetar 19 remove all traces of aikali, Cast party easy alsa be cleaned with stam deaner, CANTON: Care should be exercised to avoid sicia tgehes and inhaltion of vapors when using alka Thoroughly dry all pets coened tmmedtly moka snipe sto sf os a sorbent wiping rage ra of suasve moti soch total ila ond a oF lasing cpoone aaspecmicns The Imporiance of careful and thorough inspection of all pare cennot be overstease. eplecarer 6! parts showing Indieaiion of wear or stress will ali nate costly and avoidable failures at a Isier detw.lesen Corefully inspect al rollers, cages and cupe for weer, cxipping oF alcks to datecmine fisnass of bearings for furiher uae. Do not realsce @ baaring cona or cup individvally without repiecing ‘cup oF cone at the sane time. fier inspection, dip beerings in igen tight ell end weap tn clean lintless cloth ar paper fo protect them until installed, Cit Gale, awtads, ic, Replacement of spring load oil aeels, “O” Rings, metal sualing rings, gaskets and snap rings is more seanam~ feal whan unit Is dlaassembblad thast premature over- haul to replace these paris ai 3 future tims. Furthyr lose ff lubricant through a worn sel may result ia fallura ‘of other mare axponsive parts 9! the vssemisly- Sealing member: should be handled earafully, parileularly when being installed. Cutting, seraiching, or curling Uncar of lip of ase! seriously impsire its aificioncy. Apply a thin coat of Permatex No. 2 on the outer ‘diameter of the oit sea fo assure an oil ‘ight fit into the veininer. When assembling new mavel type seal- Ing sings, tame should be lubrieated with cost of chassis grease to stabilize rings in their araoves far eau of azrombly of m: Lobricete 6F befora aisembly, Gases and Shute If magna-flux process is av ble, use process to check we teeth on all gears carefully for wor, Ditting, chipping, nicks, cracks or scoren. (F geer teeth Show spois where case hardening is worn through or cracked, ceplace with new guar. Small nicks may be removed wiih suitable hone. Inapect shafts and quilly fo make certain they are not sprung, bert, o splines twisted, and thar shafis ae truo. Housing, Govers, ate, lospect housings, covers and besring caps tobe cavtsin they ave thorougily cleaned and that mating turfaces, boaring boras, ale., are free from nicks or burrs. Check all paris carefully tor evidence of sracks or conditions which would cause subsequent oll leaks or failures, Figure 3 Install outer race and sprag assembly tn reaction mem- ber, NOTE Gnderau? shoulder af cace must go to ward the rear of the reaction member, yur Install outer race to resection member cetsiner ving. ouiiwnact Fnerwnrets Figure 47 Hf pressure regulating valve was disassambled, re- assemble a follows: Install sew "0" ring en valve Spring siop (one on each snd, only one shown). Ine eri piston in housing. lestall inner and outer valve aprings.Instell spring slop on spring, Stop nd! Instoll apring atop rll pli. Dapress spring Figure 48 19 safety valve spring and plunger in convertor 1sFigwn 42 fnszell now gasket on vonvarter heuring, and naw “OM ring on valve housing, Fasition valve asvambly on eeaweriny housing. Figure 50 Install valve screws and lockweshers, Tighten 23 to 25 ft, Ibs, torque [31,2 - 32.8 Nan.) Apply + light eost of Permatex on the outer diametor of the oupu! shaft oil seal. Press oll seal in bearing vstainar from inside of retainer at shown and to di- mension shown. See assembly instruction shact, page & Figuse 22 Press output rear bearing in bearing retainer. Secure with eatainer ring. Pease output aheft into. bearing Use caution #8 nat to darae tion output gear an shaft. Prost front oviput bearing on that, MOT Wee bascige with Soll loner Shoulder only, Be net ges bering with ot or shin raaves an lange ace, Inzial hearing vatainar ring. Install aviput Hange, °O" ring, wevher and flange aut. Tighten rut 200 40 250 fr. Ibs. torque (270.2 928,9 N.m.] Install new “O” ring on oviput shatt boar Position aviaut assembly on converter Install lockwashers, cap screws and stud auts. tighien aivd nuts 4} to 45 fr Ibe, torque [$5,481,0 Num.) Tighten eapscraws 87.40 41 fi tbs. torque [80,2 - 55,5 Mend “weC2000 SERIES CONVERTER OIL FLOW DIAGRAM FROM FILTER | re Gi craviry a suction GRAVITY DRAIN TO ‘TRANSMISSION SUMP Figure BFigure BB Insta new oil sealing ring expander spring and ol sealing ring ‘on reaction member suppar. Expander spzing gap to be 180" ‘rorn sealing ting hak. fins. Higura 86 Install bearing on wuppor. HOW Searing part nur. ber rust he up, Press bes Wigues 57 If turbine shaft bearing ws fon shaft, MD turbine shaft oil sealing ring. removed, press bearing : Ball bearing landing notches musi be away from shoulder of turbine shaft. install new gore lastall turbine shaft assorally in react por Uno ceution ok not to damage Bi sealing ring. mombor sup: ine theft oil Figure 20 Position turbine shaft gear on sliafl, Install gear ro= fining ring. See nos on pags 12 and reessomble sccordiogly. megure esi rein membar support and turbine shat te gine sneibly ia converter hoveing, Inetall pump shaft and bearing assembly in converter housing. From front af converter housing start pump drive gear on shaft, Figure 2 Ineteil support washars and scrows. Torgus ecewa 57 10 83 fi Ins torque [77,9 - 254 Mand pore tater ree Miguoe a5 Bee eae “ ee PE a EE ge eae gg See Figura 38 Install pump shaft soar bearing lecsting ring. Press rear bearing on pump sheft with bearing snep ring foward rear of aba. install bearing spacer and press front bearing an chaft un‘ll & shoulders against Bear gcse 63 ng spacer. Install reteiner washer snap ring.enove 07" inaill pup drive gear retainer rings. Figuae 20 Install three (2) oll baffle bolts and lockwashars, Tight an batfie bolis evenly te provent damaging vil buifle So" ving. Figuee €9) Position impaller hols gear on reachion member supe WOVE Use extreme esution as act ie ee, raat er unhook the sil sealing ring on the aupport. Figuees 2 Install new oil baffle oil seal as shown in asuembly instrustion sheet on page 5. Install new oll battle “O" ting. Aliga three (3) oil baffle bolt holes with Figura 9 leale holes th converter how Ol baffle installed.BE ge er sk EE 5 ge fa i 2h be £8 é Ee ae Figure 72 Insiall new fenpetler to impeller ub °C" ring, IF freewheeling rexe- fon mamber jz vasd if will raguine 2 differant spacer than the one Used with & Install rosction member specer and reaction member fixed reaction member. fon reaction member support. jpeller bub, Usp caution af not Install impaller on to damage "O” ring. MUST FREESAERL Ie CLOGKWISE ENGINE ROTETION ‘Check rotation of fesewhealing reaction member fo be ture of proper freewheel assembly. 8 Nae} Install impeller to impeller hub lock tabe and cop ~33, screws. Tighten cap serawe 23 t6 25 ft. Ibs, torque [31.2 -20-106@ quer If the impeller cover bearing retaining washar or beur- ing wat replaced, use the following procedure for reaseambly. Heat eover 200° to 250° F [93°-127 Cl. Position snap ring in graove. Place hearing ratainar is cover. While cover Ie hot ress bearing Into position spreading pere on snap ring at the same tims, Align snap riag gfoove in bearing with snap ring. Release snap ring. Cheek eng 10 he weriair: itis in jul petition in groove. iguce 8 igure 2 Position naw "OY ring on impalier cover. Figure 83 Install impeller cover assembly on impeller. tse cav- Fepure 89 tion es not 1o damage “O" ring. Bearing retainer plate Iestall turbine on shaft, mnust be aligned with turbine sh =i) We i i i iy Figure 86 Tighten 11" impeller caver capserews 12 10 16 ft Ibs. 8 Kura) Impeller cover eapscrews 28 10 25 #, tbs, [16,3 -21, Tighten 12% torque 2-33,8 Nem} torque [31 Pesition new Install plug i Lubricate cing fo facilitate sxsembly. Figure 2s Install turbine raiainer ring. See ¥igure 36. Install bore plug vetainer cing. -22—Position drive plate snd weld nut assembly on impel- In gover mth wale nus Toward ever. Align inter Figs 99 mediate drive plate and backing ring with holes In iimpolior caver. NOTE Two dimples 280° spar in Tlglnon, flex plate eapssrawe 28 vo 25 f, Ibe, sorgue baciing ring must be out (toward engine flywheel), £31,2 -33,8 Nem] Insrall capscrews and washers, Install pump adeptors, cherging and accessory pumps. Ce OOD SEE PAGE 31 FOR SPEED SENSOR INSTALLATION. = 28‘SHAFT NUY 200 70260 (88 FF (2712.390.86 Hiv] TORQUE 2, ALLLEADUN CHAMFERS FOR OL Seats, meron nines ORINGS wus [BUnns. INSPECT AT ASSEMBLY. | LUBRICATE ALL PISTON RINGS & REGULATOR VALVE 4. Use PERMATEX a CRANE SEALER ‘ONLY wnene srecired. ‘5. APPLY VERY UGHT COAT OF PERMATEX NO.270 0.0 OF ALL DW Seals sePORE ASSEMBLY. ‘SMOOTH ANDFREEFROM —g, ArTER ASSEMBLY OF USING. PERMATEX OM CRANE SEALER. ‘FaEME MUST GE MO TREE OR EXCESS MATERIAL THAT COULD ENTER THE LUBE HOLES TO BE CHECKED. PRIOR TO ASSEMBLY. HOLES MUST GE FREE OF DIRT & BURRS. NEEDLE BEARING TO BE. PRESSED .03-.08 (0. BELOW END OF GEAR U 008 {0.421 MIN. CLEARANCE INSPECT po) ATASSEMBLY, ii hi POWER TAKE-OFF & GOVERNOR DRIVE STRAIGHT THRU DRIVE NOTE: METRIC DIMENSIONS SHOWN IN BRACKETS} Figure E = 24—(OlL PRESSURE AND LUBRICATION SPECIFICATIONS FOR C2000 SERIES CONVERTERS CONVERTER QUT PRESSURE Converter outlet oil temperature 18 Transmission in NEUTRAL. + 200° F, [82,3° - 93,3° C] Operating specifications: 25 °P.S.1. [172,d KPa] minimum pressure at 2000 R.P. M. engine speed AND a maximum of 70 P.S.1. [482,6 KPa] outlet pressure with engine operating st noload governed speed. Converter outlet pressure equals the total pressure drop of the cooler, cooler lines and back pressure of the transmission lubrication system. CONVERTER LUBE FLOW Disconnect CONVERTER DRAIN BACK line at transmission with engine running at 2000 RPM and measure cil into # gallon container. Measure oil leakage for 15 seconds and multiply the volume of cil by four to get gallons per minute leaka: LEAKAGE IN CONVERTER Leakage in C2000 series not to excoed 2 gal. max. LUBRICATION RECOMMENDED LUBRICANTS FOR CLARK POWER SHIFTED TRANSMISSION Prevaing Ambion Temperaure TWPEOFOL Sea ube Our. trodatfor sytem capac. Tomwe Cowone, YF EA EL Tammnind aeemacde mmonrate | “thy Eo ROO Cyc OLY we rae anon nmin Hanst Sach ae aah Ce eT cncecow Seer arise mee ae co me 93,3° Cl foe “ vag ye Bergin tro Stents ge tS no nue rombatanen antec 1 Dr wonenson nomen sue see sn erect Seems tom soe wees hones oe Seema acaces 1a hare oe and a See ee fra senegy Cts Soemusegagaaey “natal new clements, ‘camo, emen i netomat wn attic (era wmamiovon w LOW eae mare er thatianeunnsessemrns (ete tt water ning sracietanmece tara ies ert {LOW mare When ol tmgerature hot fa0200"F11622035" C) make Fal ‘ileal check. BRING OM LEVEL TO. Poni mani ‘tNormal drain periods and filtor change intervals aro for avorage environmental and duty cycle conditions. Sevé fF sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated detarioration and contamination. For extreme conditions judgment must be used to determine the required change intervals. -25—IRREGULARITIES IN PERFORMANCE 2000 Series Converters ‘Make all checks with converter outlet temperature at least 180° - 200° F. [82,3°-93,3° C.] ‘TROUBLE 1. Low eonverter OUT pressure (Below 25 P.S.L [172.4 kPa] with engine at 2000 RPM - NO Loao) (See Convertor Prossure Specifications. 2. Svetion line taking air. 3. High converter OUT pressure [Above 70 P.S1. [482.6 kPa) with engine operating at no- load governed speed. (See Converter Pressure Specifications): 4. Over-heating Noisy Converter. 6. Low clutch pressure. (Gee pressure specifications) PROBABLE CAUSE Worn oil sealing and "0" tings Worn oil pump. Safety Valve stays open. Low oil level, Suction line connections taking sir Worn oil pump. Oil cooler oF oil lines restricted, Oil too heavy Cold oil. Oil cooler oF oil cooler lines restricted causing safety valve to stay open. Oil cooler too small Worn oil pump Converter drain line to transmission or oil sump. not installed properly. Worn oil pump Damaged bearing. Worn drive gears. Transmission malfune- ion. Worn oil pump. Regulator valve stuck open. ~26— REMEDY Trouble is internal and will require a com- plete tear-down of the converter Replace. Clean and cheek valve spring and valve. Fill to proper level. Check cil line connections and tighten securely. Replace. Check oil cooler fine and oil cooler for restrictions. Clean or replace. Check ions. weight. See oil recommenda- Converter pressure in cold weather will vary. As soon as converter gets hot, pres- sure should drop. Clean and check oil cooler and cil cooler lines. Replace if necessary. Replace with larger cooler. Replace oil pump. Install at lowest drain opening in conver- ter housing. Line must maintain constant gradual drop to oil sump for gravity drain. Replace. A complete teardown will be necessary to determine this. Replace if necessary. Replace. Close pressure line to transmission con- trol valve. If clutch pressure returns to normal, trouble is in transmission, Replace. Clean and check valve for worn or dirty parts, replace if necessary.IRREGULARITIES IN PERFORMANCE (Cont'd.) €2000 Series Converters ‘TROUBLE PROBABLE CAUSE 7. High clutch pressure. Regulator valve stuck (Gee prossure specifications) closed, 8. Lack of pow Improper engine fune- tion. Engine stall speed below normal Low converter out pres Air in the oil. Improper oil. 9. Oil in engine flywheel “O" ring betwee housing. ler cover and damaged. Oil baffle YO" ring damaged. Oil baffle damaged. Impeller cover bere plug “O" ring damaged. il seal GENERAL INFORMATION: Use Clark 1533614 Oil Filter only. Use Clark 215502 Oil Filter Element only. Use minimum number of Pipe and Hose Fi ings. Gravity drain from Converter Sump to Transmission must be of minimum length and have no “U" bends to trap air or oil. REMEDY Clean and check valve for worn of dirty parts, replace if necessery. Tune engine. Tune engine. Check governor. See item No. 1 See item No. 2. See oil recommendations. Replace. Replace. Replace. Replace. Cooler capacity for normal application, 30 per cent of net Engine Horsepower at Governed Speed. Check i level with engine idling and transmission in neutral TRANSMISSION CLUTCH OIL PRESSURE P.S.1. ‘The C2000 Convertor will be equipped with one of three variations involving the clutch regulating valve. They are as follows: 1. Inlet cover for Converter oil only with clutch pressure valve in transmission control cover. 180 to 220 P.S.1. [1241.1 - 1516,8kPa] pressure range. (See note}, 2. Pressure regulator valve on Convertor with 2 240 to 280 P.S, |. [1654.8 - 1930,5 kPa] pressure range. (See note} 3. Pressure regulator valve on Converter with a 180 to 220 P.§,|.[1241,1 - 1516,8kPa] pressure range. (Sea note) NOTE: All pressure must he equal within 6 P.S.L. [34,4 kPa]. If clutch pressure varies in any one clutch more than 5 P.S.. [34,4 kPa] repair clutch. All pressures must be taken with two clutches engaged. 27 —DRIVE PLATE INSTALLATION Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below. Note four (4) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits with three intermediate drive plates. ALIGNMENT HOLES 1) DIVE PLATE AND IYELD NUT ASSEMBLY INTERMENT Dimension Bolt Gkcle Diameter ~R" Dimension (Bolt Giele Diameter) 11.38" [288,900 mm] Diameter 11.38” [288,900 mm] Diameter Kit No. 802229 Kit No. 802494 13.12” [333,375 mm] Diameter 13.12" [333,375 mm] Diameter Kit No. 802230 Kit No. 802393 13.50" [342,900 mm| Diameter 13.50” |342,900 mm] Diameter Kit No, 802231 Kit No, 802232, 17.00" [431.800 mm] Diameter Kit No, 802356 Each Kit will include the following parts: Each Ki wl include the following pis: 3 Intermediate Drive Paes. 2 Intermediate Drive Plates. 10 Screw and Lockwasher Assembly. 1 Drive Plate and Weld Nut Assembly. 1 Instruction Sheet. 1 Becki Rr 10 Screw and Lckwesher Assembly NOTE: Some div les and boskng ngs wit hve 1 Instruction Sheet. ‘fourteen (14) mounting holes. Only ten (10) mounting holes will be used. TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES — SEE ILLUSTRATION ABOVE. 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 180° apart in backing ring must be out ‘toward engine flywheel), Install capscrews and washers. Tighten 23 to 25 Ibf ft torque [31,2 - 33,8 Nem. ~28—1 aed. 5 6. 7 CONVERTER TO ENGINE Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. ‘Check engine flywheel and housing for conform- ‘ance to standard SAE. #3-S.AE, J-927 tolerance ‘specifications for pilot bore size, pllot bore runout and mounting face flainess. Measure and record engine crankshaft end play. Install two 2.50 [63, 50 mm) long transmission to flywheel housing avide studs in the engine fly- wheel housing as shown. Rotate the engine flywheel to align 2 drive plate mounting screw hole with the flywheel housing access hole, Install « 4.00 (101, 60 mm] long drive plate locat: ing stud .9750-24 fine thread in a drive plate nut. Align the locating stud in the drive plato with the flywheel drive plate mounting screw hole posi- tioned in step No. 3. Locate transmission on flywheel housing aligning drive plate to flywheel and transmission to. fly- wheel housing. NOTE: Fig. 4 instalation, align drive plate holes with flywheel studs. Install transmission to flywheel housing screws. serews to specified torque. Remove trans. guide studs. Install remaining screws and tighten to specified torque. Remove drive’ plate locating stud. Install drive plate attaching serew and washer. Snug screw but do not tighten. NOTE: Fig. 4 in. stallation, install drive plate attaching washers and ‘nuts, Tighten each nut 28 to 30 ft. Ibs. torque [38,0-40.6 Nil. Some engine flywheel housings have a hole located on the flywheel housing cit- cumference in line with the drive plate screw access hole. A serowdriver or pry bar used to hold the drive plate against the fiywhool will facilitate in- stellation of the drive plate screws. Rotate the en- ‘gine flywheel and install the remaining seven (7) fiywheel to drive plate attaching screws. Snug screws but do not tighten. Afterall eight (8) screws are installed torque each one 25 to 30 ft. Ibs. torque [339-406 Nomj. This will require torquing each screw and rotating the engine flywheel until the full amount of eight (8) serews have been tightened. Meare engnn crankst ond play aftr transmit sion hes been completely installed on engine fy- ‘wheel. This vaive must be within O01, [0,025] Of the end play recorded in sop, No. 2 % Does not apply to drive plates. See having 3 intermediate 4 INSTALLATION PROCEDURE Za {= o> 2SERVICING MACHINE AFTER TORQUE CONVERTER OVERHAUL The transmission, torque converter, and its allied 5. On remote mounted torque converters remove hydraulic system ore important Tinks ip the dive line Grain plug from torque converter ond napoct between the engine and the wheels. The proper oper- terior of converter housing, gears, etc. If ation of either Un depends greatly on the condition protonce. of contiderable foreign ‘materiel. it and operation of the other therefore, whenever repatr Fotec twill be necesery thar convertor be re Grioverhaul of one unit's performed: the balenee of moved, dlssstembled. ard clouned thovovghly. the stem must be considered before the job ean be Iris realized this entail extra labor? howevee, fonsidered completed uch labor is a minor cos! compared to cost of diffcutos which can result fom presence of Aor tho overhauled or ropaired transmission has See atesal inthe sescne boom installed In the mechine, th oil eocler, and con ing hydraulic systom musi be thovovahly cleaned. 6 Reasusmble all components and use only This can be sccomplahed n several manners onda de: Reosuemble all components and use only type gree of judgmont must be exercised os to the method fransmizsion through filer opening until fluid employed. ‘comes up to LOW mark on transmi lipstick. NOTE: “If tho dipstick is not accassible ol level check plugs are provided. Remove LOWER check plug, fill until oil runs 1. Drain entire system thoroughly. from LOWER cil hole. Replace fillor and level plug. un engine two minutos at 500-600 RPM 10 prime torque converter and hydraulic lines, Re- check level of fluid in transmission with engine 3. Replace oil filter clements, cleaning out filter running at idle (500-600 RPM). cates thoroughly ‘Add quantity necessary to bring fluid level to LOW mork on dipstick or runs freely from “+ Botan shosld ‘bo sbace Tooke eta ad LOWER oil level check plug hole. Ineall oil compresred sir until all foreign material hes been Gsoe2bo eS rea ats geteenese with hot il Femoved. Floshing in direction of normal sl flow The following are considered the minimum steps to be taken: 2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning, will not adequately clean the cooler. If neces: Bring oil level to FULL mark on dipstick or sary, cooler assembly should be removed from runs freely from UPPER oil level plug. machine for cleaning, using oil, compressed ait and steam cleaner for that purpose. DO NOT 7. Recheck all drain plugs, lines, connections, ete,, Use flushing compounds for cleaning purposes. for leaks and tighten where necessary. CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURE 1. The cause for pump failure must be found and corrected before a replacement pump is installed. Check all of the hoses, ‘tubes, “0” rings, adaptors and split flanges. 2. Replace any collapsed or damaged hoses, damaged split flange “O" rings, tube “O” rings and adaptors. 3. After all checks have boon made and corrections completed install the pump. 4, See filling instructions in paragraph 6 above. 5. ‘Start the engine. Run the engine st low idle for two minutes, watch the clutch pressure gage and listen for cavitation of the pump. 6. I the pressure does not come up, check the oil level and bleed off sir from system as follows. 7. To bleed off the airfrom the system, loosen the pressure gage line at the pressure regulating valve or loosen the pressure hose at the oil filter or pressure regulating valve. Crank the engine over until the ais dieplaced with oil. DO NOT START. THE ENGINE, 8. bleeding the lines does not correct the problem it may become necessary to prime the pump. Disconnect the suction hose or pressure hose. whichever is higher, and fill the port with transmission oil, reconnect the hose and tighten. 8. Start the ongine and check pressure, 10. Recheck oil level with hot oil (180+200°F) with engine at idle. Add oil as necessary to bring oll level to full mark. 20.SPEED SENSOR INSTALLATION VIEW “T"" (Pump Drive Goar Sensor) Inspect at assembly. Dim, “U" from gear tooth REAR VIEW OF CONVERTER Stake 9 places approx. equally spaced, Alter curing of Loctite, speed sensor bushing must be secure with 40 Ft, Lb. [54.2 Nim] torque. VIEW "S" (Output Drive Gear Sensor) Inspect at assembly. Dim. "W" from gear tooth. ‘Assemble Speed Sensor Bushing in housing to speciied dimension “U" or "WW" with Loctite 262 and stake (9) three places. See Pump Drive and Output Gear Charts for dimensions, PUMP DRIVE RATIO. | DRIVE GEAR | DRIVEN GEAR | SPEED SENSOR BUSHING RaTIO_NOLOF TEETH | NOOFTEETH | DEPTH “U" PER VIEW-"T [ass 2 110603 007 [269 17] i 39 1.060.007 [26.9 .17] ‘OUTPUT GEAR RATIO (6 PITCH) TORSINE SHAFT | cuTPUT nario | '&.GEAR ASS'Y GEAR | SPEED SENSOR BUSHING NO OF TEETH | NO.OF TEETH | DEPTH "W" PER VIEW "S" 1288 2a ai 4.060.007 [268.17] 118 a a) 4.060.007 [26.82 17) 1.097 27 2a | 1.990.007 959.47) | 96 | 28 27, 1.3003. 007 95.32.47) * 897 23 26 1,390 4.007 [35.32.17] “Requires straight thru housing plus bore plug OUTPUT GEAR RATIO (5.35 PITCH) TURBINE SHAFT | OUTPUT remio | 'B.GEAR ASSY GEAR | SPEED SENSOR BUSHING NO.OF TEETH | NO.OF TEETH _| DEPTH "W" PER VIEW "S 1388 2 1.080.007 [2682.17] Tso [ as 25 1.060 007 [26.9 17] 10a | 24 25 7.390.007 [95.82.17] 960 25 24 | 1.300.007 [35.3 17] 865 | 26 23 | 4,800:.007 [35.3 + 17]NOTESCLARICHURTE> COMPONENT: Statesville, North Carolina Brugge, Belgium ‘Arco, Italy Sao Paulo, Brazil 59.005 0085, PaHFED INUSA Price on request