Manual 8fw21060 Torque

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
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
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

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.

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

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

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

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

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

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.

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.

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.

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

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

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

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

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

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.

NOTES

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.

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.

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.

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.

NOTES

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.

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.

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.

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

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

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

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

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

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.
2202
Figure 37. Install Seal Carriers and Bearing
4. Install the seal rings onto the two carriers.

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.

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 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

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.

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.

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

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

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.

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

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.

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.

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

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.
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.

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

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

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

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.

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.

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

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

Special Tools Twin Disc, Incorporated

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

Manual 8fw21060 Torque

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Manual 8fw21060 Torque

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TWIN DISC TWIN DISC

Document Number: 1025550

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

Hydraulic Torque Converter

December 14, 2007 TDWP0002 rev 2008

Model Series R&R Repair & Test

Matching Torque Converters

Industrial Torque Converters

Universal Control Drive

Marine Control Drive

December 14, 2007 TDWP0002A rev2008

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

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

Power Shift Transmission Shop Manual #1025550 7

8 Power Shift Transmission Shop Manual #1025550

Torque Converter Disassembly

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

Figure 1. Lockup Clutch Assembly Capscrews

Remove Output Flange

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

3. Remove the washer.

4. Remove the O-ring.

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.

Figure 3. Remove Output flange

10 Torque Converter Shop Manual #1025550

Remove the External Components

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

Torque Converter Shop Manual #1025550 11

Remove Internal Components

Figure 5. Support Torque Converter with Front Side Up

Figure 6. Remove the Pilot Cover

12 Torque Converter Shop Manual #1025550

4. Remove and tag the shims.

Figure 7. Remove the Clamping Plate

1466a mvc 002

Figure 8. Remove the Lockup Clutch Carrier

Torque Converter Shop Manual #1025550 13

Figure 9. Remove the Turbine Assembly

14 Torque Converter Shop Manual #1025550

9. Remove thrust roller bearing.

10. Remove the stator assembly by lifting straight up.

Figure 10. Remove Thrust Bearing and Stator Assembly

11. Remove the roller bearing.

12. Remove the rotating housing assembly by lifting straight up

Figure 11. Remove Thrust roller Bearing and Rotating Housing

Torque Converter Shop Manual #1025550 15

Disassemble Converter Housing

3. Turn the torque converter housing over

5. Remove the three bearing lock nuts with washers.

Figure 13. Remove Bearing Lock Nuts

16 Torque Converter Shop Manual #1025550

6. Place the converter housing with the shaft horizontal.

Note: An alternative method would be to use wooden blocking

Figure 14. Remove Pump Drive Gears

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

Torque Converter Shop Manual #1025550 17

Figure 15. Remove Capscrews from Rear of Housing

15. Remove the fluid distributor from the shaft assembly.

Figure 16. Support Stator Carrier Assembly and Remove Shaft

18 Torque Converter Shop Manual #1025550

1. Remove the bearing spacer from the shaft.

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

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

For previously sealed joints, scrape surfaces to remove old gasket

Clean surfaces with solvent to remove oil and grease residue.

Replace cast parts or housings that are cracked.

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

Inspect threaded openings for damaged threads. Chase damaged

Inspect studs for damaged threads and looseness. Replace defective

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

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