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TE27 / 32 - This is Test page

1.
2. 27 32 4 50 12 2002 9 2 27132 Assembly instructions lead in chamfers for oil seals pistonrings and 0 1 must be smooth and free from burrs Inspect at assembly Add some grease to 0 rings before assembly Add some grease to piston rings before assembly Apply a thin coating of grease between seal lips on lip type seals prior to assembly Use only precoated pipe plugs On uncoated pipe plugs apply a light coat of Loctite 592 Pump must be filled up with oil prior to assembly After assembly of parts using Loctite there must not be any free or excess material which might enter the oil circuit Apply a light coat of Loctite 262 or 270 to all thru hole stud holes Teflon seals must sized prior to assembly Add some grease to seal diameter of clutch hub before assembly Fwd Rev Clutch TE32 11 seperator plates with outer splines 11 friction plates friction material on both sides with inner splines Clearance Min 6 0mm 0 23in Max 6 4mm 0 2511 TE27 10 seperator plates with outer splines 10 friction plates friction material on both sides with inner splines Clearance Min 6 0mm 0 23in Max 6 4mm 0 2511 Use one of the different thickness end plates available to obtain this clearance CAU
3. 27 TE 27 32 Ath speed clutch shaft GROUP uuu ei na 28 27 32 4th speed clutch shaft GROUP nn ee 29 TE 27 32 Ist shaft gear GROUP nn a a 30 27 32 1st shaft gear GROUP un nannte 31 TE 27 32 Output shaft GROUP sans nein 32 27 32 output shaft group A ee A aaa aa aaa 33 27 32 Oro UD G 34 TE 27 32 Regulator Valve 35 27 32 control valve GROUP nee 36 27 32 control valve GROUP na ae 37 27 32 control Valve GROUP Contt u u na 38 27 32 control valve GROUP A td 39 TE 27 32 remote filter adapter GROUP uch 40 TE 27 32 remote filter adaptor 2 2 22 42 41 9 ASSEMBLY INSTRUCTIONS 1 10 DISASSEMBLY AND REASSEMBLY OF THE TRANSMISSION 1 IT SPESIAETOOBS ee d TE UE IE 1 TE27 32 4 SD 12 2002 TOWING OR PUSHING Before towing the vehicle be sure to lift the rear 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hydraulic system the engine cannot be started by pushing or towing Copyright Dana Spicer Off Higwhay Products Division Unpublished Material All rights reserved Limited Distri
4. 1 8 a her 0 O in e 0 E 1 CS p E CONVERTER SECTION CONTROL VALVE TE27 32 4 SD 12 2002 6 3 Transmission Operation 6 1 2 The 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 ex ternal 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 opposite direction as long as no pressure 15 present in that specific clutch To engage the clutch the solenoid will direct oil under pressure 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 di ameter clamping against discs with teeth on the inner diameter enables
5. Stop Spool Not Sold Seperate Spool Accumulator Not Sold Seperate Spring Accumulator Not Sold Seperate TE27 32 4 SD 12 2002 TE 27 32 REMOTE FILTER ADAPTER GROUP 8 40 12 2002 TE27 32 4 SD TE 27 32 REMOTE FILTER ADAPTOR GROUP Description Qty 1 mili an a 0 1 2 een 1 3 ASS dis 1 4 an RO 1 5 pool Dale VaVe 8 1 6 o 1 1 9 SPANO PPP A A a S a 1 9 Fil E E PEA Eee E 2 10 lu een ieh 2 14 Cap ANG Seti att UU see S 2 12 RNO ee ee 2 13 A eee eee ee 8 14 Bele i a neues ee 9 27 32 4 50 12 2002 8 41 9 ASSEMBLY INSTRUCTIONS TE27 32 4SD 12 2002 9 1 27132 Assembly instructions
6. 10 74 11 SPECIAL TOOLS TE27 32 4 SD 12 02 11 5 10015 To 007006 O0 Sel 11 2 12 02 TE27 32 4 SD 11 special tools 75 00 E a NI CC 35 00 60 00 5 840 2 792 DI ES 50 50 020 4 06000 10 x 45 4 PLACES 0 38 00 150 00 gt 50 00 a 290 00 gt TE27 32 4 SD 12 02 11 3 11 special tools 0006 91 499 WIN 1108444 00 6 00 sopIS 0 06 X 8 ON 408 54015 8 X gt 006 006 005 00 00 66 11 4 12 02 TE27 32 4 SD 11 5 10015 APPLICATION POLICY Capability ratings features and specifications vary depending upon the model type of service Application approvals must be obtained from Spicer Off Highway Products Division We reserve the right to change or modify our product specifications configurations or dimensions at any time without prior notice SPICER OFF HIGHWAY PRODUCTS DIVISION DANA Ten Briele 3 B 8200 Brugge Belgium
7. 2 26 Oll ae cios 1 27 COVER aa 1 28 00 di dias 3 29 0 6 30 E 3 31 SS CREW en E UA 3 32 Covers 0 1 33 A RING M Hn 1 34 A E A 4 35 ee OL keines 4 27 32 4 50 12 2002 8 5 27 32 TURBINE SHAFT GROUP TE27 32 4 SD 12 2002 TE 27 32 TURBINE SHAFT GROUP Description Qty 1 Bearings mime Wohl see kaa Suasana a 1 2 Beads Turbine eisen 1 3 SAC Sa DEAN A e aaa LE aaa a 1 4 2130 0222 O oe 1 5 Fl um dedu i M Mac Rene re 1 6 en da 1 7 SCHEW tator SUDDO or 7 9 A O RUE 7 9 lalo 1 10 m cT erden 1 11 A 8 osa 1 12 5 uu X E kuu Pr SETA St 1 13 Dame Fetal uti elek 1 14 RO no NM IP 1 15 uiae inc Mu ca MR quacum MUI de 1 16 6 EI O
8. 2 LOCKWASHEr 2 A 1 will cT 1 1 X Hom 1 1 Ms 3 3 00 3 alme cr 1 A E a 2 een 0 0 5 E 2 Pl DOW 0 00 2 cH 14 CAD SCI CW CA o 9 MO ad 23 gasket Converter to transmission case 1 BUSNIMO Zee ete 1 Tm ER 1 im 1 SWITCH Temperature 08 1 Temperature 6 leeren 1 DENSON A A a aa E E 1 ORIG 0 1 Sensor Speed GONI dd 1 SUDPONL Speed SENSON EE 2 CaP CEW CP An a a a a 2 wm AAE 2 606 SPIELT Ange o dada cus 3 A DEA A E E A EE 3 12 LOCKWAS 12 aic 1 HQ M 1 27 32 4 50 12 2002 8 3 TE 27 32 TRANSMISSION CASE 8
9. 4 TE 27 32 TRANSMISSION CASE amp REAR COVER 5 27 32 TURBINE SHAFT GROUP l ee aeg 6 27132 TURBINE SHAFT GROUP ina era 7 TE 27 32 PUMP DRIVE GROUP ti denen ee 8 TE 27132 PUMP DRIVE 9 TE 27 32 ADAPTOR SLEEVE 10 TE 27132 ADAPTOR SLEEVE GROUP io a 11 TE 27 32 WHEEL aad 12 TE 27132 WHEEL GROUP aii a adictos 13 27 32 4 SD 12 2002 27 32 DRIVE PLATE a 14 27 32 DRIVE PLATE GROUP uu ayy a a 15 TE 27 32 FWD 8 REV 2ND AND 3TH OR 4TH CLUTCH SHAFT ASSY 16 TE 27 32 FWD 8 REV 2ND AND 3TH OR 4TH CLUTCH SHAFT ASSY 17 27 32 forward cluteh shiaft GROUP aa 18 27 32 forward clutch shaft GROUP een ee a 19 27 32 3rd speed clucth shaft GROUP a en uni an 20 27 32 3rd speed clucth shaft 22 2 2 2 2 21 TE 27 32 3rd speed gear nennen 22 27 32 3rd Speed u ne nee daa 23 TE 27 32 REV 72nd schaft GROUP u En ci an 24 27 32 2nd schaft GROUP ae ende en 25 27 32 15 speed clutch shaft GROUP en 26 27 32 1st speed clutch shaft
10. 4 19 4 27 32 4 50 12 2002 8 35 TE 27 32 CONTROL VALVE GROUP Ss 2 7 gt m _ YO VHS A S 5 ADAN ake INN 57 OY 8 36 12 2002 27 32 4 50 TE 27 32 CONTROL VALVE GROUP Description Qty 1 PASS COMMON VAY Cia tod 1 2 A A 1 3 an Qu ukawa aya 17 4 u A 17 27 32 4 50 12 2002 8 37 TE 27 32 CONTROL VALVE GROUP 6 2 oo 8 38 12 2002 TE27 32 4 SD TE 27 32 CONTROL VALVE GROUP Item gt Description Spacer ONCE ETE Plale Adapter ua Sc A A Plug Restriction Not Sold Seperate Spool Not Sold Seperate VES Nor Sold Seperate ibi Solenoid 24V Not Sold Seperate Clamp VFS Not Sold Seperate Clamp On Off Not Sold Seperate
11. 2 KS r _ PLATES TO INSTALLED 8 Measure engine crankshaft end play after transmission WITH CONCAVE SIDE has been completely installed on engine flywheel This irs value must be within 0 025 mm 0 001 of the end play recorded in step No 2 Does not apply to units having 3 intermediate drive plates See Fig 4 FIG 5 TE27 32 4 SD 12 2002 5 3 Installation details 5 3 EXTERNAL PLUMBING remote filter 1 to remote filter 1 from pump 1 remote filter 2 A Hd Inm m Lr cooler SUN A 4 from remote filter 1 from cooler to transmission 1 to cooler TO from remote filter 2 J 5 3 1 Cooler amp filter lines specifications e Minimum 32 mm 1 25 inch internal diameter for lines and fittings e Suitable for operation from ambient to 120 C 248 F continuous operating temperature e Must withstand 30 bar 435psi continuous pressure and with 40 bar 652 psi intermittent surges e Conform SAE J1019 and SAE
12. 1 9 Washer 6 9 10 Spacer 1 11 eo 1 12 Retales 0 1 13 BEANO 1 14 ISl 1 15 BC AMG 1 16 aiia dl 1 17 RING PISION TEE 2 18 BEAMING cloaca 1 19 o 2 20 PUG esc seed 2 21 nome er ee 2 22 Ro cM 1 23 CBSO GW unas 4 24 LOCKWAS MOT zen ts cada 4 25 1 26 Spacers Mr 1 27 o Le O 1 28 1 29 BEANN RE 1 30 ee 1 31 OP een ae 1 32 1 27 32 4 50 12 2002 8 27 TE 27 32 SPEED CLUTCH 5
13. Figure 198 Figure 201 Remove piston sealing rings Remove retaining snapring from shaft Figure 199 Figure 202 Remove bearing snap ring Remove end plate retaining ring Figure 200 Figure 203 Using a puller as shown remove bearing from Remove end plate shaft TE27 32 4 SD 12 2002 10 38 2 DISASSEMBLY 4 CLUTCH Figure 204 Figure 207 Remove inner and outer clutch plates Remove spacer Figure 205 Figure 208 Remove Compress spring and remove snapring Remove clutch piston Figure 206 Remove spring retainer and spring TE27 32 4 SD 12 2002 10 39 2 REASSEMBLY 4 CLUTCH 1 I Figure 209 Figure 212 Refer to Cleaning amp Inspection pages Install spring and spring retainer The bleed hole in the piston must be clean and free of any foreign material 2 Install clutch piston inner seal See note figure 59 EIA Figure 210 Figure 213 Install clutch piston outer seal And install piston Compress spring and install spring retaing into drum snapring See note figure 59 Figure 211
14. 3SOH 12 2002 2896 3S0H INIA ALIS Jed JAVA 34055 3SOH 160 JAVA 3300038 0 1 01 B 0 0 0 4000 1 02 0 01 9 0 38166388 8 03193135 ANZ A38 19q0 01 9 3NWANQIIVI00ON G3TIONLNOD 17 NOISSINSNVAL 1 5 N LLI E Transmission Operation 6 4 7 Reverse 2nd speed continued TE27 32 4 SD 15 3 O O e FWD 3RD REV 2ND 4TH 12 2002 6 20 Transmission Operation Reverse 3rd speed 6 4 8 H01019 18 086 que 6 21 dins 10 N3339S lt gt 8 HOLNTO HOLATO HOLATO HOLNTO HOLATO 15 CHIP aM nn 6 6 600 6 Je 59 2775 C 8s di ind lt ISOH 3SOH ES D RN Jeq 9 p 1p SSvd A8 3NWA SSVd A8 SHO JONVE NOLLWOMENT 3SOH 3SOH Pd e O N 11 N vr ONZ
15. Install clutch driven gear and hub assembly 1 Warm bearing race to 120 248 F and install Align splines on clutch gear hub with internal omenan splines of friction discs Do not force this opera tion Gear splines must be in full position with internal teeth of all inner discs Figure 252 Figure 255 Warm taper bearing to 120 C 248 F and install Install piston sealing rings on shaft Figure 253 Figure 256 Install bearing spacer Turn shaft and install gear TE27 32 4 SD 12 2002 10 48 2 REASSEMBLY 15 CLUTCH TE Figure 257 Install gear retaing snap ring Figure 258 Install gear retaing snap ring shield Figure 259 Warm bearing race to 120 C 248 F and install on shaft TE27 32 4 SD 12 2002 10 49 2 DISASSEMBLY OF OUTPUT SHAFT Figure 260 Figure 263 Using a puller remove bearing from shaft Remove gear Figure 261 Figure 264 Turn shaft and Using remove bearing inner Remove snapring race from shaft Figure 262 Remove snapring
16. uama 1 2 Fev Shall drum dome liada 1 3 Ord sha assy Speed co UD Ped aaa leise 1 3 4th shaft drum shaft assy on 4 speed unse delle 1 TE27 32 4 SD 12 2002 8 17 TE 27 32 FORWARD CLUTCH 5 GROUP TE27 32 4 SD 12 2002 8 18 TE 27 32 FORWARD CLUTCH SHAFT GROUP Item Description Qty e ace aa M iu ui E 1 0 1 Seal 51910 4 unu 1 MOE Sold Seperate dit 1 2 5011 a NE 11 DUERO O ARA 11 ia AAA A ra nee 1 SEA 1 c uU aiu RI Utd 1 Ae t A e Ett E ee 15 zu mu cu ue aM CI 1 SPACER anne t 1 Bearno 1 NS 1 RM PRIM A 1 Aa nn A 1 FRINGS S terme eee te eiu c el M i ci ee 2 A 2 MON uuu u a 1 a a A a a 1 SMP a 1 O 1 1 27 32 4 50 12 2002 8 19 27 32 3RD SPEED
17. M E 1 SI An 10 AD AE A a a 5 MPEG nee aaa tua Qu aguan M E 1 O a ua tu 1 SEIEN a tM MEI 32 BOCKWA 32 2 ua 2 T 1 y sino T rr pa a ee 1 8 Ring Impeller hub Serew DackiNnd uoc oes ee nn una 1 BEANO tearre a ee 1 S T A 1 A A A A A E 1 So A 1 O RING gas NP 1 M MERE ER 1 1 WDC ICI T 1 27 32 4 50 12 2002 8 13 27 32 27 32 4 50 12 2002 27 32 DRIVE GROUP Description 1 Assembly Drive plate and when used welded nuts 2 Pale DIVE PET 3 FRING BACKING ae 4 CAPS 27 32 4 50 12 2002 8 15 TE 27 32 FWD 8 2 AND 4 SHAFT ASSY 8 16 12 2002 27 32 4 50 TE 27 32 FWD 8 2 AND 4 CLUTCH 5 ASSY Description Qty 1 yuy unpu ETUR au
18. SHAFT GROUP TE27 32 4 SD 12 2002 27 32 3RD SPEED SHAFT GROUP Description Qty 1 O y cent sn MI ee ae rae 1 2 Seseli 2 u uu 1 3 25110210 1 4 MOE SOIG Seperate 0 TERM 1 5 I 50112 ner pt ma UE TM NE 11 6 7 11 7 Disce sc Mall st 2 Rate y Lo ee 1 9 O Ute 1 10 551 ee 15 11 u AS 1 12 Retainer A T ee en ee AE 1 13 etre D I RP 1 14 07 1 15 Edge tb M LI iE 1 16 lag see en 1 17 2 18 2130 ee MEAM M 1 19 lalo sisti icut M 2 20 1 21 3rd speed shaft rear 1 22 7 1 23 li j 5 A HET 1 24 apus ETE 1 25 dde s eM 1 26
19. assembly Figure 225 Remove bearing spacer TE27 32 4 SD 12 2002 Figure 226 Remove end plate retaining ring Figure 227 Remove end plate Figure 228 Remove inner and outer clutch plates 10 43 2 DISASSEMBLY 15 CLUTCH Figure 229 Figure 232 Using a bearing puller remove lower hub taper Remove piston return spring pack roller bearing from shaft Figure 230 Figure 233 Compress piston return spring and remove piston Remove piston return spring spacer return spring snapring Figure 231 Figure 234 Remove spring retaining ring Remove clutch piston 27 32 80 77 1054 2 DISASSEMBLY 15 CLUTCH nz Figure 235 Turn shaft and remove outer bearing race from shaft Figure 236 Remove snapring shield Figure 237 Remove snapring TE27 32 A SD 12 2002 Figure 238 Remove gear 10 45 2 REASSEMBLY 15 CLUTCH Figure 239 Refer to Cleaning amp Inspection pages The bleed hole in the piston must be clean and free gt of any
20. 2 DISASSEMBLY IMPELLOR AND Figure 278 Remove impellor hub gear retaining ring Figure 279 Remove impellor hub gear Figure 280 Remove oil baffle from impellor hub TE27 32 4 SD Figure 281 Remove impellor hub bolts Figure 282 Remove impellor hub backing ring 12 2002 Figure 283 Remove impellor from impellor hub 10 54 2 DISASSEMBLY IMPELLOR AND Figure 284 Remove impellor from impellor hub Figure 285 Remove impellor hub bearing retaining ring Figure 286 Remove impellor hub bearing TE27 32 4 SD 12 2002 10 55 2 DISASSEMBLY IMPELLOR AND Figure 287 Figure 290 Install impellor hub bearing Position impellor hub O ring on hub Figure 288 Figure 291 Install impellor hub bearing retaining ring Position impellor hub bolt backing ring Figure 289 E Position new impellor hub O ring on hub TE27 32 4 SD 12 2002 10 56 TE32 REASSEMBLY OF AND BAFFLE Figure 292
21. Clamp scene eier ie T s u Spool Not Sold Seperate Spool Not Sold Seperate Spring pilot valve Not Sold Spool Switch pilot Not Sold Seperate Plate Separater Not Sold Spool Pressure reducer Not Sold Seperate Spring Pressure reducer Not Sold Seperate Spool Pressure check Not Sold 5 Spring Pressure check Not Sold Seperate Plate Separater Not Sold Stop Not Sold Seperate Intensifier Spool Not Sold Seperate Spring Not Sold O Ring Not Sold Seperate Plug restriction Not Sold
22. Figure 335 Using special tool install output shaft and 1st clutch assembly 5 TE27 32 4 SD 12 2002 ax TUR WAN Install bearing snapring Figure 338 10 65 2 REASSEMBLY OF TRANSMISSION Figure 339 Install transmission case to rear cover new gasket and rings 3 Figure 340 Install 2 aligning studs and install transmission case rear cover Figure 341 Install rear cover to transmission case bolts and tighten to specified torque TE27 32 4 SD 12 2002 Figure 342 Raise output shaft slightly and install bearing retaining ring T Figure 343 Raise 3rd shaft slightly and install bearing retain ing ring Figure 344 bd Install ball bearing assembly onto 1st shaft 10 66 2 REASSEMBLY OF TRANSMISSION Figure 345 Figure 348 Install lock nut on 1st shaft Install nuts and lockwashers to bearing cap and tighten to specified torque See torque chart Figure 349 Fit new seal and ring to 3rd shaft bearing cap and install cap Figure 346 Using special tool torque lock nut to 145 160 Nm 107 118 Lbs ft Figure 347 Figure 350 Fit new seal and O ring to output shaft bearing Install nuts and lockwashers to bearing cap and cap and install cap tighten to specified torque See torque chart TE27 32 4 SD
23. I 1 27 32 4 50 12 2002 8 7 27 32 8 8 12 2002 27 32 4 50 TE 27 32 PUMP DRIVE GROUP Description 1 oupport s ana u 3 2 SCHEW BEANO SUDDO nee mem 4 3 55255525 ET 4 4 4 5 ooo 2 6 ocrew Bearing SUDDO Henne 2 7 Bearing gear nm 3 8 3 9 Gear FAUX PUMP a ado 2 10 Pulm t 1 11 Gear Impeler NOD ei 1 12 A 1 27 32 4 SD 12 2002 8 9 TE 27 32 ADAPTOR SLEEVE GROUP TE27 32 4 SD 12 2002 8 10 TE 27 32 ADAPTOR SLEEVE GROUP Description Qty 1 Sleeve uu uu uuu ua el 1 2 1 27 32 4 50 12 2002 8 11 TE 27 32 GROUP 8 12 12 2002 27 32 4 50 TE 27 32 WHEEL GROUP O1 0 Description Qty MembDer ku uuu u u uu eee ere eae 1 1 Spacer u 1 O 1 AA a re 1 000 1
24. ie ace a RM D TEMOR 4 13 I II S I mE 4 14 mm T v M IM I RP 4 15 PM 1 16 FS AMIN I EM Seu D 1 17 ciis 1 18 NWS 1 19 BO TMU A A A A 1 20 El C a A 1 27 32 4 50 12 2002 8 33 TE 27 32 REGULATOR VALVE GROUP TE27 32 4 SD 12 2002 TE 27 32 REGULATOR VALVE GROUP Description 1 ASSy Valve 60010 1 2 Gasket Valve to converter housing 1 3 o a 1 4 A 1 5 AIL Ge arto tdi as 1 6 SDAPEING er CE 1 7 CREW nn e O 2 8 Adaptor SUCTION TUDE 0 _ _ __ ____ 1 9 Adaptor Suction transmission 00 1 10 0 8 14 o eo e 1 12 2 13 2 14 virile x 8 15 e a aa E 8 16 0 1 17 dme e 1 18 CAS CROW assess
25. 2 DISASSEMBLY 3RD CLUTCH Figure 171 Figure 174 Remove one 1 piston ring Remove spacer Figure 172 Figure 175 Remove clutch gear bearing retaining ring Remove end plate retainnig ring Figure 173 Figure 176 Remove 3rd clutch driven gear and bearing Remove end plate TE27 32 4 SD 12 2002 10 33 2 DISASSEMBLY 3RD CLUTCH Figure 177 Figure 180 Remove inner and outer discs Remove spring retainer Figure 178 Figure 181 Compress spring and remove snapring Remove clutch piston Figure 179 Remove spring and spring retainer TE27 32 4 SD 12 2002 10 34 2 REASSEMBLY 3RD CLUTCH Figure 182 Refer to Cleaning amp Inspection pages The bleed hole in the piston must be clean and free of any foreign material X Install clutch piston inner seal See note figure 59 Figure 183 Install clutch piston outer seal And install piston into drum X See note figure 59 Figure 184 Install piston spacer TE27 32 4 SD 12 2002 Figure 185 Install piston return spring Figure 186 Install piston return spring r
26. TE27 32 4 SD 12 2002 10 58 TE32 REASSEMBLY OF COVER AND TURBINE ASSEMBLY Figure 300 Figure 303 Align holes in turbine and turbine hub Position lock Install washer tabs and install bolts Tighten bolts to specified torque See torque chart Bend a corner of the lock tab over a flat of the bolt heads See figure 301 Figure 301 Figure 304 Install bearing retaing snapring Figure 302 Center impeller cover over turbine Install impeller cover bearing in impeller cover and over turbine hub Tap bearing into place TE27 32 4 SD 12 2002 10 59 2 DISASSEMBLY 8 REASSEMBLY OF PUMP DRIVE GEAR Figure 305 Figure 308 Remove snapring Press support into bearing and install assembly into gear Figure 306 Figure 309 Remove bearing Install bearing snapring Figure 307 Remove support TE27 32 4 SD 12 2002 10 60 2 REASSEMBLY OF CONVERTER HOUSING Figure 310 Install outer pump drive gear assemblies Left and right Put new O rings 4 on bolts install bolts and tighten to specified torque See torque chart Figure 311 Install center pump drive gear assembly Tighten bolts to s
27. p WHLNSN WLOL X X X 9 SA x 3univei3dial ININLEVANOO 0 0 02 0 01 9 0 YIIAISNILNI 38056380 8 03193138 A34 129 0 019 3ATVA NOLLYINAON 0311051 02 0 19313 9 WV vI NOISSINSNVAL 1 TE27 32 4 SD Transmission Operation 6 4 9 Reverse 4th speed continued TS O FWD REV 2ND ATH TE27 32 4 SD 151 77 12 2002 6 24 Transmission Operation 6 5 GEAR AND CLUTCH LAY OUT TE27 32 4 SD 12 2002 7 TROUBLESHOOTING GUIDE TE27 32 4SD 12 2002 7 1 27 32 troubleshooting guide The following information is presented as to isolate and determine specific problem area in transmis sion 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 correct functioning of the other components of the group Therfore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmis sion fluid charging pump torque converter transmission assembly oil cooler
28. TE27 32 4 SD 12 2002 10 50 2 REASSEMBLY OF OUTPUT SHAFT Figure 265 Figure 268 Install snapring Heat bearing inner race to 120 C 248 F and install on shaft Figure 266 Figure 269 Install gear Heat bearing inner race to 120 C 248 F and install on shaft Figure 267 Install snapring TE27 32 4 SD 12 2002 10 51 2 DISASSEMBLY OF TURBINE 5 Figure 270 Figure 273 Remove piston sealing ring Use a hydraulic press to remove bearing Figure 271 Remove bearing retaining ring Figure 272 Remove spacer TE27 32 4 SD 12 2002 10 52 2 REASSEMBLY OF TURBINE 5 Figure 274 Warm bearing to 120 C 248 F and install on shaft Note that retaining ring groove is up Figure 275 Install spacer Figure 276 Install snapring TE27 32 4 SD Figure 277 Install piston sealing ring 12 2002 10 53
29. and install bearing on shaft bearing on shaft with groove down as shown Figure 129 Figure 132 Install bearing snapring Install bearing snapring Figure 130 Figure 133 Install outer bearing thrust washer Install three 3 clutch shaft piston rings TE27 32 4 SD 12 2002 10 25 2 DISASSEMBLY FWD CLUTCH Figure 134 Figure 137 Remove bearing snap ring Remove Remove large snapring from shaft Figure 135 Figure 138 Remove bearing spacer Remove two 2 piston seal rings Figure 136 Figure 139 Remove bearing Remove bearing snap ring TE27 32 4 SD 12 2002 10 26 2 DISASSEMBLY FWD CLUTCH Figure 140 Remove bearing inner race Figure 141 Remove retaining ring Figure 142 Use a puller and remove clutch gear and outer bearing TE27 32 4 SD 12 2002 Figure 143 Remove end plate retaining ring Figure 144 Remove end plate Figure 145 Remove inner and outer clutch discs 10 27 2 DISASSEMBLY FWD CLUTCH Figure 146 Figure 149 Remove inner bearing Remove clutch piston wear sleeve Figure 147 Figure 150 Compress retu
30. GROUP TE27 32 4 SD 12 2002 8 28 TE 27 32 SPEED CLUTCH 5 GROUP Description Qty 1 maji ge ae TERN 1 2 cual i Ono c 1 3 A 1 4 ocreen notsold separate a aa aa A n aa oia 1 5 DISCS CUCAN er ee is 11 6 SX Een Ber Dee 2 7 Dise CCEOU o id DT 14 9 O 1 9 255542 O a 1 10 CIC hi IS COMA MEER 1 11 BIN ii is NS ee DNE 1 12 MING 1 13 RINGS mee te 1 14 umanuan uya MMC HMM 1 15 n a See See 1 16 RE 1 17 aE MEE E 1 18 1 19 RING A ee 2 27 32 4 50 12 2002 8 29 TE 27 32 1ST SHAFT GEAR GROUP 8 30 12 2002 TE27 32 4 SD TE 27 32 1ST SHAFT GEAR GROUP Description Qty 1 sun 1 2 c
31. een LM 1 27 UMP 4 28 89 WAS 2445 4 29 uix phu diu I Md 1 27 32 4 50 12 2002 8 21 TE 27 32 SPEED GEAR N N N N N N 5 5 8 22 12 2002 27 32 4 50 TE 27 32 SPEED GEAR Description Qty 1 Gal Speed usu Si eee ected ca yo caste elle 1 2 SC al ord 5086 01 1 22 un Tm 1 27 32 4 50 12 2002 8 23 TE 27 32 REV 2ND SCHAFT GROUP GRP TE32121 rev 240902 TE27 32 4 SD 12 2002 8 24 TE 27 32 REV 2ND SCHAFT GROUP Item Description Qty 1 ERR 1 2 Seal DISTOMOUIEN e cales dos 1 3 Seal 1 4 Screen Not 1 5 Washer Bolleville eM C 7 6 zn 1 7 RENING ec E 1 9 50 51 o e la 7 9 50501 1 AA A gu A 7 10 1 14 ee eee eee 1 12 mis 1 13 Soal outer ra 1 14 Seale CUCA 0 1 15 Screen NOE Sold Separate 1 16 1 6 AA uuu muta mi oT 1 17 AO zes A 11 18 DISC amp l t
32. Qut 4 N QNZ CHLP 1296 3S0H 9NDIOVMO 3AWA ALJVS 431009 FAA 60 22 3NTVA 1 Z E Z r1 uo1vino3y 4 7 y 1 33058384 ISOH 2 8 8 162 JAWA 0 256 34055344 FE AN SNOOL 0 ES T P WHLNAN WLOL 2 4 L 7 X X X X Y O O O E lt lt 39nv9 gt 0 INSNLSVANOD 0 200 2 0 OL 9 0 YILAISNALNI 38086334 8 09199135 15 3 o 129 0 01 9 3ATVA 0311081 09 2INOH1233 NOISSINSNVAL 631 O CN Transmission Operation 6 4 6 Reverse 1st speed continued O FWD REV 2 4TH 1ST TE27 32 4 SD 12 2002 6 18 Transmission Operation Reverse 2nd speed 6 4 7 6 19 dNNS 10 83825 lt 7 8 HOLM HOLNTO HOLMIO que 15 CHIP QN lt udi 6 6 18 00 udi 26 je 68 3S0H 1eq lt gt INIVASSVAAG Luar 3A WA SSVd A8 6 4311 SIHILND 39NYH
33. 5 1 GONVERTER DRIVE COUPEING gt i aee us illinois aaa 2 5 2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURFE 3 5 3 EXTERNAL 4 5 3 1 COOLER amp FILTER LINES SPECIFICATIONS nennen 4 54 SPEED SENSOR INSTALLATION coccion 5 27 32 4 50 12 2002 1 7 TRANSMISSION 6 6 1 THE IRANSMISSION ASSEMBLYu uuu rri a ea 2 6 1 1 THE CONVERTER PUMP DRIVE SECTION AND PRESSURE REGULATING VALVE 3 6 1 2 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES 4 6 1 3 THE RANGE CLUTCHES na een 5 THE QUTPUT SECTION ito mua energie 5 6 2 THETRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM 6 6 9 ELECTRIC SOLENOID CONTROLS a Eee I 6 6 4 POWERFLOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUlT 7 641 NEUTRAL SELECTED ux tiet an 7 O42 FORWARD SPEED anne een 9 6 43 FORWARD 2ND SPEED uu ae eae leche 11 644 FORWARD SRD SPEED ns ee ee ee 13 6 4 9 FORWARD u ee ee 15 6 4 6 REVERSE TST SPEED ee dit iu 17 8 4 7 REVERSE SPEED sau ted ine ee 19 64 6 REVERSE 9RD SPEED 21 REVERSE4TIPESPEED Am utanwa ed 23 065 XSE
34. Using an impact gun remove output flange nut Remove bolts from 3rd clutch shaft rear bearing cap Figure 45 Figure 48 Output flange nut washer and ring removed Remove 3rd clutch shaft rear bearing cap and ring TE27 32 4 SD 12 2002 10 9 2 DISASSEMBLY OF TRANSMISSION Figure 49 Figure 52 Remove 3rd clutch shaft rear bearing cap locating Remove nuts from output bearing seal and cover ring assy Figure 50 Figure 53 1 Remove 1st clutch shaft rear bearing cap bolts Remove output bearing cover assy L Figure 51 Figure 54 Remove 1st clutch shaft rear bearing cap O rings Remove output bearing locating ring and spring disc TE27 32 4 SD 12 2002 10 10 2 DISASSEMBLY OF TRANSMISSION Figure 55 Figure 58 Remove transmission rear cover bolts Using a hoist remove rear cover from transmis sion case Tap 3rd 1st shaft with a spoft hammer to assist removal and avoid bending shaft aL 8 a fine LS Figure 56 Figure 59 Use special tool to remove nut from 1st shaft Remove snap ring from 3rd shaft bearing See Section 11 Special Tools 4 pN E T __ Figure 57 Figure 60 Remove bearing inner and outer race Remove spacer TE27 32 4 S
35. 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 CAUTION AN Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried immediately by using moisture free compressed air soft lintless absorbent wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound 2 2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 2 2 1 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 Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed TE27 32 4 SD 12 02 2 1 Cleaning inspection and
36. filter connecting lines and con trols including the engine as a complete system By analysing the principles of operation together with the information in this section it should be possible to iden tify and correct any malfunction which may occur in the system 7 1 THE TRANSMISSION TE27 32 powershift transmission with torque converter troubles fall into four general categories 1 Mechanical problems 2 Hydraulical problems 3 Electrical problems 4 Controller problems In addition to mechanical and electrical components all of which must be in 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 5 sures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components 7 2 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES 7 2 1 Stall test A stall test identifies transmission converter or engine problems Use the following procedure 1 Put the vehicle against a solid barrier such as a wall and or apply the parking brake block the wheels 2 Put the directional control lever in FORWARD or REVERSE as applicable 3 Select the highest speed With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission co
37. 2 REASSEMBLY OF TRANSMISSION ee 4 r Figure 362 Figure 365 Install control valve See assembly instructions Install pump drive shaft 5 Figure 363 Figure 6 Install regulator valve and new gasket to converter With new ring in place install pump assem 1 housing bly m 7 oom 364 Figure 367 Install capscrews and torque to specified torque Install pump capscrews and lockwashers and See torque chart tighten to specified torque See torque chart TE27 32 4 SD 12 2002 10 70 2 REASSEMBLY OF TRANSMISSION Figure 368 Install pump manifold and hose fitting new rings if required Figure 369 Install capscrews and lockwashers and torque to specified torque See torque chart Figure 370 Tighten clips on suction hose TE27 32 4 SD 12 2002 Figure 371 Install pump drive shipping covers if fitted and install bolts and lockwashers Tighten to specified torque See torque chart Figure 372 Install impeller and baffle assembly 1 Figure 373 Install impeller hub bearing inner race 10 71 TE32 REASSEMBLY OF TRANSMISSION Figure 374 Using a soft drive tap oil baffle down to seat cor rectly Figure 375 Install oil baf
38. J517 100Rl TE27 32 4 SD 12 2002 5 4 Installation details 5 4 SPEED SENSOR INSTALLATION Position sign On the sensor body there is a small plastic triangular position sign Make sure the position sign on the sensor points as shown below in the direction of the movement of the gearteeth Teeth rotation as shown Teeth rotation 1 65 42 0 Screw Tighten to 5 9 7 4 Ibf ft Position sign 8 10 Nm Plug Screw Tighten to 5 9 7 4 Ibf ft O rin Support S 22 8 10 IT ng Sensor installed Hole plugged Sensor position on transmission TE27 32 4 SD 12 2002 5 4 SPEED SENSOR INSTALLATION CONTINUED Position sign 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 Following table shows the relation between wire colour pin number and connection Colour PinNumber Function Connection __ BROWN Current Input BLUE Current Output Position sign Pin 2 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 Following table shows the relation between wire colour pin number and connection Function Connection Current Input Curren
39. OHLY 1846 3SOH 9NDIOVHO 3NIVA 331009 F 164 zz 3NWA E m _ m ra 1 7_ 7 TT 1 38058384 ISOH Z 2 8 8 1 8 Si 0 38155384 MW 3NOYOL 21 TWIN WLOL 4 4 2 0 I 3onvo 00 1 0 208 02 0 O 9 0 YILAISNALNI 38056380 8 03193135 086 WVYOVIC OFINVYCAH NOISSINSNVAL 2531 184 0 OL 9 SATIVA NOLLWIACON GATIONLNOD SINOYLOATA TE27 32 4 SD Transmission Operation 6 4 8 Reverse 3rd speed continued TE27 32 4 SD 12 2002 Transmission Operation Reverse 4th speed 6 4 9 181 082 due 6 23 dNNS 110 3925 6 gt Y3HIVIY8 HOLNTO HOLNTO HOLNTO HOLNTO HOLNTO 15 My 216 ye utur1 01 6 Je 69 RS lt lt 3SOH 3SOH D D 4 Jeq N 160 9 3AWASSVd A8 Lun ANTWA SSVd A8 c 49111 SSHOLNTO JONVY F CN 7a 7 N N QN 1896 3SOH ONDMIOVEO ALIVS 431000 F 1 2 164 lu _ r1 Z r1 7 YOLWIN9I8 7 ad T U 34058384 3S0H 8 8 189 Z IATA von 6 34055344 MW 3NOYOL
40. REAR COVER GROUP BO oo 00 Gy 8 4 27 32 4 50 12 2002 TE 27 32 TRANSMISSION CASE 8 REAR COVER GROUP Description Qty 1 Case TRANSMIS MN e 1 2 Tube 1stspeedcluich pressure E 1 3 Tube Low shaft rear bearing 1 4 Tube 3rd speed 5 reelle 1 5 Sleeve Pressure amp IUDr TUD6 en 1 6 Eee 6 7 COVEr e o a e 1 8 ET 1 9 DOW Gl di aaa 2 10 echter 37 11 Ele 7 12 LOCKWAS MOT see 44 13 Gasket Rear cover to transmission 1 14 wit ME 2 15 o Too LIE 1 16 Sensor SPEE 1 17 ent PH 1 18 DENSOP Speed ASS amuka m 1 19 SO ee 1 20 DUPPONL Speed Sensor u u uu di dias 2 21 CAS ChOW Pu 2 22 C 1 23 emm 1 24 000 __ 2 25 A
41. foreign material A Install clutch piston inner seal See figure 243 See note figure 59 Figure 242 lt Install clutch piston return disc springs First spring with large diameter of bevel towards wear sleeve Alternate nine 9 springs PISTON ah Figure 240 Figure 243 Install clutch piston outer seal And install piston into drum See note figure 59 Figure 241 Figure 244 E Install wear sleeve Install clutch piston return disc springretainer us Make sure return spring retainer is fitted with stepped groove up TE27 32 4 SD 12 2002 10 46 2 REASSEMBLY 15 CLUTCH Figure 245 Compress return spring and install return spring retainer Make sure retaining ring is in full contact in groove Figure 246 Install one 1 friction disc Alternate steel and froction plates until proper amount of discs are installed Figure 247 Install end plate TE27 32 4 SD 12 2002 Figure 248 p 4 zu Install end plate retaining snapring Figure 249 Warm taper bearing to 120 C 248 F and install on shaft Figure 250 Install bearing spacer 2 REASSEMBLY 15 CLUTCH Figure 251 Figure 254
42. reverse pressure intensifier Range selection 3rd and 4th clutch are fed with modulated pressure supplied through their respective pressure intensifiers and electronic controlled modulation valves 1st clutch is selected when 1st 3rd electronic controlled modulation valve and 1st 3rd solenoid are activated The pilot pressure of the 1st 3rd solenoid will move the shift spool so that 1st clutch can be fed with modulated pressure 2nd clutch is selected when 4th 2nd electronic controlled modulation valve and 4th 2nd solenoid are activated The pilot pressure of the 4th 2nd solenoid will move the shift spool so that 2st clutch can be fed with modulated pressure Pressure switch The control valve also has a pressure switch installed between the total neutral shift spool and the pressure in tensifiers supply This switch will verify that pressure to the various pressure intensifiers is supplied only when the total neutral solenoid is activated This information is an input of the APC200 box 6 3 ELECTRIC SOLENOID CONTROLS Transmission gear Activated solenoids Activated clutches Forward 4 N FWD 2nd 4th Forward 4th Forward 3 N FWD 1st 3rd Forward 3rd Forward 2 FWD 2nd 4th 2nd 4th range Forward 2nd Forward 1 N FWD 15 3 1st 3rd range Forward 1st Neutral Reverse 3 N REV 1st 3rd Reverse 3rd Reverse 2 N REV 2nd 4th 2nd 4th range Reverse 2nd Reverse 1 N REV 1st 3rd 1st 3rd range Reverse 1st TE27 32 4 SD 12 20
43. stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No 3 Locate transmission on flywheel housing FLYWHEEL DRIVE _ ob SS PLATE Aligning drive plate to flywheel and transmission to flywheel housing guide studs Install transmission to flywheel housing screws Tighten screws to specified torque Remove transmission to engine guide studs Install remaining screws and tighten to specified torque SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER 6 Remove drive plate locating stud BE 7 Install drive plate attaching screw and washer Snug screw but do not tighten Some engine flywheel housings have a hole located on the flywheel housing 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 Torque each 35 to 39 N m 26 29ft lbs This will require tightening each screw and rotating the engine FIG 3 FIG 4 flywheel until the full amount of eight 8 screws have been tightened to specified torque li AS FLYWHEEL 22 E COVER 22222224 INTERMEDIATE DRIVE PLATES
44. xo 7 NIYIVYI JAWA 1488 431009 1 2 20 SATA 22 2 uolv1n933 4 7 T 3 065344 ISOH c 8 8 8 180 Z SATA NN 0 34155384 2 Tal Tal Pal AN 3NVEOL pm ru WLOL 7 7 0 O O 39nvo lt enr JUNLVWZANAL ININLEIVINOD YO 0 189 02 0 01 9 0 Y314ISNILNI 34188350 8 03193135 AM4 OFINVYCAH NOISSINSNVAL GEIL 1840019 JAVA NOILVINGOW 041104109 TE27 32 4 SD Transmission Operation 6 4 5 Forward 4th speed continued TE27 32 4 SD c FWD REV 2ND 4 3RD 1ST 12 2002 6 16 Transmission Operation 6 17 ISINSNZEILH dNNS 10 N3389S 6 gt HOLNTO HOLNTO HOLNTO HOLNTO HOLNY H91n19 que 15 My 2 E lt lt 20 wdi 6 6 600 216 3e utu 09 lt ISOH 3SOH D D 1eq 52 Jeq Gp FATWA SSvd A8 SSVd A8 6 S3HILND TL 3SOH 3SOH u 18
45. 02 6 6 6 4 POWERFLOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT Neutral Selected Transmission Operation 6 4 1 6 7 dNNS 10 N33408 lt se HOLATO HOLNTO HOLATO HOLATO HOLNTO HOLATO que 18 My amd d 6 ye utu 900 76 ye utu 8 dnd dnd lt lt 350 3SOH D D 260 9 p 1 y 3AWASSVd A8 JAVA 55 48 811 T 3SOH 3SOH 1 4 ot N H 4 f N 18 086 N 1896 ONDIOVEO JAWA ALJVS 431000 F 1 ZZ 3ATVA rg uolv1no3y 1 3unss3ud ISOH A gt 8 8 8 220 Z 3ATVA yon 8 E 34155380 YSILIIANOO Tal Tal Tal Tal AN 30401 m WULNAN 17101 0 0 0 4 0 3 1 0 266 02 0 01 9 0 53148 31 34185384 8 03193138 NOISSINSNVAL 1 1840 OL 9 NOILVINGOW 01311041509 9INOS193T3 TE27 32 4 SD Transmission Operation 6 4 1 Neutral Continued TE27 32 4 SD 12 2002 6 8 ission Transm 6 4 2 Forward 1st speed HOLNTO 18 086 7 ISLAM4ZEILH 21119 HOLNTO HOLNTO 18 A38 02 0 OL 9 0 H3IHISN31NI 38166380 8 1840 OL 9 SAT
46. 12 2002 10 67 2 REASSEMBLY OF TRANSMISSION Figure 351 Figure 354 Install 1st shaft bearing cap with new rings 3 Install output flange ring washer and nut and spring disc Figure 352 Figure 355 Install bolts and lockwashers to bearing cap and Tighten output flange nut to 339 407 Nm 250 tighten to specified torque See torque chart 300 Lbs ft Figure 353 Figure 356 Install new oil seal on output flange and install Install 4th clutch hub and snapring flange on shaft TE27 32 4 SD 12 2002 10 68 2 REASSEMBLY OF TRANSMISSION Figure 357 Install 204 clutch hub Figure 358 Install 2 clutch hub retaining ring spacer and snapring Figure 359 Install new converter housing to transmission case gasket and new rings 3 27 32 4 50 12 2002 Figure 360 Install alignment studs and position converter housing assembly on on studs Note Turning output shaft will assist in aligning clutch hubs with clutch assembly Install converter housing to transmission housing bolts and lockwashers and tighten to specified torque See torque chart Caution Bolts are not to be used to pull converter and transmission housing together A Figure 361 Install aligning studs and install new valve gasket 10 69
47. 21 Piston Wear sleeve Shaft Figure 118 Figure 121 Install clutch piston in drum as shown Use caution as not to damage inner and outer piston sealing rings TE27 32 4 SD 12 2002 10 23 2 RESASSEMBLY 8 2ND CLUTCH Figure 122 Figure 125 Compress spring and install retaining ring Install install end plate in drum and fit end plate retaining ring Note Make sure ring is in full position in groove Figure 123 Figure 126 Install one 1 steel disc into drum Alternate fric Warm inner bearing to 120 248 F and install tion and steel discs until proper amount of discs is bearing on shaft installed First and last disc are steel Figure 124 Figure 127 Install new seal in end plate Install two 2 bearing retaining rings in clutch gear 3 and install clutch gear and hub into clutch drum Align splines on clutch hub with internal teeth of frintion discs Tap gear into position Do not force this operation Gear splines must be aligned with internal teeth of all friction discs TE27 32 4 SD 12 2002 10 24 2 RESASSEMBLY 8 2ND CLUTCH Figure 128 Figure 131 Warm outer to 120 248 and install Warm outer bearing to 120 248
48. 5 5 bar 311 8 369 8 PSI activated Filter bypass valve set at 4 1 to 4 5 bar 59 4 to 65 2 PSI Lube pressure port 33 1 76 2 64 bar 25 5 38 2 PSI at 73 I min 19 2 GPM converter flow Internal total leakage at 1000 engine RPM Fwd Rev 4 l min 1 GPM 1st 10 5 I min 2 7 GPM 2nd 3rd 4th 4 min 1 GPM Safety valve cracking pressure 9 0 bar 130 5 PSI To cooler convereter out pressure port 32 2 bar min 29 0 PSI at 2000 RPM and max 5 0 bar 72 5 PSI at no load governed speed All pressures and flows to be measured with oil temperature of 82 93 C 180 200 F Refer to section troubleshooting for check port identification TE27 32 12 2002 3 5 Technical specifications 3 5 ELECTRICAL SPECIFICATIONS Electronic controlled modulation valves VFS 2nd 4th VFS 1st 3rd VFS Fwd VFS Rev coil resistance 4 35 0 35 Q at 25 C 77 F On Off Solenoids Total neutral and 1st 3rd amp 2nd 4th range solenoids Coil resistance 12V 28 2 at 20 C 68 F Coil resistance 24V 28 2 at 20 C 68 F Speed sensor Type Magneto resistive sensor Sensing distance 0 1 8 mm 0 0 07 Sensor signal generates a square current with a fixed amplitude changing between 7 and 14 mA 3 6 HYDRAULIC COOLER LINES SPECIFICATIONS Minimum 37 mm 1 25 internal diameter for lines and fittings Suitable for operation from ambient to 120 C 248 F continuous operating temperature Must w
49. 9 0 UIIISNILNI 34088384 8 NOISSINSNVAL 6641 461 0 01 9 SATVA NOILVINGOW 0311041 09 09IN0319313 6 11 40105 110 3905 lt 4 6 500 6 6 68 7 3SOH 3SOH FU 200 9 7 INIVASSVAAG 831113 SSVd A8 6 4311 SSHOLNTO 8 1 m 3SOH ISOH N 4 N 1806 3S0H SNDIOVNO JAVA ALAS 431009 1 ZZ 3ATVA 1 350 120 Z FATWA 34055344 2 ANOYOL WHLNAN WLOL 39nv9 3onvo lt 3unss3ug JYNLYYJANIL INAWLYVdNOO YOLVYSdO TE27 32 4 SD Transmission Operation 6 4 3 Forward 2nd speed continued FWD REV TE27 32 4 SD 2ND 4 3RD 1ST lt I 12 2002 6 12 ission Operation 6 4 4 Forward 3rd speed Transm HOLATO que QUEOMAZEI H HILNDD HOLATO HOLATO 18 129 07 0 OL 9 0541 48 31 38188384 8 0 019 NOILVINGOW 0411081 19413 aur HOLATO HILNDD aua 41941385 046 IN
50. AD COARSE THREAD LBF FT Nom LBF FT N m LBF FT N m 5 6 9 6 7 8 6 7 8 10 8 10 12 15 10 12 13 16 15 18 20 25 22 28 80 35 26 30 35 40 30 37 40 50 44 48 60 65 48 55 65 75 27 32 12 2002 Technical specifications THREAD SIZE TORQUE LBF FT Num 10 1 8 10 14 1 5 10 12 M18 1 5 34 41 M22 1 5 148 60 M33 x 2 112 140 3 3 2 ELASTIC STOP NUT TORQUE THREADSIZE LBF FT 9 16 18 12 15 16 20 34 16 20 25 27 34 3 3 3 TORQUE TABLES FOR O RING PLUGS THREAD SIZE TORQUE 1H8x27 7 8 1 8 x 27 9 14 sei 3 3 4 TORQUE TABLE FOR PIPE PLUGS THREAD SIZE TORQUE quem ws M18 x 1 5 6H 25 30 34 41 M26 x 1 5 6H 45 50 61 68 27 32 12 2002 Technical specifications 3 4 PRESSURE amp TEMPERATURE SPECIFICATIONS Normal operating temperature 70 120 C 158 248 F measured at temperature check port to cooler port 71 maximum allowed transmission temperature 120 C 248 F Transmission regulator presure neutral port 31 at 600 RPM 17 bar 246 5 PSI minimum at 2650 RPM 22 bar 319 0 PSI maximum Pump flow System pump flow 100 5 l min 26 34 GPM at 1973 RPM Lube pump flow 85 1 l min 22 48 GPM at 1973 RPM Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 Fwd clutch port 45 Rev clutch port 46 at 2200 RPM 21 5 2
51. ARANDCEUTGCEPEAYOLET uuu einer 25 ZTROUBLESHOOTING GUIDE 4 ee esse 1 3 TAE TRANSMISION Sui y kuu uu A LU Mu d ui uU 2 7 2 THE INPUT SHAFT AND DIRECTIONAL 5 2 7 2 STALL TEST einen 2 7 2 2 TRANSMISSION PRESSURE CHECK uyu u nun nun anne nun en eren 3 7 2 3 MECHANICAL AND ELECTRICAL CHECKS 3 ZA TAY DRAUEIG CHECR CT 3 1 3 TROUBLESHOOTING GUIDE iter a 4 1 31 PRESSURE ee eier 4 7 3 2 LOW CHARGING PUMP OUTPUT 4 7 33 OVERHEATING uu u 25555254 22 8 553 22 225524 29222424922 222520146 2543620 0 2 525055 4 7 34 NOISE CONVERTER coros di 4 1 3 9 OF POWER itii ERE 4 TA CHECKPOINTS 5 7 5 SPEED SENSOR STATIC 8 8 SECTIONAL VIEWS 8 PARTS 1 TE 27 32 TORQUE CONVERTER GROUP rere a ea Eee 2 TE 27 32 TORQUE CONVERTER GROUP uuu Ri 3 TE 27 32 TRANSMISSION CASE amp REAR COVER
52. AVECAH NOISSINSNVAL 6631 120 JAVA 38068384 6 13 dNNS 10 N33u2S c uidi 6 6 Je 6 00 uidi 6 6 je 98 diANd 3SOH Jeq lt gt JAVA SSvd A8 Luar 3NWA SSVd A8 54 91019 39NYH 1 3S0H 12 2002 4816 350 ONDIOVHO AL3VS Jed JAVA HO1V 10938 1 34058384 ISOH 0 3NOYOL lt INSAWLYVdNO9 YOLVYsAdO TE27 32 4 SD Transmission Operation 6 4 4 Forward 3rd speed continued TE27 32 4 SD FWD REV 2ND 12 2002 4TH 3RD 1ST 6 14 6 15 Transmission Operation Forward 4th speed 6 4 5 HLFOMSZEILH IAS 10 lt Y3HLV388 HOLNTO HOLNTO HOLNTO de 15 My aM 3 2 3 2 3 2 6 Je utu 500 6 6 3e 8 lt 3SOH 3SOH L2 D 1 3NWA SSVd A8 ya 0 8 6 SSHOLNTO NOILVOINANT 3SOH Ot NY CN q 1811 que 126
53. CAREFULL THAT THE VEHICLE DOES MOVE UNEXPECTEDLY WHEN OPERATING THEENGINE AND CONVERTER AT STALL RPM 7 2 5 Controller APC200 Please refer to functional description TE27 32 4 SD 12 2002 7 3 27 32 troubleshooting guide 7 3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles 7 3 1 Low clutch pressure Cause 1 Low oil level 2 Clutch pressure regulating valve stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings 5 Clutch piston bleed valve stuck open 7 3 2 Low charging pump output flow Cause 1 Low oil level 2 Suction screen clogged 3 Defective charging pump 7 3 3 Overheating Cause 1 Worn oil sealing rings 2 Worn charging pump 3 Low oil level 4 Dirty oil cooler 5 Restriction in cooler lines 7 3 4 Noisy converter Cause 1 Worn charging pump 2 Worn or damaged bearings 7 3 5 Lack of power Cause 1 Low engine RPM at converter stall 2 See Overheating and make same checks TE27 32 4 SD Remedy 1 Fill to proper level 2 Clean valve spool and housing 3 Replace pump 4 Replace sealing rings 5 Clean bleed valve thoroughly Remedy 1 Fill to proper oil level 2 Clean suction screen 3 Replace charging pump Remedy 1 Remove disassemble and rebuild converter assy 2 Replace charging pump 3 Fill to proper level 4 Clean co
54. D 12 2002 10 11 2 DISASSEMBLY OF TRANSMISSION In MI Figure 61 Figure 64 N Use a puller to remove shaft bearing Whilst hoisting shaft and drum remove baffle plate Figure 62 Figure 65 Remove plate bolts 3 1st shaft drum assy and output shaft assy removed A a A 1 Figure 63 Figure 66 1 Use special tool as shown and remove 1st shaft Remove 3rd shaft drum assy L drum assy and output shaft together as shown 4 See also figure 67 before hoisting TE27 32 4 SD 12 2002 10 12 2 DISASSEMBLY OF TRANSMISSION Figure 67 Forward drum assy removed showing snapring and front bearing snapring sits under gear and must be removed before forward drum can be hoisted Figure 68 Remove forward drum assy bearing oil retainer Figure 69 Remove 1st shaft drum assy front bearing retaining ring TE27 32 4 SD 12 2002 Figure 70 Remove 1st shaft drum assy front bearing oil retainer Figure 71 Remove 1st shaft drum assy front bearing Figure 72 Remove output shaft front bearing snapring 10 13 2 DISASSEMBLY OF TRANSMISSION Figure 7 Remove output shaft front bearing oil retainer Figure 74 Remove output shaft front bearing F
55. ESSURE TESTING THE FOLLOW ING MECHANICAL AND ELECTRICAL CHECKS SHOULD BE MADE CHECK THE PARKING BRAKE AND INCHING PEDAL FOR CORRECT ADJUSTMENT BE SURE ALL LE VER LINKAGE IS PROPERLY CONNECTED AND ADJUSTED IN EACH SEGMENT AND AT ALL CONNECTING POINTS THE CONTROLS ARE ACTUATED ELECTRICALLY CHECK THE WIRING AND ELECTRICAL COMPONENTS BE SURE THAT ALL COMPONENTS OF THE COOLING SYSTEM ARE GOOD CONDITION AND OPERATING CORRECTLY THE RADIATOR MUST BE CLEANTO MAINTAIN PROPER COOLING AND OPERATING TEMPERA TURES FOR THE ENGINE AND TRANSMISSION AIR CLEAN THE RADIATOR IF NECESSARY 7 2 4 Hydraulic checks ALSO BEFORE CHECKING THE TRANSMISSION CLUTCHES TORQUE CONVERTER CHARGING PUMP AND HYDRAU LIC CIRCUIT FOR PRESSURE AND RATE OF FLOW IT IS IMPORATANT TO MAKE THE FOLLOWING TRANSMISSION FLUID CHECK CHECK OIL LEVEL IN THE TRANSMISSION THE TRANSMISSION FLUID MUST AT THE CORRECT FULL LEV EL ALL CLUTCHES AND THE CONVERTER AND ITS FLUID CIRCUIT LINES MUST BE FULLY CHARGED FILLED AT ALL TIMES NOTE AN THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 93 C 180 200 F TO OBTAIN CORRECT FLUID LEVEL AND PRESSURE READINGS DO ATTEMPT 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 CONVERTER AT STALL REFER 6 2 1 STALL TEST CAUTION
56. Figure 214 lt Install spacer Install one 1 half disc friction material on one 1 side steel side down TE27 32 4 SD 12 2002 10 40 2 REASSEMBLY 4 CLUTCH Figure 215 Figure 218 Install 1 friction disc Alternate steel Install end plate retaining ring froction plates until proper amount of discs are installed Figure 216 Figure 219 Install one 1 half disc friction material on one 1 Install snapring over shaft to be used when side steel side up installing drum shaft in casing Figure 217 Figure 220 Install end plate Warm bearing to 120 C 248 and install on shaft TE27 32 4 SD 12 2002 10 41 2 REASSEMBLY 4TH CLUTCH Figure 221 Install bearing retaining ring Figure 222 Install piston rings TE27 32 4 SD 12 2002 10 42 2 DISASSEMBLY 15 CLUTCH Figure 223 Remove piston rings T c A Figure 224 Using a puller remove gear bearing bearing outer race and spacer
57. Figure 294 Make sure that hub mounting surface and tapped N Install impeller hub gear holes are cleaned with solvent Install self locking screws and tighten to 58 64 Ft Ins 79 87 Nm Note Assembly of hub must be completed within a fifteen minute period from start of screw installation The special screw is to be used for one 1 installation only If the screw is removed for any reason it must be replaced The epoxy left in the hub holes must be removed with the proper tap and the hole must be cleaned with solvent Dry the holes thoroughly and use a new screw for reinstallation k Figure 295 Install impeller hub gear retaining ring Figure 293 coat of Loctite 638 to the outer di ameter of the oil baffle oil seal press oil seal in oil baffle wit lip of seal down Install oil baffle O ring TE27 32 4 SD 12 2002 10 57 2 DISASSEMBLY OF IMPELLOR COVER AND TURBINE ASSEMBLY Figure 296 Figure 299 Remove turbine hub front bearing retaining ring Remove turbine hub bolts and lock tabs Figure 297 Remove turbine hub front bearing washer Figure 298 turbine hub from impeller cover
58. ISESE clics ds ad caco 1 27 32 4 SD 12 2002 8 31 TE 27 32 OUTPUT SHAFT GROUP ANN AAG MOH ANN NAKA NW AAAS T 3 lt A E eet AN x c Fe Y 5 NJ Z ES NY bah onu d gt 2 LA NNN NS 5 5 MAN ND a N N NW 5 AY A 5 lt C 22 gt 2222 NNN ler 22 lt k N 5 0 7 lt 20 2 8 32 12 2002 27 32 4 50 TE 27 32 OUTPUT SHAFT GROUP Description Qty 1 l anpi 1 2 Heer 1 3 BEIN amma c TS 1 4 REIS Me E ee 1 5 SIVA MING ee Al tt 1 6 1 ON 1 8 SEA 01101101 20 05 5 E mau mua 1 9 1 10 ee LIO 1 11 N S LIU ES 1 12 251
59. Maintenance and Service manual TE27 32 POWERSHIFT TRANSMISSION 4 SPEED SHORT DROP SPICER OFF HIGHWAY PRODUCTS DIVISION Manual 8100102 CD ROM 8100101 able Contents TOWING OR PUSHING FOREWORD SAFETY PRECAUTIONS ee 1 2 CLEANING AND INSPECTION u ul uy Es 1 21 CEEANING re ee 2 2 121 BEARINGS vu E 2 2 1 2 Lei rcl 2 22 2 2 2 1 2 2 22 OIL SEAES GASKETS BIC een ine ee 3 2 2 3 GEARS 8 SHAFTS tn 3 2 2 4 HOUSINGS COVERS OU cucuta ci dai lie 3 2 3 LEGEND SYMBOLS a A As 3 3 TECHNICAL SPECIFICATIONS 2 eters umanan sas basa 1 3 1 IDENTIFICATION OF THE 2 3 2 WEIGHT DIMENSIONS OIL CAPACITY 2 3 3 TIGHTENING TORQUES zn ns 8442 0010 05022058 dla 3 3 4 PRESSURE 8 TEMPERATURE SPECIFICATIONS 5 35 ELECTRICAL SPECIFICATIONS ana ee qua 6 3 6 HYDRAULIC COOLER LINES SPECIFICATIONS J 6 MAINTENANCE diana lion 1 41 OIL SPECIFICATION Studi di 2 4 1 1 RECOMMENDED LUBRICANTS 2 4 2 MAINTENANCE 2 211 DAM ec 2 422 NORMAL DRAIN PERIOD cu oo 2 4 3 SERVICING MACHINE AFTER COMPONENTS 3 S INSTALLATION DET Sian 1
60. Normal drain period Normal drain period and oil filter element change are for average environment and duty cycle condition Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination For extreme conditions judgement must be used to determine the required change intervals Every 500 hours Change oil filter element Every 1000 hours Drain and refill system as follows Drain with oil at 65 93 C 150 200 1 Drain transmission 2 Remove and discard filter Install new filter 3 Refill transmission to FULL mark TE27 32 4 SD 12 2002 4 2 Maintenance 4 Run engine at 500 600 RPM to prime convertor and lines 5 Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 82 2 93 3 C 180 200 F make final oil level check and adjust if ecessary to bring oil level to FULL mark NOTE IS RECOMMENDED THAT FILTER CHANGED AFTER 100 HOURS OF OPERATION ON NEW REBUILT OR REPAIRED 4 3 SERVICING MACHINE AFTER COMPONENTS 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
61. Output speed sensor Turbine speed sensor 4 Mounting holes Metric flange for dip stick 25 4mm M20 x 2 5 THD 30mm DEEP RIGHT VIEW Port 41 Pressure check port lst clutch Oil level check port 14 LEFT VIEW TE27 32 4 SD 12 2002 7 6 27 32 troubleshooting guide 7 4 POINTS CONTINUED Port 13b To remote filter from pump 2 TE27 32 4 SD TOP VIEW 12 2002 Port 13a To remote filter from pump 1 Oil fill hole 74 1 4NPTF 7 7 27 32 troubleshooting guide TE27 32 4 SD Checkpoint A VFS 4th 2nd Checkpoint B VFS FWD Checkpoint C VFS 3rd 1st Checkpoint D VFS REV Checkpoint E Booster REV Checkpoint Booster FWD Checkpoint G Booster 4th 2nd Checkpoint H Booster 3rd 1st Checkpoint System pressure before Total Neutral Checkpoint System pressure After Total Neutral Checkpoint L Pilot pressure Checkpoint M Pressure check range clutches 5 12 2002 7 8 27 32 troubleshooting guide 7 6 SPEED SENSOR STATIC STANDALONE TEST In order to be able to sense the currents a series resistor of e g 200 2 must be used This resistor 15 integrated the controller but when the sensor 15 to be used it must be connected extern
62. TION The seperator plates for Fwd and Rev and Ist and 2nd are not the same DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES gt Ist Clutch TE32 11 seperator plates with outer splines 11 friction plates friction material on both sides with inner splines Clearance Min 4 35mm 0 171 Max 4 75 0 19 n TE27 10 seperator plates with outer splines 10 friction plates friction material on both sides with inner splines Clearance Min 4 35mm 0 1711 4 75 0 19 n Use one of the different thickness end plates available to obtain this clearance TE27 32 4 SD 12 2002 9 3 27132 Assembly instructions 2nd Clutch TE32 7 seperator plates with outer splines 7 friction plates friction material on both sides with inner splines Clearance Min 2 75mm 0 10 Max 3 15mm 0 121 TE27 6 seperator plates with outer splines 6 friction plates friction material on both sides with inner splines Clearance Min 2 75mm 0 10 Max 3 15mm 0 12in Use one of the different thickness end plates available to obtain this clearance gt 3rd Clutch TE32 12 seperator plates with outer splines 11 friction plates friction material on both sides with inner splines 2 l sided friction plates friction material on one 1 side with outer splines Clearance Min 3 5mm 0 141 Max 3 9mm 0 16in TE27 6 seperator plates with outer splines 6 friction plates friction material on both sides with inner splines 2 l sid
63. VA 0311081 9IN0319313 CHL HOLM H LNTO 03193135 15 OFINVYCAH NOISSINSNVAL 2531 18101 N 180 Z 34065344 6 9 dNNS 10 lt gt 6 6 Je ur 800 6 Je uiu 8 414 3S0H Jeq lt gt SSVd A8 Luar 5 8 6 4311 S3H91019 39NYH 1 3SOH 12 2002 1846 350 ONDIOVHO JAVA AL3VS 124 3NIVA 1 33058384 ISOH 0 01 39nv9 39nv9 1 4 TE27 32 4 SD Transmission Operation 6 4 2 Forward 1st speed continued TE27 32 4 SD FWD REV 2ND 4TH 3RD 1ST 12 2002 Transmission Operation 6 4 3 Forward 2nd speed HOLMTO HOLNTO HOLNTO HOLNTO HOLNTO 18 A38 DN DN DN q lt y er ANZ OHLY 7 086 18 L r1 n ro r1 2 2 03193138 129 02 0 OL
64. ally 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 7mA ImA current level or 2 6 3 0V for 14mA ImA current level If the teeth can be moved slowly distinct toggling between the two levels should be noticed sensor 200 Ohm 1 Watt TE27 32 4 SD 12 2002 7 9 8 SECTIONAL VIEWS 8 PARTS IDENTIFICATION TE27 32 4 SD 12 2002 8 1 TE 27 32 TORQUE CONVERTER GROUP 2 2 4 67 p O de r Pd A cru des dea niv 1 PA 10 7 I mW 101 ltr ity N 4 Ir as 6 25 nn 2 2 uu RT 22 TE27 32 4 SD 12 2002 8 2 27 32 00 4 O gt Description Qty Torque 68 a aba 1 uz uruy tal 1 PIUG _ _ _________ Aa 3 Pl 1 SORIN e atados 1 jc een 1 1 1 A ee 2 lao PP e 2
65. at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter This element receives fluid at its outer diameter and discharges it at its centre The reaction member of the torque converter is located between and at the centre 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 function of the blading impeller turbine and reaction member and the converter out put 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 in direct relation with the engine speed
66. bution No part of this work may be reproduced in any form under any means without direct written permission of the Dana Spicer Off Highway Products Division TE27 32 4 SD 12 02 This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF HIGWAY PRODUCTS product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechanic studies the instructions in this manual carefully and uses it as refer ence when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAY PRODUCTS ap proved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment SPICER OFF HIGHWAY PRODUCTS does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied or ap proved b
67. ch 0ller o 11 19 Plate EI a 1 20 1 21 Tarifi uhuy P 1 22 Wasner Bel 15 23 tese pn 1 24 e 1 25 000 1 26 FNC CELUI uuu OO 0 asa shu 1 27 aille ER CLAIM E 1 28 a 1 29 1 20 RING zes nee ee 1 31 Washers eeepc 1 32 Flip PPP 1 33 ee 1 34 VUNG T hinasqa qaa 1 35 A PA 1 36 RING PISION IP e 3 27 32 4 SD 12 2002 8 25 TE 27 32 1ST SPEED CLUTCH SHAFT GROUP 8 26 12 2002 TE27 32 4 SD TE 27 32 1ST SPEED CLUTCH SHAFT GROUP Description Qty 1 PISION se ETT 1 2 1 3 Sd PISTOM NMG 1 4 Screen NOt Seperate 0 1 5 DISC 11 6 Clica cct 11 7 wikio rm 1 8 m
68. 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 cleaning 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 using oil compressed air and steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes IMPORTANT AN DO NOT USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES 5 Reassemble all components and use only type oil recommended for lubrication section Fill transmission through filler opening until fluid comes up to the oil level check port Run engine 2 minutes at 500 600 R P M to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 R P M Add quantity necessary to bring fluid level to oil l
69. ed friction plates friction material on one 1 side with outer splines Clearance Min 3 5mm 0 141 Max 3 9mm 0 16in Use one of the different thickness end plates available to obtain this clearance gt 4th Clutch TE32 11 seperator plates with outer splines 10 friction plates friction material on both sides with inner splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Min 3 1mm 0 121 Max 3 5mm 0 141 TE27 8 seperator plates with outer splines 7 friction plates friction material on both sides with inner splines 2 1 sided friction plates friction material on one 1 side with outer splines Clearance Min 3 1mm 0 121 Max 3 5mm 0 141n Use one of the different thickness end plates available to obtain this clearance TE27 32 4 SD 12 2002 9 4 27132 Assembly instructions Be sure shielded and sealed bearings mounted as shown Tighten air breather to 31 41 Nm 25 30 Lbs ft Tighten nut to 145 160 Nm 107 118 Lbs ft Tighten nut to 339 407 Nm 250 300 Lbs ft VVVVV TE27 32 4 SD 12 2002 Seals must be pressed in perpendicular upon shaft axis from bearing side 9 5 27132 Assembly instructions 12 2002 e e e 27132 Assembly instructions Disassembly of control valve Make sure that aera oround the valve is clean and that no foreign material can enter the control valve during disassembly R
70. efer to Cleaning and Inspection pages Unscrew the 4 hex bolts marked red with white numbers on the drawing until you feel that the bolts is loose Do not remove the bolt Unscrew the 17 other hex bolts until all hex bolts are handloose You should be able to move the valve slightly Remove 2 hex bolts and replace with aligning studs Now remove the remaining loose bolts and remove the valve Reinstalling the valve Using aligning studs install valve and a new gasket Handtighten all bolts 21 pieces in the sequence as on the drawing page 8 6 Torque all bolts in the same sequence to 20 25 Nm 14 7 18 5Lbs ft TE27 32 4 SD 12 2002 9 7 10 DISASSEMBLY AND REASSEMBLY OF TRANSMISSION TE27 32 4 SD 12 2002 10 1 2 DISASSEMBLY OF TRANSMISSION Figure 1 Figure 4 Front view of the TE32 Transmission Remove impeller cover bearing cap and ring Figure 2 Figure 5 Remove flex plate mouting bolts and washers Remove turbine shaft outer retaining snap ring Caution bearing cover may drop Figure 3 Figure 6 Drive plate and backing ring removed Remove converter assembly bolts TE27 32 4 SD 12 2002 10 2 2 DISASSEMBLY OF TRANSMISSION Figure 7 1 Figure 10 Use special tool to lift impeller and cover assembly Remove reaction member Figure 8 Figure 11 Remove turbine locating rin
71. eing disassembled 5 Figure 86 Figure 89 Remove piston sealing rings 3 Remove bearing spacer Figure 87 Figure 90 Remove bearing retaining ring Remove clutch gear retainning snapring Figure 88 Figure 91 Use bearing puller 0 remove bearing Remove clutch gear and outer bearing as an L assembly 1 TE27 32 4 SD 12 2002 10 17 2 DISASSEMBLY 8 2ND CLUTCH Figure 92 Remove end plate snapring Figure 93 Remove end plate and seal assy Figure 94 Remove clutch gear inner bearing Figure 95 Remove inner and outer discs Figure 96 Compress piston return springs and remove spring retaining snapring Caution A Force of springs is 3399N Figure 97 Remove piston return springs TE27 32 4 SD 12 2002 10 18 2 DISASSEMBLY 8 2ND CLUTCH 2nd being diassenbled Figure 98 Figure 100 Remove piston return springs spacer Remove 2nd clutch end plate snapring Figure 99 Figure 101 Remove reverse clutch piston Remove 2nd clutch end plate Figure 102 Remove inner and outer discs No
72. ening a clamping device 27 32 4 50 Eventualimente riutilizzable sostituire necessario Possibly still serviceable renew if necessary 12 02 Insere pressione nel circuito idraulico pressure into hydraulic circuit Pulire To clean 2 2 3 TECHNICAL SPECIFICATIONS TE27 32 4 SD 12 2002 3 1 Technical specifications Oe OTTO rs SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 BELGIUM MODEL SERIAL 3 1 IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number 3 2 WEIGHT DIMENSIONS OIL CAPACITY Weight dry 865 1903 Ibs Max length 940 mm 37 0 Max width 665 mm 26 2 Max heigth 970 mm 38 2 Oil capacity 60 liter 15 9 US gallon without cooler and hydraulic lines Consult Operators manual on applicable machine for system capacity TE27 32 12 2002 3 2 Technical specifications 3 3 TIGHTENING TORQUES 3 3 1 TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED SCREW THREADS GRADE 5 FINE THREAD COARSE THREAD LB FT N m LB FT N m 9 1 123 149 8 10 GRADE 8 FINE THREAD COARSE THREAD LB FT N m LB FT N m ES 180 2500 11 13 150 178 9 1 CLASS 8 8 CLASS 10 9 GRADE 12 9 COARSE THREAD COARSE THRE
73. etainer Figure 187 Compress spring and Install piston return spring retainer retaining ring 10 35 2 REASSEMBLY 3RD CLUTCH Figure 188 Figure 191 Install half disc friction material on one side with Install clutch disc end plate steel side down Figure 189 Figure 192 Install one steel disc Alternate friction and steel Install clutch disc end plate retaing ring disc until proper amount of discs are installed First and last disc are steel Figure 190 Figure 193 Install half disc friction material on one side with Install spacer steel side up TE27 32 4 SD 12 2002 10 36 2 REASSEMBLY 3RD CLUTCH Figure 194 Heat gear and bearing assy to 120 C 248 F and install gear Align splines on clutch hub gear with internal teeth of friction discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs 2 Figure 195 Install bearing retaining ring 4 Figure 6 Install piston ring TE27 32 4 SD 12 2002 Figure 197 Install piston ring 10 37 2 DISASSEMBLY 4TH CLUTCH
74. evel check port Recheck with hot oil 180 200 F 82 93 C 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary DEXRON is a registered trademark of GENERAL MOTORS CORPORATION TE27 32 4 SD 12 2002 4 3 5 INSTALLATION DETAILS TE27 32 4 SD 12 2002 5 1 Installation details 5 1 CONVERTER DRIVE COUPLING Measure the A dimension bolt circle diameter and order drive plate kit listed below Note three 3 kits have 2 intermediate drive plates and one 1 drive plate and weld nut assembly Three 3 kits with three intermediate drive plates 1 DRIVE PLATE AND WELD NUT ASSEMBLY BOLT CIRCLE DIA BOLT CIRCLE DIA BACKING RING 2 INTERMEDIATE DRIVE PLATES BACKING RING 3 INTERMEDIATE DRIVE PLATES Dimension Bolt circle diameter Dimension Bolt circle diameter 15 381 0 mm diameter 15 381 0 mm diameter 16 406 4 mm diameter 16 406 4 mm diameter 17 431 8 mm diameter e 17 431 8 mm diameter Each kit will include the following parts Each kit will include the following parts 2 Intermediate drive plates 3 Intermediate drive plates 1 Drive plate and weld nut assembly 1 Backing ring 1 Backing ring 6 Mounting screws 6 Mounting screws 6 Lock washers e 6 Lock washers 1 Instruction sheet 1 Instruction sheet Position drive plate and weld nut assembly on torque converter assembly
75. fle retaing ring Make sure retaining ring is in full contact in grrove L Figure 377 Install reaction member with thin side of blades inwards to impeller 4 11 1 Figure 378 Install reaction member snapring Figure 376 Figure379 Install reaction member spacer Install turbine hub rear retaining snapring on shaft TE27 32 4 SD 12 2002 10 72 2 REASSEMBLY OF TRANSMISSION Figure 380 Figure 383 gt Position new ring on impeller cover and install di new ring on bearing cap and install cover and turbine assembly on shaft Figure 381 Install impeller cover bolts and lockwashers and tighten to specified torque See torque chart Figure 384 Position flex plates on turbine cover Figure 382 Figure 385 Install turbine retaining snapring Position flex plates backing ring TE27 32 4 SD 12 2002 10 73 2 REASSEMBLY OF TRANSMISSION Figure 386 Install flex plate mounting bolts and lockwashers and tighten to specified torque Figure 387 Install speed sensors 3 Figure 388 Install temperature sensor TE27 32 4 SD 12 2002
76. g from turbine shaft Remove reaction member spacer Figure 9 Figure 12 Remove reaction member retaining snap ring Remove oil baffle retaining ring TE27 32 4 SD 12 2002 10 3 2 DISASSEMBLY OF TRANSMISSION Figure 13 Figure 16 An impeller removal tool like the one shown can Remove pump manifold screws be fabricated to facilitate the removal of the impel ler and oil baffle Figure 14 Figure 17 1 Remove pump manifold screws and hose clips Remove pump manifold cap screws m Figure 5 Figure 8 Remove pump manifold screws and hose Remove pump drive sleeve TE27 32 4 SD 12 2002 10 4 2 DISASSEMBLY OF TRANSMISSION Figure 19 Figure 22 Remove regulator valve cap screws Remove pump drive blanking cover plate and gasket If fitted Figure 20 Figure 23 Remove regulator valve and gasket Remove stator support bolts and lockawashers Figure 21 Figure 24 Remove pump drive blanking cover plate bolts Remove stator support fitted TE27 32 4 SD 12 2002 10 5 2 DISASSEMBLY OF TRANSMISSION E Figure 25 Figure 28 Remove pump drive idler gear bolts Remove Pump drive Position A Figure 26 1 Figure 29 Remove Pump drive idler gear bearing and sup Remove Pump drive gear bolts Position port 55 Figure 27 Figure 30 Rem
77. igure 75 Remove turbine shaft bearing snapring TE27 32 4 SD Figure 76 Remove turbine shaft needle roller bearings 2 Figure 77 Remove inner baffle plate bolts 3 12 2002 Figure 78 Remove suction tube assy bolts 10 14 2 DISASSEMBLY OF TRANSMISSION Figure 79 Remove suction tube assy and ring TE27 32 4 SD 12 2002 10 15 2 DISASSEMBLY OF CONVERTER HOUSING Figure 80 1 Figure 83 Using external snapring pliers open rev 2nd drum Remove turbine shaft bearing retaining ring shaft assy bearing retaining ring and remove shaft Figure 81 Figure 84 Remove 4th drum shaft assy retaining ring Using a soft hammer tap turbine shaft and bear ing assy from converter housing Figure 82 1 Figure 85 Remove 4th drum shaft assy m Pry forward shaft bearing from housing as shown Note Check 3 wear sleeves in converter housing and replace if necessary TE27 32 4 SD 12 2002 10 16 2 DISASSEMBLY 8 2ND CLUTCH Reverse b
78. ithstand 30 bar 435 PSI continuous pressure and 45 bar 652 PSI intermittent surges Conform SAE J1019 and SAE J517 100RI TE27 32 12 2002 3 6 4 MAINTENANCE 27 32 4 50 12 2002 4 1 Maintenance 4 1 SPECIFICATION 4 1 1 Recommended lubricants Only Dexron Ill is approved to use SUMP PREHEATERS Preheat the transmission fluid to the mimimum temperature for the oil viscosity used before engine startup NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hrs for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated detioration or contami nation Judgement must be used to determine the required change intervals for extreme conditions EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids Appropriate change intervals should be deter mined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metals analysis can provide useful inforamtion but a transmission should not be removed from service based solely on this analysis FILTERS Service oil filter element every 500 hrs under normal envirronmental and duty cycle conditions 4 2 MAINTENANCE INTERVALS 4 2 1 Daily Check oil level daily with engine running at idle 600 RPM and oil at 82 93 C 180 200 F Maintain oil level at full mark 4 2 2
79. legend symbols 2 2 2 Oil Seals Gaskets Etc Replacement of spring load oil seals rings metal sealing rings gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time Further 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 particularly when being installed Cutting scratching or curling under of lip of seal seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recommended type Automatic Transmission Fluid before assembly 2 2 3 Gears and Shafts If magna flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or splines twisted and that shafts are true 2 2 4 Housing Covers etc Inspect housings covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefu
80. lly for evidence of cracks or conditions which would cause subsequent oil leaks or failures 2 3 LEGEND SYMBOLS Smontaggio di sottogruppi Disassembly of assembly groups Montaggio di sottogruppi Reassemble to from assembly group Sostituire con ogni montaggio Renew at each reassembly Smontaggio di particollari ingombranti Remove obstruction parts Togliere mettere la sicura Unlock lock e g split pin locking plate etc Montaggio di particollari ingombranti Reinstall remount parts which had obstructed disassembly Mettere la sicura incollare mastice liquido Lock adhere liquid sealant Attenzione indicazione importante Attention important notice Evitare danni ai materiali danni ai pezzi Guard against material damage damage to parts Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc Marchiari prima dello smontaggio per il montaggio Mark before disassembly observe marks when reasembl T Attrezzature speciali Pagina T Special tool P Page Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc Rispettare direzione di montaggio Note direction of installation Scarricare olio lubrificante Drain off oil lubricant Controllare esaminare controllo visuale Visual inspection Tendere Tighten clamp tight
81. nd plate and install plate Install two 2 bearing locating rings in clutch gear and install clutch gear into clutch drum Align splines on clutch hub with internal teeth of steel discs Tap gear into position See note figure 127 Figure 159 Figure 162 Install end plate retaining ring Warm outer bearing to 120 C 248 F and install bearing on shaft TE27 32 4 SD 12 2002 10 30 2 REASSEMBLY CLUTCH Figure 163 Install bearing snapring Figure 164 Install bearing inner race Figure 165 Install bearing retainig ring TE27 32 4 SD 12 2002 Figure 166 Install two 2 piston rings Figure 167 Install retaining ring over shaft before fitting bear ing Figure 168 Warm outer bearing to 120 C 248 F and install bearing on shaft with groove down as shown 10 31 2 REASSEMBLY CLUTCH Figure 169 Install bearing spacer Figure 170 Install snapring TE27 32 4 SD 12 2002 10 32
82. nverter outlet oil temperature reaches the operating range 70 C 158 F 4 Once the oil temperature reaches 70 C 158 F check max 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 Be tween gears allow the converter outlet temperature to cool down to 70 C 158 F by selecting neutral If max stall speed measured is below specifications it could indicate an engine or converter problem If max stall speed measured is above specifications it could indicate slipping clutches CAUTION 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 EXCESSIVETEMPERATURE 120 C 250 F MAXIMUM WILL CAUSE DAMAGETO TRANSMISSION CLUTCHES FLUID CONVERTER AND SEALS TE27 32 4 SD 12 2002 7 2 27 32 troubleshooting guide 7 2 2 Transmission pressure checks TRANSMISSION PROBLEMS CAN BE ISOLATED BY THE USE OF PRESSURE TESTS WHEN THE STALL TEST INDI CATES SLIPPING 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 7 2 3 Mechanical and electrical checks PRIOR TO CHECKING ANY PART OF THE SYSTEM FOR HYDRAULIC FUNCTION PR
83. oil retainer See case figure 325 TRANSMISSION OIL RETAINER BEARING Figure 322 Figure 325 Install suction tube bolts and washers and tighten to specified torque See torque chart Pes AED Figure 323 Figure 326 Install oil baffle plate and spacers 3 Add Loctite Install output shaft and oil retainer snapring 262 to bolts threads and install from other side of transmission Torque to specified torque See torque chart TE27 32 4 SD 12 2002 10 63 2 REASSEMBLY OF TRANSMISSION Y Figure 327 Figure 330 Install 1st clutch shaft bearing Install 1st clutch shaft bearing snap ring Figure 328 Figure 331 Install 1st clutch shaft oil retainer Install fwd shaft bearing oil retainer E See figure 328 See figure 332 TRANSMISSION TRANSMISSION SHAFT SHAFT 1 7 Pad OIL RETAINER OIL RETAINER BEARING BEARING Figure 329 Figure 332 TE27 32 4 SD 12 2002 10 64 2 REASSEMBLY OF TRANSMISSION Figure 333 Install clutch and drum as an assembly Figure 336 Warm 3rd shaft bearing to 120 248 F and istall on shaft with snap ring groove up NM Figure 334 Install special tool as shown Figure 337 Install bearing spacer
84. oler 5 Change cooler lines Remedy 1 Replace charging pump 2 A complete disassembly will be necassary to determine which bearing is faulty Remedy 1 Tune engine check governor 2 Make corrections as explained in Overheating 12 2002 7 4 27 32 troubleshooting guide 7 4 CHECK POINTS TE27 32 A SD Port 34a Pressure check port Lube Port 42 Pressure check port 2nd clutch IR EN PN PN Port 46 Pressure check port Rev clutch Port 44 Pressure check port 4th clutch i AC 2 Tm FRONT VIEW ug Magnetic drain M22 x 1 5 UNI Port 16b From remote filter 1 2 ort 32 Pressure check port 4 9 cooler 5 Temperature switch 47 Port 43 Pressure check port 3rd clutch eo REAR VIEW 12 2002 7 5 27 32 troubleshooting guide 7 4 POINTS CONTINUED Port 31 Port 11 Pressure check port To cooler Regulator Engine speed sen sor Port 45 Pressure check port Fwd clutch Clutch drum gear speed sensor Port 42 From cooler
85. ove Pump drive gear bolts Position A Remove Pump drive Position B TE27 32 4 SD 12 2002 10 6 2 DISASSEMBLY OF TRANSMISSION Figure 31 Figure 34 See assembly instructions for disassembly of Remove temperature sensor control valve Figure 32 Figure 35 Remove control valve and gasket Remove converter housing to transmission case and washers Figure 33 Figure 36 Remove all sensors from converter housing 3 Support converter housing with chain hoist and strap Use a soft hammer to seperate converter housing from transmission case TE27 32 4 SD 12 2002 10 7 2 DISASSEMBLY OF TRANSMISSION Figure 40 Figure 37 T Converter assembly removed L Remove inner retaining ring from 2nd clutch hub Note REVERSE AND 2NS AND 4TH CLUTCH DRUMWILL RE MAIN IN THE CONVERTER HOUSING Figure 38 Figure 41 Remove snap ring from 2nd clutch hub Driven gear Remove 2nd clutch hub Figure 39 Figure 42 Remove washer from 2nd clutch hub Remove snapring from 4th clutch hub and remove hub TE27 32 4 SD 12 2002 10 8 2 DISASSEMBLY OF TRANSMISSION 1 Figure 43 Figure 46 Install special tool to prevent 1st shaft from dam Remove output flange aging bearing See special tool section Figure 44 Figure 47
86. pecified torque L 4 i Figure 312 Install 4th speed outer roller bearing in converter housing TE27 32 4 SD 12 2002 Figure 313 From the rear of the housing tap turbine shaft and bear ing in converter housing Tap shaft until gear shoulders is against converter housing Figure 314 From the front of the housing install turbine shaft bearing locating ring Tap shaft until ring is in full position in groove Figure 315 Install new O ring on stator support Position stator support on turbine shaft Turn stator support to clear pump drive gear Align support holes with converter housing 10 61 TE32 REASSEMBLY OF CONVERTER HOUSING Figure 316 Figure 319 Install stator support nolts and washers and tighten bolts to Install 4th shaft and drum assembly snap ring specified torque Figure 317 Figure 320 Spread ears on snapring and install 2nd Rev clutch drum Install needle roller bearings on 2nd Rev and 4th shafts assembly into converter housing Figure 318 Install 4th shaft and drum assy into converter housing TE27 32 4 SD 12 2002 10 62 TE32 REASSEMBLY OF TRANSMISSION Figure 321 Figure 324 Install suction tube and ring into transmission Install output shaft bearing and
87. rn spring and remove snapring Remove clutch piston Note Force of disc spring is 3381N Figure 148 Remove return spring pack TE27 32 4 SD 12 2002 10 28 2 REASSEMBLY FWD CLUTCH Figure 151 Refer to Cleaning amp Inspection pages The bleed hole in the piston must be clean and free of any foreign material Figure 154 Install clutch piston return disc springs First spring with large diameter of bevel towards wear sleeve Alternate fifteen 15 springs Install clutch piston inner seal See figure 155 See note figure 59 Piston Wear sleeve VA Shaft Figure 152 Install clutch piston outer seal N Figure 155 See note figure 59 Figure 153 Figure 156 Install clutch piston wear sleeve Compress spring and install snapring TE27 32 4 SD 12 2002 10 29 2 REASSEMBLY FWD CLUTCH Figure 157 Figure 160 Install one steel disc Alternate friction and steel Warm outer bearing to 120 C 248 F and install disc until proper amount of discs is installed bearing on shaft First and last disc are steel Figure 158 Figure 161 Install new seal in e
88. t Output Temp Input NOTE THE SENSOR WIRES POLARITY BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR TE27 32 4 SD 12 2002 5 6 6 TRANSMISSION OPERATION TE27 32 4 SD 12 2002 6 1 Transmission Operation 6 1 THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies 1 EE The converter pump drive section and pressure regulating valve Egg The input shaft and directional clutches mg The range clutches EE The output section Eg The transmission control valve N 5778 4 ur ss TE27 32 4 SD 12 2002 6 2 Transmission Operation 6 1 1 The converter pump drive section and 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 to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its centre and discharges it
89. te The steel discs in FWD REV and 1518 2nd are the same DO NOT MIX TE27 32 4 SD 12 2002 10 19 2 DISASSEMBLY 8 2ND CLUTCH Figure 103 Figure 106 Compress return springs and remove snapring Remove clutch piston Note Force of disc springs is 2888 N Figure 104 Remove belleville washer disc springs Figure 105 Remove clutch piston wear sleeve TE27 32 4 SD 12 2002 10 20 2 RESASSEMBLY 8 2ND CLUTCH 2nd being reassenbled Figure 107 Refer to Cleaning amp Inspection pages Figure 109 Install clutch piston wear sleeve The bleed hole in the piston must be clean and free _ of any foreign material X Install clutch piston inner seal Note Ring must be sized before installing in clutch drum Sizing is best accomplished by rotating clutch piston while holding a round object against the new sealing ring Rotate piston until seal ring is flush with outer diameter of piston Figure 110 Install piston return springs First spring with large diameter of bevel towards wear sleeve See figure 110 Alternate 7 springs Wear sleeve Piston uer m Ed o d
90. 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 valve or holes in the clutch piston into the transmission sump These bleed valves 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 INPUT SECTION TE27 32 4 SD 12 2002 6 4 Transmission Operation 6 1 3 The range clutches Once a directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the directional clutches is similar to the range clutches The engagement of the directional clutches is modulated RANGE CLUTCHES 6 1 4 The 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 OUTPUT SECTION TE27 32 4 SD 12 2002 6 5 Transmission Operation 6 2 THE TRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM The transmission is controlled by an APC200 box This unit has a microprocessor that receives certain inpu
91. ts gear selector position speed senors which are processed and will give output signals to the control valve Operation of the valve Regulated pressure 22 bar 319 PSI is directed to the total neutral shift spool and the pressure reducer that will decrease the pressure to 10 bar 145 psi This reduced pressure will be used to supply the electronic controlled modulation valves total neutral solenoid 3rd 1st solenoid and 4th 2nd solenoid When activated the electronic controlled modulation valves will give an output pressure curve from 0 to 6 bar 0 87PSI The pressure intensifiers will multiply this pressure curve so that a curve from 0 to 20 bar 290 PSI is available for each directional and range clutches Between each electronic controlled modulation valve and pres sure intensifier is placed an accumulator to dampen any hydraulic vibration In neutral position the total neutral solenoid is not activated and no pressure is supplied to the pressure intensi fiers Total neutral solenoid will be activated only when forward or reverse direction is requested When forward is selected total neutral solenoid and forward electronic modulation valve are activated The for ward clutch is fed with modulated pressure supplied through the forward pressure intensifier When reverse is selected total neutral solenoid and reverse electronic modulation valve are activated The re verse clutch is fed with modulated pressure supplied through the
92. ud Shaft Figure 108 Figure 111 Install clutch piston outer seal See figure 105 for sizing 27 32 4 50 12 2002 10 21 2 RESASSEMBLY 8 2ND CLUTCH Figure 112 Figure 115 Compress spring and install spring retaining snap Install end plate retaining ring ring Note Be sure ring is in full position in groove Figure 113 Install clutch pack discs into drum Start with one steel disc against piston Alternate friction and steel discs until proper amount are installed Last disc is friction disc Figure 114 Install end plate TE27 32 4 SD 12 2002 10 22 2 RESASSEMBLY 8 2ND CLUTCH 2nd being reassenbled Figure 116 Refer to Cleaning amp Inspection pages Figure 119 Install clutch piston wear sleeve The bleed hole in the piston must be clean and free of any foreign material Install clutch piston inner seal Size as described in figure 106 Figure 117 Install clutch piston outer seal Figure 120 Install clutch piston return disc springs First spring with large diameter of bevel towrds wear Note sleeve Alternate fifteen 15 springs See figure 107 for sizing See figure 1
93. various CAUTIONS and NOTES that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the unit or render it unsafe It is also important to understand that these CAUTIONS and NOTES are not exhaustive because it is impossible to warn about all the possible hazardous consequences that might result from failure to follow these instructions TE27 32 4 SD 12 02 1 1 2 CLEANING INSPECTION AND LEGEND SYMBOLS 2 1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION AN Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type clean ers 2 1 1 Bearings Remove bearings from cleaning fluid and strike 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 bearing to avoid spinning Do not spin bearings when drying Bearings may be rotated slowly by hand to facilitate drying process 2 1 2 Housings Clean interior and exterior of housings bearing caps
94. with welded nuts toward converter Align intermediate drive plates and backing ring with holes in torque converter assembly NOTE AN Two pIMPLES 180 APART IN BACKING RING MUST BE OUT TOWARD THE ENGINE FLYWHEEL INSTALL CAP SCREWS AND WASHERS TIGHTEN 40 50 30 37 LBFT TORQUE TE27 32 4 SD 12 2002 5 2 Installation details 5 2 TRANSMISSION TO ENGINE INSTALLATION FLYWHEELHOUSING MOUNT PROCEDURE DIAL INDICATOR HERE 1 Remove all burrs from flywheel mounting face and nose pilot bore Clean drive plate surface with solvent ENGINE 2 Check engine flywheel amp housing for conformance to standard SAE per SAE J927 and J1033 tolerance specifications for pilot bore size pilot bore runout and TUNES mounting face flatness Measure and record engine crankshaft end play Fig 1 FLYWHEEL 3 Install two 63 50 mm 2 50 long transmission to flywheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel hous ing access hole Fig 2 FLYWHEEL HOUSING CONVERTER HOUSING 4 Install a 101 60 mm 4 00 long drive plate locating stud 3750 24 fine thread in a drive plate nut Align the locat ing stud in the drive plate with the flywheel drive plate h mounting screw hole positioned in step No 3 4 STUD 21 ALIGNING 1 51005 5 Rotate the transmission torque converter to align the locating
95. y SPICER OFF HIGHWAY PRODUCTS IMPORTANT A ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS TE27 32 4 SD 12 02 1 TE27 32 4 SD ls ES C O e E O FWD 3RD 2 REV 2ND ISS 12 02 1ST 1 SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage 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 by a spare part which has the same part number or with an equivalent part DO NOT USE A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare parts service procedure or tool which is not recommended by SPICER OFF HIGHWAY PRODUCTS must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the spare part service procedure or tool selected It is important to note that this manual contains

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