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Service Manual - Allied Systems Company

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1. 1 A f TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Assembly Instructions e All lead in chamfers for oil seals piston rings and o rings must be smooth and free from burrs Inspect at assembly e Add some grease to o rings before assembly e Add some grease to piston rings before assembly Apply a thin coating of grease between seal lips on lip type seals prior to assembly e Use only pre coated pipe plugs On uncoated pipe plugs apply a light coat of LOCTITE 592 M e Pump must be filled up with oil prior to assembly e After assembly of parts using LOCTITEG there must be any free or excess material which might enter the oil circuit Hefer to the picture on previous page to match step number to the transmission area where the step is performed b Apply a light coat of LOCTITEO 262 or 270 to all thru holes stud holes b Teflon seals must be sized prior to assembly Add grease to seal diameter of clutch hub before assembly Forward and Reverse Clutch gt 2 11 separator discs with outer sp
2. 21 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Controls Transmission Controls Refer to the Hydraulic Diagrams starting on page 24 The transmission is controlled by a TCON ECU This unit has a microprocessor that receives certain inputs gear selec tor position speed senors etc which are processed and will give output signals to the control valve Operation of the Valve Regulated pressure 319 377 PSI 22 26 bar is directed to the proportional valve and selector valves to activate the clutches required When activated the proportional valve will give an output pressure curve from 0 26 bar proportional to a current from 0 mA to 1000mA Dampers are used to dampen any hydraulic vibration Directional Selection When a direction forward or reverse is selected the required selector valve is activated for forward or reverse and the proportional valve will provide a pressure rise from O to 26 bar feeding the directional clutch with modulated pressure Range Selection When 1st clutch is selected the 1st 8rd selector valve is activated and the 1st 3rd proportional valve will provide a pres sure rise from O to 26 bar feeding the 1st clutch with modulated pressure When 2nd clutch is selected the 2nd 4th selector valve is activa
3. TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 20 Range Clutches Range Clutches Once a directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the direc tional clutches is similar to the range clutches The engagement of the directional clutches is modulated For the 1st clutch assembly there is an extra bleed hole to allow full drain when the pressure to the piston is released 3RD E 23 a f M IND 4ST LLL rA a E q P TS Sh TUR Output Section With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the same to input rota tion when the forward clutch is engaged
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5. 2 lt cc e gt gt l LL l gt LL e lt 2 o lt cc k N co E N N LLI LJ Low pressue Q 5 0 D I EH Lubrucaion BY PASS VALVE 100 7 L min Q 2170 rpm 4 1 4 5 bar PUMP 1 C SCREEN PRESSURE GAUGE VALVE 22 ba FILTER 1 OPERATOR COMPARTMENT TORQUE CONVERTER AR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP e 5 E E LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE 2 lt gt HOSE HOSE HOSE TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 32 Power Flows Activated Solenoids and Hydraulic Circuits Forward 4th Speed Continued TOP _ m 33 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 1st Speed ae aw 00 9 aN x zE 3 3 5 ea c N J Q ce Tta OE a o 2 co 2 E S 2 amp h 9 2 3 U Uc Q ba x ae D amp 23 z e a 5 E 5 g o 2 LU 2 OG ie 9 c U D oe D x 5 p 1 FWD N REV ES L
6. 25 _ Paii E e 24 9 S U oe D di 5 RE 1 FWD N REV B rn E gt lt Zh 46 OR 0 9 lt 5 lt 5 lt oc e gt T LLI lt n Sa n t dit 2 ui u N Su 5 DP e lt oc CN m N LLI LJ Low pressue Q 5 0 D I EH Lubrucaion 100 7 L min Q 2170 rpm BY PASS VALVE 4 1 4 5 bar PUMP 1 C SCREEN PRESSURE GAUGE VALVE 22 ba FILTER 1 OPERATOR COMPARTMENT TORQUE CONVERTER AR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP e 5 E E LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE e xD HOSE HOSE HOSE TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 38 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 3rd Speed Continued om TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service M anual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 4th Speed ae a 00 9 aN ben d zE 1 ps ag ce 4 o E S 2 amp LZ a ce o C 2 co gt amp E 5 g gt o o 2 o a U g c e Lu E
7. ws SPICER Off Highway Products Service Manual Powershift Transmission TE27 amp TE32 4 Speed Long Drop with Full Flow Control Valve TSM 0064 80 1070 Rev 5 12 2014 August 2012 5 CONTENTS i TOWING OF PUSHING naan 1 2 ORC WOUG SS E 2 Safety Precautions 2 SPECIFICATIONS idia aa 3 Identification Tag 3 General Specifications 3 Hydraulic Cooler Lines Specifications 3 Pressure and Temperature Specifications 4 Electrical Specifications 5 MAINTENANCE ii aaa 6 SUMP BFrehealelsS 6 milite po T 6 Clutch Calibration ea 6 t 6 Servicing Machine After Component Overhaul 7 Automatic Calibration Procedure 8 Drive Plate Installation 12 Transmission to Engine Installation 13 EXTERNAL PLUMBING INSTALLATION 14 SPEED SENSOR INSTALLATION 15 TEMPERATURE SENSOR INSTALLATION 17 TRANSMISSION OPERATION _ 18 Converter Pump Drive amp Pressure Regulating MOV se II EAE IM RUNDE 19 Input Shaft and Directional Clutches 20 FRANGe CIUICHES Mr 21 Transmission Controls
8. HEATING UP THE TRANSMISSION BY USING THE HEAT MODE The HEAT mode allows to select forward reverse while the parking brake is activated without forcing neutral and will disable the inching and declutch function During the heat mode the highest gear is forced even when the shift lever is in a lower gear This combination allows the driver to heat up the transmission by going into stall HEAT mode can be activated in the same way automatic calibration mode is entered see ENTERING AUTOMATIC CALIBRATION MODE on page 8 Once tran is displayed on the screen press the M button once to go into the HEAT mode The APC200 will display ne Ae To trigger the HEAT mode push the S button The APC200 will display the sump temperature This means the actual sump temperature of the transmission is 20 Perform the following steps in order to heat up the transmission 1 2 Make sure the parking brake is active and works properly Put the transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throt tle Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever Keep the engine at full throttle Keep the gearbox in neutral at full engine throttle for about 15 seconds again Release the throttle pedal and decelerate the engine to idle Go back to point 2 and repea
9. TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 42 TROUBLESHOOTING The following information is presented as an aid to isolate and determine the specific problem areas in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and cor rect functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assem bly oil cooler filter connecting lines and controls including the engine as a complete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system Transmission Problems TE27 30 power shift with torque converter transmission troubles fall into four general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems 4 Controller problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the
10. n up ES Zh OS 0 9 e LLI e LLI l LLI o e o ce o cc LLI gt cc lt cc e aea e 2 lt cc e c gt gt l LL l H gt LL lt o lt OC N co lt N LLI LJ Low pressue Q 5 0 D E EH Lubrucaion B Drain 100 7 L min 2170 rpm BY PASS VALVE PUMP 1 4 1 4 5 bar KS C SCREEN REGULATOR VALVE 22 bar PRESSURE GAUGE OPERATOR COMPARTMENT TORQUE CONVERTER AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP e E z LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE 2 xD HOSE HOSE HOSE TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 34 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 1st Speed Continued 35 Dana Hol ding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Reverse 2nd Speed a ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar PRESSURE INTENSIFIER 0 6 TO 0 20 bar lt o lt e e 2 lt cc e gt a A ag n 2 l Ls 3g Du 5 o o 0 gt lt cc CN ce LLI Lr mm CN LLI m 008 FWD N REV BY PASS VALVE 4 1
11. Checkports Checkports 6 FWOMREV Regulated Pressure 2na Regulated Pressure 2nd 4th Regulated Pressure All M10x1 o ring ports 31A 45B 66 46B 68 43B 67 41B 44B 42B TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 50 s Seve m 1 A M E A bx im 1st 3rd Selector Valve FWD REV Selector Valve FWD REV Ath 2nd Proportional Valve gt Proportional Valve 5 gt 0 gt O 2nd 4th Srd ist 4th 2nd 0 4 D C O O D gt Oo gt gt O LL E LL Full Flow Valve Components 3rd 1st Pressure Sensor TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 51 Speed Sensor Static Standalone Test Speed Sensor Static Standalone Test In order to be able to sense the currents a series resistor of e g 200 W must be used This resistor is integrated in the controller but when the sensor is to be used it must be connected externally The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor The voltage reading should be either 1 2V from the 7mA 1mA current level or 2 6 3 0V for the 14mA 1mA current level If the teeth can be moved slowly distinct toggling between the
12. I o eO co iL ae E 5 z 2 5 Lr gt Lu c amp R o 0 LL Lu 2 Je 0 TE _ XUI n wa a 2 U G oe 1 FWD N REV iE L n m _ els Zh OS 0 9 v CN lt o c l 2 lt cc e gt A E lt gt W 0n r OF cc do a gt LL LLI on zx on lt cc LE CN mM CN LLI LJ Low pressue Q 5 0 D I EH Lubrucaion EW Drain 100 7 L min Q 2170 rpm BY PASS VALVE PUMP 1 4 1 4 5 bar KS C SCREEN REGULATOR VALVE 22 bar PRESSURE GAUGE OPERATOR COMPARTMENT TORQUE CONVERTER AR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP g N lt E WO LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE HOSE HOSE HOSE 2 lt gt 7 GAD TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 40 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 4th Speed Continued L 2 L fT SSS as D 41 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Gear amp Clutch Layout Gear amp Clutch Layout
13. LE 3 Pn TEE S P BN Bie ey ye op yap a UIT bere 4 Steaks Arr gi i 3 epe 1 rlro CX A H LL AN Fi ta t E E Zn 3 la a Ww j ec E n UT esa cen FL ar x rU FAE ei Fo C TJ 182 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual
14. N O N 10 11 12 13 14 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DESCRIPTION Member Reaction Snap Ring Spacer Reaction Member Turbine Hub Turbine Snap Ring Snap Ring Capscrew Locktab Impeller O ring Screw Lock washer Hub Impeller 32 32 Torque Converter Assembly Group ITEM 15 16 17 18 19 20 21 22 23 24 25 26 27 DESCRIPTION O ring Screw Ring Impeller Hub Backing Bearing Snap Ring Cover Impeller Bearing Turbine Hub O ring Spacer Snap Ring Shaft Input Screw Bearing Ball QTY Dana Holding Corporation 62 Forward Reverse Second amp Third or Fourth Clutch Shaft Assembly Forward Reverse Second amp Third or Fourth Clutch Shaft Assembly 63 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Forward Reverse Second amp Third or Fourth Clutch Shaft Assembly ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 4rd Shaft Drum Assembly on 4 1 Fwd Shaft Drum Assembly 1 3 Speed 2 Rev 2nd Shaft Drum Assembly 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 64 Forward Clutch Shaft Group Forward Clutch Shaft Group 65 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Forward Clutch Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
15. mode 1 of the calibration 4 When all clutches have been calibrated the APC200 displays dant 5 At this point the automatic calibration has completed successfully The normal duration of a complete transmission calibration is around 15 minutes 6 To exit the automatic calibration mode switch off the vehicle ignition key Make sure that the APC200 has powered down wait for 2 seconds Now restart the vehicle and the new tuning results will be activated automatically Troubleshooting If anything different than described above appears on the APC200 display there can be two possible reasons e The calibration conditions are not fulfilled temperature is too low parking brake switched off the vehicle is moving engine rpm is too high or too low Acalibration error has occurred during the calibration This message starts with an E see CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS on page 11 By selecting REVERSE on the shift lever while the automatic calibration is performing the procedure will abort the auto matic calibration immediately and restart the APC200 This feature can be used when something goes wrong during the calibration procedure NOTE By aborting the automatic calibration the calibration is not finalized and needs to be done from the beginning 9 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Automatic Calibration Procedure
16. 2170 rpm BY PASS VALVE PUMP 1 4 1 4 5 bar oO C SCREEN REGULATOR VALVE 22 bar PRESSURE GAUGE OPERATOR COMPARTMENT TORQUE CONVERTER AIR BREATHER SAFTY VALVE CRACKING 9 bar OIL SUMP g N E z lt lt LUBRICATION RANGE CLUTCHES PUMP 2 TEMPERATURE GAUGE HOSE HOSE HOSE HOSE 7 GAD lt gt TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 28 Power Flows Activated Solenoids and Hydraulic Circuits Forward 2nd Speed Continued E ae 29 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 3rd Speed ae a 00 9 aN bn 4 2 ps ag bc 4 Te E V S 2 amp LZ E a C 2 co E Ss g gt o o 2 o a U g Q I o ET co ae E 5 T gt 2 5 Eg I Lu 5 amp gj o 2 1 prr Lu A 2 OG TE _ paii E e wa 9 U G oe 5 1 FWD N REV sof TET C lt cc o c e lt cc c gt X u E lt lu So ce mo A 55 A o cc eo a o
17. EH Lubrucaion 100 7 L min 2170 rpm BY PASS VALVE 4 1 4 5 bar PUMP 1 C SCREEN PRESSURE GAUGE VALVE 22 ba FILTER 1 SAFTY VALVE CRACKING AIR BREATHER 9 bar OIL SUMP OPERATOR COMPARTMENT TEMPERATURE GAUGE HOSE g N E z wo LUBRICATION RANGE CLUTCHES PUMP 2 2 xD HOSE HOSE HOSE TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 26 Power Flows Activated Solenoids and Hydraulic Circuits Forward 1st Speed Continued 2 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 2nd Speed ae aw 00 9 aN 4TH CLUTCH 2ND CLUTCH ma 9o 0 9 aN a 00 9 aN 3RD CLUTCH 1ST ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar CLUTCH PRESSURE INTENSIFIER 0 6 TO 0 20 bar o 00 9 SS 00 9 FWD CLUTCH REV CLUTCH FWD N REV sof ITE 3 c O LLI o c e O o c lt cc o LL lt cc e aea e 2 lt cc e c gt gt l LL l H gt LL o 2 o lt OC N co N LLI EB ubrucdion LJ Low pressue EB High pressue 100 7 L min
18. Failure to comply can cause personal injury Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 96 Remove 4th drum shaft assembly using special tool See 4th Drum Lifting Hook on page 181 MS LER Se FIGURE 99 Using a soft hammer tap turbine shaft and bearing assembly from converter housing a s FIGURE 97 Using external snap ring pliers open Rev 2nd drum shaft assembly bearing snap ring and remove shaft assembly TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 120 Reverse amp Second Clutch Disassembly FIGURE 100 Pry forward shaft bearing from housi Check three wear sleeves in converter housing and necessary Reverse amp Second Clutch Disassembly Reverse Clutch Disassembly FIGURE 102 Remove bearing snap ring Use caution when removing snap ring Failure to comply can cause personal injury 121 Dana Holding Corporation ng as shown FIGURE 103 Using a bearing puller remove bearing replace if FIGURE 105 Remove clutch gear snap ring Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 106 Remove clutch gear and outer bearing as an assembly TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Reverse amp Second Clutch Disassembly Use caution when removing snap ring Failure to co
19. 40 C 33 38 cSt at 212 F 100 C 7 8 cSt Maintenance Intervals Daily Check oil level daily with engine running at idle 600 RPM and oil at 180 200 F 82 93 C Maintain oil level at full mark Normal oil change interval Drain and refill system every 1000 hours for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Every 1000 hours e Change oil filter element e Drain oil at 150 200 65 93 and refill system as follows Drain transmission Remove and discard filter Install new filter Refill transmission to FULL mark Run engine at 500 600 RPM to prime converter and lines Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 180 200 F 82 2 93 3 C make final oil level check and adjust if necessary to bring oil level to FULL mark NOTE It is recommended that oil filter be changed after 100 hours of operation on new rebuilt or repaired unit OU NM T Extended oil change interval Extended oil service life may result when using synthetic fluids Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metal
20. Transmission Case Reassembly Transmission Case Reassembly FIGURE 328 housing FIGURE 332 Install inside suction tube bolt and nut Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 333 Install suction tube capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 330 Install needle roller bearings on 2nd Rev and 4th shafts 159 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 334 Install oil baffle with LOCTITE 262 on threads FIGURE 337 Install inside front cap bolts and tighten to specific of capscrews Torque to specified torque Refer to TORQUE torque Refer to TORQUE SPECIFICATIONS on page 175 SPECIFICATIONS on page 175 a i L E c 8 m a j Y d FIGURE 338 Position output gear in transmission case with long FIGURE 335 Install three 3 bolts with Loctite 243 hub of gear to the rear side ET FIGURE 336 Install inside front cap FIGURE 339 Install snap ring on output shaft Use caution when installing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 160 Transmission Case Reassembly Use caution when installing snap ring Failur
21. d Use caution when installing snap ring Failure to comply can cause personal injury s g FIGURE 416 Install converter housing front cover with Loctite 515 FIGURE 413 Install input shaft support with new o ring FIGURE 417 Install bolts and washers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 414 Install bolts and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 173 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 418 Install input flange alu FIGURE 419 Install input flange o ring washer and nut FIGURE 422 Install temperature sensor FIGURE 420 Tighten nut to specified torque Refer to TORQUE SPECIFICATIONS on page 175 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 174 TORQUE SPECIFICATIONS Lubricated or Plated Screws COARSE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 Ibs ft Nem Ibs ft Nem 8 10 10 8 13 6 9 11 12 2 14 9 12 16 16 3 21 7 26 30 35 2 40 7 23 25 31 2 33 9 33 36 44 7 48 8 37 41 50 2 55 6 52 57 70 5 77 3 57 63 77 85 80 88 108 119 82 90 111 122 115 127 156 172 113 124 153 168 159 175 216 237 200 220 271 298 282 310 382 4
22. lt cc LE N co mM N LLI LJ Low pressue Q 5 0 D I EH Lubrucaion 100 7 L min Q 2170 rpm BY PASS VALVE 4 1 4 5 bar PUMP 1 C SCREEN PRESSURE GAUGE VALVE 22 ba FILTER 1 SAFTY VALVE CRACKING AR BREATHER 9 bar OIL SUMP OPERATOR COMPARTMENT TEMPERATURE GAUGE HOSE g N lt E WO LUBRICATION RANGE CLUTCHES PUMP 2 2 lt gt HOSE HOSE HOSE TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 30 Power Flows Activated Solenoids and Hydraulic Circuits Forward 3rd Speed Continued 31 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Forward 4th Speed ae a 00 9 aN FWD N REV sof TET 3 ELE 1 gt E a2 amp b P d Te 2 amp Z ts a o 2 co 2 gt amp S 3 8 E 8 Pe U U ce oc 5 o ag ao u acs ES D om S 2 Lr o amp mc Ce wa x t Eg rs ans Lu _ elo i A _ XUI s E o EZ a a Sg Q c U 7 5 oe e gt Lu l LLI o c 3 oe cc 5 e or lt cc e e
23. 153 Remove snap ring Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 154 Using a puller remove clutch gear and outer bearing Use caution when removing snap ring Failure to comply can cause personal injury 129 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Forward Clutch Disassembly Use caution when removing snap ring Failure to comply can cause personal injury Use caution when removing snap ring Force of spring is 3381N m Failure to comply can Cause personal injury FIGURE 156 Remove end plate ok ek FIGURE 157 Remove clutch inner and outer discs FIGURE 160 Remove Belleville washers TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 130 Forward Clutch Reassembly FIGURE 161 Remove clutch piston spacer wear sleeve FIGURE 164 Install clutch piston outer seal FIGURE 162 Remove clutch piston FIGURE 165 Install clutch piston spacer wear sleeve Forward Clutch Reassembly aa A FIGURE 166 Install clutch piston Belleville washers Position first washer with large diameter of bevel toward spacer wear GNO ROE BEEN sleeve Alternate fifteen 15 washers Refer to Figure 167 Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and
24. 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 22 log Lollo M OT o 01140 Electric Solenoid Controls Gear Selector Valve Proportional Valve Clutches FWD FWD EE L LLL REV REV 23 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Power Flows Activated Solenoids and Hydraulic Circuits Neutral Selected aw a 00 9 mS tm ed zE o 2 tT 3 c 3 a ce o e co gt s g Se 5 2 d a s U 7 c ce d o t og Is ae E 53 a 5 G Eg ce 5 R o Lu BE as Lu T OG i 2 OC E Po 7 E BZ C LLI LLI c2 a ce 5 E 2 Oa c U D 5 oe D a ed 2 1 FWD N REV c Lu m O Lu o lt OC gt H i tts E lt e c e D lt cc c gt rT LLI gt gt O LL gt LL o o en o lt oc k N co LLI p lt CN _ LJ Low pressue Q 5 0 S Lubrucdion 100 7 L min 2170 rpm Y PASS VALVE PUMP 1 B 4 1 45 b lt gt SCREEN PRESSURE GAUGE AIR BREATHE
25. 4 5 bar OPERATOR COMPARTMENT KS PRESSURE GAUGE REGULATOR VALVE 22 bar CRACKING SAFTY VALVE 9 bar LUBRICATION TEMPERATURE GAUGE RANGE CLUTCHES TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual HOSE HOSE ae HOSE a 0 9 mS 4TH CLUTCH 2ND CLUTCH 9o 0 9 aN a 00 9 3RD CLUTCH 1ST CLUTCH o 00 9 SS aC 00 9 P ERES FWD CLUTCH REV CLUTCH EH Lubrucaion 100 7 L min 2170 rpm PUMP 1 N I ex t PUMP 2 Dana Holding Corporation LJ Low pressue AIR BREATHER Q 5 0 D E B Drain C SCREEN OIL SUMP Power Flows Activated Solenoids and Hydraulic Circuits 36 Power Flows Activated Solenoids and Hydraulic Circuits Reverse 2nd Speed Continued E ae 37 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Power Flows Activated Solenoids and Hydraulic Circuits Reverse 3rd Speed ae aw 00 9 aN bn 4 zE 1 ey E 5 2 c E M S amp LZ E c a ce o C e co E S 2 amp 2 2 a U Q ee x o al E T gt 2 2 oR Q O E Lu 5 R 2 E nc ans Lu 2 OG
26. 5 00 2 X 45 CHAMFER BOTH SIDES i 92 00 15 00 12 00 i Bolt 4375 14 UNC 3B X 20 both sides NLM 657 16 49 00 30 00 12 00 179 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Shaft Nut Socket Shaft Nut Socket 0 25 75 00 rp 54 00 me 52 00 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 180 4th Drum Lifting Hook 4th Drum Lifting Hook iow 245 A m r NACE ERN 770 A 0 H III 8 AA N x _ FL _ 1 ZTN SPANST FT A log os 49x76 DIM 581 N F RI i Sis 3 L 7 po mm 181 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual x L a 5 gt CC N A 2nd Rev Drum Lifting Hook oy fa i at d 299 gli E n dap A ERES n p tf vega p 8 9001 T AP Fas o9 pos
27. Conforms SAE J1019 and SAE J517 100RI Remote Filter 1 ru q 2 O CE ARM lt ge 2 O O Cooler N D S 2 5 ler t S rom cooler to E 2 O transmission o e 8 i 9 m o Bot b IEEE Ic cec cie cUERILLE H Em TA M m 8 T Ds ED from remote filter 2 LIE pa e Mh TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 14 15 SPEED SENSOR INSTALLATION The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14 mA The sensor has an integrated AMP superseal 2 pin connector The two pins are numbered 1 and 2 The following table shows the relation bet
28. Dipstick Group INSTALLATION DIAGRAMS Transmission Assembly Instructions Control Valve Assembly Instructions Cleaning and Inspection DISASSEMBLY amp REASSEMBLY Getting Started Transmission Case Disassembly Converter Housing Disassembly Reverse amp Second Clutch Disassembly Reverse amp Second Clutch Reassembly Forward Clutch Disassembly Forward Clutch Reassembly Third Clutch Disassembly Third Clutch Reassembly Fourth Clutch Disassembly Fourth Clutch Reassembly First Clutch Disassembly First Clutch Reassembly Idler Shaft Disassembly Idler Shaft Reassembly Turbine Shaft Disassembly Turbine Shaft Reassembly Impeller Disassembly Impeller Reassembly Impeller Cover amp Turbine Disassembly Impeller Cover amp Turbine Assembly Converter Cover Disassembly Converter Cover Reassembly Pump Drive Gear Disassembly Pump Drive Gear Reassembly Converter Housing Reassembly Transmission Case Reassembly TORQUE SPECIFICATIONS Lubricated or Plated Screws Pipe Plugs SPECIAL TOOLS Dana Holding Corporation TOWING OR PUSHING Before towing the vehicle be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid dam age to the transmission during towing NOTE Because of the design of the hydraulic system the engine cannot be started by pushing or towing 1 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Servi
29. Inspection see page 103 section of the manual 131 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Forward Clutch Reassembly Piston p AF Wear sleeve LL 2 FIGURE 170 Install new seal in end plate and install plate ilIa Use caution when installing snap ring Use caution when installing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 169 Install steel discs Alternate friction and steel discs FIGURE 172 Install two 2 bearings in clutch gear and warm until proper number of discs are installed First and last discs are assembly to 248 F 120 C Install clutch gear and hub into clutch steel drum Align splines on clutch hub with internal teeth of friction discs Tap gear into position NEVER force the operation in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 132 Forward Clutch Reassembly Use caution when installing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 178 Warm bearing to 248 F 120 C and install on shaft with groove down as shown Use caution when installing snap ring Failure
30. Shaft Reassembly FIGURE 284 Warm bearing to 248 F 120 C and install on shaft ensuring that snap ring groove is up as shown Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 283 Using a hydraulic press remove bearing Use caution when installing snap ring Failure to comply can cause personal injury 151 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Impeller Disassembly FIGURE 287 Install piston ring Impeller Disassembly FIGURE 291 Remove impeller hub backing ring E FIGURE 288 Remove impeller hub gear snap ring Use caution when removing snap ring Failure to comply can cause personal injury y wa t FIGURE 292 Remove impeller from impeller hub A FIGURE 289 Remove impeller hub gear TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 152 Impeller Reassembly Impeller Reassembly FIGURE 293 Remove impeller hub o ring from hub FIGURE 296 Install bearing to impeller hub Use caution when removing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 295 Remove bearing from impeller hub FIGURE 298 Position new impeller hub o ring on hub 153 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Con
31. Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly 4 Ls 7 1 ah il mum i mi FIGURE 370 Using special tool Idler amp Low Shaft Lifting Hook see page 178 install idler shaft and 1st clutch assembly Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 371 Warm 3rd shaft bearing to 248 F 120 C and install on shaft with snap ring groove up as shown ri gt Use caution when installing snap ring FIGURE 374 Install transmission case to rear cover new gasket Failure to comply can cause personal injury and o rings a f 1 A To ET ase Cs e FIGURE 375 Install two aligning studs and install transmission FIGURE 372 Install spacer rear cover TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 166 Transmission Case Reassembly M Id Z L 4 Fw 4 FIGURE 376 Install rear cover to transmission case bolts and FIGURE 379 Install bearing assembly onto 1st shaft tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 380 Install lock nut on 1st shaft Use caution when installing snap ring Failure to comply can cause personal injury e LE E E FIGURE 381 Using special tool Shaft Nu
32. analysis can provide useful information but a transmission should not be removed from service based solely on this analysis TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 6 Servicing Machine After Component Overhaul Servicing Machine After Component Overhaul The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for clean ing 3 Replace oil filter element 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 ne
33. check maximum stall speed at full throttle in all gears 7 The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be equal in all gears Between gears allow the converter outlet temperature to cool down to 158 F 70 C by selecting neutral 8 Exit the stall mode with the M button or switch off the ignition If maximum stall speed measured is below specifications it could indicate an engine or converter problem If maximum stall speed measured is above specifications it could indicate slipping clutches Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure can also be measured TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 44 Troubleshooting Procedures Mechanical and Electrical Checks Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and electrical checks should be made e Check the parking brake and inching pedal for correct adjustment e Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points The controls are actuated electrically Che
34. lapping compound BEARINGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning NEVER SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate the dry ing process HOUSINGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lint free absor bent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound Inspection The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts show ing indication of wear or stress will eliminate costly a
35. life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components Troubleshooting Procedures Input Shaft and Directional Clutch Problems Stall Test NEVER operate the converter at stall condition longer than 30 seconds at one time shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached Excessive temperature 250 F 120 C maximum will cause damage to transmission clutches fluid converter and seals A stall test to identifies transmission converter or engine problems Use following procedure 1 Putthe vehicle against a solid barrier such as a wall and or apply the parking brake block the wheels 2 Activate calibration mode during power up and holding the S button for 15 seconds 3 Select STAL using the M button 4 Select the requested range gear with the S button 43 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Troubleshooting Procedures Z Oona see ENGINE SPEED Z J WEE amada cnc gt ENGINE SPEED gt cn c ENGINE SPEED Cu uu CN 1 woo ENGINE SPEED 5 Select FWD or REV in the selected range gear Once the oil temperature reaches 158 F 70
36. the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydraulic pump is connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump speed is directly related to engine speed CONVERTER SECTION CONTROL VALVE 19 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Input Shaft and Directional Clutches Input Shaft and Directional Clutches The turbine shaft driven from the turbine transmits power to the directional clutches fwd rev These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston The piston is oil tight by the use of sealing rings The steel discs with internal splines and friction discs with external splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to
37. to comply can cause personal injury 133 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Third Clutch Disassembly FIGURE 179 Install spacer Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 180 Install snap ring Use caution when installing snap ring Failure to comply can cause personal injury Third Clutch Disassembly FIGURE 184 Remove spacer FIGURE 181 Remove one 1 piston ring TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 134 Third Clutch Disassembly Use caution when removing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 186 Remove end plate FIGURE 187 Remove clutch inner and outer discs FIGURE 190 Remove piston spacer 135 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Third Clutch Reassembly FIGURE 191 Remove clutch piston Third Clutch Reassembly FIGURE 195 Install spring FIGURE 192 Install clutch piston inner seal NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection see page 103 section of the manual FIGURE 196 Install spring retainer FIGURE 193 Install
38. 0064 TE27 32 4 TSM Dana Holding Corporation 55 10 11 12 13 14 15 16 17 18 19 20 21 22 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DESCRIPTION Case Transmission Tube 1st Speed Clutch Pressure Tube Low Shaft Rear Bearing Lube Tube 3rd Speed Clutch Pres sure Sleeve Pressure and Lube Tube Not Used in This Model Not Used in This Model Not Used in This Model Plug O ring O ring Cover Rear Assembly Plug Sensor Temperature Pin Capscrew Capscrew Lockwasher Gasket Rear Cover Plug Oil Level Plug Magnetic Drain Sensor Speed Transmission Case amp Rear Cover Group QTY 37 44 N N 23 24 25 26 2f 28 29 30 31 32 33 34 35 36 37 38 39 39A 40 41 42 43 DESCRIPTION O ring Sensor Speed O ring Tube Suction Assembly Flange Suction Tube Clamp Suction Tube Capscrew Lockwasher Nut O ring Lockwasher Screw Retainer Washer Baffle Not Used in This Model Not Used in This Model Washer Seal Capscrew Spacer Baffle Cover Split Flange O ring Capscrew Lockwasher N N wo O Dana Holding Corporation 56 Turbine Shaft Group Turbine Shaft Group 57 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Turbine Shaft Group ITEM DESCRIPTION QTY ITEM 1 Bearing Turbine Sh
39. 09 FIGURE 305 Remove turbine hub front bearing washer FIGURE 309 Screw heads with locktabs FIGURE 306 Tap turbine hub from impeller cover 155 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual FIGURE 310 Center impeller cover over turbine hub Install bearing in impeller cover and over turbine hub Tap bearing into place aO ue FIGURE 311 Install spacer Use caution when installing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Converter Cover Disassembly Converter Cover Disassembly FIGURE 313 Remove oil seal Converter Cover Reassembly FIGURE 314 Using a standard seal driver install the converter cover oil seal Pump Drive Gear Disassembly Use caution when removing snap ring Failure to comply can cause personal injury Dana Holding Corporation 156 Pump Drive Gear Reassembly FIGURE 316 Remove pump drive gear bearing Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 317 Remove bearing support Pump Drive Gear Reassembly FIGURE 320 Install left and right outer auxiliary pump drive gear assemblies Put new o rings 4 on bolts install bolts and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 318 Press bearing support into bearing
40. 1 Piston 1 14 Bearing Rear 1 2 Seal Piston Outer 1 15 Bearing 1 Seal Piston Inner 1 16 Ring Retaining 1 4 Screen 1 17 Ring Piston 2 5 Disc Clutch Inner 11 18 Ring Retaining 2 6 Disc Clutch Outer 11 19 Bearing 1 7 Plate End 1 20 Spacer 1 8 Seal 1 21 Snap Ring 1 9 Snap Ring 1 22 Retainer Oil 1 Washer Belleville Not as illustrated e Snap ring f 11 Ring Retaining 1 24 Clutch Driven Gear 1 12 Sleeve Selective Lube 1 29 Shaft Forward Clutch 1 13 Bearing Clutch Driven Gear 1 Not Sold Separately TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 66 Third Clutch Shaft Group Third Clutch Shaft Group 6 DanaHolding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Third Clutch Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 16 Washer 1 2 Seal Piston Outer 1 17 Snap Ring 2 3 Seal Piston Inner 1 18 Snap Ring 1 4 Screen 1 19 Ring Piston 2 5 Disc Clutch Inner 11 20 Bearing 1 6 Disc Clutch Outer 11 21 in vel 1 7 Disc Clutch Outer Half 2 22 Spacer 1 8 Plate End 1 23 Snap Ring 1 9 Snap Ring 1 24 O ring 1 10 Washer Belleville 15 25 Plug 1 11 Spacer Clutch Piston 1 26 O ring 1 12 Retainer Spring 1 27 Capscrew 4 13 Ring Retainer 1 28 Lockwasher 4 14 Bearing 1 29 O ring 1 15 Bearing 1 Not Sold Separately TSM 0064 TE27 32 4 Speed LD
41. 2 3 15 mm Choose an end plate with suitable thickness to obtain this clearance Clutch gt 2 12 separator discs with inner splines 11 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 14 3 5 mm Max 0 16 3 9 mm TE2T 9 separator discs with inner splines 8 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 14 3 5 mm Max 0 16 3 9 mm Choose an end plate with suitable thickness to obtain this clearance 99 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Assembly Instructions V V WV NW N NW gt 4th Clutch 2 11 separator discs with inner splines 10 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 12 3 1 mm Max 0 14 3 5 mm TE2T 11 separator discs with inner splines 10 friction discs friction material on both side with outer splines 2 one sided friction discs friction material on one side with outer splines Clearance Min 0 12 3 1 mm Max 0 14 3 5 mm Choose an end plate with suitable thickness to obtain this clearance Be sure that shie
42. 2 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly I CO 3 i Fr p a gt i f AAN FIGURE 83 Remove rear cone bearing and snap ring FIGURE 86 Remove inside front cap Use caution when removing snap ring Failure to comply can cause personal injury Ex i L3 ER E ran i i 1 p a 1 i 9 ry TNI 1 2 Lo m are aA Ran FIGURE 88 Remowve oil baffle FIGURE 85 Remove inside front cap bearing bolts TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 118 Transmission Case Disassembly Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 91 Tap rear oil seal from case 119 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Converter Housing Disassembly Converter Housing Disassembly using special tool See 2nd Rev Drum Lifting Hook on i i page 182 WARNING Use caution when removing snap ring Failure to comply can cause personal injury rai mE j Ma NEN NX M a YN hh X X J i H n La gt k 4 af FIGURE 95 Remove 4th drum shaft assembly snap ring Use caution when removing snap ring
43. 20 FINE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 Ibs ft Nem Ibs ft Nem 9 11 12 2 14 9 11 13 14 9 17 6 16 20 21 7 27 1 28 32 38 0 43 4 26 29 35 2 39 3 37 41 50 2 55 6 41 45 56 61 58 64 79 87 64 70 87 95 90 99 122 134 91 100 123 136 128 141 174 191 129 141 174 191 180 198 224 268 223 245 302 332 315 347 427 470 175 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Lubricated or Plated Screws COARSE PITCH TYPE OF BOLT MD Grade 8 8 Grade 10 9 Grade 12 9 Ibs ft Nem Ibs ft Nem Ibs ft Nem M5 x 0 8 3 7 4 4 5 6 5 2 5 9 7 8 5 9 7 4 8 10 M6 x 1 5 9 7 4 8 10 8 9 11 1 12 15 9 6 11 8 13 16 M8 x 1 25 14 8 18 4 20 25 22 1 25 8 30 35 25 8 29 5 35 40 M10 x 1 5 29 5 36 9 40 50 44 3 47 9 60 65 47 9 55 3 65 75 M12 x 1 75 50 55 68 75 74 81 100 110 85 96 115 130 M14 x2 81 92 110 125 111 129 150 175 133 155 180 210 M16 x2 125 140 170 190 177 203 240 275 207 236 280 320 M20 x 2 5 236 266 320 360 332 369 450 500 387 443 525 600 M24 x 3 420 479 570 650 590 664 800 900 664 774 900 1050 M30 x 3 5 848 959 1150 1300 1180 1328 1600 1800 1364 1549 1850 2100 M36 x 4 1475 1660 2000 2
44. 22 Electric Solenoid Controls 23 Power Flows Activated Solenoids amp Hydraulic erret EE 24 Gear amp Clutch Layout esee 42 TROUBLESHOOTING 43 Transmission Problems 43 Troubleshooting Procedures 43 Troubleshooting Guide 46 Check 25d poo nein Ee 47 GHECKDONS a 50 Full Flow Valve Components 51 Speed Sensor Static Standalone Test 52 EAPEODED VIEWS Sa 53 Converter Housing Group 53 Transmission Case amp Rear Cover Group 55 Turbine Shaft Group 57 Charging Pump Drive Group 59 Torque Converter Assembly Group 61 Forward Reverse Second amp Third or Fourth Clutch Shaft 63 Forward Clutch Shaft Group 65 Third Clutch Shaft Group 67 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Third Speed Gear Group Reverse Second Clutch Shaft Group First Shaft Group Fourth Clutch Shaft Group First Speed Gear Group Output Shaft Group Regulator Valve Group Control Valve Group Remote Filter Adapter Group Converter Housing Cover Group Input Flange Group Idler Shaft Gear Group Idler Shaft Group External
45. 250 2028 2323 2749 3149 2397 2729 3249 3699 FINE PITCH TYPE OF BOLT SIZE OF BOLT Grade 8 8 Grade 10 9 Grade 12 9 Ibs ft Nem Ibs ft Nem Ibs ft Nem M8 x 1 17 20 23 28 25 28 34 39 30 34 41 46 M10 X 1 35 42 47 57 52 60 71 81 62 69 84 94 M10 x 1 25 32 40 44 54 49 57 67 77 58 66 79 89 M12 x 1 25 60 68 82 92 89 96 120 130 105 116 143 158 M12 x 1 5 58 65 78 88 86 94 117 127 101 112 138 153 M14 x 1 5 94 105 128 143 142 153 193 208 162 184 220 250 M16 x 1 5 159 169 215 228 216 227 293 308 258 273 350 370 M18 x 1 5 221 236 300 320 319 330 433 448 369 398 500 540 M18x2 207 221 280 300 304 315 413 428 347 376 470 510 20 1 5 302 332 410 450 439 476 595 645 503 559 683 758 M22 x 1 5 413 443 560 600 586 623 795 845 681 736 923 998 M24 x 1 5 531 590 720 800 767 841 1040 1140 882 992 1195 1345 M24 x 2 509 568 690 770 730 804 990 1090 845 955 1145 1295 M27 x 1 5 789 848 1070 1150 1129 1202 1530 1630 1808 1420 1175 1925 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 176 Pipe Plugs Pipe Plugs THREAD SIZE Ibs ft Nem M10 x 1 6 7 8 10 M14 x 1 5 7 9 10 12 M18 x 1 5 25 30 34 41 M22 x 1 5 35 44 48 60 M26 x 1 5 45 50 61 68 M33 x 2
46. 27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 112 Transmission Case Disassembly FIGURE 56 Using a hoist remove rear cover from transmission case Tap 3rd 1st shaft with a soft hammer to assist removal and avoid bending shaft FIGURE 54 Use special tool to remove nut from 1st shaft See Shaft Nut Socket on page 180 Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 55 Remove bearing inner and outer race FIGURE 58 Remove spacer 113 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 59 Using a puller remove 3rd shaft bearing FIGURE 62 Forward drum assembly removed showing snap ring and front bearing Snap ring sits under gear and must be removed before forward drum assembly can be hoisted Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 60 Shown are the 1st shaft drum and idler shaft as an assembly removed See Idler amp Low Shaft Lifting Hook on page 178 FIGURE 61 Remove 3rd shaft drum assembly FIGURE 64 Remove 1st shaft drum assembly front bearing snap ring Use caution when removing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporatio
47. 4 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation Electrical Specifications Electrical Specifications FWD REV 1st 3rd 2nd Ath Coil Resistance 7 250 at 68 F 20 C FWD N REV 1st 3rd Selection Valves Coil Resistance 12V 7 10 at 68 F 20 Coil Resistance 24V 28 50 at 68 F 20 Proportional Valves Type Magneto resistive sensor Sensing Distance 0 0 07 0 1 8 mm Sensor Signal Generates a square current with a fixed amplitude changing between 7 and 14 mA Speed Sensor Material Silicon Resistance 77 F 25 20000 196 Supply Voltage 4 5 5 5V Maximum Current 10mA Pressure Sensor Pressure Range 14 5 450 PSI 1 31 bar 1 296 full scale 450 PSI 31 bar range 14 5 363 PSI 1 25 bar 2 596 full scale 450 PSI 31 bar range 363 450 PSI 25 31 bar Temperature Sensor 5 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual MAINTENANCE Sump preheaters Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up Filters Service oil filter elements the first time at 100 hours and then every 1000 hours under normal environmental and duty cycle conditions Clutch Calibration Perform automatic clutch calibration every 2000 hours Lubricants Recommended Lubricants Only Dextron III is approved Viscosity at 104 F
48. 83 103 112 140 THREAD SIZE Ibs ft Nem 1 16 27 5 7 7 9 1 8 27 7 10 9 14 1 4 18 15 20 20 27 5 16 24 3 5 4 7 3 8 24 5 8 7 11 3 8 18 25 30 34 41 1 2 14 30 35 41 47 1 2 20 10 13 14 18 3 4 10 40 45 54 61 3 4 14 40 45 54 61 7 16 20 7 10 9 14 9 16 18 12 15 16 20 3 4 16 20 25 27 34 7 8 14 30 35 41 47 11 16 12 45 50 61 68 15 16 12 65 75 88 102 1 11 1 2 50 55 68 75 1 1 4 11 1 2 60 65 81 88 1 5 8 12 75 85 102 115 1 7 8 12 75 85 102 115 177 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual SPECIAL TOOLS Idler amp Low Shaft Lifting Hook m2 75 00 E SSSR SE IN NN E 35 00 I 60 00 S 0 2 a g ge d 650 50 7a 60 00 10 x 45 4 PLACES e 900 p 58 00 150 00 50 00 290 00 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 178 Impeller Cover Lifting Hook Impeller Cover Lifting Hook 60 00 104 00 4 60 00 52 00 0 2 12 5 30 00 5 00 180 00
49. E 267 Install gear snap ring shaft Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 265 Install two 2 piston rings FIGURE 268 Install bearing spacer TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 148 Idler Shaft Disassembly FIGURE 269 Warm bearing to 248 F 120 C and install on shaft Idler Shaft Disassembly Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 274 Turn shaft and using a puller remove bearing inner race from shaft FIGURE 271 Remove idler shaft rear bearing spacer 149 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Idler Shaft Reassembly Idler Shaft Reassembly FIGURE 278 Install idler shaft rear bearing spacer p i eS a L i FIGURE 275 Warm bearing inner race to 248 F 120 C and install on shaft FIGURE 279 Install idler shaft rear bearing snap ring FIGURE 276 Turn shaft and install idler shaft rear bearing spacer Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 277 Warm bearing to 248 F 120 C and install on shaft FIGURE 280 Remove piston ring TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation Turbine Shaft Reassembly Turbine
50. FIGURE 17 Remove suction adapter assembly and o rings 1 d FU as FIGURE 19 Remove pump manifold and o ring FIGURE 22 Remove regulator valve assembly and gasket 107 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 23 Remove pump drive blanking cover plate bolts if fitted FIGURE 24 Remove pump drive blanking cover plate and gasket if fitted M FIGURE 28 Remove pump drive idler gear bearing and support i F assembly FIGURE 25 Remove stator support assembly bolts and lockwashers TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 108 Transmission Case Disassembly FIGURE 33 See Control Valve Assembly Instructions on page 102 for details on the disassembly of control valve 1 E x E ee m 2 al FIGURE 31 Remove pump drive gear bolts FIGURE 34 Remove control valve and gasket 109 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 38 Converter assembly removed NOTE Reverse 2nd and 4th clutch drum will remain in the converter hous ing FIGURE 36 Remove converter housing to transmission case bolts and washers FIGURE 39 Remove snap ring from 2nd clutch hub gear Use caut
51. Manual First Clutch Disassembly FIGURE 239 Using a bearing puller remove lower hub taper FIGURE 242 Remove Belleville washers roller bearing from shaft FIGURE 243 Remove clutch piston spacer FIGURE 240 Compress Belleville washers and remove piston return spring snap ring Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 244 Remove clutch piston FIGURE 241 Remove spring retainer TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 144 First Clutch Reassembly FIGURE 245 Turn shaft and remove outer bearing race from FIGURE 248 Remove gear shaft First Clutch Reassembly FIGURE 246 Remove bearing spacer FIGURE 249 Install clutch piston inner seal NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection see page 103 section of the manual Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 250 Install clutch piston outer seal and install piston into drum 145 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual First Clutch Reassembly FIGURE 251 Install clutch piston spacer wear sleeve FIGURE 254 Install spring retainer making sure it is fitted with stepped groove upward FIGURE 252 Insta
52. R ATN SAFTY VALVE CRACKING 9 bar OIL SUMP OPERATOR COMPARTMENT TORQUE CONVERTER e lt 2 x co l CLUTCHES 52 4 L min 2170 rpm PUMP 2 HOSE HOSE HOSE TEMPERATURE GAUGE HOSE zal NA RANGE FILTER 2 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 24 Power Flows Activated Solenoids and Hydraulic Circuits Neutral Continued oe h prem REV 2ND gt 187 Te E Lh qwe 3 25 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service M anual Power Flows Activated Solenoids and Hydraulic Circuits Forward 1st Speed ae a 00 9 aN x zE 3 e 5 eE E 2 E V S x 2 AC L a co 2 E S 3 g h 9 2 Q ba x ae D 52 e a 5 E 5 o 2 LU 2 OG ie 9 D ec x 5 ai 1 FWD N REV A rn E P lt N 46 CAD 0 9 zu lt oc 5 lt e e 5 lt oc e S T sg at c zou O o zi zu io 5 n QS gt o lt oc m N Lu CN EN LJ Low pressue Q 5 0 D E
53. Valve Service Manual Reverse amp Second Clutch Reassembly Reverse Clutch Reassembly FIGURE 134 Install clutch piston Belleville washers Position first washer with large diameter of bevel toward spacer wear FIGURE 131 Install clutch piston inner seal Size as described in sleeve Alternate fifteen 15 washers Refer to Figure 135 Figure 106 NOTE Piston Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection see page 103 section of the manual m FIGURE 132 Install clutch piston outer seal _ FIGURE 136 Compress spring and install snap ring making sure ring is in full position in groove FIGURE 133 Install clutch piston spacer wear sleeve Use caution when installing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 126 Reverse amp Second Clutch Reassembly FIGURE 137 Install one 1 clutch inner outer steel disc into FIGURE 140 Install two 2 bearings in clutch gear and warm drum Alternate friction and steel discs until proper number of assembly to 248 F 120 C Install clutch gear and hub into clutch discs are installed First and last discs are steel drum Align splines on clutch hub with internal teeth of friction discs Tap gear into position NEVER force the ope
54. aft Front 1 9 2 Bearing Turbine Shaft Rear 1 10 3 Spacer Front Bearing 1 11 4 Snap Ring 1 12 5 Ring Piston 1 13 6 Stator Support Assembly 1 14 7 Screw Stator Support 7 15 8 Lockwasher 7 16 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DESCRIPTION QTY Ring Piston 1 Baffle Oil 1 Seal Oil 1 Ring Oil Baffle Seal 1 Ring Oil Baffle Retaining 1 O ring 1 Snap Ring 1 Turbine Shaft 1 Dana Holding Corporation 58 2 C Q E D I O Charging Pump Drive Group Speed LD with Full Flow Control Valve Service Manual 0064 TE27 32 4 TSM Dana Holding Corporation 59 Charging Pump Drive Group ITEM DESCRIPTION QTY ITEM 1 Support Pump Drive Bearing 2 9 2 Capscrew Bearing Support 4 10 3 Washer Plain 4 11 4 Washer Seal 4 12 5 Lockwasher 2 13 6 Capscrew Bearing Support 2 14 7 Bearing Pump Drive Gear 2 15 8 Snap Ring 2 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DESCRIPTION QTY Gear Auxiliary Pump Drive 2 Gear Charge Pump Drive 1 Gear Impeller Hub 1 Snap Ring 1 Support Pump Drive Bearing 1 Snap Ring 1 Bearing Ball 1 Dana Holding Corporation 60 Torque Converter Assembly Group Torque Converter Assembly Group 61 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual
55. ana Holding Corporation 170 Transmission Case Reassembly FIGURE 400 Install adapter suction hose assembly to FIGURE 403 Install hydraulic pump drive shipping covers if hydraulic pump assembly fitting new o rings if required fitted and install bolts and lockwashers Tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 401 Install capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 405 Install impeller hub bearing inner race 171 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 406 Install reaction member spacer Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 407 Install reaction member with thin side of blades inward to impeller FIGURE 410 Position new o ring on impeller cover and install cover and turbine assembly on shaft Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 411 Install impeller cover screws and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 172 Transmission Case Reassembly FIGURE 415 Warm input shaft support bearing to 248 F 120 C and install on input shaft
56. and install assembly into gear FIGURE 321 Install center charging pump drive gear assembly Tighten bolts to specified torque Refer to TORQUE SPECIFICATIONS on page 175 157 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Converter Housing Reassembly FIGURE 322 Install forward speed outer roller bearing in converter housing support Position stator support assembly on turbine shaft Turn stator support assembly to clear pump drive gear Align support assembly holes with converter housing 5 p F a ES Om CX FIGURE 323 From the rear of the housing tap turbine shaft and Ne OWN E bearing converter housing Tap shaft until gear shoulders against converter housing FIGURE 326 Install stator support assembly bolts and lockwashers and tighten to specified torque Refer to TORQUE nl D SPECIFICATIONS on page 175 X n lb XM a FIGURE 324 From the front of the housing install turbine shaft DA e m il bearing snap ring Tap shaft until snap ring is in full position in i groove FIGURE 327 Spread ears on snap ring and install 2nd Rev clutch drum assembly into converter housing Use caution when installing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 158
57. asure engine crankshaft end play after transmission has been completely installed on engine flywheel This value must be within 0 001 0 025 of the end play recorded in Step 2 10 Axial force acting on flywheel is continuous 940 N FLYWHEEL IMPELLER COVER INTERMEDIATE DRIVE PLATES FIG 4 intermittent 1885 N P 11 Hose line operating requirements presse lines pu TESTO BEINGTALIED suitable for operating from ambient to 120 C contin WITH CONCAVE SIDE TOWARD ENGINE FLYWHEEL uous operating temperature must withstand 25 bar NN continuous pressure with 50 bar intermittent surges m Reference SAE spec J 517 100RI hydraulic hose E specification All hose lines used must be conform to SAE spec J 1019 tests and procedures for high tem perature transmission oil hose All hose lines and fit ting have a 19 mm inside diameter unless noted FIG 5 Does not apply to units having 3 intermediate drive plates See Figure 4 13 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual EXTERNAL PLUMBING INSTALLATION Cooler amp Filter Line Specifications Minimum 1 25 4 mm internal diameter for lines and fittings e Suitable for operation from ambient to 248 F 120 C continuous operating temperature Must withstand 435 PSI 30 bar continuous pressure and with 652 PSI 40 bar intermittent surges e
58. avoided may result in moderate or minor injury Indicates a situation which if not avoided may result NOTICE in damage to components TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 2 SPECIFICATIONS Identification Tag The nameplate contains both the model and serial number of the unit General Specifications Weight dry Length maximum Width maximum o o B 2 4 t SPICER OFF HIGHWAY TEN BRIELE 3 B g200 BELGIUM MODEL SERIAL 2204 Ibs 1000 kg 39 8 1011 mm for T models 46 8 1189 mm for MT models 27 7 703 mm Height maximum 49 6 1260 mm Oil Capacity 7 9 US gallons 30 liters Without cooler and hydraulic lines Consult equipment operator s manual for complete system capacity Hydraulic Cooler Lines Specifications Lines and Fittings Minimum Continuous Operating Temperature Continuous Pressure 1 25 4 mm internal diameter Ambient to 248 F 120 C 406 PSI 28 bar continuous pressure and 595 PSI 41 bar intermittent surges Conformance SAE J1019 and SAE J517 100RI 3 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Pressure and Temperature S
59. bolts and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 NOTE Turning output shaft will assist in aligning clutch hubs with clutch assembly NCAUTION NEVER use bolts to pull converter and transmission housing together Failure to comply may cause equipment damage FIGURE 390 Install 2nd clutch hub snap ring spacer and snap ring Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 393 Install aligning studs and install new valve gasket 169 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 394 Install control valve and tighten capscrews to specified torque refer to TORQUE SPECIFICATIONS on page 175 following the sequence outlined in the Transmission Assembly Instructions on page 97 of the manual xu A 3 A 2 z FIGURE 398 With new o ring in place install hydraulic pump assembly FIGURE 395 Install regulator valve and new valve to converter housing gasket to converter housing FIGURE 399 Install hydraulic pump capscrews and lockwashers and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 396 Install capscrews and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual D
60. ce Manual INTRODUCTION Foreword This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Spicer products Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight out lay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and adjustments as indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjust ments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when perform ing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana Spicer approved parts as listed in the appli cable service parts list should be used Use of will fit or non approved parts may endanger proper operation and per formance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS Safety Precautions To reduce the chance of personal injury and or property damage the following instructions must be carefull
61. cessary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose IMPORTANT NEVER use flushing compounds for cleaning purposes 5 Reassemble all components and use only type oil See chapter 4 1 1 Recommended lubricants Fill the transmission through filler opening until fluid comes up to FULL mark on transmission dipstick e Remove filler plug and fill oil until FULL mark e Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic lines e Recheck level of fluid in transmission with engine running at idle 500 600 RPM e Add quantity necessary to bring fluid level to LOW mark on dipstick e Recheck with hot oil 180 200 F 82 2 93 3 C e Adjust oil level to FULL mark on dipstick Hecheck all drain plugs lines connections etc for leaks and tighten where necessary 7 Perform automatic calibration 7 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Automatic Calibration Procedure Automatic Calibration Procedure Introduction The APC200 firmware contains an automatic transmission calibration procedure which is able to optimize the shift quality of the transmission An automatic calibration has to be done e When the vehicle is build at the OEM e Every 2000 hours of transmission operation e When an overhaul of the transmission is done e When the trans
62. ck the wiring and electrical components Besure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary e The engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications Hydraulic Checks Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the con verter and its fluid circuit lines must be fully charged filled at all times The transmission fluid must be at operating temperature of 180 200 F 82 93 C to obtain correct fluid level and pressure readings NEVER attempt to make these checks with cold oil To raise the oil temperature to this specification it is necessary to either operate work the vehicle or run the engine with the converter at stall see Stall Test on page 43 DANGER Be careful the vehicle does not move unexpectedly when operating the engine and converter at stall rpm 45 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Serv
63. clutch piston outer seal and install piston into drum TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 136 Third Clutch Reassembly FIGURE 200 Install clutch outer half disc friction material on one side with steel side up FIGURE 198 Install clutch outer half disc friction material on one side with steel side down FIGURE 201 Install end plate FIGURE 199 Install steel discs Alternate friction and steel discs until proper number of discs are installed First and last discs are steel Use caution when installing snap ring Failure to comply can cause personal injury 137 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Fourth Clutch Disassembly Use caution when installing snap ring Failure to comply can cause personal injury ce FIGURE 204 Install gear and bearing into clutch drum by warming the assembly to 248 F 120 C Align splines on clutch hub with internal teeth of friction discs Tap gear into position NEVER force the operation in this step Gear splines must be in full position with internal teeth of all inner discs Failure FIGURE 207 Install piston ring to comply may cause equipment damage Fourth Clutch Disassembly FIGURE 208 Remove piston rings Use caution when installing snap ring Failure to comply can cause personal injury TSM 0064 TE27 32 4 Speed LD with Ful
64. d toward engine flywheel hollow side facing torque converter assembly 4 Install capscrews and lockwashers Tighten capscrews to 30 37 1 5 ft 40 50 Nem NOTE Assembly of all plates must be completed within 15 minutes from when screws are installed If a screw is removed for any reason it must be replaced The adhesive left in the tapped holes must be removed with the proper tap and cleaned with solvent Dry the hole thoroughly and use a new screw for reinstallation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 12 TRANSMISSION TO ENGINE INSTALLATION 1 Remove all burrs from flywheel mounting face and FLYWHEEL H OUSING MOUNT nose pilot bore Clean drive plate surface with sol ues oum vent Dry thoroughly 2 Check engine flywheel and housing for conformance to standards SAE 3 per SAE J 927 and J 1033 tolerance specifications for pilot bore size pilot bore runout and mounting face flatness Measure and record engine crankshaft end play dcc 3 Install two 2 50 63 5 mm long transmission to fly wheel housing guide studs in the engine flywheel hous ing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole 4 Install a 4 00 101 6 mm long drive plate locating stud 3 50 24 fine thread in a drive plate nut Align the locat ing stud in the drive plate with the flywheel drive plate mounting screw hole p
65. e Manual Dana Holding Corporation 92 idler Shaft Group Idler Shaft Group 93 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual idler Shaft Group DESCRIPTION QTY Capscrew 4 Lock washer 4 ITEM DESCRIPTION 1 Shaft Idler Bearing Ball Bearing Retainer Oil Snap Ring Spacer Front Bearing O QC A C N O ring TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual ITEM 10 11 12 13 14 Idler Bearing Cap amp Plug Assembly 1 Plug Expansion 1 O ring 1 Snap Ring 1 Bearing Needle 1 Dana Holding Corporation 94 External Dipstick Group External Dipstick Group p gt ih R8 cS ZZ b LF 4 0 I Y C s M P ism 2 Y af BIN d m 1 95 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual External Dipstick Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Tube Dipstick amp Flange Assembly 1 4 Capscrew 2 2 Dipstick 1 5 Lock washer 2 3 O ring 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 96 INSTALLATION DIAGRAMS Transmission Assembly Instructions CN
66. e to comply can cause personal injury FIGURE 341 Insert output shaft and taper bearing from rear of case and through output gear g FIGURE 344 Install oil seal Am FIGURE 342 Install bearing cup FIGURE 345 Install output shaft front spacer 161 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 346 Install front bearing cone and warm to to 248 F 120 FIGURE 350 Tighten bearing cap bolts to specified torque Refer to TORQUE SPECIFICATIONS on page 175 bi i E E P E FIGURE 348 Position shims on transmission case FIGURE 351 Tap and rotate output shaft to seat taper bearings Loosen front bearing cap bolts Using an torque wrench determine the rolling torque of the output shaft and record Tighten front bearing cap bolts to specified torque Refer to TORQUE SPECIFICATIONS on page 175 Check rolling torque with bolts tight Torque must be 4 10 Ibs in 0 46 1 1 Nem more than when bearing cap bolts were loose Add or omit shims on the front bearing cap to achieve the proper preload TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 162 Transmission Case Reassembly FIGURE 354 Tighten front output flange nut to 250 300 Ibs ft 339 407 Nem 163 Holding Corporation FIGURE 356 Install o ring s
67. et 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 84 Q O lt TE J O D Remote Filter Adapter Group TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 85 Remote Filter Adapter Group TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DESCRIPTION Filter Adapter Filter Assembly Filter Adapter Body Cover QTY DESCRIPTION O ring Capscrew Lockwasher Hemote Filter Adaptor Kit Note 2 sets are required QTY Dana Holding Corporation 86 Converter Housing Cover Group Converter Housing Cover Group 2 x a bat P 2 P x zt wu P 2 2 2 2 Pad ES 22 96 Par amp 7 b hoy Lf Ml FON PS 24 N E ES E M ae S Ec mE DES Az E A 72 ES Nu M UM law P PN E a S vM CRON gt WSs wu P Sed n E e N 5 la VM N Zu s N es MI 7 NS Ve e a S m We N i SASS INS 1 T iJ d m A N NO NN Nau i zz NX 6 SAY WY yy Na 7 CVM N pas SAEC MNS SA RM NN plu EE 4 Zz M d NAN A VY 53 amp N NON Va B
68. ever to be in NEUTRAL but finds it in another position FORWARD or REVERSE cC c THE APC200 expects the parking brake to be ON while it is OFF o C C The APC200 has detected output speed Lt P e mm Engine RPM is to low according to the limit that is necessary for calibration Im 2 co Engine RPM is to high according to the limit that is necessary for calibration T co After being to low or to high the engine RPM is coming back into the correct boundaries for calibration m 2 o When during the automatic transmission calibration the temperature becomes to low the APC200 display indicates the actual transmission temperature e t Calibration errors Put the shift lever back in NEUTRAL Put the parking brake ON Verify that the parking brake is ON and working properly If this is already the case keep the machine at standstill by using the brake Once the machine has been stopped the APC200 will ask the driver to shift to FORWARD before continuing the calibration When during the automatic transmission calibration the temperature becomes to low the APC200 display indicates the actual transmission temperature rPH Use the M button on the APC200 to go back to the HEAT mode and the S but ton to trigger this mode Then warm up the transmission again until the temper ature is above 140 F 60 C Then go back to the automatic tuning mode by the M bu
69. heck Port Lube Plug Magnetic Drain M10x1 o ring port M22 x 1 5 UNI Rear View Plug 16B From Remote Filter M bor 32 Pressure Check Port to Cooler Converter Out M12x1 5 o ring port Port 41 Check Pot Eu Temperature Pressure Check Port Sensor 1st Clutch M10x1 o ring port Port 43 Pressure Check Port 3rd Clutch M10x1 o ring port 47 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Check Points Right View Port 31 Pressure Check M12x1 5 o ring port Port 11 to Cooler Port 37 Pressure unec 17 Port Converter In M10x1 o ring port g Engine Speed Sensor Port 45 Pressure Check FI MES Port Fwd Clutch M12x1 5 o ring port Port 12 Drum Speed From Cooler Sensor PCM Port 16A F rom Messe X Remote Filter 2 Sensor M Turbine Speed Sensor 4 Mounting Holes M20 x 2 5 THD 30 mm Deep Metric Flange for Dipstick Dia 25 4 mm 9 Left View Oil Level Check Port 1 4 NPT TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 48 Check Points Top View Port 13B to Port 13A to Remote Filter Remote Filter fromPump2 from Pump 1 IST Oil Fill Hole 3 4 14 NPTF Lifting Eyes M20 x 2 5 THD Air Breather 28mm Deep 49 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual
70. ice Manual Troubleshooting Guide Troubleshooting Guide Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles Low Clutch Pressure Cause Remedy Low oil level Fill to proper level Clutch pressure regulating valve stuck open Clean valve spool and housing Faulty charging pump Replace pump Broken or worn clutch shaft or piston sealing rings Replace sealing rings Clutch piston bleed valve stuck open Clean bleed valves thoroughly Low Charging Pump Output Remedy Low oil level Fill to proper level Suction screen plugged Clean suction pump Defective charging pump Replace pump Overheating Restriction in cooler lines Noisy Converter Remedy Worn charging pump Replace charging pump A complete disassembly will be necessary Worn or damaged bearings to determine which bearing is faulty Defective charging pump Replace pump Lack of Power Remedy Low engine RPM at converter stall Tune engine check governor See the Overheating section above and make same checks Make corrections as explained in Overheating TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 46 Check Points Check Points Front View Port 42 Pressure Check BM Por 2nd Clutch 1 8 27 NPTF Port 46 Pressure Check Port Reverse Clutch Xo 1827 NPTF Port 44 Pressure Check Port 4th Clutch M12x1 5 o ring port Port 34 Pressure C
71. in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection see page 103 section of the manual NOTE Seal must be sized before installing in clutch drum Sizing is best accomplished by rotating clutch piston while holding a round object against the new seal P Ke E m FIGURE 123 Install clutch piston outer seal FIGURE 121 Remove clutch piston FIGURE 124 Install clutch piston spacer wear sleeve TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 124 Reverse amp Second Clutch Reassembly FIGURE 125 Install piston Belleville washers Position first FIGURE 128 Install clutch inner and outer discs into drum Start washer with large diameter of bevel toward spacer wear sleeve with one steel disc against piston Alternate friction and steel Hefer to Figure 126 Alternate seven washers discs until proper number of discs are installed Last disc is friction disc d FIGURE 129 Install end plate FIGURE 127 Compress spring and install snap ring making sure ring is in full position in groove Use caution when installing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury 125 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control
72. increase in speed or rotate in the oppo site direction as long as no pressure is present in that specific clutch To engage the clutch the solenoid will direct oil under 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 diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit When the clutch is released a return spring will push the piston back and oil will drain back via the shift spool the bleed hole or holes in the clutch piston into the transmission sump These bleed holes will only allow quick escape of oil when the pressure to the piston is released The engagement of all range and directional clutches is modulated and electronically controlled This means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive
73. ion when removing snap ring Failure to comply can cause personal injury FIGURE 37 Support converter housing with chain hoist and strap Use a soft hammer to separate converter housing from transmission case i J P d o k 3 1 T1 DL k 1 j ox d F fr d F OS d 7 E 24 1 i b P B s p E Fs FIGURE 40 Remove retainer from 2nd clutch hub TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 110 Transmission Case Disassembly O aA Mm bns 7 i FIGURE 44 Remove bolts from 3rd clutch shaft rear bearing Use caution when removing snap ring Failure to comply can cause personal injury Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 43 Remove snap ring from 4th clutch hub and remove hub Use caution when removing snap ring Failure to comply can cause personal injury 111 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 48 Remove 1st clutch shaft rear bearing cap o rings and spring disc Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 49 Remove nuts from idler bearing cover assembly FIGURE 52 Remove transmission rear cover bolts TSM 0064 TE
74. l Flow Control Valve Service Manual Dana Holding Corporation 138 Fourth Clutch Disassembly Use caution when removing snap ring Use caution when removing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury FIGURE 210 Using a puller as shown remove front bearing shaft m 9 FIGURE 211 Remove snap ring FIGURE 214 Remove clutch inner and outer discs Use caution when removing snap ring Failure to comply can cause personal injury 139 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Fourth Clutch Reassembly FIGURE 218 Remove clutch piston Fourth Clutch Reassembly Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 219 Install clutch piston inner seal NOTE Bleed hole in the piston must be clean and free of any foreign mate rial Instructions for cleaning can be found in the Cleaning and Inspection see page 103 section of the manual sii FIGURE 220 Install clutch piston outer seal and install piston into drum FIGURE 217 Remove spacer TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 140 Fourth Clutch Reassembly FIGURE 221 Install spacer FIGURE 224 Install one 1 clutch outer half disc friction material on one side steel side down FIGURE 225 Install one 1 friction disc Alternate
75. lded and sealed bearings are mounted as shown Seals must be pressed in perpendicular upon shaft axis from bearing side Tighten air breather to 25 30 Ibs ft 31 41 Nem Tighten nut to 107 118 Ibs ft 145 160 Nem Tighten nut to 250 300 Ibs ft 339 407 Nem Tighten two coil nuts to 5 7 Ibs ft 6 8 9 5 Nem Tighten one valve to 39 54 Ibs ft 53 73 Nem Tighten six screws to 3 7 4 4 Ibs ft 5 6 Nem Tighten two coil nuts to 5 7 Ibs ft 6 8 9 5 Nem Tighten two pressure sensors to 5 8 Ibs ft 7 11 Nem Tighten two valves to 25 27 lbs ft 34 36 Nem TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 100 Transmission Assembly Instructions 0 Hi LA eL o 2 101 Holding Corporation TSM 0064 27 32 4 Speed LD with Full Flow Control Valve Service Manual Control Valve Assembly Instructions Control Valve Assembly Instructions Remove the Valve Refer to the Cleaning and Inspection see page 103 section of this manual The area around the valve must be clean and free of any foreign material Unscrew 16 bolts indicated on drawing below a few turns When all bolts are loose you should be able to move the valve Replace two bolts by aligning studs Remove the remaining 14 hex bolts and valve from the transmission case Install the Va
76. lines 11 friction discs friction material on both side with inner splines Clearance Min 0 23 6 0 mm Max 0 25 6 4 mm 27 8 separator discs with outer splines 8 friction discs friction material on both sides with inner splines Clearance Min 0 23 6 0 mm Max 0 25 6 4 mm Choose an end plate with suitable thickness to obtain this clearance The separator discs in the Fwd Rev clutches and in the 1st and 2nd clutches look similar to each other but are not the same NEVER mix them TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 98 Transmission Assembly Instructions 1st Clutch gt 2 11 separator discs with outer splines 11 friction discs friction material on both side with inner splines Clearance Min 0 17 4 35 mm Max 0 19 4 75 mm TE2T 10 separator discs with outer splines 10 friction discs friction material on both sides with inner splines Clearance Min 0 17 4 35 mm Max 0 19 4 75 mm Choose an end plate with suitable thickness to obtain this clearance 2nd Clutch gt 2 7 separator discs with outer splines 7 friction discs friction material on both side with inner splines Clearance Min 0 10 2 75 mm Max 0 12 8 15 mm TE2T 6 separator discs with outer splines 6 friction discs friction material on both sides with inner splines Clearance Min 0 10 2 75 mm Max 0 1
77. ll Belleville washers Position first washer with large diameter of bevel toward spacer wear sleeve Alternate FIGURE 255 Compress return spring and install snap ring nine 9 washers Refer to Figure 253 Make sure retainer ring is in full position in groove Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 253 Spring and spacer position FIGURE 256 Install one 1 steel disc Alternate steel and friction discs until proper number of discs are installed TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 146 First Clutch Reassembly FIGURE 257 Install end plate FIGURE 261 Install clutch driven gear and hub assembly Align splines on clutch gear hub with internal splines of friction discs NEVER force the operation in this step Gear splines must be in full position with internal teeth of all inner discs Failure to comply may cause equipment damage Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 262 Warm taper bearing to 248 F 120 C FIGURE 259 Warm taper bearing to 248 F 120 C and install on shaft 147 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual First Clutch Reassembly FIGURE 263 Install washer FIGURE 266 Turn shaft and install gear FIGURE 264 Warm bearing to 248 F 120 C and install on FIGUR
78. lve 1 Ur cmo GS I Install two 2 aligning studs Install new gasket and valve body Install fourteen 14 bolts and hand tighten in the numerical sequence indicated on the drawing below Replace the studs by bolts Then torque all bolts twice to 15 18 Ibs ft 20 25 Nem in the correct sequence Recalibrate the transmission TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 102 CLEANING AND INSPECTION DANGER Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type and alkali cleaners Cleaning Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials Thoroughly dry all cleaned parts immediately by using moisture free compressed air or soft lint free absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or
79. mission is repaired e When the APC200 is replaced ENTERING AUTOMATIC CALIBRATION MODE The automatic calibration mode is entered by pressing the S button on the APC200 display for 15 seconds during power up during power up REED keep for 15 seconds TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 8 Automatic Calibration Procedure PERFORMING AUTOMATIC CALIBRATION Before the automatic calibration can be started a number of conditions need to be fulfilled e The parking brake on the vehicle has to be activated e The transmission temperature needs to be above 60 C See the next paragraph how to use the HEAT mode to do this in a time effective way The engine speed has to be kept at around 800 rpm x 200 rpm during the complete calibration If the APC200 has control over the engine the engine speed will be adapted automatically 1 If all the conditions mentioned above are met the actual automatic calibration can be performed starting from the following display on the APC200 2 Totrigger the automatic calibration procedure push the S button once The APC200 display readout will show bo F 3 The APC200 asks for the shift lever to be put in FORWARD The automatic transmission calibration procedure starts This is indicated on the APC200 display cll cd cell C1 stands for clutch 1 being forward while 1 stands for
80. mply can cause personal injury FIGURE 111 Compress piston return springs and remove spring snap ring Use caution when removing snap ring Force of spring is 3399 Nem Failure to comply can Cause personal injury FIGURE 109 Remove clutch gear inner bearing FIGURE 112 Remove Belleville washers TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 122 Reverse amp Second Clutch Disassembly FIGURE 114 Remove reverse clutch piston FIGURE 117 Remove clutch inner and outer discs 2nd Clutch Disassembly The steel discs in the Fwd Rev clutches and in the 1st and 2nd clutches look similar to each other but are not the same NEVER mix them To ensure correct reassembly be sure to keep the different types of discs separated and identified Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 118 Compress return springs and remove snap ring Use caution when removing snap ring Force of spring is 2888 Nem Failure to comply can Cause personal injury 123 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Reverse amp Second Clutch Reassembly Reverse amp Second Clutch Reassembly Second Clutch Reassembly FIGURE 122 Install clutch piston inner seal Rotate piston until seal is flush with outer diameter of piston NOTE Bleed hole
81. n 114 Transmission Case Disassembly q CMS E uc EP 0 9 FIGURE 65 Remove 1st shaft drum assembly front bearing oil FIGURE 68 Remove idler shaft front bearing oil retainer retainer i i SEL FIGURE 66 Remove 1st shaft drum assembly front bearing Use caution when removing snap ring Use caution when removing snap ring _ Failure to comply can cause personal injury Failure to comply can cause personal injury 115 DanaHolding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 71 Remove turbine shaft bearings 2 FIGURE 74 Remove front output flange FIGURE 72 Using an impact wrench remove front output flange FIGURE 75 Loosen front output cap bolts nut FIGURE 76 Remove front output cap and o ring FIGURE 73 Remove front output flange nut washer and o ring TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 116 Transmission Case Disassembly FIGURE 77 Remove output cap shims m pn c FIGURE 78 Using an impact wrench loosen rear output flange nut 777 Use caution when removing snap ring Failure to comply can cause personal injury Ea Clem FIGURE 82 Push output shaft through bearing and gear from the rear side 117 Dana Holding Corporation TSM 0064 TE27 3
82. nd avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use NEVER REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAINING RINGS Replacement of spring loaded oil seals gaskets and retaining rings are more economical when the unit is disassem bled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particu larly when being installed Cutting scratching or curling under the lip of the seal seriously impairs its efficiency At reas sembly lubricate rings and seals with Multipurpose Lithium Grease Grade 2 for axles and Automatic Transmission Fluid for transmissions GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use this process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect
83. ositioned in Step 3 FLYWHEEL HOUSING CONVERTER HOUSING 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step 3 Locate transmission on flywheel housing 6 Align drive plate to flywheel and transmission to fly wheel housing guide studs Install transmission to fly E wheel housing screws Tighten screws to specified ENGINE FLYWHEEL torque Remove transmission to engine guide studs 2 ALIGNING Install remaining screws and tighten to specified torque pios g 7 Remove drive plate locating stud i ON m DRIVE 8 Install drive plate attaching screw and washer Snug PERNE screw but do not tighten Some engine flywheel hous ings have a hole located on the flywheel housing cir cumference in line with the drive plate screw access SPECIAL STUD WASHER AND hole A screwdriver or pry bar used to hold the drive FLYWHEEL HOUSING CR plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed tighten each capscrew to 26 29 Ibs ft 35 39 Nem This will require tightening each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened to specified torque 9 Me
84. p Ring 1 6 Disc Clutch Outer Half 2 16 Snap Ring 1 7 Disc Clutch Outer 10 17 Hub 1 8 Plate End 1 18 Snap Ring 1 9 Snap Ring 1 19 Ring Piston 2 10 Spacer Clutch Piston 1 Not Sold Separately TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 76 First Speed Gear Group First Speed Gear Group 77 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual First Speed Gear Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Gear 1st Speed 69T 1 2 Assembly 3rd Clutch Shaft 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 78 Output Shaft Group Output Shaft Group 9 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Output Shaft Group ITEM DESCRIPTION QTY 1 Shaft Output 1 2 Bearing 1 3 Bearing 1 4 Snap Ring 1 5 Snap Ring 1 6 Spacer 1 7 Cap Shimming 1 8 O ring 1 9 Seal Oil Output 2 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual ITEM 10 11 12 13 14 15 16 17 DESCRIPTION Shims Capscrew Lock washer O ring Washer Flange Locknut Flange Companion Flange Companion QTY AR 11 MPO N N N Dana Holding Corporation 80 Regulator Valve Group Regulator Valve Group 81 Dana Holding Corporation TSM 0064 TE27 32 4 S
85. pacer and nut ex a I t i A FIGURE 357 Tighten rear output flange nut to 250 300 Ibs ft 339 407 Nem TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly FIGURE 361 Install 1st clutch shaft bearing le a AE a E FIGURE 359 Install idler shaft oil retainer and snapring Refer FIGURE 362 Install 1st clutch shaft oil retainer and snap ring to Figure 360 Refer to Figure 363 Bearing NWARNING Ne Use caution when installing snap ring E Failure to comply can cause personal injury Bearing id snapring Oil retainer snapring Oil retainer FIGURE 360 Idler shaft bearing and oil retainer position FIGURE 363 Clutch shaft bearing and oil retainer position TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 164 Transmission Case Reassembly ze FIGURE 365 Install turbine shaft needle roller bearing snapring FIGURE 368 Install forward clutch assembly and snap ring Use caution when installing snap ring Use caution when installing snap ring Failure to comply can cause personal injury Failure to comply can cause personal injury hb a EAM FIGURE 366 Install forward shaft bearing oil retainer Refer to FIGURE 369 Install 3rd clutch assembly Figure 367 165 Dana Holding Corporation TSM 0064 TE27 32 4
86. pecifications Pressure and Temperature Specifications Normal Operating Temperature 158 248 F 70 120 C Measured at temperature check port converter out port 71 or port 32 Maximum Temperature 248 F 120 C Regulator Pressure Vehicle in Neutral amp Port 31 At 600 RPM minimum 326 3 PSI 22 5 bar minimum At 2650 RPM 369 8 PSI 25 5 bar maximum Pump Flow At 1900RPM 31 5 GPM 119 3 l min minimum Lube Pump Flow At 2170 RPM selective lube 12 5 GPM 47 2 l min minimum Clutch Pressure 1st clutch Port 41 2nd clutch Port 42 3rd clutch Port 43 Ath clutch Port 44 Forward clutch Port 45 Reverse clutch Port 46 At 2200 RPM 297 3 PSI 20 5 bar minimum with 1st clutch activated Filter Bypass Valve Set at 59 4 65 2 PSI 4 1 4 5 bar Lube Pressuret Port 34 58 80 PSI 4 0 5 5 bar at 2200 RPM Internal Total Leakage At 1000 engine RPM FWD REV 1 GPM 4 l min maximum 1st 2 43 GPM 9 2 l min maximum 2nd 3rd 4th 1 GPM 4 min maximum Converter 1 3 3 2 GPM 5 12 l min at 1000 RPM Safety Valve Cracking Pressure 127 6 139 2 PSI 8 8 9 6 bar Converter Out Pressure Port 33 72 5 PSI 5 bar minimum 2000 RPM and maximum 123 3 PSI 8 5 bar at no load governed speed Refer to TROUBLESHOOTING for check port identification f All pressures and flows to be measured with oil temperature 180 200 F 82 93 C TSM 006
87. peed LD with Full Flow Control Valve Service Manual Regulator Valve Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Assembly Valve Regulator 1 12 Clamp Suction 2 Valve To Converter 1 13 O ring 1 Housing 3 O ring 1 14 Screw 8 4 Pump Hydraulic 1 15 Lock washer 8 5 Shaft Gear To Pump 1 16 Cap Flange 1 6 Snap Ring 1 17 O ring 1 7 Screw 2 18 Capscrew 4 8 Adapter Suction Tube Side 1 19 Lock washer 4 Side ay 1 10 Capscrew 4 21 O ring 1 11 Hose Suction 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 82 Control Valve Group Control Valve Group o 67 f Ng Og O 25 24 3 83 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Control Valve Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Control Valve Housing 1 16 O ring 2 2 Plug Expansion 22 17 O ring 2 3 Plug Expansion 3 18 O ring 2 4 Plug Expansion 4 19 Spool 3 4A Plug Orifice 1 19A Pin Accumulator Stop 3 5 Valve Solenoid 3 20 Spring Accumulator 3 6 O ring 3 21 Plug 3 7 O ring 6 22 O ring 3 8 Capscrew 6 23 Sensor Valve Pressure 2 Solenoid Assembly 1 24 Plug 2 10 O ring 1 25 O ring 2 11 O ring 1 26 Plug 10 12 O ring 1 27 O ring 10 13 O ring 1 28 Lock washer 16 14 Solenoid Assembly 2 29 Capscrew 16 T5 O ring 2 30 Gask
88. ration in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 139 Install end plate in drum and fit end plate snap ring Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 142 Install outer bearing thrust washer 127 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Forward Clutch Disassembly Forward Clutch Disassembly FIGURE 143 Warm outer bearing to 248 F 120 C and install on shaft with groove down as shown Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 144 Install bearing snap ring Use caution when installing snap ring NM Failure to comply can cause personal injury FIGURE 147 Remove spacer FIGURE 148 Remove bearing FIGURE 145 Install three 3 piston rings TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 128 Forward Clutch Disassembly RA by E a zi p ji L OUS A FIGURE 149 Remove large snap ring from shaft FIGURE 152 Remove bearing inner race Use caution when removing snap ring Failure to comply can cause personal injury FIGURE
89. result of this imbalance may adversely affect overall life of springs Transmission Case Disassembly FIGURE 4 Remove bolts and washers securing front cover to converter housing FIGURE 1 Front view of the TE32 transmission TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 104 Transmission Case Disassembly coa Ae FIGURE 5 Remove converter housing front cover with three 3 FIGURE 8 Remove turbine shaft outer snap ring standard eye bolts 3 4 UNC attached to a chain Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 6 Remove input shaft support bearing FIGURE 7 Remove input shaft support FIGURE 10 Use special tool to lift impeller cover assembly See Impeller Cover Lifting Hook on page 179 105 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Disassembly FIGURE 14 Remove reaction member spacer FIGURE 15 Use a standard bar style puller to remove the impeller and oil baffle Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 13 Remove reaction member TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 106 Transmission Case Disassembly j E LI z j P z 1 d m 4 4 E d 4 E
90. s J A QW Ne NIS NOM S Vy wu Xe rd Y Pd a m S LOANS 6M SS ly M B tO E ov d d pL ze p pL ju oe 1 E P 8 z n P 87 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Converter Housing Cover Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Cover Converter Housing 1 6 Not Used On This Model 2 Screw 12 7 Not Used On This Model 3 Lock washer 12 8 Not Used On This Model 4 Seal Front Cover Oil 1 9 Not Used On This Model 5 Hose 1 10 Plug 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 88 Input Flange Group Input Flange Group 89 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Input Flange Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Flange Companion 1 3 Washer Flange 1 2 O ring 1 4 Nut Flange 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 90 idler Shaft Gear Group Idler Shaft Gear Group 91 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Idler Shaft Gear Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1st Speed Shaft amp 3rd Driven Gear Assembly 1 2 Gear Output 55T 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Servic
91. section TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 18 Converter Pump Drive amp Pressure Regulating Valve Converter Pump Drive amp Pressure Regulating Valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its center and discharges it at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque con verter This element receives fluid at its outer diameter and discharges it at its center The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the converter to multiply torque The torque multiplication is a function of the blading impeller turbine and reaction member and the converter output speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when
92. shafts to make certain they are not sprung bent or have twisted splines HOUSINGS COVERS AND CAPS Inspect housings covers and caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures 103 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DISASSEMBLY amp REASSEMBLY Getting Started Cleanliness is of extreme importance in the repair and over haul of the transmission Before conducting repairs the exterior of the unit must be thoroughly cleaned to prevent dirt and foreign debris from entering the transmission When maintenance work requires welding disconnect both connectors from the APC200 and from the control valve unit before any welding is started NOTE CLUTCH RETURN SPRING PACKS ARE CERTIFIED ACCORDING TO COMPRESSION WEIGHT SPECIFICATIONS AND ARE PRE PACKED IN QUANTITIES TO REPAIR ONE 1 SPECIFIC CLUTCH The disc spring packs are to be used as complete assem blies and care should be taken not to intermix the individ ual disc springs with disc springs in another clutch or disc spring pack Each disc spring assembly is made up of selected springs to precisely match each part within this assembly Failure to replace all piston return springs can result in unequal deflection within the spring pack The
93. st Hub 2nd Clutch Disc Snap Ring Retainer Snap Ring Ring Piston Gear Clutch Driven Reverse 2nd Clutch Shaft Dana Holding Corporation 12 First Shaft Group First Shaft Group 73 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual First Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 17 Ring Piston 2 2 Seal Piston Outer 1 18 Cap Bearing 1 Seal Piston Inner 1 19 O ring 1 4 Screen 1 20 Plug 2 5 Disc Clutch Inner 11 21 O ring 2 6 Disc Clutch Outer 11 22 O ring 1 7 Plate End 1 23 Capscrew 4 8 Snap Ring 1 24 Lock washer 4 Washer Belleville 9 25 Bearing 1 10 Spacer Clutch Piston 1 26 Spacer Bearing 1 11 Retainer Spring 1 27 Snap Ring 1 12 Ring Retainer 1 28 Snap Ring 1 13 Bearing 1 29 Bearing 1 14 Washer 1 30 Bearing 1 15 1 31 Spring Disc 1 16 Retainer Oil 1 32 Nut 1 Not Sold Separately TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 74 Fourth Clutch Shaft Group Fourth Clutch Shaft Group 75 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Fourth Clutch Shaft Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Piston 1 11 Retainer Spring 1 2 Seal Piston Outer 1 12 Spring 1 Seal Piston Inner 1 13 Ring Retainer 1 4 Screen 1 14 Bearing 1 5 Disc Clutch Inner 11 15 Sna
94. steel and friction discs until proper number of discs are installed FIGURE 226 Install one 1 clutch outer half disc friction material on one side steel side up Use caution when installing snap ring Failure to comply can cause personal injury 141 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Fourth Clutch Reassembly Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 227 Install end plate FIGURE 230 Warm bearing to 248 F 120 C and install on shaft FIGURE 228 Install end plate snap ring Use caution when installing snap ring Failure to comply can cause personal injury Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 229 Install snap ring over shaft to be used when installing drum shaft in casing TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 142 First Clutch Disassembly FIGURE 232 Install two 2 piston rings First Clutch Disassembly Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 234 Using a puller remove gear bearing outer race and spacer as an assembly FIGURE 235 Remove bearing washer FIGURE 238 Remove clutch inner and outer discs 143 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service
95. t Socket see page 180 torque lock nut to 107 118 Ibs ft 145 160 Nem m Use caution when installing snap ring Failure to comply can cause personal injury 167 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Transmission Case Reassembly d 4 1 V d E FIGURE 382 Fit o ring 2 to idler shaft bearing cap and install bearing cap FIGURE 383 Install nuts and lockwashers to bearing cap and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 384 Fit o ring 2 to 3rd shaft bearing cap and install bearing cap TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual FIGURE 385 Install nuts and lockwashers to bearing cap and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 FIGURE 386 Install 1st shaft bearing cap with new o rings 3 and spring disc FIGURE 387 Install bolts and lockwashers to bearing cap and tighten to specified torque Refer to TORQUE SPECIFICATIONS on page 175 Dana Holding Corporation 168 Transmission Case Reassembly FIGURE 391 Install new converter housing to transmission case gasket and new o rings 3 Use caution when installing snap ring Failure to comply can cause personal injury FIGURE 392 Install alignment studs and position converter housing assembly onto studs Install converter housing to transmission housing
96. t until the APC200 display shows a temperature above 140 F 60 C When the tem perature is above 140 F 60 C the temperature indication on the display starts blinking Now switch to automatic calibration by pressing the M button several times until the APC200 displays tran During this warm up procedure it is possible for the converter out temperature of the transmission to exceed the maxi mum limit This is a consequence of heating up the transmission using this quick procedure When this occurs the engine speed will be limited to half throttle when the APC200 has engine control or forcing neutral when the APC200 has no engine control To solve this simply leave the transmission in neutral for a minute and throttle the engine to around 1300 rpm This will allow the heat in the converter to be evacuated After one or two minutes resume the heat ing up procedure if the transmission temperature has not reached 60 yet FULL IDLE forward neutral TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 10 Automatic Calibration Procedure CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS This chapter gives an overview of the most common calibration condition messages Many calibration condition mes sages can be corrected however if any calibration error messages appear contact the OEM of the machine Calibration Condition Messages The APC200 expects the shift l
97. ted the 1st 8rd proportional valve will decrease pres sure from 26 to 0 bar thus releasing the 1st clutch in a controlled manner At the same time the 2nd 4th proportional valve is activated and will provide a pressure curve from 0 to 26 bar which will provide clutch overlap When the shift is finalized the 1st 3rd selector valve is deactivated When 3rd clutch is selected the 3rd 1st selector valve is not activated The 2nd 4th proportional valve will decrease pressure from 26 to O bar thus releasing the 2nd clutch in a controlled manner At the same time the 1st 3rd propor tional valve is activated and will provide a pressure curve from O to 26 bar which will provide clutch overlap When the shift is finalized the 2nd Ath selector valve is deactivated When 4th clutch is selected the 2nd 4th selector valve is not activated The 1st 3rd proportional valve will decrease pressure from 26 to O bar thus releasing the 3rd clutch in a controlled manner At the same time the 2nd 4th propor tional valve is activated and will provide a pressure curve from O to 26 bar which will provide clutch overlap Restriction Plug The pressure line is connected to the drain line via a restricted hole This ensures the drain line to remain air free at all times and guarantees the reliable functioning of the proportional valves Pressure Sensor The control valve also has a pressure sensor installed to monitor overlap on range clutches TSM 0064 TE27
98. trol Valve Service Manual Impeller Reassembly FIGURE 302 Install impeller hub gear FIGURE 300 Position impeller hub backing ring Use caution when installing snap ring Failure to comply can cause personal injury IE 2 FIGURE 301 Make sure that hub mounting surface and tapped holes are cleaned with solvent Install self locking screws and tighten to 58 65 Ibs ft 79 87 Nem NOTE Assembly of the hub must be completed within a fifteen minute period from the start of screw installation The special screw is to be used for one 1 installation only If the screw is removed for any rea son it must be replaced The epoxy left in the hub holes must be removed with the proper tap and the hole must be cleaned with sol vent Holes must be dried thoroughly and a new screw used for reinstallation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 154 Impeller Cover amp Turbine Disassembly Impeller Cover amp Turbine Disassembly FIGURE 307 Remove turbine hub screws and locktabs Impeller Cover amp Turbine Assembly Use caution when removing snap ring Failure to comply can cause personal injury FIGURE 308 Align holes in turbine and turbine hub Position locktabs and install screws Tighten screws to specified torque Refer to TORQUE SPECIFICATIONS on page 175 Bend a corner of the locktab over a flat of the screw heads Refer to Figure 3
99. tton and trigger this one again to continue calibration Calibration errors have the form E1 xx or E2 xx example E1 25 Please contact the OEM of the machine if an error of this form appears on the display 11 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual DRIVE PLATE INSTALLATION Proper identification is determined by measuring the bolt circle diameter see dimension A in the illustration below and then ordering the appropriate drive plate kit from the table DRIVE PLATE AND WELD NUT ASSEMBLY 1 BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 2 BACKING RING 7N BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 3 BACKING RING Each kit includes 3 Intermediate Drive Plates 1 Backing Ring 6 Mounting Capscrews 6 Lockwashers Instruction Sheet Each kit includes 2 Intermediate Drive Plates 1 Drive Plate amp Weld Nut Assembly 1 Backing Ring 6 Mounting Capscrews 6 Lockwashers Instruction Sheet 15 881 0 mm diameter 15 881 0 mm diameter 16 406 4 mm diameter 16 406 4 mm diameter 17 431 8 mm diameter 17 431 8 mm diameter Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter 2 Align intermediate drive plates and backing ring with holes in torque converter assembly 3 Two dimples 180 apart in backing ring must be facing outwar
100. two levels should be noticed sansar 200 Ohm 1 Walt TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 52 EXPLODED VIEWS Converter Housing Group 53 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Converter Housing Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Torque Converter Housing 1 23 O ring 2 2 Not Illustrated 1 24 Pin Dowel 2 3 Plug Expansion 3 25 Capscrew 14 4 Plug 1 26 Capscrew 9 5 O ring 1 27 Lockwasher 23 6 Tube 1 28 Gasket Converter To 1 Transmission Case 7 Tube 1 29 Bushing 1 8 Tube 1 30 Breather Air 1 9 Clip 2 31 Plug 1 10 O ring 2 32 Sensor Speed 1 11 Capscrew 2 33 O ring 1 12 Lockwasher 2 34 Sensor Speed 1 13 Tube 1 35 O ring 1 14 Sleeve 1 36 Plug 2 15 Sleeve 1 37 Cover Split Flange 3 16 Sleeve 1 38 O ring 3 17 Sleeve 1 39 Capscrew 12 18 Washer 3 40 Lockwasher 12 19 Capscrew 3 41 Plug 1 20 Lockwasher 3 42 O ring 1 21 Plug 1 43 Not Used in This Model 22 Plug 2 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 54 O gt O 3 0 CC 0 O C 7 2 2 C Transmission Case amp Rear Cover Group Speed LD with Full Flow Control Valve Service Manual
101. ween wire color pin number and connection 2 Blue Current Output Ground Wire The sensor wires have a polarity Be sure to correctly observe sensor polarities as wrong connections will deactivate the sensor Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Speed Sensor Installation GEAR ROTATION Dm SENSOR WITH POSITION SIGN POINTING IN THE DIRECTION OF GEAR TEETH MOVEMENT OR 180 ROTATED 2 gt rorave SCREW 9 11 Ibs ft 12 15 Nm INSTALL CLIP UNDER ANGLE X SEE TABLE TRANSMISSION ASSY Partnr CONNECTOR X POSITION MODEL TE27 32 4209752 AMP 2 Pins 180 Degrees 4209752 AMP 2 Pins 180 Degrees 4209750 AMP 2 pins 180 Degrees 4209751 2 Pins Turbine Speed 90 Degrees TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 16 TEMPERATURE SENSOR INSTALLATION MATERIAL STAINLESS STEEL HOUSING BSS303 equiv DIN 1 4305 NPTF 1 8 X 21 SPADE TERMINALS X 0 8 DIN 46244 WITHOUT HOLE 17 Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual TRANSMISSION OPERATION BR j Ji Jr REV 2ND D IST Es I Moooooe The transmission is composed of five main assemblies Converter pump drive section and pressure regulating valve Input shaft and directional clutches Range clutches Output
102. with Full Flow Control Valve Service Manual Dana Holding Corporation 68 Third Speed Gear Group Third Speed Gear Group K 69 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Third Speed Gear Group ITEM DESCRIPTION QTY 1 Gear 3rd Speed 64T 1 TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 70 Reverse Second Clutch Shaft Group Reverse Second Clutch Shaft Group 71 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual N O C 10 11 12 13 14 15 16 17 18 19 DESCRIPTION Piston Seal Clutch Piston Outer Seal Clutch Piston Inner Screen Washer Belleville Spacer Clutch Piston Ring Retaining Disc Clutch Inner Disc Clutch Outer Plate End Snap Ring Piston Seal Clutch Piston Outer Seal Clutch Piston Inner Screen Ring Retaining Disc Clutch Inner Disc Clutch Outer Plate End Not Sold Separately TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual QTY 11 11 Reverse Second Clutch Shaft Group ITEM 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 DESCRIPTION Seal Snap Ring Washer Belleville Spacer Clutch Piston Bearing Bearing Ring Retaining Ring Retaining Bearing Ring Retaining Ring Washer Bearing Thru
103. y observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part NEVER use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of unique tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither their safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various precautions that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may also damage the unit or render it unsafe It is important to understand that these precautions are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions Indicates an imminently hazardous situation which DANGER if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not

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