DANA SPICER TE27 Service Manual Download

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TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual

Dana Holding Corporation

CONTENTS

.................................................... i

Towing or Pushing

........................................... 1

Introduction

..................................................... 2

Foreword

.......................................................... 2

Safety Precautions

........................................... 2

SPECIFICATIONS

.......................................... 3

Identification Tag

.............................................. 3

General Specifications

..................................... 3

Hydraulic Cooler Lines Specifications

.............. 3

Pressure and Temperature Specifications

....... 4

Electrical Specifications

................................... 5

Maintenance

................................................... 6

Sump preheaters

............................................. 6

Filters

............................................................... 6

Clutch Calibration

............................................ 6

Lubricants

........................................................ 6

Servicing Machine After Component Overhaul

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, & Pressure Regulating
Valve

................................................................ 19

Input Shaft and Directional Clutches

................ 20

Range Clutches

............................................... 21

Transmission Controls

..................................... 22

Electric Solenoid Controls

................................ 23

Power Flows, Activated Solenoids, & Hydraulic
Circuits

............................................................. 24

Gear & Clutch Layout

...................................... 42

TROUBLESHOOTING

.................................... 43

Transmission Problems

................................... 43

Troubleshooting Procedures

............................ 43

Troubleshooting Guide

..................................... 46

Check Points

.................................................... 47

Checkports

....................................................... 50

Full Flow Valve Components

........................... 51

Speed Sensor Static Standalone Test

.............. 52

EXPLODED VIEWS

........................................ 53

Converter Housing Group

................................ 53

Transmission Case & Rear Cover Group

........ 55

Turbine Shaft Group

........................................ 57

Charging Pump Drive Group

............................ 59

Torque Converter Assembly Group

.................. 61

Forward, Reverse/Second, & Third or Fourth Clutch
Shaft Assembly

................................................ 63

Forward Clutch Shaft Group

............................ 65

Third Clutch Shaft Group

................................. 67

Third Speed Gear Group

.................................. 69

Reverse/Second Clutch Shaft Group

............... 71

First Shaft Group

.............................................. 73

Fourth Clutch Shaft Group

............................... 75

First Speed Gear Group

................................... 77

Output Shaft Group

.......................................... 79

Regulator Valve Group

..................................... 81

Control Valve Group

......................................... 83

Remote Filter Adapter Group

........................... 85

Converter Housing Cover Group

...................... 87

Input Flange Group

.......................................... 89

Idler Shaft Gear Group

..................................... 91

Idler Shaft Group

.............................................. 93

External Dipstick Group

.................................... 95

INSTALLATION DIAGRAMS

...........................97

Transmission Assembly Instructions

................ 97

Control Valve Assembly Instructions

................ 102

Cleaning and Inspection

..................................103

DISASSEMBLY & REASSEMBLY

...................104

Getting Started

................................................. 104

Transmission Case Disassembly

.................... 104

Converter Housing Disassembly

...................... 120

Reverse & Second Clutch Disassembly

........... 121

Reverse & Second Clutch Reassembly

........... 124

Forward Clutch Disassembly

............................ 128

Forward Clutch Reassembly

............................ 131

Third Clutch Disassembly

................................. 134

Third Clutch Reassembly

................................. 136

Fourth Clutch Disassembly

.............................. 138

Fourth Clutch Reassembly

............................... 140

First Clutch Disassembly

.................................. 143

First Clutch Reassembly

.................................. 145

Idler Shaft Disassembly

.................................... 149

Idler Shaft Reassembly

.................................... 150

Turbine Shaft Disassembly

............................... 150

Turbine Shaft Reassembly

............................... 151

Impeller Disassembly

....................................... 152

Impeller Reassembly

........................................ 153

Impeller Cover & Turbine Disassembly

............ 155

Impeller Cover & Turbine Assembly

................. 155

Converter Cover Disassembly

.......................... 156

Converter Cover Reassembly

.......................... 156

Pump Drive Gear Disassembly

........................ 156

Pump Drive Gear Reassembly

......................... 157

Converter Housing Reassembly

....................... 157

Transmission Case Reassembly

...................... 159

TORQUE SPECIFICATIONS

..........................175

Lubricated or Plated Screws

............................ 175

Pipe Plugs

........................................................ 177

SPECIAL TOOLS

............................................178

CONTENTS

Summary of Contents for SPICER TE27

Page 1: ...Service Manual PowershiftTransmission TE27 TE32 4 Speed Long Drop with Full Flow ControlValve TSM 0064 August 2012 80 1070 Rev 5 12 2014 ...

Page 2: ......

Page 3: ...rth Clutch Shaft Assembly 63 Forward Clutch Shaft Group 65 Third Clutch Shaft Group 67 Third Speed Gear Group 69 Reverse Second Clutch Shaft Group 71 First Shaft Group 73 Fourth Clutch Shaft Group 75 First Speed Gear Group 77 Output Shaft Group 79 Regulator Valve Group 81 Control Valve Group 83 Remote Filter Adapter Group 85 Converter Housing Cover Group 87 Input Flange Group 89 Idler Shaft Gear G...

Page 4: ...vice Manual 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 ...

Page 5: ...nd or property damage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part NEVER use a replacement part of lesser quality The service procedures recommended in this manual a...

Page 6: ...maximum 39 8 1011 mm for T models 46 8 1189 mm for MT models Width maximum 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 Lines and Fittings Minimum 1 25 4 mm internal diameter Continuous Operating Temperature Ambient to 248 F 120 C Continuous Pressure 406 PSI 28 bar c...

Page 7: ... 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 4th 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 Pressure Port 34 5...

Page 8: ...8 F 20 C Coil Resistance 24V 28 5 at 68 F 20 C Speed Sensor 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 Temperature Sensor Material Silicon Resistance 77 F 25 C 2000 1 Pressure Sensor Supply Voltage 4 5 5 5V Maximum Current 10mA Pressure Range 14 5 450 PSI 1 31 bar 1 2 full scale 450 PSI...

Page 9: ...will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Every 1000 hours Change oil filter element Drain oil at 150 200 F 65 93 C and refill system as follows 1 Drain transmission 2 Remove and discard filter 3 Install new filter 4 Refill transmission to FULL mark 5 Run engine at 500 600 RPM to prime converte...

Page 10: ...hydraulic lines should be removed from machine for clean ing 3 Replace oil filter element 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning using oil...

Page 11: ...ure which is able to optimize the shift quality of the transmission An automatic calibration has to be done When the vehicle is build at the OEM Every 2000 hours of transmission operation When an overhaul of the transmission is done When the transmission is repaired When the APC200 is replaced ENTERING AUTOMATIC CALIBRATION MODE The automatic calibration mode is entered by pressing the S button on...

Page 12: ...le M1 stands for mode 1 of the calibration 4 When all clutches have been calibrated the APC200 displays 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 rest...

Page 13: ...r and then accelerates the engine to full throt tle 3 Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever Keep the engine at full throttle 4 Keep the gearbox in neutral at full engine throttle for about 15 seconds again 5 Release the throttle pedal and decelerate the engine to idle 6 Go back to point 2 and repeat until...

Page 14: ... 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 Engine RPM is to low according to the limit that is necessary for calibration When during the automatic transmission calibration the temperature becomes to low t...

Page 15: ... to 30 37 lbs ft 40 50 N m 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 Each kit includes 2 Intermediate Drive Plates 1 Drive Plate...

Page 16: ...d on the flywheel housing cir cumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but d do not tighten After all eight 8 screws are installed tighten ...

Page 17: ...tings 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 Conforms SAE J1019 and SAE J517 100RI to remote filter 1 from pump 1 from remote filter 1 from remote filter 2 from transmission to cooler from cooler to transmission Cooler Remote Filter 1 to remote filter 2 from pu...

Page 18: ...en 7 mA and 14 mA The sensor has an integrated AMP superseal 2 pin connector The two pins are numbered 1 and 2 The following table shows the relation between wire color pin number and connection Pin Color Function Connection 1 Brown Current Input Hot Wire 2 Blue Current Output Ground Wire The sensor wires have a polarity Be sure to correctly observe sensor polarities as wrong connections will deac...

Page 19: ...TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual Dana Holding Corporation 16 Speed Sensor Installation Speed Sensor Installation ...

Page 20: ...17 Dana Holding Corporation TSM 0064 TE27 32 4 Speed LD with Full Flow Control Valve Service Manual TEMPERATURE SENSOR INSTALLATION ...

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