DANA SPICER TE27, Service Manual

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TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Dana Holding Corporation
i
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 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, & 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