CL5000
CL5000
Converter
CL5000
Maintenance & Service Manual CL5000
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 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 principal 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,
Before towing the vehicle, be sure to lift the rear wheels off the ground or
disconnect the driveline to avoid damage to the transmission 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
Maintenance & Service Manual CL5000
TABLE OF CONTENTS
Maintenance & Service Manual CL5000
The torque converter portion of the power train enacts an important role in delivering engine power to the driving wheels. In order to properly
maintain and service these units it is important to first understand their function and how they operate,
The torque converter and transmission function together and operate through a common hydraulic system. To obtain maximum serviceability they
have been designed and built as 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.
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 is splined to the converter support and does not rotate in either direction, The impeller
and drive disc form the outer shell. The turbine runs within the outer shell and is connected to the output shaft. The oil is the only connection between the
turbine and impeller members.
Three pump drive gears are bearing mounted in the converter housing and meshed with a gear splined to 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 the splined pump shafts are inserted in the
pump gear shaft.
With the engine running, the converter charging pump draws oil from the transmission sump and directs it through oil filters to the pressure
regulating valve located in the control cover. The control cover is mounted on the top of the transmission. From the regulating valve it is then directed
through the control cover to the transmission clutches and to 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 a hardened valve spool operating in a closely fitted bore. The valve spool is backed up by a spring to hold the valve spool
against its 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 a line to the converter inlet port.
After entering the converter, the oil is directed into the converter support through the impeller bearing and to the converter cavity.
Three members of the torque converter are composed of a series of blades. The blades are curved in such a manner as to force the oil to circulate from
the impeller to 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 oil again enters the inner diameter of the impeller.
The oil exits between the turbine shaft and converter support and through an oil distributor which directs the oil out of the converter, through a
regulating valve and to the oil cooler. After leaving the cooler the oil is directed to the lubricating 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.
Maintenance & Service Manual CL5000
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 oil to return to the transmission sump.
A safety valve is built in the transmission control cover and will open to bypass oil 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
throttle "stalls" for more than 30 seconds at a time will generate excessive heat and may cause converter or transmission seal damage.
The converter pressure regulator valve consists of a valve body, valve spool and back-up spring. The spool is backed up by a spring to hold the valve
closed until a specified oil pressure builds up. The valve is used to maintain a given pressure within the converter to insure proper performance under all
conditions.
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CL5000 CONVERTER
Maintenance & Service Manual CL5000
Figure D
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CLEANING AND INSPECTION
CLEANING
Bearings
Clean all parts thoroughly using solvent type cleaning fluid. It is
recommended that parts be immersed in cleaning fluid and moved up and Carefully inspect all rollers, cages and cups for wear, chipping or nicks to
down slowly until all old lubricant and foreign material is dissolved and parts determine fitness of bearings for further use. Do not replace a bearing cone
are thoroughly cleaned. or cup individually without replacing the mating cup or cone at the same
time. After inspection, dip bearings in Automatic Transmission Fluid and
CAUTION: Care should be exercised to avoid skin rashes, fire hazards and wrap in clean lintless cloth or paper to protect them until installed.
inhalation of vapors when using solvent type cleaners.
Oil Seals, Gaskets, Etc
Bearings Replacement of spring load oil seals, "'0" Rings, metal sealing rings,
Remove bearings from cleaning fluid and strike flat against a block of gaskets and snap rings is more economical when unit is disassembled than
wood to dislodge solidified particles of lubricant. Immerse again in cleaning premature overhaul to replace these parts at a future time. Further loss of
fluid to flush out particles. Repeat above operation until bearings are lubricant through a worn seal may result in failure of other more expensive
thoroughly clean. Dry bearings using moisture-free compressed air. Be parts of the assembly. Sealing members hould be handled carefully,
careful to direct air stream across bearing to avoid spinning. Do not spin particularly when being installed. Cutting, scratching, or curling under of lip of
bearings when drying. Bearings may be rotated slowly by hand to facilitate seal seriously impairs its efficiency. Apply a thin coat of Permatex No.2 on
drying process. the outer diameter of the oil seal to assure an oil tight fit into the retainer.
When assembling new metal type sealing rings, same should be lubricated
Housing with coat of chassis grease to stabilize rings in their grooves for ease of
assembly of mating members. Lubricate all "'0" Rings and seals with
Clean interior and exterior of housings, bearing caps, etc., thoroughly.
Automatic Transmission Fluid before assembly.
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
Gears and Shafts
remain in solution and rinse water Parts cleaned in solution tanks must be
thorougly rinsed with clean water to remove all traces of alkali. Cast parts If magna-flux process is available, use process to check parts. Examine
may also be cleaned with steam cleaner. 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,
CAUTION: Care should be exercised to avoid inhalation of vapors and skin replace with new gear . Small nicks may be removed with suitable hone.
rashes when using alkali cleaners. Inspect shafts and quills to make certain they are not sprung, benl or splines
twisted, and that shafts are true.
All parts cleaned must be thoroughly dried immediately by using mositure-
free compressed air or soft, lintless absorbent wiping rags free of abrasive Housing, Covers, etc.
materials such as metal filings, contaminated oil or lapping compound. Inspect housings, covers and bearing caps to be certain they are
thoroughly cleaned and that mating surfaces, bearing bores, etc., are free
INSPECTION from nicks or burrs. Check all parts carefully for evidence of cracks or
The importance of careful and thorough inspection of all parts cannot be condition which would cause subsequent oil leaks or failures.
overstressed. Replacement of all parts showing indication of wear or stress
will eliminate costly and avoidable failures at a later date.
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 Ibf-ft [122.0-134.2 N .m] for turbine and 58-64 Ibf-ft [78.6-86.8 N.m]
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 the hole thoroughly and use a new screw for
reinstallation.
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Maintenance & Service Manual CL5000
The following are considered the minimum steps to Remove LOWER check plug, fill until oil runs from LOWER oil
be taken: hole. Replace filler and level plug.
1. The cause for pump failure must be found and corrected before a replacement pump is installed. Check all of the hoses,
2. Replace any collapsed or damaged hoses, damaged split flange "0" rings, tube "0" rings and adaptors.
3. After all checks have been made and corrections completed install the pump.
5. Start the engine. Run the engine at low idle for two minutes, watch the clutch pressure gage and listen for cavitation of the pump.
6. If the pressure does not come up, check the oil level and bleed off air from system as follows.
7. To bleed off the air from 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 air is displaced with oil. DO NOT START THE ENGINE.
8. If 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.
10. Recheck oil level with hot oil (180-200°F) with engine at idle. Add oil as necessary to bring oil level to full mark.
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Maintenance & Service Manual CL5000
LUBRICATION
* 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.
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Maintenance & Service Manual CL5000
A. Clutch Pressure at Transmission Control Cover B. Transmission See Specifications and Service Data.
to Converter Line See External Oil Flow Diagram.
C. Converter-Out Pressure See Pressure and Oil Flow Checks.
See External Oil Flow Diagram.
D. Temperature Gauge Connection
25 p.s.i. [172,4 kPa] Maximum at High Free Idle. See
E. Lubricating Pressure
External Oil Flow Diagram.
Converter Return Line
See Pump Chart.
Converter Pump Output
The following data is presented as an aid to locating the source of difficulty in a malfunctioning unit. It is necessary to consider the
torque converter charging pump, transmission, oil cooler and connecting oil lines as a complete system when running down the source of
trouble since the proper operation of any unit therein depends greatly on the condition and operation of the others. By studying the principles
of operation together with data in this section, it may be possible to correct any malfunction which may occur in the system.
TROUBLE SHOOTING PROCEDURE BASICALLY CONSISTS OF TWO CLASSIFICATIONS: MECHANICAL AND
HYDRAULIC.
MECHANICAL CHECKS
Prior to checking any part of the system from a hydraulic standpoint, the following mechanical checks should
be made.
1. A check should be made to be sure all control lever linkage is properly connected and adjusted at all connecting points.
2, Check shift levers and rods for binding or restrictions in travel that would prevent full engagement. Shift levers by hand at
transmission case, if full engagement cannot be obtained, difficulty may be in control cover and valve assembly.
HYDRAULIC CHECKS
Before checking on the torque converter, transmission and allied hydraulic systems for pressures and rate
of oil flow, it is essential that the following preliminary checks be made.
1. Check oil level in transmission. This should be done with oil temperatures of 180-200°F, [82,2-93,3°C.]. DO NOT A TTEMPT
THESE CHECKS WITH COLD OIL. To bring the oil temperature to this specification it is necessary to either work the machine or "stall"'
out the converter. Where the former means is impractical, the latter means should be employed as follows:
Engage shift levers in forward and high speed and apply brakes. Accelerate engine half to three-quarter throttle.
Hold stall until desired converter outlet temperature is reached, CAUTION: FULL THROTTLE STALL SPEEDS
FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT THE CONVERTER.
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Maintenance & Service Manual CL5000
Whenever improper performance is evident the following basic pressure and oil flow checks should be performed and recorded. It is
also recommended that these checks be taken periodically as a preventative maintenance measure, Doing so will permit possible detection
of difficulties in advance of actual breakdown, thus permitting scheduling of repair operation. likewise, repair of minor difficulties can be
made at considerably less cost and down-time than when delayed until major and complete breakdowns occur.
Analyzing the results of these checks by comparison with specifications and with each other will indicate in most cases the basic item
or assembly in the system as the source of difficulty. Further checking of that assembly will permit isolation of the specific cause of trouble,
Install hydraulic pressure gauge at PRESSURE connection on Converter Regulator Valve or at CONVERTER OUT pressure tap. (All
models do not have pressure regulating valves.) Check and record oil pressure at 2000 RPM and at maximum speed (engine at full throttle)
(see instructions on Stalling Converter previously listed).
If a flow meter is available, install in line between converter charging pump and oil filters. Flow meter must be able to
withstand 300 p.s.i. [2068,4 kPa].
Disconnect hose between pump and filter at filter end and using suitable fittings connect to pressure port of tester.
Install hose between filter and tester, connecting same to reservoir port of tester.
DO NOT USE TESTER LOADVALVE AT ANY TIME DURING TEST. When taking flow reading, all readings should be taken on the first (left) half of flow
gauge. Whenever the needle shows on the right half of gauge, correct by switching to higher scale.
If a flow meter is not available for checking converter pump output, proceed with manual transmission and converter checks. If the converter shows
leakage within specifications and clutch pressures (180 to 220 p.s.i.) 11241,1 -1516,8 kPa] are all equal within 5 p.s.i. 134,5 kPa] refer to paragraph on Low
Converter Charging Pump Output.
PUMPS ARE RATED AT 2000 RPM -Refer to Vehicle Manufacture Manual for specific pump output.
Pump output listed applies to a new pump in each case. A 20% tolerance below this figure is permissible; however, if
pump output is more than 20% below specification the pump must be replaced or rebuilt.
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Maintenance & Service Manual CL5000
Check clutch pressures at low engine idle with oil at operating temperatures 180 200° F. [82,2 -93,3° C]. Engine speed must remain constant during
entire leakage check. Shift lever into forward 4 or 8 speeds. Record pressures. Shift lever in reverse and 1 st. Record pressure. All pressure must be equal
within 5 p.s.i. [34,5 kPa]. If clutch pressure varies in anyone clutch more than 5 p.s.i. [34,5 kPa] , repair clutch.
If a flow meter is available install in line coming out of converter pump. See flow diagram for location of pressure on flow checks. Check pump
volume at 2000 RPM and at low engine idle. Record readings. See pump volume specifications at 2000 RPM,
Install flow meter in the line coming from transmission to converter. Check oil volume at 2000 RPM and at low idle in the following speed
selections. Record readings.
Subtract readings in each speed from pump volume reading to get transmission clutch leakage,
Leakage in 3000 series must not exceed 4 gal, max. Leakage in 5000
series must not exceed 4 gal. max. Leakage in 8000 series must not
exceed 6 gal. max. Leakage in 16000 series must not exceed 7 gal. max.
Disconnect CONVERTER DRAIN BACK line at transmission with engine running at 2000 RPM and measure oil into a gallon container. Measure
oil leakage for 15 seconds and multiply the volume of oil by four to get gallons per minute leakage,
LEAKAGE IN CONVERTER
CAUSE REMEDY
1. Low Oil Level. 1. Fill to proper level.
2. Broken spring in transmission regulator valve. 2. Replace spring.
3. Clutch pressure regulator valve spool stuck in 3. Clean valve spool and sleeve.
open position.
4. Faulty charging pump. 4. See paragraph on charging pump output.
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Maintenance & Service Manual CL5000
CAUSE REMEDY
2. Converter by-pass valve partially open. 2. Check for worn by-pass ball seat.
3. Remove, disassemble, and rebuild converter assembly, replacing
3, Excessive converter internal leakage. See paragraph on converter
all worn or damaged parts.
lube flow.
4. See paragraph on Clutch leakage,
4. Broken or worn sealing rings in transmission clutches.
OVERHEATING
I. Worn oil sealing rings. See paragraph on converter lube flow. I. Remove, disassemble, and rebuild converter assembly.
2. Worn oil pump. 2. Replace.
3. low oil level. 3. Fill to proper level.
4. Pump suction line taking air. 4. Check oil line connections and tighten securely.
NOISY CONVERTER
LACK OF POWER
2. See “Over-heating" and make same checks 2. Make corrections as explained in "Over-Heating.
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When servicing the C-5000 flywheel ring gear with 24 bolt holes you will use 72 of the 96 Belleville washers
(3 on each stud) and 24 stud nuts. Tighten the nuts to 35 Ibs, ft, [47,0N.m] torque.
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