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Service Manual

1. 91 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Transmission Assembly Instructions All lead in chamfers for oil seals piston rings and o rings must be smooth and free from burrs Inspect at assembly e Add some grease to o rings before assembly e Add some grease to piston rings before assembly e Apply a thin coating of grease between seal lips on lip type seals prior to assembly e Use only pre coated pipe plugs On uncoated pipe plugs apply a light coat of LOCTITE 592 M e Pump must be filled up with oil prior to assembly e After assembly of parts using there must not be any free or excess material which might enter the oil circuit Hefer to the picture on previous page to match step
2. E ES H a p Ii H i C 7 hh M H cab 1 1 Cr J H i CONVERTER SECTION CONTROL VALVE 19 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Input Shaft and Directional Clutches Input Shaft and Directional Clutches The turbine shaft driven from the turbine transmits power to the directional clutches fwd rev These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston The piston is oil tight by the use of sealing rings The steel discs with internal splines and friction discs with external splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the oppo site direction as long as no pressure is present in that specific clutch To engage the clutch the solenoid will direct oil under pre
3. d ILU 07 7 wo Pa t CIRC Se 7445 Ur Sul TI OII ip MET from remote filter 2 IJ d TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 14 SPEED SENSOR INSTALLATION The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14 mA The sensor has an integrated AMP superseal 2 pin connector The two pins are numbered 1 and 2 The following table shows the relation between wire color pin number and connection Pinole Function Connection _ 2 Current Output The sensor wires have a polarity Be sure to correctly observe sensor polarities as wrong connections will deactivate the sensor 15 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Speed Sensor Installation GEAR ROTATION NS 01 EA ALL SENSOR WITH POSITION SIGN TING IN THE DIRECTION OF TEETH MOVEMENT OR 180 ROTATED gt 2 gt SCREW 9 11 Ibs ft 12 15 Nm INSTALL CLIP UNDER ANGLE SEE TABLE ZU Z TRANSMISSION ASSY Partnr CONNECTOR POSITION MODEL 1E27 32 4209752 4209752 2 Pins 180 Degrees 4209750 2 pins 180 Degrees
4. 3RD FWD REV 1ST 4TH RN 35 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 2nd Speed aw J0 00 9 5 zE EE 5 E S3 8 OL 62 C 2 2 amp os 3 g a e a U U T x ag 9 5 Eg 2 amp 5 c x as Lu OG i wa 24 E Oa U 9 5 5 Eae 5 oe To FWD N REV H ao o Rog a GOD 6 00 9 a o Lu Lu o O LLI N LLI eo gt Lu lt oc e a S D lt oc a gt I gt gt m gt L Z o 2 o lt oc N oD H I Low pressue D L Lubrucaion ac git 100 7 L min 0 2170 rpm Y PASS VALVE 4 1 4 5 ba PUMP 1 C SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OI
5. 29 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 3rd Speed aw J0 00 9 5 x GS a lt amp 4 gt E M ue S amp Co Lu d E 3 OE 2 9 a s U U x o ac TE 5 a 5 ce amp R 5 2 ud c Lu 2 i 02 EZ Oa y 5 E 1 Oo FWD N REV S lt cc c 2 lt cc ce gt X u c EE O lt wi zu So ce mo L Z lt o cc LL o lt cc N co lt N LLI Low pressue D L Lubrucaion z a ce x ex e 2 ans co 2 lt gt a 2 gt lt J lt gt SCREEN PRESSURE GAUGE SAFTY VALVE CRACKING AIR BREATHER 9 bar OIL SUMP OPERATOR COMPARTMENT TEMPERATURE GAUGE HOSE ZS RANGE FILTER 2 LUBRICATION CLUTCHES a N I N 9 PUMP 2 HOSE HOSE HOSE
6. D L Lubrucaion z a ge N e a S E N ans 2 2 lt a 2 2 gt lt J lt gt SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER LUBRICATION CLUTCHES a N I N 9 PUMP 2 gt HOSE HOSE TEMPERATURE GAUGE HOSE ZS RANGE FILTER 2 HOSE TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 32 Power Flows Activated Solenoids and Hydraulic Circuits Forward 4th Speed Continued FWD 3RD 33 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 1st Speed aw J0 00 9 x xe 7v3 Cx Lr 2 f M S 2 LZ O Lu d 8
7. 5 1 d FWD N REV A TEX S lt l 2 e gt T 2 5 Sa w OC a 2 L Su na en lt N lt CN LLI Low pressue D L Lubrucaion ac git 100 7 L min 2170 rpm Y PASS VALVE 4 1 4 5 ba PUMP 1 9 lt gt SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER LUBRICATION CLUTCHES a N I N 9 PUMP 2 gt HOSE HOSE TEMPERATURE GAUGE HOSE ZS RANGE FILTER 2 HOSE TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 38 39 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 3rd Speed Continued Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual B i n J FWD O REV 2ND ATH 3RD
8. D HOSE TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 24 Neutral Continued Power Flows Activated Solenoids and Hydraulic Circuits sumi 1ST Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 1st Speed aw a 00 9 xe Sa E E amp tre ce M 2 amp cZ Q ce a co 3 T E S 3 g E E a y U mm uu al ac x eu E 77 1 o e E z LLI 5 c gj o ce mas cc as a OG Qt 2 cc E wa E 1 9 U g mm ag o cn N REV oe C cC lt 5 gt T LI at zu On 22 5 n QS zz LL 72 oc CN co LLI LE CN
9. 1ST Power Flows Activated Solenoids and Hydraulic Circuits Reverse 4th Speed aw aw 00 9 5 TE ag c C i s a 2 E M ue S amp Co Es E C co LLI gt s 3 g a e E a 2 U U Gc ae x BE 9 5 5 45 LE o z g 2 LEE 1 ce as Lu n i 02 wm EZ 2 7 p 5 E gt 1 oO FWD N REV TAX lt cc c 2 lt ce gt nO A oO 1 lt lt gt o r O Lr O zu LL WD 2 gt o lt cc N co Lu nm N LLI Low pressue D L Lubrucaion ac git 100 7 L min 2170 rpm PUMP 1 Y PASS VALVE 4 1 4 5 ba 9 lt gt SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER a N I N 9 LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE ZS FILTER 2 HOSE HOSE HOSE 7 TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Servi
10. Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury Indicates a situation which if not avoided may result NOTICE in damage to components TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 2 SPECIFICATIONS Identification Tag The nameplate contains both the model and serial number of the unit SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 BELGIUM MODEL SERIAL General Specifications Weight dry 1903 Ibs 865 kg Length maximum 39 8 1011 mm Width maximum 27 7 703 mm Height maximum 38 7 982 mm Oil Capacity 15 9 US gallons 60 liters Without cooler and hydraulic lines Consult equipment operator s manual for complete system capacity Hydraulic Cooler Lines Specifications Lines and Fittings Minimum 1 25 4 mm internal diameter Continuous Operating Temperature Ambient to 248 F 120 C Continuous Pressure 406 PSI 28 bar continuous pressure and 595 PSI 41 bar intermittent surges Conformance SAE J1019 and SAE J517 100RI 3 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Pressure and Temperature Specifications Pressure and Temperature Specifications Normal Operating Temperature 158 248 F 70 120 C Measure
11. Control Valve Group Control Valve Group 87 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Control Valve Group ITEM 6A 6B 6C 10 11 12 13 14 15A 15B 16 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual DESCRIPTION Control Valve Housing Plug Expansion Plug Expansion Plug Restriction Plug Orifice Proportional Valve Forward Reverse Proportional Valve 2nd 4th Proportional Valve 3rd 1st O ring O ring Capscrew Selector Valve Forward Reverse O ring O ring O ring O ring Selector Valve 1st 3rd Selector Valve 4th 2nd O ring QTY 22 ITEM 17 18 19 20A 20B 20C 21 22 23 24 25 26 27 28 29 30 31 32 DESCRIPTION O ring O ring O ring Accumulator Spool Forward Reverse Accumulator Spool 2nd 4th Accumulator Spool 3rd 1st Pin Accumulator Stop Spring Plug O ring Sensor Valve Pressure Plug O ring Plug O ring Lockwasher Capscrew Gasket QTY Oo 10 10 16 16 Dana Holding Corporation 88 Remote Filter Adapter Group Remote Filter Adapter Group 89 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Remote Filter Adapter Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Filter 1 8 Spring 1 2 Adapter Filte
12. Power Flows Activated Solenoids and Hydraulic Circuits Power Flows Activated Solenoids and Hydraulic Circuits Neutral Selected aw a 00 9 aN T xe 5 ra a2 8 o NA I en S 2 8 8 LZ E a c o co a b d EB 3 amp a 2 a 2 U y a ac T o ra amp 5 E z e Pua Q E c z 5 2 ceo x r ans Lu e M eo E e E Eg DD Z lu Lu cn a _ 5 E ES 2 e y 9 T ag 2 T 5 ELE gt cn o FWD N REV Li Q f 2 AT S Lu o lt cc gt lt cc e e e 2 lt cc a gt LI Lu gt gt o LL gt m o o lt N co Lu lt N Lu EJ Low pressue 5 n D ES Lubrucaion Bp c N E E SS 2 3 S Qn 421 2 lt SS 8 ze zm F REGULATOR VALVE 22 bar C SCREEN PRESSURE GAUGE OPERATOR COMPARTMENT TORQUE CONVERTER OIL SUMP AIR BREATHER oN SAFTY VALVE CRACKING 9 bar g E N TU N t TEMPERATURE GAUGE HOSE LUBRICATION RANGE CLUTCHES PUMP 2 HOSE HOSE FILTER 2
13. a y FIGURE 29 Remove pump drive gear bolts position B FIGURE 32 Remove control valve and gasket ai d Pi am i P a eT oma catena 1 2 2 FIGURE 31 Refer to the Assembly Instructions section of the FIGURE 34 Remove temperature switch manual for details on the disassembly of control valve 104 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly FIGURE 35 Remove converter housing to transmission case FIGURE 38 Remove snap ring from 2nd clutch hub driven bolts and washers gear Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 36 Support converter housing with chain hoist and strap Use a soft hammer to separate converter housing from transmission case 9 i D or e 4 s Ch o Tm x d FIGURE 39 Remove retainer from 2nd clutch hub d EN LM T k d EE eu EX L SETS 1 re FIGURE 37 Converter assembly removed NOTE Reverse 2nd and 4th clutch drum will remain in the converter hous ing FIGURE 40 Remove inner retaining ring from 2nd clutch hub TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 105 Transmission Case Disassembly F
14. 1 Piston 2 Seal Piston Outer 3 Seal Piston Inner 4 Screen 5 Disc Clutch Inner 6 Disc Clutch Outer 7 Disc Clutch Outer Half 8 Plate End 9 Snap Ring 10 Washer Belleville 11 Spacer Clutch Piston 12 Retainer Spring 13 Ring Retainer 14 Bearing 15 Bearing Not Sold Separately TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual QTY 11 11 ITEM 16 17 18 19 20 21 22 23 24 25 26 27 28 29 DESCRIPTION Washer Snap Ring Snap Ring Ring Piston Bearing Cap 3rd Speed Shaft Rear Bear ing Spacer Snap Ring O ring Plug O ring Capscrew Lockwasher O ring QTY gt Dana Holding Corporation 72 E CN X N N N N et Korr u A Wee 4 D C Third Speed Gear Group TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 73 Third Speed Gear Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Gear 3rd Speed 1 2 Gear 3rd Speed Driven 1 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 74 Reverse Second Shaft Group Reverse Second Shaft Group 75 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Reverse Second Shaft Group ITEM DESCRIPTION QTY ITEM DESCR
15. 27 32 4 Speed SD with Full Flow Control Valve Service Manual INTRODUCTION Foreword This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Spicer products Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight out lay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and adjustments as indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjust ments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when perform ing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana Spicer approved parts as listed in the appli cable service parts list should be used Use of will fit or non approved parts may endanger proper operation and per formance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS Safety Precautions To reduce the chance of personal injury and or property d
16. AMP2Pins Turbine Speed TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 16 TEMPERATURE SENSOR INSTALLATION MATERIAL STAINLESS STEEL HOUSING BSS303 equiv DIN 1 4305 LESER zc SPADE TERMINALS A 0 8 DIN 46244 WITHOUT HOLE 17 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual TRANSMISSION OPERATION L H FWD 3RD REV lt 1ST Y 2ND A5 oe 4TH The transmission is composed of five main assemblies Converter pump drive section and pressure regulating valve Input shaft and directional clutches Range clutches Output section Control valve TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 18 Converter Pump Drive Section amp Pressure Regulating Valve Converter Pump Drive Section amp Pressure Regulating Valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing
17. 14 40 45 54 61 7 16 20 7 10 9 14 9 16 18 12 15 16 20 3 4 16 20 25 27 34 7 8 14 30 35 41 47 11 16 12 45 50 61 68 15 16 12 65 75 88 102 1 11 1 2 50 55 68 75 1 1 4 11 1 2 60 65 81 88 1 5 8 12 75 85 102 115 1 7 8 12 75 85 102 115 TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation SPECIAL TOOLS Low amp Output Shaft Lifting Hook 75 00 15 00 Bolt M10 x 40 g Eyebolt M16 i 1 5 60 00 Vit 10 x 45 4 PLACES D46 00 90 00 130 00 50 00 290 00 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 168 Impeller Cover Lifting Hook Impeller Cover Lifting Hook 60 00 104 00 60 00 52 00 0 2 roo 30 00 5 00 180 00 5 00 2 X 45 CHAMFER BOTH SIDES 1 92 00 15 00 12 00 4 Bolt 4379 14 UNC 3B X 20 EYEBOLT both sides NLM 6587 16 549 00 30 00 12 00 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 169 Low Shaft Nut Socket Low S
18. Remove bearing from impeller hub Impeller and Baffle Reassembly FIGURE 285 Install bearing to impeller hub FIGURE 289 Position impeller hub backing ring Use caution when installing snap ring Failure to comply can cause personal injury TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 147 Impeller Cover amp Turbine Disassembly FIGURE 290 Make sure that hub mounting surface and tapped holes are cleaned with solvent Install self locking screws and tighten to 58 65 Ibs ft 79 87 Nem FIGURE 293 Install impeller hub gear snap ring NOTE Assembly of the hub must be completed within a fifteen minute Use caution when installing snap ring period from the start of screw installation The special screw is to be Failure to comply can cause personal injury used for one 1 installation only If the screw is removed for any rea son it must be replaced The epoxy left in the hub holes must be Impeller Cover amp Turbine Disassembly removed with the proper tap and the hole must be cleaned with sol vent Holes must be dried thoroughly and a new screw used for reinstallation Use caution when removing snap ring FIGURE 291 Apply a light coat of LOCTITE 638 to the outer Failure to comply can cause personal injury diameter of the oil baffle seal ring press oil baffle seal ring into oil baffle with lip of seal ring down Install oil baffle retaini
19. charging pump torque converter transmission assem bly oil cooler filter connecting lines and controls including the engine as a complete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system Transmission Problems 27 30 power shift with torque converter transmission troubles fall into four general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems 4 Controller problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components Troubleshooting Procedures Input Shaft and Directional Clutch Problems Stall Test Do not operate the converter at stall condition longer than 30 seconds at one time shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached Excessive temperature 250 F 120 C maximum will cause damage to transmission clutches fluid converter and seals A stall test to identifies transmission
20. converter or engine problems Use following procedure 1 Putthe vehicle against a solid barrier such as a wall and or apply the parking brake block the wheels 2 Activate calibration mode during power up and holding the S button for 15 seconds 3 Select STAL using the M button 4 Select the requested range gear with the S button 43 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Troubleshooting Procedures 4 4 Cut 4 Z NENMEN CHIC CI S ENGINE SPEED rnc addu ENGINE SPEED ITN Foe gt t ENGINE SPEED FL Cee acan ENGINE SPEED 5 Select FWD or REV in the selected range gear 6 Once the oil temperature reaches 158 F 70 C check maximum stall speed at full throttle in all gears The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be equal in all gears Between gears allow the converter outlet temperature to cool down to 158 F 70 C by selecting neutral 8 Exit the stall mode with the M button or switch off the ignition If maximum stall speed measured is below specifications it could indicate an engine or converter problem If maximum stall speed measured is above specifications it could indicate slipping clutches Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping
21. fitted and install bolts lockwashers Tighten to specified FIGURE 369 Install adapter suction hose assembly to hydraulic torque Refer to TORQUE SPECIFICATIONS on page 165 pump assembly fitting new o rings if required PEE FIGURE 373 Install impeller and oil baffle assembly FIGURE 370 Install capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 161 Transmission Case Reassembly FIGURE 374 Install impeller hub bearing inner race FIGURE 377 Install reaction member spacer FIGURE 375 Using a soft hammer tap oil baffle down to seat FIGURE 378 Install reaction member with thin side of blades correctly inward to impeller FIGURE 376 Install oil baffle retaining ring Make sure retaining ring is in full contact in groove Use caution when installing snap ring Failure to comply can cause personal injury 162 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly Use caution when installing snap ring Use caution when installing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 381 Position new o ring on impeller cover and install cover and turbine assembly on shaft FIGURE 385 Position
22. hollow side facing torque converter assembly 4 Install capscrews and lockwashers Tighten capscrews to 30 37 Ibs ft 40 50 Nem NOTE ee Assembly of all plates must be completed within 15 minutes from when screws are installed If a screw is removed for any reason it must be replaced The adhesive left in the tapped holes must be removed with the proper tap and cleaned with solvent Dry the hole thoroughly and use a new screw for reinstallation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 12 TRANSMISSION TO ENGINE INSTALLATION 1 Remove all burrs from flywheel mounting face and FLYWHEEL H OUSING nose pilot bore Clean drive plate surface with sol vent Dry thoroughly MOUNT DIAL INDICATOR HERE 2 Check engine flywheel and housing for conformance to standards SAE 3 per SAE J 927 and J 1033 tol ENGINE erance specifications for pilot bore size pilot bore runout and mounting face flatness Measure and ee record engine crankshaft end play PILOT BORE 3 Install two 2 50 63 5 mm long transmission to fly wheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the fly wheel housing access hole 4 Install a 4 00 101 6 mm long drive plate locating stud 3750 24 fine thread in a drive plate nut Align the locating stud in the drive plate with the flywh
23. For the 1st clutch assembly there is an extra bleed hole to allow full drain when the pressure to the piston is released Output Section With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the opposite to input rotation when the forward clutch is engaged a TN 4 21 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Transmission Controls Transmission Controls Refer to the Hydraulic Diagram The transmission is controlled by a TCON ECU This unit has a microprocessor that receives certain inputs gear selec tor position speed senors etc which are processed and will give output signals to the control valve Operation of the Valve Regulated pressure 319 377 P
24. Install converter housing to transmission housing bolts and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 159 Transmission Case Reassembly FIGURE 364 Install regulator valve and new valve to converter housing gasket to converter housing NOTE Turning output shaft will assist in aligning clutch hubs with clutch assembly NCAUTION Do not use bolts to pull converter and transmission housing together Failure to comply may cause equipment damage FIGURE 365 Install capscrews and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 E 1m 1 e P FIGURE 363 Install control valve and tighten capscrews to specified torque refer to TORQUE SPECIFICATIONS on page 165 following the sequence outlined in the Transmission Assembly Instructions on page 91 of the manual 0 24 T FIGURE 367 With new o ring place install hydraulic pump assembly 160 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly FIGURE 368 Install hydraulic pump capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 FIGURE 372 Install hydraulic pump drive shipping covers if
25. LLI Low pressue 3 ER L E Lubrucaion 100 7 L min 2170 rpm Y PASS VALVE 4 5 bar PUMP 1 B 4 1 4 5 b C SCREEN PRESSURE GAUGE REGULATOR VALVE 22 bar AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT a e TES N LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE FILTER 2 HOSE TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 26 Power Flows Activated Solenoids and Hydraulic Circuits Forward 1st Speed Continued 3RD 1ST 4TH 27 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 2nd Speed aw a 00 9 4TH CLUTCH 2ND CLUTCH E 0 9 Z4 x aw a 00 9 AN CLUTCH 3RD 1ST ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar CLUTCH PRESSURE INTENSIFIE
26. Remove pump drive gear bearing 150 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Converter Housing Reassembly Converter Housing Reassembly FIGURE 308 Install left outer auxiliary pump drive gear assembly Put new o rings 4 on bolts install bolts and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 on FIGURE 309 Install right outer auxiliary pump drive gear assemblies Put new o rings 4 on bolts install bolts and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 S 4 A an b ef 2 lt EQ P E FIGURE 310 Install center charging pump drive gear assembly Tighten bolts to specified torque Refer to TORQUE SPECIFICATIONS on page 165 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual x E T Weis FIGURE 311 Install forward speed outer roller bearing in converter housing 1 EL inm FIGURE 312 From the rear of the housing tap turbine shaft and bearing in converter housing Tap shaft until gear shoulders are against converter housing NN i A af t ur FIGURE 313 From the front of the housing install turbine shaft bearing snap ring Tap shaft until snap ring is in full position in groove Use caution when installing snap ring Failure to comply can cause personal injury Dana
27. TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 30 Power Flows Activated Solenoids and Hydraulic Circuits Forward 3rd Speed Continued FWD 3RD 4TH 31 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 4th Speed aw aw 00 9 FWD N REV Q S 5 I E T ag zi o MA 0g 2 a ce o E co LLI gt gt e 3 9 a E 8 o P 0 Q 90 Lu c d m 5 5 5 5 E amp DE 2 2 79 x c og _s Hj 55 Lu J 2 Q U 2 l LLI o oc a LL a lt o LL lt oc e a D lt oc gt rT LLI gt gt O 1 L 1 gt IL o o o lt oc N oD H lt N LLI Low pressue
28. another position FORWARD or REVERSE Put the shift lever back in NEUTRAL C c THE APC200 expects the parking brake to be ON while it is OFF Put the parking brake ON Verify that the parking brake is ON and working properly If this is already the case keep the machine at standstill by The APC200 has detected output using the brake speed Once the machine has been stopped the APC200 will ask the driver to shift to FORWARD before continuing the calibration E P e m NE Engine RPM is to low according to the limit that is necessary for calibration Im 2 272 When during the automatic transmission calibration the temperature becomes to low the APC200 display indicates the actual transmission temperature rPH Engine RPM is to high according to the limit that is necessary for calibration Im oO 22 After being to low or to high the engine HPM is coming back into the correct boundaries for calibration Im i Use the M button on the APC200 to go back to the HEAT mode and the S but When during the automatic transmission ton to trigger this mode Then warm up E calibration the temperature becomes to the transmission again until the temper a low the APC200 display indicates the ature is above 140 F 60 C Then go actual transmission temperature back to the automatic tuning mode by the M button and trigger this one again to continue calibration Calibration
29. bearing outer race and spacer as an assembly Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 223 Remove bearing washer FIGURE 220 Install two 2 piston rings 136 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service First Clutch Disassembly FIGURE 227 Using a bearing puller remove lower hub taper roller bearing from shaft Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 228 Compress Belleville washers and remove piston return spring retainer ring FIGURE 229 Remove spring retainer FIGURE 226 Remove clutch inner and outer discs TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 137 First Clutch Disassembly FIGURE 230 Remove Belleville washers FIGURE 233 Turn shaft and remove outer bearing race from shaft FIGURE 234 Remove bearing spacer FIGURE 232 Remove clutch piston Use caution when removing snap ring Failure to comply can cause personal injury 138 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service First Clutch Reassembly FIGURE 236 Remove gear First Clutch Reassembly FIGURE 237 Install clutch piston inner seal NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be
30. bent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound Inspection The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts show ing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAINING RINGS Replacement of spring loaded oil seals gaskets and retaining rings are more economical when the unit is disassem bled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particu larly when being installed Cutting scratching or curling under the lip of the seal seriously impairs its efficiency At reas sembly lubricate rings and seals with Multipurpose Lithium Grease Grade 2 for axles and Automatic Transmission Fluid for transmissions GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use this process to check parts
31. errors Calibration errors have the form E1 xx or E2 xx example E1 25 Please contact the OEM of the machine if an error of this form appears on the display 11 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual DRIVE PLATE INSTALLATION Proper identification is determined by measuring the bolt circle diameter see dimension A in the illustration below and then ordering the appropriate drive plate kit from the table DRIVE PLATE AND WELD NUT ASSEMBLY 1 BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 2 BACKING RING N BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 3 BACKING RING Each kit includes 3 Intermediate Drive Plates 1 Backing Ring 6 Mounting Capscrews 6 Lockwashers Instruction Sheet Each kit includes 2 Intermediate Drive Plates 1 Drive Plate amp Weld Nut Assembly 1 Backing Ring 6 Mounting Capscrews 6 Lockwashers Instruction Sheet 15 381 0 mm diameter 15 881 0 diameter 16 406 4 mm diameter 16 406 4 diameter 17 431 8 mm diameter 17 431 8 mm diameter 1 Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter 2 Align intermediate drive plates and backing ring with holes in torque converter assembly 3 Two dimples 180 apart in backing ring must be facing outward toward engine flywheel
32. found in the Cleaning and Inspection section of the manual FIGURE 238 Install clutch piston outer seal and install piston into drum TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual FIGURE 240 Install Belleville washers Position first washer with large diameter of bevel toward spacer wear sleeve Alternate nine 9 washers Refer to Figure 241 FIGURE 241 Spring and spacer position Dana Holding Corporation 139 First Clutch Reassembly FIGURE 242 Install spring retainer making sure it is fitted with FIGURE 245 Install end plate stepped groove up FIGURE 243 Compress return spring and install return spring retainer ring Make sure retainer ring is in full position in groove Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 244 Install one 1 steel disc Alternate steel and friction discs until proper number of discs are installed FIGURE 247 Warm taper bearing to 248 F 120 C and install on shaft 140 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service First Clutch Reassembly FIGURE 251 Install washer FIGURE 249 Install clutch driven gear and hub assembly Align FIGURE 252 Warm bearing to 248 F 120 C and install on splines on clutch gear hub with internal splines of friction discs shaft Do not force the operation in this step Gear splines must be in ful
33. g 8 5 amp 2 E x TE QE E a 52 a S gt E c 5 2 Lu e Lu E 1 OG j fis Oa g 5 Q 5 Eae gt 2 gt cc 1 FWD N REV H ao o _ Rog gee a 48 00 9 O LLI l LLI o o cc o cc LLI gt lt oc e a e 2 t cc gt c gt gt o IL gt am o o lt oc N oD N LLI I Low pressue D L Lubrucaion ac git 100 7 L min 0 2170 rpm Y PASS VALVE 4 1 4 5 ba PUMP 1 lt lt gt SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER LUBRICATION CLUTCHES a N 221 N 9 PUMP 2 gt HOSE HOSE TEMPERATURE GAUGE HOSE ZS RANGE FILTER 2 HOSE TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 34 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 1st Speed Continued
34. have been calibrated the APC200 displays dont 5 At this point the automatic calibration has completed successfully The normal duration of a complete transmission calibration is around 15 minutes 6 To exit the automatic calibration mode switch off the vehicle ignition key Make sure that the APC200 has powered down wait for 2 seconds Now restart the vehicle and the new tuning results will be activated automatically Troubleshooting If anything different than described above appears the APC200 display there can be two possible reasons e The calibration conditions are not fulfilled temperature is too low parking brake switched off the vehicle is moving engine rpm is too high or too low e A calibration error has occurred during the calibration This message starts with an E see CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS on page 11 By selecting REVERSE on the shift lever while the automatic calibration is performing the procedure will abort the auto matic calibration immediately and restart the APC200 This feature can be used when something goes wrong during the calibration procedure NOTE By aborting the automatic calibration the calibration is not finalized and needs to be done from the beginning 9 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Automatic Calibration Procedure HEATING UP THE TRANSMISSION BY USING THE
35. using oil compressed air and steam cleaner for that purpose IMPORTANT NEVER use flushing compounds for cleaning purposes 5 Reassemble all components and use only type oil See chapter 4 1 1 Recommended lubricants Fill the transmission through filler opening until fluid comes up to FULL mark on transmission dipstick e Remove filler plug and fill oil until FULL mark e Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines e Recheck level of fluid in transmission with engine running at idle 500 600 RPM e quantity necessary to bring fluid level to LOW mark on dipstick e _ Recheck with hot oil 180 200 F 82 2 93 3 C e Adjust oil level to FULL mark on dipstick 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary Perform automatic calibration 7 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Automatic Calibration Procedure Automatic Calibration Procedure Introduction The APC200 firmware contains an automatic transmission calibration procedure which is able to optimize the shift quality of the transmission An automatic calibration has to be done e When the vehicle is build at the OEM e Every 2000 hours of transmission operation e When an overhaul of the transmission is done e When the transmission is repaired e When the APC200 is replaced ENTERING AUTOMATIC C
36. 134 91 100 123 136 128 141 174 191 129 141 174 191 180 198 224 268 223 245 302 332 315 347 427 470 165 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Lubricated Plated Screws COARSE PITCH TYPE OF BOLT EOE ROR Grade 8 8 Grade 10 9 Grade 12 9 Ibs ft Nem Ibs ft Nem Ibs ft Nem M5 x 0 8 3 7 4 4 5 6 5 2 5 9 7 8 5 9 7 4 8 10 M6 x 1 5 9 7 4 8 10 8 9 11 1 12 15 9 6 11 8 13 16 8 x 1 25 14 8 18 4 20 25 22 1 25 8 30 35 25 8 29 5 35 40 M10 x 1 5 29 5 36 9 40 50 44 3 47 9 60 65 47 9 55 3 65 75 M12 x 1 75 50 55 68 75 74 81 100 110 85 96 115 130 M14 x2 81 92 110 125 111 129 150 175 133 155 180 210 M16 x2 125 140 170 190 177 203 240 275 207 236 280 320 M20 x 2 5 236 266 320 360 332 369 450 500 387 443 525 600 M24 x 3 420 479 570 650 590 664 800 900 664 774 900 1050 M30 x 3 5 848 959 1150 1300 1180 1328 1600 1800 1364 1549 1850 2100 M36 x 4 1475 1660 2000 2250 2028 2323 2749 3149 2397 2729 3249 3699 FINE PITCH TYPREOFBOLT 0000004 SIZE OF BOLT Grade 8 8 Grade 10 9 Grade 12 9 Ibs ft Nem Ibs ft Nem Ibs ft Nem M8 x 1 17 20 23 28 25 28 34 39 30 34 41 46 M10 X 1 35 42 47 57 52 60
37. 1mA current level or 2 6 3 0 for the 14mA 1mA current level If the teeth can be moved slowly distinct toggling between the two levels should be noticed Sensor 200 Ohm 1 Watt TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 52 EXPLODED VIEWS Converter Housing Group o3 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Converter Housing Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Torque Converter 1 24 Pin Dowel 2 2 Not Illustrated 1 25 Capscrew 14 3 Plug Expansion 3 26 Capscrew 9 4 Plug 1 27 Lockwasher 23 Gasket Converter To ed Transmission Case 6 Tube 1 29 Bushing 1 7 Tube 1 30 Breather Air 1 8 Tube 1 31 Plug 1 9 Clip 2 32 Switch Temperature 1 10 O ring 2 33 1 11 Capscrew 2 34 Sensor Speed 1 12 Lockwasher 2 35 O ring 2 13 Tube 1 36 Sensor Speed 60 mm 1 14 Sleeve 1 37 Support Speed Sensor 2 15 Sleeve 1 38 Capscrew 2 16 Sleeve 1 39 Plug 2 17 Sleeve 1 40 Cover Split Flange 3 18 Washer 3 41 O ring 3 19 Capscrew 3 42 Capscrew 12 20 Lockwasher 3 43 Lockwasher 12 21 Plug 1 44 Plug 1 22 Plug 2 45 O ring 1 23 O ring 2 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 54 Transmission Case amp Rear Cover Group Tran
38. 4th Regulated Pressure 31A 45 tt 66 i 7 68 L 43 67 1 41 44 d ML i TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 50 4 CO me M NR 59 4 Ke WE vx wA CS AN 1st 3rd Selector Valve Proportional Valve Proportional Valve M gt gt gt O O 9 O T M cal ro 119 N Co C go m O0 0 J cC O gt gt gt O 2 LL Full Flow Valve Components 3rd 1st Pressure Sensor TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 51 Speed Sensor Static Standalone Test Speed Sensor Static Standalone Test In order to be able to sense the currents a series resistor of e g 200 W must be used This resistor is integrated in the controller but when the sensor is to be used it must be connected externally The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor The voltage reading should be either 1 2V from the 7mA
39. 71 81 62 69 84 94 M10 x 1 25 32 40 44 54 49 57 67 77 58 66 79 89 M12 x 1 25 60 68 82 92 89 96 120 130 105 116 143 158 M12 x 1 5 58 65 78 88 86 94 117 127 101 112 138 153 M14 x 1 5 94 105 128 143 142 153 193 208 162 184 220 250 M16 x 1 5 159 169 215 228 216 227 293 308 258 273 350 370 M18 x 1 5 221 236 300 320 319 330 433 448 369 398 500 540 M18x2 207 221 280 300 304 315 413 428 347 376 470 510 M20 x 1 5 302 332 410 450 439 476 595 645 503 559 683 758 M22 x 1 5 413 443 560 600 586 623 795 845 681 736 923 998 M24 x 1 5 531 590 720 800 767 841 1040 1140 882 992 1195 1345 M24 x 2 509 568 690 770 730 804 990 1090 845 955 1145 1295 M27 x 1 5 789 848 1070 1150 1129 1202 1530 1630 1808 1420 1175 1925 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 166 Pipe Plugs Pipe Plugs THREADSIZE 1 4 Nem M10 x 1 6 7 8 10 M14 x 1 5 7 9 10 12 M18 x 1 5 25 30 34 41 M22 x 1 5 35 44 48 60 M26 x 1 5 45 50 61 68 M33 x 2 83 103 112 140 THREADSIZE Nem Y O 1 16 27 5 7 7 9 1 8 27 7 10 9 14 1 4 18 15 20 20 27 5 16 24 3 5 4 7 3 8 24 5 8 7 11 3 8 18 25 30 34 41 1 2 14 30 35 41 47 1 2 20 10 13 14 18 3 4 10 40 45 54 61 3 4
40. ALIBRATION MODE The automatic calibration mode is entered by pressing the S button on the APC200 display for 15 seconds during power up during power up 9 B888J E Rojo keep for 15 seconds TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 8 Automatic Calibration Procedure PERFORMING AUTOMATIC CALIBRATION Before the automatic calibration can be started a number of conditions need to be fulfilled parking brake on the vehicle has to be activated e The transmission temperature needs to be above 60 C See the next paragraph how to use the HEAT mode to do this in a time effective way e The engine speed has to be kept at around 800 rpm 200 rpm during the complete calibration If the APC200 has control over the engine the engine speed will be adapted automatically 1 If all the conditions mentioned above are met the actual automatic calibration can be performed starting from the following display on the APC200 2 Totrigger the automatic calibration procedure push the S button once The APC200 display readout will show bo F 3 The APC200 asks for the shift lever to be put in FORWARD The automatic transmission calibration procedure starts This is indicated on the APC200 display cll cite ceni a C1 stands for clutch 1 being forward while M1 stands for mode 1 of the calibration 4 When all clutches
41. ATIONS on page 165 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 153 Transmission Case Reassembly FIGURE 326 Install 1st clutch shaft bearing Use caution when installing snap ring Failure to comply can cause personal injury ILE 50 42 S p ema A r taf 2 e a tet 27 1 he el a eo i Ts p F Load W FIGURE 327 Install 1st clutch shaft oil retainer Refer to Figure 328 Bearing Oil E snapring l FIGURE 328 Clutch shaft bearing and oil retainer position Use caution when installing snap ring Failure to comply can cause personal injury 154 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly FIGURE 332 Install forward shaft bearing oil retainer Refer to Figure 333 Bearing snapriag Te aa Ss retainer FIGURE 336 Using special tool refer to Special Tools section install output shaft and 1st clutch assembly with baffle FIGURE 337 Warm 3rd shaft bearing to 248 F 120 C and install on shaft with snap ring groove up as shown Use caution when installing snap ring Failure to comply can cause personal injury TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corpora
42. Daily Check oil level daily with engine running at idle 600 RPM and oil at 180 200 F 82 93 C Maintain oil level at full mark Normal oil change interval Drain and refill system every 1000 hours for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Every 1000 hours e Change oil filter element Drain oil at 150 200 65 93 and refill system as follows Drain transmission Remove and discard filter Install new filter Refill transmission to FULL mark Run engine at 500 600 RPM to prime converter and lines Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 180 200 F 82 2 93 3 C make final oil level check and adjust if necessary to bring oil level to FULL mark NOTE It is recommended that oil filter be changed after 100 hours of operation on new rebuilt or repaired unit o gr m Extended oil change interval Extended oil service life may result when using synthetic fluids Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metal analysis can provide useful information but a transmission should not be r
43. Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines 97 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Inspection HOUSINGS COVERS AND CAPS Inspect housings covers and caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 98 DISASSEMBLY amp REASSEMBLY Getting Started CAUTION Cleanliness is of extreme importance in the repair and over haul of the transmission Before conducting repairs the exterior of the unit must be thoroughly cleaned to prevent dirt and foreign debris from entering the transmission CAUTION When maintenance work requires welding disconnect both connectors from the APC200 and from the control valve unit before any welding is started NOTE CLUTCH RETURN SPRING PACKS ARE CERTIFIED ACCORDING TO COMPRESSION WEIGHT SPECIFICATIONS AND ARE PRE PACKED
44. HEAT MODE The HEAT mode allows to select forward reverse while the parking brake is activated without forcing neutral and will disable the inching and declutch function During the heat mode the highest gear is forced even when the shift lever is in a lower gear This combination allows the driver to heat up the transmission by going into stall HEAT mode can be activated in the same way automatic calibration mode is entered see ENTERING AUTOMATIC CALIBRATION MODE on page 8 Once tran is displayed on the screen press the M button once to go into the HEAT mode The 200 will display To trigger the HEAT mode push the S button The APC200 will display the sump temperature This means the actual sump temperature of the transmission is 20 Perform the following steps in order to heat up the transmission 1 Make sure the parking brake is active and works properly 2 Put the transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throt tle 3 Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever Keep the engine at full throttle 4 Keep the gearbox in neutral at full engine throttle for about 15 seconds again 5 Release the throttle pedal and decelerate the engine to idle 6 Go back to point 2 and repeat until the APC200 display shows a temperatur
45. Holding Corporation 151 Converter Housing Reassembly FIGURE 314 Install new o ring and piston ring on stator FIGURE 317 Install 4th shaft and drum assembly converter support Position stator support assembly on turbine shaft Turn housing stator support assembly to clear pump drive gear Align support assembly holes with converter housing lockwashers and tighten screws to specified torque Refer to TORQUE SPECIFICATIONS on page 165 Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 316 Spread ears on snap ring and install 2nd Rev clutch drum assembly into converter housing E FIGURE 319 Install needle roller bearings on 2nd Rev and 4th shafts 152 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly Transmission Case Reassembly FIGURE 323 Install output shaft bearing and oil retainer Refer to Figure 324 FIGURE 320 Install suction hose and o ring into transmission Bearing Oil ED E snapring FIGURE 321 Install suction hose capscrews lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 FIGURE 322 Install oil baffle cover and spacers 3 Add LOCTITE 262 to threads of capscrews and install from other side of transmission Torque to specified torque Refer to TORQUE SPECIFIC
46. IGURE 41 Remove 2nd clutch hub FIGURE 44 Shown are the output flange nut washer and o ring removed ee FIGURE 42 hub FIGURE 45 Remove output flange Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 46 Remove bolts from 3rd clutch shaft rear bearing FIGURE 43 Using an impact gun remove output flange nut 106 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly FIGURE 47 Remove 3rd clutch shaft rear bearing cap and FIGURE 50 Remove 1st clutch shaft rear bearing cap o rings O ring and spring disc 4 Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 52 Remove output bearing cover assembly and o ring FIGURE 49 Remove ist clutch shaft rear bearing cap bolts TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 107 Transmission Case Disassembly Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 57 Using a hoist remove rear cover from transmission case Tap 3rd 1st shaft with a soft hammer to assist removal and avoid bending shaft FIGURE 58 Remove snap ring from 3rd shaft bearing EAS Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 55 Use special tool refer to Special Tools se
47. IN QUANTITIES TO REPAIR ONE 1 SPECIFIC CLUTCH The disc spring packs are to be used as complete assem blies and care should be taken not to intermix the individ ual disc springs with disc springs in another clutch or disc spring pack Each disc spring assembly is made up of selected springs to precisely match each part within this assembly Failure to replace all piston return springs can result in unequal deflection within the spring pack The result of this imbalance may adversely affect overall life of springs Transmission Case Disassembly FIGURE 1 Front view of the TE32 transmission 99 Dana Holding Corporation FIGURE 2 Remove drive plate assembly mounting capscrews and lockwashers NCAUTION Be prepared to support the weight of the bearing cover after removing securing hardware as the cover may drop Failure to comply may cause equipment damage kd FIGURE 4 Remove impeller cover hub and o ring TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Transmission Case Disassembly Use caution when removing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 7 Use special tool refer to Special Tools section to lift impeller cover assembly FIGURE 10 Remove reaction member 100 Dana Hol
48. IPTION QTY 1 Piston 1 19 Plate End 1 2 Seal Clutch Piston Outer 1 20 Seal 1 3 Seal Clutch Piston Inner 1 21 Snap Ring 1 4 Screen 1 22 Washer Belleville 15 5 Washer Belleville 7 23 Spacer Clutch Piston 1 6 Spacer Clutch Piston 1 24 Bearing 1 7 Ring Retaining 1 20 Bearing 1 8 Disc Clutch Inner 7 26 Ring Retaining 1 9 Disc Clutch Outer 7 27 Ring Retaining 1 10 Plate End 1 28 Bearing 1 11 Snap Ring 1 29 Ring Retaining 1 12 Piston 1 30 Ring 1 13 Seal Clutch Piston Outer 1 31 Washer Bearing Thrust 1 14 Seal Clutch Piston Inner 1 32 Hub 2nd Clutch Disc 1 15 Screen 1 33 Snap Ring 1 16 Ring Retaining 1 34 Retainer 1 17 Disc Clutch Inner 11 35 Snap Ring 1 18 Disc Clutch Outer 11 36 Ring Piston 3 Not Sold Separately TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 76 First Shaft Group First Shaft Group 77 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual First Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 17 Ring Piston 2 2 Seal Piston Outer 1 18 Cap Bearing 1 3 Seal Piston Inner 1 19 O ring 1 4 Screen 1 20 Plug 2 5 Disc Clutch Inner 11 21 O ring 2 6 Disc Clutch Outer 11 22 O ring 1 7 Plate End 1 23 Capscrew 4 8 Snap Ring 1 24 Lockwasher 4 9 Washer Belleville 9 25 Bearing 1 10 Spacer Clutch Piston 1 26 Spacer Bearing 1 11 Retainer
49. L SUMP OPERATOR COMPARTMENT TORQUE CONVERTER LUBRICATION CLUTCHES a N 221 N 9 PUMP 2 gt HOSE HOSE TEMPERATURE GAUGE HOSE ZS RANGE FILTER 2 HOSE TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 36 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 2nd Speed Continued 3RD FWD REV 2ND NS 4TH 37 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 3rd Speed aw J0 00 9 5 TE EA a E a3 amp ee 17 gt E M ue S amp Co C Lu d T OE B gt 9 a s 7 U x o x 55 a 5 amp ce R 5 2 ud c Lu d o i 02 Q wm EZ Oa 7 p 5
50. R 0 6 0 20 bar o 00 9 00 9 FWD CLUTCH REV CLUTCH FWD N REV S O LLI LLI o e o LLI eo E o lt oc e a e 2 t oc a gt c gt gt IL 1 gt am o 2 o lt oc N oD N LLI I Low pressue D L Lubrucaion ac git 100 7 L min 0 2170 rpm PUMP 1 Y PASS VALVE 4 1 4 5 ba C SCREEN PRESSURE GAUGE AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER a N 221 N 9 LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE ZS FILTER 2 HOSE HOSE HOSE 7 TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 28 Power Flows Activated Solenoids and Hydraulic Circuits Forward 2nd Speed Continued FWD 3RD 2ND
51. SI 22 26 bar is directed to the proportional valve and selector valves to activate the clutches required When activated the proportional valve will give an output pressure curve from 0 26 bar proportional to a current from 0 mA to 1000mA Dampers are used to dampen any hydraulic vibration Directional Selection When a direction forward or reverse is selected the required selector valve is activated for forward or reverse and the proportional valve will provide a pressure rise from 0 to 26 bar feeding the directional clutch with modulated pressure Range Selection When 1st clutch is selected the 1st 3rd selector valve is activated and the 1st 3rd proportional valve will provide a pres sure rise from to 26 bar feeding the 1st clutch with modulated pressure When 2nd clutch is selected the 2nd 4th selector valve is activated the 1st 3rd proportional valve will decrease pres sure from 26 to 0 bar thus releasing the 1st clutch in a controlled manner At the same time the 2nd 4th proportional valve is activated and will provide a pressure curve from 0 to 26 bar which will provide clutch overlap When the shift is finalized the 1st 3rd selector valve is deactivated When 3rd clutch is selected the 3rd 1st selector valve is not activated The 2nd 4th proportional valve will decrease pressure from 26 to 0 bar thus releasing the 2nd clutch in a controlled manner At the same time the 1st 3rd propor tional valve is activated and will p
52. Service Manual Dana Holding Corporation 62 Torque Converter Assembly Group Torque Converter Assembly Group 63 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual ITEM Oo oa A N 10 11 12 13 TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual DESCRIPTION Member Reaction Snap Ring Spacer Reaction Member Turbine Hub Turbine Snap Ring Snap Ring Screw Turbine Hub Locktab Impeller O ring Screw Lockwasher QTY 32 32 Torque Converter Assembly Group ITEM 14 15 16 17 18 19 20 21 22 23 24 25 DESCRIPTION Hub Impeller O ring Screw Ring Impeller Hub Backing Bearing Snap Ring Cover Impeller Bearing Turbine Hub O ring Spacer Snap Ring Hub Impeller Cover QTY Dana Holding Corporation 64 Drive Plate Group Drive Plate Group 65 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Drive Plate Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY Assembly Drive Plate and when used Welded Nuts 5 Plate Drive 5 4 Capscrew 14 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 66 gt O Qo lt d U X on zem O O C T LL 5 Cc Q 0 gt D Iz 2 O LL For
53. Shaft Assemb Forward Shaft Group Thite ShatGroup ee Third Speed Gear Group Reverse Second Shaft Group First Shat GOUD oie oe e eese Fourth Shalft GEOUD First Speed Gear Group Output Shaft Group ene Regulator Valve Group Control Valve Group eran Remote Filter Adapter Group INSTALLATION DIAGRAMS Transmission Assembly Instructions Control Valve Assembly Instructions Cleaning and Inspection DISASSEMBLY amp REASSEMBLY Geld SIal ted SERVE Transmission Case Disassembly Converter Housing Disassembly Reverse and Second Clutch Disassembly Reverse amp Second Clutch Reassembly Forward Clutch Disassembly Forward Clutch Reassembly Third Clutch Disassembly Third Clutch Reassembly Fourth Clutch Disassembly Fourth Clutch Reassembly First Clutch Disa
54. Spring 1 27 Snap Ring 1 12 Ring Retainer 1 28 Snap Ring 1 13 Bearing 1 29 Bearing 1 14 Washer 1 30 Bearing 1 15 Bearing 1 31 Spring Disc 1 16 Retainer Oil 1 32 Nut 1 Not Sold Separately TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 78 Fourth Shaft Group Fourth Shaft Group 79 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Fourth Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 11 Retainer Spring 1 2 Seal Piston Outer 1 12 Spring 1 3 Seal Piston Inner 1 13 Ring Retainer 1 4 Screen 1 14 Bearing 1 5 Disc Clutch Inner 11 15 Snap Ring 1 6 Disc Clutch Outer Half 2 16 Snap Ring 1 7 Disc Clutch Outer 11 17 Hub 1 8 Plate End 1 18 Snap Ring 1 9 Snap Ring 1 19 Ring Piston 2 10 Spacer Clutch Piston 1 Not Sold Separately TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 80 D O D D LL First Speed Gear Group gt Ze e Ee TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual 81 Holding Corporation First Speed Gear Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Gear Idler 1 2 Assembly 1st Speed Clutch 1 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manua
55. URE 69 Remove 1st shaft drum assembly front bearing spacer FIGURE 70 Remove 1st shaft drum assembly front bearing TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly xs he a FIGURE 74 Remove turbine shaft bearing snap ring Use caution when removing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury ry m re b ee FIGURE 73 Remove output shaft front bearing FIGURE 76 Remove inner oil baffle cover capscrews 3 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 111 Converter Housing Disassembly ne dii J m 9 FIGURE 80 Remove 4th drum shaft assembly retaining ring LJ i ie I aJ 4 4 r ji fsa FIGURE 78 Remove suction tube assembly and o ring Converter Housing Disassembly I ey ene FIGURE 79 Using external snap ring pliers open Rev 2nd drum shaft assembly bearing retaining ring and remove shaft assembly Use caution when removing snap ring Failure to comply can cause personal injury 112 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Reverse and Second Clutch Disassembly FIGURE 83 Using a soft hammer tap turbine shaft and bearing assembly from conve
56. amage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part NEVER use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of unique tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither their safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various precautions that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may also damage the unit or render it unsafe It is important to understand that these precautions are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions Indicates an imminently hazardous situation which DANGER if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury
57. and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials Thoroughly dry all cleaned parts immediately by using moisture free compressed air or soft lint free absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound BEARINGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate the dry ing process HOUSINGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lint free absor
58. area around the valve must be clean and free of any foreign material Unscrew 16 bolts indicated on drawing below a few turns When all bolts are loose you should be able to move the valve Replace two bolts by aligning studs Remove the remaining 14 hex bolts and valve from the transmission case Install the Valve 1 Install two 2 aligning studs Install new gasket and valve body Install fourteen 14 bolts and hand tighten in the numerical sequence indicated on the drawing below Replace the studs by bolts Then torque all bolts twice to 15 18 Ibs ft 20 25 Nem in the correct sequence gt a Recalibrate the transmission TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 96 CLEANING AND INSPECTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type and alkali cleaners Cleaning Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid
59. ce Manual Dana Holding Corporation 40 41 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 4th Speed Continued 3RD Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual l O B i n J i FWD O REV 2ND 1ST Gear amp Clutch Layout Gear amp Clutch Layout TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 42 TROUBLESHOOTING The following information is presented as an aid to isolate and determine the specific problem areas in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and cor rect functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid
60. clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure can also be measured TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 44 Troubleshooting Procedures Mechanical and Electrical Checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and electrical checks should be made e Check the parking brake and inching pedal for correct adjustment sure all lever linkage is properly connected and adjusted in each segment and at all connecting points e The controls are actuated electrically Check the wiring and electrical components e Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary e he engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications Hydraulic Checks Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid check Chec
61. ction to remove nut from 1st shaft 108 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly i ET il i MM WW ud S FIGURE 62 Using special tool see Low amp Output Shaft Lifting Hook on page 168 remove 1st shaft drum assembly and output shaft together as shown pa FIGURE 63 While hoisting shaft and drum assembly remove oil baffle cover FIGURE 61 Remove oil baffle cover capscrews FIGURE 64 Shown are the 1st shaft drum assembly and output shaft as an assembly removed TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 109 Transmission Case Disassembly mc FIGURE 65 Remove 3rd shaft drum assembly FIGURE 66 Forward drum assembly removed showing snap ring and front bearing Snap ring sits under gear and must be removed before forward drum assembly can be hoisted Col TM Eoo ELE ms j FIGURE 67 Remove forward drum assembly bearing oil retainer 110 Dana Holding Corporation DA I pAr s UTI he i i TN es FIGURE 68 Remove 1st shaft drum assembly front bearing snap ring Use caution when removing snap ring Failure to comply can cause personal injury ari ae UV FU ut 1 4 dn roy 5 z 2 EE TUO FIG
62. d at temperature check port converter out port 71 or port 32 Maximum Temperature 248 F 120 C Hegulator Pressure Vehicle in Neutral amp Port 31 At 600 RPM minimum 326 3 PSI 22 5 bar minimum At 2650 RPM 369 8 PSI 25 5 bar maximum Pump Flowt At 2170 RPM 26 60 GPM 100 7 l min minimum Lube Pump Flow At 2170 RPM selective lube 13 84 GPM 52 4 l min minimum At 2910 RPM 22 35 GPM 84 6 l min minimum Clutch Pressure 1st clutch Port 41 2nd clutch Port 42 3rd clutch Port 43 Ath clutch Port 44 Forward clutch Port 45 Reverse clutch Port 46 At 2200 RPM 297 3 PSI 20 5 bar minimum with 1st clutch activated Filter Bypass Valvet Set at 59 4 65 2 PSI 4 1 4 5 bart Lube Pressure Internal Total Leakage Safety Valve Cracking Pressure Converter Out Pressure Port 34 58 80 PSI 4 0 5 5 bar at 2200 RPM At 1000 engine RPM FWD REV 1 GPM 4 l min maximum 1st 2 43 GPM 9 2 l min maximum 2nd 3rd 4th 1 GPM 4 min maximum Converter 1 3 3 2 GPM 5 12 at 1000 RPM 127 6 139 2 PSI 8 8 9 6 bar Port 33 72 5 PSI 5 bar minimum 2000 RPM and maximum 123 3 PSI 8 5 bar at no load governed speed Refer to TROUBLESHOOTING for check port identification f All pressures and flows to be measured with oil temperature 180 200 F 82 93 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Ho
63. ding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly FIGURE 11 Remove reaction member spacer FIGURE 12 Remove oil baffle retaining ring FIGURE 15 Remove adapter suction hose assembly and o rings from hydraulic pump FIGURE 13 An impeller removal tool like the one shown can be fabricated to facilitate the removal of the impeller and oil baffle FIGURE 16 Remove capscrews from hydraulic pump Refer to Special Tools section for tool design TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 101 Transmission Case Disassembly FIGURE 17 Remove hydraulic pump and o ring FIGURE 20 Remove regulator valve assembly and valve to converter housing gasket FIGURE 21 Remove pump drive blanking cover plate bolts if fitted ro _ _ DIETS 5 FIGURE 19 Remove regulator valve assembly capscrews 1 A E a RE FIGURE 22 Remove pump drive blanking cover plate and gasket if fitted 102 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Disassembly FIGURE 26 Remove pump drive idler gear bearing and support assembly Y TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 103 Transmission Case Disassembly
64. drive plates on turbine cover FIGURE 382 Install impeller cover screws and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 163 Transmission Case Reassembly FIGURE 386 Position drive plates backing ring FIGURE 389 Install temperature switch FIGURE 387 Install drive plate mounting capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 FIGURE 388 Install speed sensor 3 164 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service TORQUE SPECIFICATIONS Lubricated or Plated Screws COARSE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 lbs ft Nem lbs ft Nem 8 10 10 8 13 6 9 11 12 2 14 9 12 16 16 3 21 7 26 30 35 2 40 7 23 25 31 2 33 9 33 36 44 7 48 8 37 41 50 2 55 6 52 57 70 5 77 3 57 63 77 85 80 88 108 119 82 90 111 122 115 127 156 172 113 124 153 168 159 175 216 237 200 220 271 298 282 310 382 420 FINE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 Ibs ft Nem Ibs ft Nem 9 11 12 2 14 9 11 13 14 9 17 6 16 20 21 7 27 1 28 32 38 0 43 4 26 29 35 2 39 3 37 41 50 2 55 6 41 45 56 61 58 64 79 87 64 70 87 95 90 99 122
65. e above 140 F 60 C When the tem perature is above 140 F 60 C the temperature indication on the display starts blinking Now switch to automatic calibration by pressing the M button several times until the APC200 displays tran During this warm up procedure it is possible for the converter out temperature of the transmission to exceed the maxi mum limit This is a consequence of heating up the transmission using this quick procedure When this occurs the engine speed will be limited to half throttle when the APC200 has engine control or forcing neutral when the 200 has no engine control To solve this simply leave the transmission in neutral for a minute and throttle the engine to around 1300 rpm This will allow the heat in the converter to be evacuated After one or two minutes resume the heat ing up procedure if the transmission temperature has not reached 60 C yet FULL IDLE forward neutral TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 10 Automatic Calibration Procedure CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS This chapter gives an overview of the most common calibration condition messages Many calibration condition mes sages can be corrected however if any calibration error messages appear contact the OEM of the machine Calibration Condition Messages The APC200 expects the shift lever to be in NEUTRAL but finds it in
66. ed SD with Full Flow Control Valve Service Third Clutch Reassembly Third Clutch Reassembly FIGURE 177 Remove spring FIGURE 180 Install clutch piston inner seal ja NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection section of the manual FIGURE 178 Remove spring retainer FIGURE 181 Install clutch piston outer seal and install piston into drum FIGURE 179 Remove clutch piston FIGURE 182 Install clutch piston spacer TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 129 Third Clutch Reassembly FIGURE 183 Install spring FIGURE 186 Install clutch outer half disc friction material on one side with steel side down FIGURE 184 Install retainer FIGURE 187 Install steel discs Alternate friction and steel discs until proper number of discs are installed First and last discs are steel FIGURE 185 Compress spring and install retainer FIGURE 188 Install clutch outer half disc friction material on one side with steel side up 130 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Third Clutch Reassembly FIGURE 189 Install end plate FIGURE 192 Heat gear and bearing assembly to 248 F 120 C and install gear Align splines on clutch hub gear with internal teeth of friction di
67. eel drive plate mounting screw hole positioned in Step 3 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step 3 Locate transmission on flywheel housing 6 Align drive plate to flywheel and transmission to fly wheel housing guide studs Install transmission to CONVERTER HOUSING 4 STUD 21 ALIGNING flywheel housing screws Tighten screws to specified c torque Remove transmission to engine guide studs FLYWHEEL AN DRIVE 4 Install remaining screws and tighten to specified torque 7 Remove drive plate locating stud SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED 8 Install drive plate attaching screw and washer Snug FLYWHEEL HOUSING BY ENGINE MANUFACTURER screw but do not tighten Some engine flywheel housings have a hole located on the flywheel hous ing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed tighten each capscrew to 26 29 Ibs ft 35 39 Nem This will require tightening each screw and rotating the engine flywheel un
68. emoved from service based solely on this analysis TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 6 Servicing Machine After Component Overhaul Servicing Machine After Component Overhaul The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for clean ing 3 Replace oil filter element 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning
69. en removing snap ring Failure to comply can cause personal injury FIGURE 267 Heat outer bearing race to 248 F 120 C and install on shaft Turbine Shaft Disassembly FIGURE 268 Remove piston ring FIGURE 271 Using a hydraulic press remove bearing 144 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Turbine Shaft Reassembly Turbine Shaft Reassembly FIGURE 275 Install piston ring FIGURE 272 Warm bearing to 248 F 120 C and install on Impeller and Baffle Disassembly shaft ensuring that retaining ring groove is up as shown Use caution when removing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 277 Remove impeller hub gear TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 145 Impeller and Baffle Disassembly FIGURE 278 Remove oil baffle seal from impeller hub FIGURE 281 Remove impeller from impeller hub FIGURE 282 Remove impeller hub o ring from hub FIGURE 280 Remove impeller hub backing ring FIGURE 283 Remove impeller hub bearing snap ring Use caution when removing snap ring Failure to comply can cause personal injury 146 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Impeller and Baffle Reassembly FIGURE 284
70. er bearing to 248 F 120 C and install on shaft Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 164 Install two 2 piston rings Use caution when installing snap ring Failure to comply can cause personal injury 126 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Third Clutch Disassembly FIGURE 168 Install snap ring Use caution when installing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury Third Clutch Disassembly FIGURE 166 Warm bearing to 248 F 120 C and install on shaft with groove down as shown FIGURE 169 Remove one 1 piston ring FIGURE 167 Install spacer Use caution when removing snap ring Failure to comply can cause personal injury TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 127 Third Clutch Disassembly FIGURE 171 Remove 3rd clutch driven gear and bearing FIGURE 174 Remove end plate FIGURE 172 Remove spacer FIGURE 175 Remove clutch inner and outer discs FIGURE 173 Remove end plate snap ring Use caution when removing snap ring Failure to comply can cause personal injury Use caution when removing snap ring Failure to comply can cause personal injury 128 Dana Holding Corporation TSM 0048 TE27 32 4 Spe
71. erter Pump Drive Section amp Pressure HFeg lallrig 19 Input Shaft and Directional Clutches 20 Range Gluleh s 21 Transmission Controls ceres 22 Electric Solenoid Controls 23 Power Flows Activated Solenoids and Hydraulic Scc ert 24 Gear amp Clutch Layout 42 TROUBLESHOOTING 43 Transmission Problems 43 Troubleshooting Procedures 43 Troubleshooting Guide 46 PROMIS iactis 47 e 50 Full Flow Valve Components 51 Speed Sensor Static Standalone Test 52 EXPLODED VIEWS 53 Converter Housing Group 53 Transmission Case amp Rear Cover Group 55 Turbine Shaft amp Stator Support Group 57 Charging Pump Drive Group 59 Adapter Sleeve Group 61 Torque Converter Assembly Group 63 Drive Plate Group 65 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation Forward Reverse Second amp Fourth Clutch
72. haft Nut Socket 1 0 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service
73. k oil level in the transmission The transmission fluid must be at the correct full level All clutches and the con verter and its fluid circuit lines must be fully charged filled at all times The transmission fluid must be at operating temperature of 180 200 F 82 93 C to obtain correct fluid level and pressure readings NEVER attempt to make these checks with cold oil To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with the converter at stall see Stall Test on page 43 DANGER Be careful the vehicle does not move unexpectedly when operating the engine and converter at stall rpm 45 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Troubleshooting Guide Troubleshooting Guide Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles Low Clutch Pressure 0000 Low Charging Pump Output Overheating Noisy Converter ne charging pump Replace charging pump complete disassembly will be necessary Worn or damaged bearings to determine which bearing is faulty Defective charging pump Replace pump Lack of Power Cause Remedy Low engine RPM at converter stall Tune engine check governor 2 Overheating section above and make same Make corrections as explained in Overheating TSM 0048 TE27 32 4 Speed SD with F
74. l Dana Holding Corporation 82 Output Shaft Group Output Shaft Group 83 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Output Shaft Group DESCRIPTION ITEM O oa A N NJ 10 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual DESCRIPTION Shaft Output Bearing Bearing Retainer Oil Snap Ring Snap Ring O ring Seal Output Oil Cap Bearing Plug ITEM 11 12 13 14 15 16 17 18 19 20 O ring Stud Lockwasher Nut O ring Bearing O ring Washer Flange Locknut Flange Dana Holding Corporation A A AR 84 Regulator Valve Group Regulator Valve Group 85 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Regulator Valve Group ITEM DESCRIPTION QTY 1 Assembly Valve Regulator 1 2 Gasket Valve To Converter 1 Housing 3 O ring 1 4 Pump Hydraulic 1 5 Shaft Gear To Pump 1 6 onap Ring 1 7 Screw 2 8 Adapter Suction Tube Side 1 9 Adapter Suction Transmis 1 sion Case Side 10 Capscrew 8 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual ITEM 11 12 13 14 15 16 17 18 19 DESCRIPTION QTY Hose Suction 1 Clamp Suction 2 O ring 2 Screw 8 Lockwasher 8 Cap Flange 1 O ring 1 Capscrew 4 Lockwasher 4 Dana Holding Corporation 86
75. l disc into sleeve Alternate fifteen 15 washers Refer to Figure 119 drum Alternate friction and steel discs until proper number of discs are installed First and last discs are steel Piston L Wear sleeve FIGURE 119 Spring and spacer position FIGURE 122 Install new seal in end plate TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 119 Reverse amp Second Clutch Reassembly FIGURE 123 Install end plate in drum and fit end plate snap FIGURE 126 Warm outer bearing to 248 F 120 C and install on ring shaft Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 127 FIGURE 124 Warm inner bearing to 248 F 120 C and install on shaft FIGURE 128 Install outer bearing thrust washer FIGURE 125 Install two 2 bearing retaining rings in clutch gear and install clutch gear and hub into clutch drum Align splines on clutch hub with internal teeth of friction discs Tap gear into position Do not force the operation in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage 120 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Forward Clutch Disassembly Forward Clutch Disassembly FIGURE 129 Warm outer bearing to 248 F 120 C and install on shaft with groove down as sh
76. l position with internal teeth of all inner discs Failure to comply may cause equipment damage FIGURE 253 Install two 2 piston rings FIGURE 250 Warm taper bearing to 248 F 120 C TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 141 Output Shaft Disassembly FIGURE 254 Turn shaft and install gear FIGURE 257 Warm bearing to 248 F 120 C and install on shaft Output Shaft Disassembly FIGURE 255 Install gear snap ring Use caution when installing snap ring FIGURE 258 Using a puller remove bearing from shaft Failure to comply can cause personal injury FIGURE 259 Turn shaft and using a puller remove inner bearing race from shaft FIGURE 256 Install bearing spacer 142 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Output Shaft Reassembly Output Shaft Reassembly FIGURE 263 Install snap ring Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 261 Remove gear FIGURE 264 Install gear FIGURE 262 Remove snap ring Use caution when installing snap ring Failure to comply can cause personal injury TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 143 Turbine Shaft Disassembly FIGURE 266 Heat inner bearing race to 248 F 120 C and install on shaft Use caution wh
77. lding Corporation Electrical Specifications Electrical Specifications FWD REV 1st 3rd 2nd 4th Coil Resistance 7 25Q at 68 F 20 C FWD N REV 1st 3rd Selection Valves Coil Resistance 12V 7 1Q at 68 F 20 C Coil Resistance 24V 28 50 at 68 F 20 C Proportional Valves Type Magneto resistive sensor Sensing Distance 0 0 07 0 1 8 mm Sensor Signal Generates a square current with a fixed amplitude changing between 7 and 14 mA Speed Sensor Material Silicon Resistance 77 F 25 C 20000 1 Supply Voltage 4 5 5 5V Maximum Current 10 Pressure Sensor Pressure Range 14 5 450 PSI 1 31 bar 1 2 full scale 450 PSI 31 bar range 14 5 363 PSI 1 25 bar 2 5 full scale 450 PSI 31 bar range 363 450 PSI 25 31 bar Temperature Sensor 5 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual MAINTENANCE Sump preheaters Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up Filters Service oil filter elements the first time at 100 hours and then every 1000 hours under normal environmental and duty cycle conditions Clutch Calibration Perform automatic clutch calibration every 2000 hours Lubricants Recommended Lubricants Only Dextron III is approved Viscosity at 104 F 40 C 33 38 cSt at 212 F 100 C 7 8 cSt Maintenance Intervals
78. nd Clutch Disassembly FIGURE 101 Remove clutch inner and outer discs FIGURE 104 Remove clutch piston spacer wear sleeve The steel discs in the Fwd Rev clutches and in the 1st and 2nd clutches look similar to each other but are not the same Do not mix them To ensure correct reassembly be sure to keep the different types of discs separated and identified FIGURE 105 Remove clutch piston FIGURE 102 Compress return springs and remove snap ring Use caution when removing snap ring Force of spring is 2888 Nem Failure to comply can Cause personal injury FIGURE 103 Remove Belleville washers 116 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Reverse amp Second Clutch Reassembly Reverse amp Second Clutch Reassembly Second Clutch Reassembly FIGURE 108 Install clutch piston spacer wear sleeve FIGURE 106 Install clutch piston inner seal Rotate piston until seal is flush with outer diameter of piston NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection section of the manual NOTE Seal must be sized before installing in clutch drum Sizing is best accomplished by rotating clutch piston while holding a round object against the new seal FIGURE 109 Install piston Belleville washers Position first washer with large diameter
79. ng ring FIGURE 295 Remove turbine hub front bearing washer FIGURE 292 Install impeller hub gear 148 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Impeller Cover amp Turbine Assembly FIGURE 296 Tap turbine hub from impeller cover FIGURE 299 Screw heads with locktabs FIGURE 297 Remove turbine hub screws and locktabs FIGURE 300 Center impeller cover over turbine hub Install bearing in impeller cover and over turbine hub Tap bearing into Impeller Cover amp Turbine Assembly place FIGURE 301 Install spacer Jn E mn FIGURE 298 Align holes in turbine and turbine hub Position locktabs and install screws Tighten screws to specified torque Refer to TORQUE SPECIFICATIONS on page 165 Bend a corner of the locktab over a flat of the screw heads Refer to Figure 299 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 149 Pump Drive Gear Disassembly FIGURE 305 Remove bearing support Pump Drive Gear Reassembly Use caution when installing snap ring Failure to comply can cause personal injury Pump Drive Gear Disassembly FIGURE 306 Press bearing support into bearing and install assembly into gear Use caution when removing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 304
80. number to the transmission area where the step is performed gt Apply a light coat of LOCTITEO 262 or 270 to all thru holes stud holes b Teflon seals must be sized prior to assembly Add grease to seal diameter of clutch hub before assembly Forward and Reverse Clutch gt 2 11 separator discs with outer splines 11 friction discs friction material on both side with inner splines Clearance Min 0 23 6 0 mm Max 0 25 6 4 mm TE2T 8 separator discs with outer splines 8 friction discs friction material on both sides with inner splines Clearance Min 0 23 6 0 mm Max 0 25 6 4 mm Choose an end plate with suitable thickness to obtain this clearance The separator discs in the Fwd Rev clutches and in the 1st and 2nd clutches look similar to each other but are not the same Do not mix them TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 92 Transmission Assembly Instructions 1st Clutch 2 11 separator discs with outer splines 11 friction discs friction material on both side with inner splines Clearance Min 0 17 4 35 mm Max 0 19 4 75 mm TE27 10 separator discs with outer splines 10 friction discs friction material on both sides with inner splines Clearance Min 0 17 4 35 mm Max 0 19 4 75 mm Choose an end plate with suitable thickness to obtain this clearance 2nd Clutch 2 7 separa
81. of bevel toward spacer wear sleeve Refer to Figure 110 Alternate seven washers Wear sleeve Piston Shaft FIGURE 107 Install clutch piston outer seal FIGURE 110 Spring and spacer position TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 117 Reverse amp Second Clutch Reassembly Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 112 Install clutch inner and outer discs into drum Start with one steel disc against piston Alternate friction and steel discs until proper number of discs are installed Last disc is friction disc FIGURE 115 Install clutch piston inner seal Size as described in Figure 106 19 NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection section of the manual FIGURE 113 Install end plate FIGURE 116 Install clutch piston outer seal 118 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Reverse amp Second Clutch Reassembly FIGURE 117 Install clutch piston spacer FIGURE 120 Compress spring and install retaining ring making sure ring is in full position in groove FIGURE 118 Install clutch piston Belleville washers Position first washer with large diameter of bevel toward spacer wear FIGURE 121 Install one 1 clutch inner outer stee
82. on Fourth Clutch Reassembly FIGURE 207 Install clutch piston inner seal NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection section of the manual Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 208 Install clutch piston outer seal and install piston into drum 134 Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Fourth Clutch Reassembly FIGURE 212 Install one 1 clutch outer half disc friction FIGURE 215 Install end plate material on one side steel side down FIGURE 216 Install end plate retaining ring FIGURE 213 Install one 1 friction disc Alternate steel and friction discs until proper number of discs are installed FIGURE 217 Install snap ring over shaft to be used when installing drum shaft in casing FIGURE 214 Install one 1 clutch outer half disc friction material on one side steel side up Use caution when installing snap ring Failure to comply can cause personal injury TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 135 First Clutch Disassembly First Clutch Disassembly FIGURE 218 Warm bearing to 248 F 120 C and install on shaft FIGURE 219 Install bearing snap ring FIGURE 222 Using a puller remove gear
83. on page 165 Dana Holding Corporation 157 Transmission Case Reassembly FIGURE 350 Fit new seal and o ring to 3rd shaft bearing cap FIGURE 353 Install bolts and lockwashers to bearing cap and and install bearing cap tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 FIGURE 351 Install nuts and lockwashers to bearing cap and m tighten to specified torque Refer to TORQUE SPECIFICATIONS FIGURE 354 Install output flange on page 165 FIGURE 355 Install output flange o ring washer and nut FIGURE 352 Install 1st shaft bearing cap with new o rings 3 and spring disc 158 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly HA x p 2 F XJ 1 FIGURE 356 Tighten output flange nut 250 300 Ibs ft FIGURE 359 Install 2nd clutch hub retaining ring spacer and 339 407N em snap ring Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 357 Install 4th clutch hub snap ring Use caution when installing snap ring Failure to comply can cause personal injury TE 4 FIGURE 360 Install new converter housing to transmission case gasket and new o rings 3 FIGURE 361 Install alignment studs and position converter housing assembly onto studs
84. own FIGURE 132 Remove bearing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Miti FIGURE 133 Remove spacer FIGURE 131 Install three 3 piston rings FIGURE 134 Remove bearing TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 121 Forward Clutch Disassembly Wiii FIGURE 135 Remove large snap ring from shaft FIGURE 138 Remove bearing inner race Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 140 Using a puller remove clutch gear and outer bearing Use caution when removing snap ring Failure to comply can cause personal injury 122 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Forward Clutch Disassembly FIGURE 144 Remove bearing Use caution when removing snap ring Failure to comply can cause personal injury Use caution when removing snap ring Force of spring is 3381N m Failure to comply Cause personal injury FIGURE 142 Jury FIGURE 143 Remove clutch inner and outer discs FIGURE 146 Remove Belleville washers TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 123 Forward Clutch Reassembly FIGURE 147 Remove clutch piston spacer wear sleeve FIGURE 148 Remove clutch piston FIGURE 151 Ins
85. r 1 9 Plug 2 3 band Filter Adapter 1 10 O ring 1 4 Plug 1 11 Cap Flange 2 5 Spool Safety Valve 1 12 O ring 2 6 Plug 1 13 Capscrew 8 7 O ring 1 14 Lockwasher 8 NOTE Two sets are required TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 90 INSTALLATION DIAGRAMS Transmission Assembly Instructions gt p p
86. rovide a pressure curve from 0 to 26 bar which will provide clutch overlap When the shift is finalized the 2nd 4th selector valve is deactivated When 4th clutch is selected the 2nd 4th selector valve is not activated The 1st 3rd proportional valve will decrease pressure from 26 to O bar thus releasing the 3rd clutch in a controlled manner At the same time the 2nd 4th propor tional valve is activated and will provide a pressure curve from O to 26 bar which will provide clutch overlap Restriction Plug The pressure line is connected to the drain line via a restricted hole This ensures the drain line to remain air free at all times and guarantees the reliable functioning of the proportional valves Pressure Sensor The control valve also has a pressure sensor installed to monitor overlap on range clutches TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 22 Electric Solenoid Controls Electric Solenoid Controls Gear Selector Valve Proportional Valve Clutches 4 4 d ad Neutral 1 1st 3rd 1st 3rd Heverse 4 REV FWD REV 2nd 4th Reverse 4th Reverse 3 REV FWD REV 1st 3rd Reverse 3rd Reverse 2 REV 2nd 4th FWD REV 2nd 4th Reverse 2nd Reverse 1 REV 1st 3rd FWD REV 1st 3rd Heverse 1st Neutral 2 2nd Ath 2nd Ath 2nd 23 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual
87. rter housing FIGURE 84 Pry forward shaft bearing from housing as shown Check three wear sleeves in converter housing and replace if necessary Reverse and Second Clutch Disassembly Reverse Clutch Disassembly A g FIGURE 88 Remove bearing thrust washer FIGURE 85 Remove piston rings 3 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 113 Reverse and Second Clutch Disassembly FIGURE 92 4s Fes wd snb FIGURE 90 Remove clutch gear and outer bearing as an FIGURE 93 Remove clutch gear inner bearing assembly FIGURE 94 Remowve clutch inner and outer discs Use caution when removing snap ring Failure to comply can cause personal injury 114 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Reverse and Second Clutch Disassembly FIGURE 95 Compress piston return springs and remove spring FIGURE 98 Remove reverse clutch piston retaining ring 2nd Clutch Disassembly Use caution when removing retaining ring Force of spring is 3399 Nem Failure to comply can Cause personal injury Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 97 Remove clutch piston spacer FIGURE 100 Remove 2nd clutch end plate TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 115 Reverse and Seco
88. scs Do not force the operation in this step Gear splines must be in full position with internal teeth of all inner discs Failure to comply may cause equipment damage Use caution when installing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 191 Install spacer TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 131 Fourth Clutch Disassembly FIGURE 194 Install snap ring FIGURE 197 Remove bearing snap ring EMEN m FIGURE 195 Install piston ring FIGURE 198 Using a puller as shown remove front bearing shaft Fourth Clutch Disassembly FIGURE 199 Remove snap ring FIGURE 196 Remove piston rings Use caution when removing snap ring Failure to comply can cause personal injury 132 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Fourth Clutch Disassembly Use caution when removing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 201 Remove end plate FIGURE 202 Remove clutch inner and outer discs FIGURE 205 Remove spring retainer TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 133 Fourth Clutch Reassembly FIGURE 206 Remove clutch pist
89. service Manual SPICER Off Highway Products Powershift Transmission 27 amp TE32 4 Speed Short Drop with Full Flow Control Valve TSM 0048 November 2011 CONTENTS CONTEN TS i Towing Or PUSNING lt 1 2 moli eem 2 Safety Precautions 2 SPEGCIFIGATIONS identification Tag RE eere 3 General Specifications 3 Hydraulic Cooler Lines Specifications 3 Pressure and Temperature Specifications 4 Electrical Specifications 5 Maintenance ome desu d eeu deu mus 6 SUMP prehedle S i5 caeco eo epe ctc 6 uti fes iEn 6 Clutch 6 6 6 Servicing Machine After Component Overhaul 7 Automatic Calibration Procedure _ 8 Drive Plate Installation 12 Transmission to Engine Installation 13 EXTERNAL PLUMBING INSTALLATION 14 Cooler amp Filter Line Specifications 14 SPEED SENSOR INSTALLATION 15 TEMPERATURE SENSOR INSTALLATION 17 TRANSMISSION OPERATION __ 18 Conv
90. smission Case amp Rear Cover Group oo Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual 10 11 12 13 14 15 16 17 18 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual DESCRIPTION Case Transmission Tube 1st Speed Clutch Pres sure Tube Low Shaft Rear Bearing Lube Tube 3rd Speed Clutch Pres sure Sleeve Pressure and Lube Tube O ring Cover Rear Plug Expansion Pin Dowel Capscrew Capscrew Lockwasher Gasket Rear Cover To Trans mission Case Plug Plug Magnetic Drain Sensor Speed Assembly O ring Sensor Speed Assembly Transmission Case amp Rear Cover Group QTY 37 44 ITEM 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 DESCRIPTION O ring Support Speed Sensor Capscrew Tube Suction O ring Lockwasher Capscrew Baffle Oil Cover Oil Baffle Tube Oil Baffle Lockwasher Capscrew Screw Cover Split Flange O ring Capscrew Lockwasher QTY Dana Holding Corporation 56 Turbine Shaft amp Stator Support Group Turbine Shaft amp Stator Support Group 57 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Turbine Shaft amp Stator Support Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Bearing Turbine Shaf
91. ssembly First Clutch Reassembly Output Shaft Disassembly Output Shaft Reassembly Turbine Shaft Disassembly Turbine Shaft Reassembly Impeller and Baffle Disassembly Impeller and Baffle Reassembly Impeller Cover amp Turbine Disassembly Impeller Cover amp Turbine Assembly Pump Drive Gear Disassembly Pump Drive Gear Reassembly Converter Housing Reassembly Transmission Case Reassembly TORQUE SPECIFICATIONS Lubricated or Plated Screws SPEGIAE TOOLS Low amp Output Shaft Lifting HOOK Impeller Cover Lifting Hook Low Shaft Nut Socket TOWING OR PUSHING Before towing the vehicle be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid dam age to the transmission during towing NOTE Because of the design of the hydraulic system the engine cannot be started by pushing or towing 1 Holding Corporation TSM 0048
92. ssure through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit When the clutch is released a return spring will push the piston back and oil will drain back via the shift spool the bleed hole or holes in the clutch piston into the transmission sump These bleed holes will only allow quick escape of oil when the pressure to the piston is released The engagement of all range and directional clutches is modulated and electronically controlled This means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive 162 TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 20 Range Clutches Range Clutches Once a directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the direc tional clutches is similar to the range clutches The engagement of the directional clutches is modulated
93. t Front 1 9 Ring Piston 1 2 Bearing Turbine Shaft Rear 1 10 Baffle Oil 1 3 Spacer Front Bearing 1 11 Seal Oil 1 4 Snap Ring 1 12 Ring Oil Baffle Seal 1 5 Ring Piston 1 13 Ring Oil Baffle Retaining 1 6 Stator Support Assembly 1 14 O ring 1 7 Screw Stator Support 7 15 Snap Ring 1 8 Lockwasher 7 16 Turbine Shaft 1 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 58 5 gt 5 D O Charging Pump Drive Group Speed SD with Full Flow Control Valve Service Manual 0048 TE27 32 4 TSM Dana Holding Corporation 59 Charging Pump Drive Group ITEM DESCRIPTION QTY ITEM 1 Support Pump Drive Bearing 3 7 2 Screw Bearing Support 4 8 3 O ring 4 9 4 Washer 4 10 5 Lockwasher 2 11 6 Screw Bearing Support 2 12 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual DESCRIPTION Bearing Pump Drive Gear Snap Ring Gear Auxiliary Pump Drive Gear Charge Pump Gear Impeller Hub Snap Ring QTY N Dana Holding Corporation 60 Adapter Sleeve Group Adapter Sleeve Group 61 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Adapter Sleeve Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Sleeve Pump Drive 1 2 Snap Ring 1 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve
94. tall clutch piston spacer wear sleeve Forward Clutch Reassembly FIGURE 152 Install clutch piston Belleville washers Position FIGURE 149 Install clutch piston inner seal first washer with large diameter of bevel toward spacer wear sleeve Alternate fifteen 15 washers Refer to Figure 153 NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection section of the manual 124 Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Forward Clutch Reassembly Shaft FIGURE 153 Spring and spacer position FIGURE 156 Install new seal in end plate and install plate Use caution when installing snap ring Use caution when installing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 155 Install steel discs Alternate friction and steel discs FIGURE 158 Warm inner bearing to 248 F 120 C and install on until proper number of discs are installed First and last discs are shaft steel TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 125 Forward Clutch Reassembly FIGURE 159 Install clutch gear into clutch drum Align splines FIGURE 162 Install bearing inner race on clutch hub with internal teeth of steel discs Tap gear into position FIGURE 160 Warm out
95. til the full amount of eight 8 screws have been tightened to specified FLYWHEEL IMPELLER COVER INTERMEDIATE DRIVE PLATES Qali U 1 torque FIG 3 FIG 4 9 Measure engine crankshaft end play after transmis X PLATES TO BE INSTALLED sion has been completely installed on engine fly WITH CONCAVE SIDE wheel This value must be within 0 001 0 025 mm TOWARD ENGINE Police of the end play recorded in Step 2 E FIG 5 Does not apply to units having 3 intermediate drive plates See Figure 4 13 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual EXTERNAL PLUMBING INSTALLATION Cooler amp Filter Line Specifications e Minimum 1 25 4 mm internal diameter for lines and fittings e Suitable for operation from ambient 248 F 120 C continuous operating temperature e Must withstand 435 PSI 30 bar continuous pressure and with 652 PSI 40 bar intermittent surges e Conforms SAE J1019 and SAE J517 100RI remote filter 1 to remote filter 1 from pump 1 cooler ont WU VV VV from cooler to transmission O O O O V 52 70 C 9 E O uc remote filter 2 H H a i 2 Ly A A em SEEN 2 IZA ip a La Ir E 2 E J
96. tion 155 Transmission Case Reassembly FIGURE 338 Install spacer FIGURE 341 Install two aligning studs and install transmission rear cover FIGURE 342 Install rear cover to transmission case bolts and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 165 Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 340 Install transmission case to rear cover new gasket and o rings Use caution when installing snap ring Failure to comply can cause personal injury 156 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Transmission Case Reassembly Use caution when installing snap ring Failure to comply can cause personal injury P s M S cli c Wc r FIGURE 345 Install bearing assembly onto 1st shaft FIGURE 346 Install lock nut on 1st shaft TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual FIGURE 347 Using special tool refer to Special Tools section torque lock nut to 107 118 Ibs ft 145 160 Nem Mu TRE M gt ae 7 T 2 MEM Ta FIGURE 348 Fit new seal and o ring to output shaft bearing cap and install bearing cap FIGURE 349 Install nuts and lockwashers to bearing cap and tighten to specified torque Refer to TORQUE SPECIFICATIONS
97. to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its center and discharges it at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque con verter This element receives fluid at its outer diameter and discharges it at its center The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication is a function of the blading impeller turbine and reaction member and the converter output speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydraulic pump is connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump speed is directly related to engine speed
98. tor discs with outer splines 7 friction discs friction material on both side with inner splines Clearance Min 0 10 2 75 mm Max 0 12 3 15 mm TE27 6 separator discs with outer splines 6 friction discs friction material on both sides with inner splines Clearance Min 0 10 2 75 mm Max 0 12 3 15 mm Choose an end plate with suitable thickness to obtain this clearance 3rd Clutch 2 12 separator discs with inner splines 11 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 14 3 5 mm 0 16 3 9 mm 27 9 separator discs with inner splines 8 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 14 3 5 mm Max 0 16 3 9 mm Choose an end plate with suitable thickness to obtain this clearance Dana Holding Corporation TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Transmission Assembly Instructions V VV VV NW N gt 4th Clutch 2 11 separator discs with inner splines 10 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 12 3 1 mm Max 0 14 3 5 mm TE2T 11 separator discs
99. ull Flow Control Valve Service Manual Dana Holding Corporation 46 Check Points Check Points Front View Port 42 Pressure Check Port 2nd Clutch Port 46 Pressure Check Port Reverse Clutch Port 44 Pressure Check Port 4th Clutch Plug Magnetic Drain M22 x 1 5 UNI Port 34 Pressure Check Port Lube Rear View Plug16B From Remote Filter 1 Port 32 Pressure Check Port to Cooler Temperature Switch Temperature Sensor Port 43 Pressure Check Port 3rd Clutch 47 Dana Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Check Points Right View Port 31 Pressure Check Port Regulator Port 11 to Cooler Port 37 Pressure Check Port Converter In m Engine Speed Sensor Port 45 Pressure Check Port Fwd om oon Im mm Uf 7 a UL it a nn P Cl
100. utch CH Port 12 From Drum Speed y Cooler Sensor c mn Port 16A From Remote Filter Output Speed Sensor Turbine Speed Sensor Ll oo ICH urn ILI GIU Metric Flange for Dipstick Dia 25 4 mm 4 Mounting Holes M20 x 2 5 THD 30 mm Deep Left View H H day Port 41 Pressure _9 Check Port 1st Clutch Corn Oil Level Check Port 1 4 NPT TSM 0048 27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 48 Check Points Top View Port 13B to Port 13A to Remote Filter Remote Filter from Pump 2 from Pump 1 Oil Fill Hole 3 4 14 NPTF 49 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Checkports Checkports System Pressure 65 FWO REV Regulated Pressure _ 2nd
101. ward Reverse Second amp Fourth Clutch Shaft Assembly TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual 67 Dana Holding Corporation Forward Reverse Second amp Fourth Clutch Shaft Assembly ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 4rd Shaft Drum Assembly on 4 1 Fwd Shaft Drum Assembly 1 3 Speed 2 Rev 2nd Shaft Drum Assembly 1 TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 68 Forward Shaft Group Forward Shaft Group 69 DanaHolding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Forward Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 13 Bearing Clutch Driven Gear 1 2 Seal Piston Outer 1 14 Bearing 1 3 Seal Piston Inner 1 15 Bearing 1 4 Screen 1 16 Ring Retaining 1 5 Disc Clutch Inner 11 17 Ring Piston 2 6 Disc Clutch Outer 11 18 Ring Retaining 2 1 Plate End 1 19 Bearing 1 8 Seal 1 20 Spacer 1 9 Snap Ring 1 21 Snap Ring 1 10 Washer Belleville 15 22 Retainer Oil 1 11 Ring Retaining 1 23 Snap Ring 1 12 Spacer Clutch Piston 1 Not Sold Separately TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 70 Third Shaft Group Third Shaft Group TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual 71 Holding Corporation Third Shaft Group ITEM DESCRIPTION
102. with inner splines 10 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 12 3 1 mm Max 0 14 3 5 mm Choose an end plate with suitable thickness to obtain this clearance Be sure that shielded and sealed bearings are mounted as shown Seals must be pressed in perpendicular upon shaft axis from bearing side Tighten air breather to 25 30 Ibs ft 31 41 Nem Tighten nut to 107 118 Ibs ft 145 160 Nem Tighten nut to 250 300 Ibs ft 339 407 Nem Tighten two coil nuts to 5 7 Ibs ft 6 8 9 5 Nem Tighten one valve to 39 54 Ibs ft 53 73 Nem Tighten six screws to 3 7 4 4 lbs ft 5 6 Nem Tighten two coil nuts to 5 7 Ibs ft 6 8 9 5 Nem Tighten two pressure sensors to 5 8 Ibs ft 7 11 Nem Tighten two valves to 25 27 lbs ft 34 36 Nem TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Dana Holding Corporation 94 Transmission Assembly Instructions 95 Holding Corporation TSM 0048 TE27 32 4 Speed SD with Full Flow Control Valve Service Manual Control Valve Assembly Instructions Control Valve Assembly Instructions Remove the Valve Refer to the Cleaning and Inspection See page 97 section of this manual The

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