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TWIN DISC TWIN DISC

INCORPORATED
®

Service
Manual

Torque
Converter

Model:
8-FW-2106-0

Document Number: 1025550


NOTICE

Twin Disc, Incor por ated makes no war r anty or


guaranty of any kind, expressed, implied or otherwise,
with regard to the information contained within this
manual. Twin Disc, Incorporated has developed this
manual through research and testing of the information
contained therein. Twin Disc, Incorporated assumes
no responsibility for any errors that may appear in this
manual and shall not be liable under any circumstances
for incidental, consequential or punitive damages in
connection with, or arising out of, the use of this manual.
Document Number
1025550

September, 2009

Hydraulic Torque Converter


Shop Manual
TWIN DISC, INCORPORATED
EXCLUSIVE LIMITED WARRANTY GENERAL UNITS
A. Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts on which
written warranties issued by the respective manufacturers thereof are furnished to the original customer, as to which
Twin Disc, Incorporated makes no warranty and assumes no liability) against defective materials or workmanship for a
period of twenty four (24) months from the date of original shipment by Twin Disc, Incorporated to the original customer,
but not to exceed twelve (12) months of service, whichever occurs first. This is the only warranty made by Twin Disc,
Incorporated and is in lieu of any and all other warranties, express or implied, including the warranties of
merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given
by Twin Disc, Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc,
Incorporated's application engineering.

B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the
applicable warranty period as specified, or otherwise (including tort liability), shall at the sole option of Twin
Disc, Incorporated be either the repair or replacement of any Twin Disc, Incorporated part or product found by
Twin Disc, Incorporated to be defective and the labor to perform that work and to remove and reinstall (or
equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,
Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair,
reassemble, reinstall and test the Twin Disc, Incorporated product only. Under no circumstances, including a
failure of the exclusive remedy, shall Twin Disc, Incorporated be liable for economic loss, consequential,
incidental or punitive damages. The above warranty and remedy are subject to the following terms and
conditions:

1. Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to
Twin Disc, Incorporated within sixty (60) days after completion of the in warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from
abuse, neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin
Disc, Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of
shipment to the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the
product or part with installations properly engineered and in accordance with the practices, methods and
instructions approved or provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and
otherwise identical with components of the original equipment. Replacement parts or products not of Twin Disc
origin are not warranted by Twin Disc, Incorporated.

C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin
Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for injury to persons or
properly, including without limitation, the original customer's and subsequent purchaser's employees and property, due
to their acts or omissions or the acts or omissions of their agents, and employees in the installation, transportation,
maintenance, use and operation of said equipment.

D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or expense in
the service, repair or replacement of any part or product within the warranty period, except when such cost or expense
is authorized in advance in writing by Twin Disc, Incorporated.

E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being
obligated to incorporate such changes in products of prior manufacture. The original customer and subsequent
purchasers will not use any such changes as evidence of insufficiency or inadequacy of prior designs or materials.

F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be
furnished on a no charge basis and these parts will be covered by the remainder of the unexpired warranty which
remains in effect on the complete unit.

December 14, 2007 TDWP0002 rev 2008


TWIN DISC, INCORPORATED
Flat Rate Hours Allowance for
GENERAL UNITS
(Hourly Labor Rate Must Be Acceptable to Twin Disc, Incorporated)
* Travel and related expenses are not included as a part of Twin Disc General Unit Warranty.

GENERAL UNITS

Model Series R&R Repair & Test


Powershift Transmissions
• 1000, 1100, 1300, 1400 14.0 24.0
• 1600, 2000, 2600, 3100 14.0 30.0
• 2800 14.0 18.0
• 3600 14.0 36.0
• 8500 14.0 72.0

Matching Torque Converters


• 6 1300, 6 1500 6.0 6.0
• 8 1400, 8-1450, 8-1600 6.0 8.0
• 8 1700, 8-1800, 8 1750, 8 1850 8.0 12.0
• 4-2000 6.0 12.0
• 8-2300 8.0 20.0

Industrial Torque Converters


• 6 1300 & 6 1500 6.0 8.0
• 4 1600 & 4 2000 6.0 12.0
• 4 2200 w/cooler 12.0 30.0
• 4 2600 & 4 3400 w/cooler 20.0 40.0
• 10,000 & 11,500 6.0 12.0
• 11,500 HD & 13,800
o w/Radiator 10.0 24.0
o w/o Radiator 10.0 20.0
• 16,000
o w/Radiator 14.0 32.0
o w/o Radiator 14.0 28.0

Fluid Couplings
• 14.5 HC, HM, HU & HUC 2.0 4.0
• 17.5 HC, HM, HU & HUC 2.0 4.0
• 21 HC, HM, HU & HUC 2.0 6.0
• 27 HC & HM 4.0 8.0
• 27 HUD
o w/Radiator 8.0 32.0
o w/o Radiator 8.0 28.0

Electronic Controls
• TDEC400 3.0 0.0

Universal Control Drive


• UCD 8.0 40.0

Marine Control Drive


• MCD 8.0 40.0

December 14, 2007 TDWP0002A rev2008


Twin Disc, Incorporated Table of Contents

Table of Contents
Disassembly ........................................................... 9
Torque Converter Disassembly ......................................................... 9
Remove the External Components................................................... 11
Remove Internal Components........................................................... 12
Disassemble Sub-Assemblies .......................................................... 19

Cleaning and Inspection .................................... 27


Cleaning ................................................................................................ 27
Inspection ............................................................................................. 29

Assembly .............................................................. 33
Torque Converter Assembly ............................................................. 33
Torque Converter Sub-Assemblies ................................................. 34
Torque Converter Final Assembly ................................................... 44
Install External Hoses, Fittings, and Output Flange ...................... 59

Special Tools and Engineering Drawings ....... 61


T-19371 (Gear Retaining Fixture) ..................................................... 63
X229788H (Sheet 1 of 2) Torque Converter cross section ........ 64
X229788H (Sheet 2 of 2) Torque Converter Installation .............. 65

Power Shift Transmission Shop Manual #1025550 7


Table of Contents Twin Disc, Incorporated

NOTES

8 Power Shift Transmission Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Disassembly

Torque Converter Disassembly

Note: If the customer supplied oil pumps are mounted on the


torque converter assembly, they must be removed prior
to disassembly of the torque converter. They are not Twin
Disc supplied, and are not included in this manual.

General

Use this procedure for disassembling the torque converter unit. Further
disassembly of components turbine and hub, impeller and hub, driving gear
and bearing, stator and freewheel, and suction strainer subassemblies will be
covered in following sections.

Note: All figures may not look exactly like your unit, but the
procedures are the same. There may be alternative
procedures that can be used based on shop experience
and degree of repairs needed.

It may be advisable to drain the oil from the torque converter circuit prior to
disassembly. One of the capscrews that retain the lockup clutch assembly may
be identified by colored paint on the capscrew head, indicating that it is one of
two thru drilled holes that can be used to drain the oil in the circuit.

2231

Figure 1. Lockup Clutch Assembly Capscrews


Torque Converter Shop Manual #1025550 9
Disassembly Twin Disc, Incorporated

Remove Output Flange

1. Place and block torque converter assembly face down on supporting


table or stand.

2. Remove the 5/8-11 x 3 inch capscrew that retains the output flange.

3. Remove the washer.

4. Remove the O-ring.

1511 1510

Figure 2. Remove Capscrew, Plate and O-Ring

5. Remove the output flange.

Note: It may be necessary to use a puller to remove the flange.

1509

Figure 3. Remove Output flange

10 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Remove the External Components

1. Remove the sump hose from the regulator valve and fitting on the ditch
plate..

Figure 4. Remove Regulator Valve, Hose, and Ditch Plate

2. Remove the six 1/2 - 13 x 1.38 (item 2), and two 1/2 - 13 x 4.25 (item 4)
twelve point capscrews, that retain the split flanges to the valve and
ditch plate.

3. Remove the one 1/2 -13 x1.75 (item 5) (behind the flange), 1/2 - 13 x 5
(item 6) and the 1/2-13 x 3.5 (item 7) hex head capscrews, that retain
the valve assembly to the ditch plate and remove the valve assembly.

4. Remove the seven 1/2-13 x 2.25 (item 1) hex head capscrews and two
1/2-13 x 2.25 (item 3) twelve point capscrews, and remove the ditch
plate and gasket.

Torque Converter Shop Manual #1025550 11


Disassembly Twin Disc, Incorporated

Remove Internal Components

1. Install eye bolts in the housing and the end of output shaft to aid in
repositioning the converter. Turn converter over and block sufficiently
so that the input end faces up, and the converter is stable.

Be sure the lifting device being used is rated for lifting the weight of the
torque converter.

1472

Figure 5. Support Torque Converter with Front Side Up

2. Remove twelve 1/2 - 13 x 1.25 inch capscrews with washers that retain
the flywheel pilot cover. Lift the pilot cover off of the rotating housing.

1470 1469

Figure 6. Remove the Pilot Cover

12 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

3. Remove the three 1/2 - 13 x 2.00 inch capscrews and remove the clamp
plate.

4. Remove and tag the shims.

1467 1448

Figure 7. Remove the Clamping Plate

5. Remove the twenty four 1/3 - 13 x 1.25 capscrews and washers that
retain the lockup clutch carrier to the rotating housing.

6. Use a hoist and two eyebolts to lift on the lockup clutch carrier. Only lift
a short distance. The entire torque converter will probably raise off of
the blocking.

1466a mvc 002

Figure 8. Remove the Lockup Clutch Carrier

Torque Converter Shop Manual #1025550 13


Disassembly Twin Disc, Incorporated

7. Using a mallet or a brass drift, tap downward on the end of the shaft until
the converter separates from the lockup clutch assembly. Continue the
short lifts followed by tapping on the shaft until the bearing comes off of
the shaft.

Be sure the lifting device being used is rated for lifting the weight of the
torque converter.

8. Remove the turbine assembly by lifting straight up. Set the assembly
aside for further disassembly if necessary.

1455

Figure 9. Remove the Turbine Assembly

14 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

9. Remove thrust roller bearing.

10. Remove the stator assembly by lifting straight up.

The freewheel rollers may fall out of the pockets when the stator
assembly clears the shaft.

2230 2229

Figure 10. Remove Thrust Bearing and Stator Assembly

11. Remove the roller bearing.

12. Remove the rotating housing assembly by lifting straight up

2224 2221

Figure 11. Remove Thrust roller Bearing and Rotating Housing


Assembly

Torque Converter Shop Manual #1025550 15


Disassembly Twin Disc, Incorporated

Disassemble Converter Housing

1. Remove the swivel fittings, and remove the lube distribution tube.

2. Install the T-19321 gear retaining special tool onto the three pump drive
gears.

2219 2212

Figure 12. Remove the Lube Distribution Tube. Install Gear Fixture

3. Turn the torque converter housing over

4. Remove the 1/4-20 dog-point setscrew from each of the bearing lock
nuts.

5. Remove the three bearing lock nuts with washers.

2239 2237

Figure 13. Remove Bearing Lock Nuts

16 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Note: There are several ways to press the gears from the
housing. Care should be taken to avoid damage to the
gears and bearings during removal.

6. Place the converter housing with the shaft horizontal.

7. Remove the gear retaining tool that was used to hold the gears during
removal of the nut.

8. Have an assistant hold the gears to avoid damage from the gear falling
while pressing the gear and shaft, using a bar anchored to the rear of
the housing, and a threaded pusher rod and nut. Avoid hammering that
could damage the bearings.

Note: An alternative method would be to use wooden blocking


under the gears, and lower the housing over the blocking.
Press the gear and shaft until the shaft is out of the upper
bearing, and the gear will remain on the blocking.

mvc013 mvc016

Figure 14. Remove Pump Drive Gears

9. Remove the bearing cups and spacer from the housing, and set the
gears and bearings aside for further disassembly as needed.

10. Remove the snap ring from the forward end of the output shaft if it has
not already been removed. Place the housing front face down, using
blocking to support the output shaft.

11. Remove eleven 5/8 - 11 x 1.75 hex head capscrews.

Torque Converter Shop Manual #1025550 17


Disassembly Twin Disc, Incorporated

2206

Figure 15. Remove Capscrews from Rear of Housing

12. Using a hoist, raise the housing, allowing the shaft and stator carrier
assembly to remain on the blocking.

13. Support the shaft and stator carrier assembly on the front face of the
stator carrier.

14. Remove the eleven 3/8-16 x 1.25 hex head capscrews and washers.

15. Remove the fluid distributor from the shaft assembly.

16. Remove the shaft and bearing assembly from the stator carrier.

2204 2203

Figure 16. Support Stator Carrier Assembly and Remove Shaft

17. Set the shaft assembly and the stator carrier assembly aside for further
disassembly as needed.

18 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Disassemble Sub-Assemblies

Disassemble Gears

1. Remove the bearing spacer from the shaft.

2. Use threaded holes in gear to press the bearing off of the shaft.

3. Press the plug from the face of the gear only if replacement is necessary.

Torque Converter Shop Manual #1025550 19


Disassembly Twin Disc, Incorporated

Disassemble Rotating Housing

1. Place the rotating housing on the work table with the opening down.

2. Remove the twelve 3/8-16 x 1/25 twelve point capscrews, and remove
the driving gear.

2189 2190

Figure 17. Remove Capscrews from Gear and Remove Gear

3. Turn the unit over, and remove eight 3/8 - 16 x 1 hex head capscrews
with washers, and remove the impeller from the rotating housing.

4. Do not remove the wear sleeve unless it has to be replaced.

2195 2194

Figure 18. Remove Capscrews and Wear Sleeve

20 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Disassemble the Stator Carrier

1. Stand and support the stator carrier with the large diameter down.

2. Remove six 5/16-18 x 0.875 hex head capscrews and remove the clamp
plates.

2201

Figure 19. Remove Capscrews

3. Remove the freewheel inner race from the stator carrier.

4. Remove the snap ring, and use a suitable puller to remove the bearing
inner race from the stator carrier.

2200 2198

Figure 20. Remove Freewheel Race and Remove Bearing

Torque Converter Shop Manual #1025550 21


Disassembly Twin Disc, Incorporated

Disassemble Shaft

1. Use a sleeve that is large enough to clear the shaft shoulder and press
against the forward seal carrier.

2. Press the two seal carriers and bearing from the shaft.

2202 mvc008 mvc012

Figure 21. Remove Seal Carriers and Bearing

22 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Disassemble the Turbine and Hub Assembly

1. Remove eight 1/2-13 x 1.50 inch hex head capscrews and washers.

2. Remove the turbine hub.

2188 2183

Figure 22. Remove Capscrews and Remove Turbine Hub

3. Support the turbine and drive the hub out or heat the turbine and the
clutch hub will drop out.

4. Remove the two 10 - 24 x 0.5 allen head screws only if the thrust bearing
race must be replaced.

2185

Figure 23. Remove Turbine from Clutch Hub

Torque Converter Shop Manual #1025550 23


Disassembly Twin Disc, Incorporated

Stator and Freewheel Assembly

Note: Disassemble the freewheel assembly only if necessary.

1. Remove the snap ring from the turbine side of the assembly.

2. Support the assembly with the turbine side down in an oven, with enough
vertical clearance to allow the freewheel to fall free when the stator
(aluminum) expands faster than the steel freewheel.

When handling items that have been heated, wear gloves to protect
hands from getting burned.

3. Remove remaining thrust race.

new

Figure 24. Remove Freewheel Assembly from Stator

24 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Disassembly

Disassemble Regulator Valve Assembly

1. Loosen the o-ring plugs on each end of the regulator valve assembly.
Gradually back each plug out to relieve the spring force.

The springs are pushing on the covers with high force. Use caution to
avoid damage or injury.

regulator valve

Figure 25. Regulator Valve Cross Section

2. Remove the top plug being careful to not lose the shims.

3. Remove the shims and spring, followed by the piston.

4. Remove remaining plug.

Torque Converter Shop Manual #1025550 25


Disassembly Twin Disc, Incorporated

NOTES

26 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Cleaning and Inspection

Cleaning and Inspection

Cleaning

Note: Replace all oil seals, gaskets, O-rings piston rings, seal
rings, snap rings, etc., as a part of any maintenance or
overhaul procedure. Replace shims that are damaged or
destroyed in disassembly.

‰ Clean all parts using EPA/OSHA approved solvents or by steam cleaning.


Parts must he dried and oiled immediately.

‰ Examine all parts carefully for grit, dirt and abrasives and reclean them
if necessary.

‰ Clean all oil passages by working a piece of wire back and forth through
the passages and then flushing them with cleaning solvent.

‰ Use clean solvent to flush oil pumps, valves, etc.

‰ Flush all hoses, tubing, coolers etc., particularly if the unit is being
disassembled because of an internal failure.

‰ De-burr the housing and bearing carrier with a stone or file in the vicinity
of all pusher screw locations.

‰ All male and female threads that have had loctite applied must be
chased using a suitable thread chaser.

Do not use a tap or die for this purpose. Damage may be done to the
threads.

Power Shift Transmission Shop Manual#1025550 27


Cleaning and Inspection Twin Disc, Incorporated

Cleaning Bearings

Do not remove grease in which new bearings are packed. Thoroughly wash
bearings that have been in service. Soak bearings in solvent if they are
particularly dirty or filled with hardened grease.

Never dry bearings with compressed air. Do not spin unlubricated


bearings. Oil bearings with SAE 10 engine oil immediately after cleaning.
Oil bearings before inspection.

Preventing Dirt from Entering into Bearings

Dirt and grit in bearings are often responsible for bearing failure; consequently,
it is important to keep bearings clean. Do not remove grease from new bearings.
Keep the wrapper on new bearings until they are installed. Do not expose clean
bearings if they are not to be assembled at once. Wrap them with a clean lint-
free cloth or paper to keep out dust.

Previously Sealed Joints

‰ For previously sealed joints, scrape surfaces to remove old gasket


material or silicone.

‰ Clean surfaces with solvent to remove oil and grease residue.

‰ Test for clean surfaces by applying a few drops of cool water to the
surfaces. Parts are sufficiently clean if water covers the surface in a film.
If the water puddles or forms beads, use fresh solvent and reclean.

28 Power Shift Transmission Shop Manual #1025550


Twin Disc, Incorporated Cleaning and Inspection

Inspection

Housings, Cast Parts, and Machined Surfaces

‰ Replace cast parts or housings that are cracked.

‰ Inspect bores for wear, grooves, scratches and dirt. Remove burrs and
scratches with crocus cloth or soft stone. Replace deeply grooved or
scratched parts. Do not remove excess material by sanding. This will
cause loss of press of bearings or races.

‰ Inspect oil passages for obstructions. If you find an obstruction, remove


it with compressed air or work a wire back and forth through the passage
and flush it with solvent.

‰ Inspect machined surfaces for burrs, scratches, nicks and foreign matter.
If you cannot remove the defect with crocus cloth or a soft stone, replace
the part.

‰ Inspect threaded openings for damaged threads. Chase damaged


threads with a tap of the correct size.

‰ Inspect studs for damaged threads and looseness. Replace defective


studs.

‰ Inspect dowel pins for wear or damage. Replace defective dowels. This
applies where a matched set of parts is not involved.

‰ Inspect dowel pin holes for wear due to movement between mating parts.
If a dowel pin hole is worn, re-bore and sleeve the hole when possible.
Otherwise, replace the parts. This applies where a matched set of parts
is not involved.

Valve Seats

Inspect valve seats for burrs, nicks and scratches. If you cannot remove these
defects with a crocus cloth, replace the part. Check to see that the valve is
seating properly after reworking the valve seat.

Power Shift Transmission Shop Manual#1025550 29


Cleaning and Inspection Twin Disc, Incorporated

Bearings

‰ Inspect bearings for roughness of rotation. Replace the bearing if the


rotation is rough.

‰ Inspect bearings for corrosion, and for indication of wear of balls or


rollers. Inspect for scored, scratched, cracked, pitted or chipped races.
If you find one of these defects, replace the bearing.

‰ Inspect bearing bores and shafts for grooved, burred, or galled conditions
that would indicate the bearing has been turning in its housing or on its
shaft. If you cannot repair the damage with a crocus cloth, replace the
part.

Bushings and Sleeves

Inspect bushings for size and out-of-roundness. Inspect for scores, burrs, sharp
edges, and evidence of overheating. Remove scores with a crocus cloth. If the
bushing is out-of-round, deeply scored, or excessively worn, replace it.

Thrust Washers and Spacers

Inspect thrust washers for distortion, scores, burrs and wear. Rework or replace
any defective thrust washers or spacers.

Gears

‰ Inspect gears for scuffed, nicked, burred or broken teeth. If you cannot
remove the defect with a soft stone, replace the gear.

‰ Inspect gear teeth for wear that may have destroyed the original tooth
shape. If you find this condition, replace the gear.

‰ Inspect thrust faces of gears for scores, scratches and burrs. If you cannot
remove these defects with a soft stone, replace the gear.

30 Power Shift Transmission Shop Manual #1025550


Twin Disc, Incorporated Cleaning and Inspection

Splined Parts

Inspect splined parts for stripped, twisted, chipped or burred splines. Remove
burrs with a soft stone. Replace the part if other defects are found.

Springs

Inspect springs for broken or distorted coils. Replace the spring if either of
these defects is found.

Flexible Hoses

Inspect all flexible hoses for cracks and sponginess. Replace damaged hoses.

Clutch Plates

Inspect clutch plates for signs of overheating, pitting, or excessive wear of the
friction and splined surfaces. Replace the clutch plates if one of these defects
is found.

Power Shift Transmission Shop Manual#1025550 31


Cleaning and Inspection Twin Disc, Incorporated

NOTES

32 Power Shift Transmission Shop Manual #1025550


Twin Disc, Incorporated Assembly

Assembly

Torque Converter Assembly

General

Use these procedures for assembling the torque converter.

Note: All fasteners should be lightly lubricated with oil prior to


installation unless instructions call for installation with
loctite. All bearings should be lubricated with oil during
assembly. Replace all O-rings and gaskets.

Note: In some instances, the pictures or sketches may not be


identical to your parts, however the procedures are the
same. Shop experience may result in some alternative
procedures.

Torque Converter Shop Manual #1025550 33


Assembly Twin Disc, Incorporated

Torque Converter Sub-Assemblies

Stator and Freewheel Assembly

1. Install the snap ring into the turbine side of stator, and place in oven with
snap ring down.

Note: The turbine end can be identified by the grooves for the
labyrinth seal.

2168 2169

Figure 26. Install Snap Ring

2. After approximately one half hour in a 350° F (177° C) oven, remove the
stator and place with snap ring end down.

The stator will be hot, wear gloves to protect against burns.

3. Install the cam with the impeller side up.

34 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

2177 2179

Figure 27. Install Cam


4. Install the thrust race into the spline. Tap into place if necessary.

6. Install the race into the cam.

7. Stake the stator to prevent the thrust race from falling out.

2180 2181

Figure 28. Install and Stake Thrust Plate

8. Set assembly aside for later installation.

Torque Converter Shop Manual #1025550 35


Assembly Twin Disc, Incorporated

Turbine and Hub Assembly

1. If bushing was removed from the turbine hub, press in a new bushing
after applying a small amount of Loctite 609 to the o.d.. of the bushing.

2. Install the thrust bearing race onto the hub, and install two 10-24 x 0.5
inch flat head screws with washers, using MA-908 (loctite 242)
threadlocker. Torque the screws to 40 lb-in.

2183 2184

Figure 29. Install Bushing and Thrust Race

3. Install the turbine over the spline of the lockup clutch hub. It may be
necessary to tap it into place.

Note: Assembly is easier if the aluminum turbine is warmed


slightly prior to assembly, although it is not absolutely
necessary.

2185 2186

Figure 30. Install Turbine onto Clutch Hub


36 Torque Converter Shop Manual #1025550
Twin Disc, Incorporated Assembly

4. Using guide studs, install the turbine hub into the bore of the lockup
clutch hub.

5. Install eight 1/2-13 x 1.5 hex head capscrews with washers, clamping
the lockup clutch hub to the turbine hub. Torque the capscrews to 90 lb-
ft.

2187 2188

Figure 31. Install Turbine Hub

6. Set assembly aside for later installation.

Torque Converter Shop Manual #1025550 37


Assembly Twin Disc, Incorporated

Rotating Housing Assembly

1. Insert two guide pins into the threaded holes, and lower the driving gear
over the guide pins onto the rotating housing.

2. Install twelve 3/8-16 x 1.25 twelve point capscrews, and torque to 38 lb-
ft.

2189 2190

Figure 32. Install Gear onto Rotating Housing

3. Turn the assembly over with the large opening up.

4. Install the frozen wear sleeve into the bore of the rotating housing.

The wear sleeve is very cold. Wear gloves to protect hands.

2191 2193

Figure 33. Install Wear Sleeve

38 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

5. install the impeller into the rotating housing.

6. install the impeller hub assembly into the rotating housing.

7. Install eight 3/8-16 x 1 hex head capscrews with washers, and torque to
38 lb-ft.

2194 2195

Figure 34. Install Bushing and Thrust Race

6. Set assembly aside for later installation.

Torque Converter Shop Manual #1025550 39


Assembly Twin Disc, Incorporated

Stator Carrier Assembly

1. Install the roller bearing onto the stator carrier, and install the retaining
snap ring.

2. Install the freewheel inner race into the spline of the stator carrier.

2198 2200

Figure 35. Install Bearing and Freewheel Race

3. Install two clamp plates, aligning the holes for the capscrews.

4. Install six 5/16-18 x 0.875 hex head capscrews and torque to 22 lb-ft.

2201

Figure 36. Install Clamp Plates

5. Set assembly aside for later installation.

40 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

Shaft Assembly

1. Stand the output shaft with the output end up.

2. Heat the seal ring carrier (one seal ring), and install it against the shoulder
of the shaft with the orifice toward the shaft shoulder. Be sure the seal
carrier is against the shoulder when it is cool.

The components will be hot, wear gloves to protect against burns.

3. Heat the ball bearing and the seal ring carrier (two seal rings), and install
them onto the shaft. Be sure they are bottomed.

The components will be hot, wear gloves to protect against burns.

2202

Figure 37. Install Seal Carriers and Bearing

4. Install the seal rings onto the two carriers.

Torque Converter Shop Manual #1025550 41


Assembly Twin Disc, Incorporated

Pump Drive Gear Assembly

1. If removed, install new plugs in the forward end of each of the three
gears.

2. Install bearing cone onto the shaft portion of each of the three gears and
press until it is seated against the gear.

3. Set the three gears aside for later installation.

42 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

Regulator Valve Assembly

1. Install the bottom o-ring plug approximately 3 turns.

regulator valve

Figure 38. Regulator Valve Cross Section

2. Install the piston with the stem facing up.

3. Install the spring and shims.

4. Install the o-ring plug andtighten both plugs.

5. Torque the o-ring plugs to 80 lb-ft.

Torque Converter Shop Manual #1025550 43


Assembly Twin Disc, Incorporated

Torque Converter Final Assembly

Assemble Shaft and Stator Carrier

1. Place the stator carrier assembly with the large diameter up, and allow
enough clearance below for the shaft to be completely installed.

2. Lubricate the seal rings, and lower the shaft into the stator carrier.

2203

Figure 39. Install Shaft into Stator Carrier

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Twin Disc, Incorporated Assembly

3. Install a new output seal into the fluid distributor (seal carrier).

4. Install the fluid distributor over the seal ring carrier and bearing, aligning
the fluid passages in the distributor and stator carrier.

5. Install eleven 3/8-16 x 1.25 hex head capscrews with washers, and
torque to 38 lb-ft.

2204

Figure 40. Install Fluid Distributor

6. Install a snap ring in the groove at the input end of the shaft.

Torque Converter Shop Manual #1025550 45


Assembly Twin Disc, Incorporated

Assemble Main Housing

1. Place the stator carrier and shaft assembly with the large diameter up.

2. Install a seal ring in the groove of the stator carrier, and an o ring on the
upper groove.

3. Install a guide stud into the stator carrier, and lower the main housing
over the shaft assembly, aligning the fluid passages in the stator carrier
with the mating passage in the main housing.

2206 2208

Figure 41. Install Stator Carrier into Main housing

4. Install eleven 5/8-11 x 1.75 hex head capscrews and torque to 130 lb-ft.

5. Turn housing assembly over with the large opening up.

46 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

Install Pump Drive Gears

1. Install a snap ring into each of the three bores.

2. Install a spacer over the snap ring in each of the three bores.

2209 2210

Figure 42. Install Snap Ring and Bearing Spacer

3. Install a bearing cup with the large opening end up in each of the three
bores.

2211

Figure 43. Install Bearing cup

Torque Converter Shop Manual #1025550 47


Assembly Twin Disc, Incorporated

4. Install each gear and bearing assembly into the bearing cup.

5. Place the special gear retaining tool (T-19371) over the gears and install
temporary retaining capscrews. Torque the capscrews to their rated
torque capacity.
6. Install two 3/8-16 capscrews into the tube clamping holes in the housing
to retain the gears and special tool.

2212

Figure 44. Install Gears and Special Tool

7. Turn the housing assembly over with the large diameter opening down.

8. Install a bearing cone spacer over each of the three pump drive gear
shafts.

2214 2215

Figure 45. Install Bearing Cone Spacers

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Twin Disc, Incorporated Assembly

9. Install a bearing cup into each of the gear bores with the large opening
up.

10. Install a bearing cone over each of the three gear shafts.

2216 2217

Figure 46. Install Bearing Cups and Cones

11. Install a bearing lock nut washer against each of the three bearing cones.

12. Install a bearing lock nut onto each of the three gears.

2218

Figure 47. Install Locknut Washer and Locknut

13. Torque the bearing lock nuts to 350 lb-ft. A torque multiplier is
recommended for this.

14. Torque the bearing lock nuts an additional amount until one of the
threaded holes in the bearing lock nut aligns with a hole in the washer.

Torque Converter Shop Manual #1025550 49


Assembly Twin Disc, Incorporated

15. Install a 1/4-20 dog-point setscrew into each of the bearing lock nuts
and torque to 7 lb-ft.

2237 2239

Figure 48. Torque and Lock Bearing Lock Nuts

16. Turn the housing assembly over with the input opening facing up.

17. Remove the special gear assembly tool.

18. Install the lube tube fittings into the housing, and torque to xx lb-ft.

19. Install the lube tube with the clamps installed onto the fittings and torque
the nuts to xx lb-ft.

20. Install a 3/8-16 x 0.75 hex head capscrew and washer through the tube
clamps into the housing. Torque the capscrews to 38 lb-ft.

2219

Figure 49. Install Lube Tube Assembly

50 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Assembly

Install Rotating Housing Assembly

1. Install seal rings in the grooves of the stator carrier assembly.

2. Generously grease the roller bearing, and sealing rings on the stator
carrier assembly.

2220

Figure 50. Install Seal Rings and Grease Bearing

3. Lower the rotating housing assembly over the shaft, and rotate it so that
the driving gear teeth align with each of the driven gears, and bearing
rollers are into the driving gear opening.

2221 2222

Figure 51. Lower Rotating Housing into Main Housing

4. Install a well oiled needle thrust bearing over the shaft and against the
impeller assembly.

Torque Converter Shop Manual #1025550 51


Assembly Twin Disc, Incorporated

5. Install the two small springs into the pockets of the freewheel cage, and
install the freewheel cage into the stator assembly opening.

2224 2226

Figure 52. Install Bearing. Install Freewheel Springs

6. Rotate the cage, compressing the springs, and put a temporary spacer
to maintain the cage in this position.

7. Install twenty two freewheel rollers into the freewheel cage, using a
generous amount of grease to keep the rollers in place in the cage.

8. Carefully lower the stator assembly over the shaft and freewheel race
until it is seated against the needle thrust bearing, and remove temporary
spacer..

2227 2228

Figure 53. Install Rollers and Lower Stator Over Shaft

9. Install a freewheel side plate into the stator spline.

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Twin Disc, Incorporated Assembly

10. Install a snap ring to retain the side plate.

11. Install a needle thrust bearing onto the freewheel side plate.

2229 2230

Figure 54. Install Freewheel Side Plate and Thrust Bearing

Torque Converter Shop Manual #1025550 53


Assembly Twin Disc, Incorporated

Install Turbine Assembly

1. Lower the turbine assembly over the shaft spline, and seat it against the
snap ring in the shaft.

2. Install the heated seal ring carrier onto the clutch hub stub shaft. Be sure
it is fully seated when it cools.

The components will be hot, wear gloves to protect against burns.

3. Install a seal ring in the seal ring groove.

1455

Figure 55. Install Turbine Assembly and Seal Ring Carrier

Note: Two of the threaded holes in the rotating housing are thru
drilled holes to provide for draining the torque converter.
They are located 180o from each other. Identify one of
these holes with a marking pencil so that the capscrew
head can be painted for future disassembly ease.

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Twin Disc, Incorporated Assembly

4. Install twenty four 5/8-11 x 1.5 capscrews and washers. Torque


to 180 lb-ft. Mark one of the capscrews that is located in the hole that
will provide drainage at the time of future disassembly.

2231

Figure 56. Install Lockup Clutch Carrier

6. Install the frozen wear sleeve into the bearing carrier.

The wear sleeve is very cold, wear gloves to protect against damage to
skin.

1459 1460

Figure 57. Install Wear Sleeve

Torque Converter Shop Manual #1025550 55


Assembly Twin Disc, Incorporated

7. Install the complete bearing into the bore and over the shaft, starting it
with a dead blow hammer to avoid damage to the bearing.

8. After the bearing is aligned and started, drive the bearing into place
with the use of a flat plate that is smaller than the o.d. of the bearing, but
large enough to drive the outer race

1464 1465

Figure 58. Install Bearing

9. Install the clamping plate without shims with three 1/2-13 x 2.00 hex
head capscrews, and torque them to 90 lb-ft.

10. Remove the capscrews and clamping plate.

1466 1467

Figure 59. Clamping Plate To Seat Parts

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Twin Disc, Incorporated Assembly

11. Measure the height difference between the end of the shaft and the face
of the lockup clutch hub. Assemble a shim pack that is 0.002 to 0.005
inch less than this dimension.

12. Install an o ring on the o.d. of the shaft inside of the clutch hub.

1446 1448

Figure 60. Measure Gap and Install Shims

13. Install the clamping plate and shims with three 1/2-13 x 2.00 hex head
capscrews, and torque them to 90 lb-ft.

1445

Figure 61. Install Clamping Plate over Shims

Torque Converter Shop Manual #1025550 57


Assembly Twin Disc, Incorporated

14. Install the flywheel pilot, aligning the cast oil passage with the drilled
passage in the housing.

15. Install twelve 1/2-13 x 1.25 hex head capscrews and washers. Torque
to 90 lb-ft.

1472

Figure 62. Install Flywheel Pilot

16. Rotate the torque converter, and support it securely with the front face
down.

Be sure lifting device being used is rated for lifting the weight of the
torque converter housing.

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Twin Disc, Incorporated Assembly

Install External Hoses, Fittings, and Output Flange

1. Install two guide studs into the housing.

2. Install a gasket over the guide studs, followed by the ditch plate.

Figure 63. Install Ditch Plate, Regulator Valve, and Hose

3. Install the seven 1/2-13 x 2.25 (item 1) hex head capscrews and two
1/2-13 x 2.25 (item 3) twelve point capscrews.

4. Install the gasket and regulator valve assembly on the ditch plate with
the 1/2 -13 x1.75 (item 5), 1/2 - 13 x 5 (item 6) and the 1/2-13 x 3.5 (item
7) hex head capscrews.

5. Install the split flanges and the six 1/2 - 13 x 1.38 (item 2), , and two 1/2
- 13 x 4.25 (item 4) twelve point capscrews.

6. Torque the hex head capscrews to 65 lb-ft, and the twelve point
capscrews to 90 lb-ft.

7. Install the 1/8 npt to 7/16 flare fitting in the regulator valve assembly, and
the 7/16 flare elbow to the ditch plate.

8. Install the hose between the two fittings and tighten.

Torque Converter Shop Manual #1025550 59


Assembly Twin Disc, Incorporated

9. Install the output flange.

10. Install the o-ring in the groove between the shaft and output flange.

1509 1510

Figure 64. Install Output Flange and O-Ring

11. Install the clamping plate and a 5/8 - 11 x 3 hex head capscrew. Torque
the capscrew to 180 lb-ft.

1511

Figure 65. Install Clamp Plate

60 Torque Converter Shop Manual #1025550


Twin Disc, Incorporated Special Tools

Engineering Drawings
and

Special Tools

‰ T-19371 (Gear Retaining Fixture)

‰ X229788H (Sheet 1 of 2) Hydraulic Torque Converter cross section

‰ X229788H (Sheet 2 of 2) Hydraulic Torque Converter Installation

Torque Converter Shop Manual #1025550 61


Special Tools Twin Disc, Incorporated

62 Torque Converter Shop Manual #1025550


1025550

Introduction Twin Disc, Incorporated

TWIN DISC ®

TWIN DISC, INCORPORATED RACINE, WISCONSIN 53403, U.S.A. 262-638-4000/262-638-4482 (FAX) WWW.TWINDISC.COM
56 EC300 Marine Control System Configuration/Troubleshooting Manual #1020XXX