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SPEED SENSOR STATIC STANDALONE TEST

Dana Incorporated

TSM-0238 - 6000 Transmission Service Manual

SPEED SENSOR STATIC STANDALONE TEST

In order to be able to sense the currents, a series resistor of e.g. 200 Ohm must be used. This resistor is integrated in the con-
troller.

When the sensor is tested separately, resistor must be integrated in sensor connector as per below schematic.

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).

By slowly moving gear teeth or a metal part in front of the sensor (1.8 mm max. distance), toggling between the two levels should
be noticed.

Содержание SPICER 6000 EHO

Страница 1: ...September 2020 TSM 0238E 6000 EHO Allied Form 80 1381 Rev 06 2022 ...

Страница 2: ...nt the English original prevails Dana shall not be liable for any misinterpretation of the content here into Photos and illustrations might not represent the exact product Copyright 2020 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or other wise without prior written approval THIS INFORMATION IS NOT INTENDED FOR...

Страница 3: ...ND CAPS 9 SPECIFICATIONS 10 IDENTIFICATION TAG 10 GENERAL SPECIFICATIONS 10 TORQUE CHARTS 11 HYDRAULIC COOLER LINES SPECIFICATIONS 13 PRESSURE AND TEMPERATURE SPECIFICATIONS 13 ELECTRICAL SPECIFICATIONS 14 MAINTENANCE 15 OIL SPECIFICATION 15 RECCOMENDED LUBRICANTS 15 MAINTENANCE INTERVALS 16 SERVICING MACHINE AFTER COMPONENT OVERHAUL 16 FILLING INSTRUCTIONS 17 INSTALLATION DETAIL 18 PLUMBING DIAGR...

Страница 4: ... REVERSE 3RD SPEED CONTINUED 47 REVERSE 4TH SPEED 48 REVERSE 4TH SPEED CONTINUED 49 TROUBLESHOOTING 50 TRANSMISSION PROBLEMS 50 TROUBLESHOOTING PROCEDURES 50 INPUT SHAFT AND DIRECTIONAL CLUTCH PROBLEMS 50 TRANSMISSION PRESSURE CHECKS 50 MECHANICAL AND ELECTRICAL CHECKS 50 CHECK POINT 51 NUMBERING OF PORTS FOR HYDRAULIC CIRCUIT DIAGRAMS 52 CHECK POINTS CONTROL VALVE 53 TROUBLESHOOTING GUIDE 54 LOW ...

Страница 5: ...SSY CONTROL VALVE 2 82 ASSY SOLENOID PLATE 85 ASSY CONTROL VALVE WITH VARIABLE RESTRICTIONS 86 FLANGE CROSS SERRATED 155KV70 88 FLANGE CROSS SERRATED 180KV70 89 GROUP FORWARD SHAFT 90 GROUP OUTPUT SHAFT 92 GROUP IDLER SHAFT 94 DISASSEMBLY ASSEMBLY 97 DISASSEMBLY 97 ASSEMBLY 112 SPECIAL TOOLS 140 AS0010005000 140 AS0010009800 142 TG1500106500 144 TG1500106700 149 AS0010012800 153 AS0010012900 153 A...

Страница 6: ...6 Dana Incorporated TSM 0238 6000 Transmission Service Manual ...

Страница 7: ... TSM 0238E_Rev 00 6000 EHO Rev 00 05 11 2019 Document issued TSM 0238E_Rev 01 6000 EHO Rev 01 21 01 2020 Updated Disassembly Assembly p 97 Added AS0010012800 p 153 Added AS0010012900 p 153 TSM 0238E_Rev 02 6000 EHO Rev 02 17 09 2020 Update Operation of the Valve p 28 Electric Solenoid Controls p 29 Added Clutch packs assembly intructions p 64 Update Assembly p 112 MODELS 6000 EHO ...

Страница 8: ... A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare part service procedure or tool which is not recommended by Dana Incorpo rated must first determine that neither his safety nor t...

Страница 9: ...f wear or stress will eliminate costly and avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection dip bearings in clean light oil and wrap in clean lint free cloth o...

Страница 10: ...e unit GENERAL SPECIFICATIONS Without cooler and hydraulic lines Consult equipment operator s manual for complete system capacity Weight dry 891 52 kg 1965 46 lb Length maximum 800 mm 314 96 in Width maximum 633 22 mm 249 29 in Height maximum 1134 54 mm 446 66 in Oil Capacity 32 Liters 8 5 US Gallons MODEL SERIAL TENBRIELE3 B 8200 BELGIUM SPICER OFF HIGHWAY ...

Страница 11: ...0 1364 1549 M36x4 2000 2250 1475 1660 2749 3149 2028 2323 3249 3699 2397 2729 TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED THREADS NOM SIZE GRADE 8 8 Grade 10 9 Grade 12 9 Coarse thread Coarse thread Coarse thread Nm Lbf ft Nm Lbf ft Nm Lbf ft M8x1 23 28 17 20 34 39 25 28 41 46 30 34 M10x1 47 57 35 42 71 81 52 60 84 94 62 69 M10X 1 25 44 54 32 40 67 77 49 57 79 89 58 66 M12x1 25 82 92 60 68 120 ...

Страница 12: ...rts Nm lbf ft 5 16x24 4 7 43588 3 8x24 7 11 43682 7 16x20 9 14 43745 1 2x20 14 18 41548 9 16x18 16 20 42339 3 4x16 27 34 20 25 7 8x14 41 47 30 35 1 1 16x12 61 68 45 50 1 5 16x12 88 102 65 75 1 5 8x12 102 115 75 85 1 7 8x12 102 115 75 85 Torque specifications for plugs METRIC Nom Size O ring ports Nm lbf ft M10x1 8 9 43652 M12x1 5 14 18 41518 M14x1 5 16 20 42339 M16x1 5 27 34 20 25 M18x1 5 34 41 25...

Страница 13: ...RPM minimum 12 4 bar 180 PSI At no load GOV speed 12 4 bar 180 PSI Pump Flow See at the torque converter manual Lube Pump Flow See at the torque converter manual Clutch Pressure 1st clutch Port 41 2nd clutch Port 42 3rd clutch Port 43 Forward High clutch Port 44 Forward Low clutch Port 45 Reverse clutch Port 46 At 2200 RPM 12 4 to 15 1 bar 180 to 220 PSI Filter Bypass Valve See Technical Specs of ...

Страница 14: ...ual ELECTRICAL SPECIFICATIONS Solenoid Valves Fwr Rev 1st 2nd 3rd 4th Coil Resistance 24V 92 7 4 Ω at 20 C 68 F Ouput Speed Sensor Type Magneto resistive sensor Sensing Distance 0 1 8 mm 0 0 07 Sensor Signal Generates a square current with a fixed amplitude changing between 7 and 14 mA ...

Страница 15: ...mperature is closest to the middle of the viscosity range Example for ambient temperature of 20 C 68 F SAE 30 is preferred over SAE 40 or SAE 50 8 Fire resistant fluid see vehicle manufacturers recommendations 9 Sump preheaters before operating the transmission fluid must be preheated to a minimum temperature according the vi scosity grade to assure sufficient pumping viscosity 10 Warm up for full...

Страница 16: ...s SERVICING MACHINE AFTER COMPONENT OVERHAUL The transmission 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 considere...

Страница 17: ...00 600 RPM to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 RPM 3 Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole 4 Install oil level plug or dipstick Recheck with hot oil 82 93 C 180 200 F 5 Bring oil level to full mark on dipstick or runs freely from UPP...

Страница 18: ...LET C CONVERTER OUTLET D LUBE PRESSURE E COOLER INLET F COOLER OUTLET OIL COOLER SUCTION LINE FROM CHARGING PUMP CONVERTER IN LINE SELECT LOWEST CONNECTION FOR GRAVITY DRAIN TO TRANSMISSION WHEN RETARDER IS USED IT MUST BE PLUMBED IN THIS LINE CHARGING PUMP PRESSURE REGULATOR VALVE COOLER OUT LINE DRAIN MUST HAVE CONTINEOUS SLOPE FROM CONVERTER TO TRANSMISSION OIL FILTER CONVERTER RETURN LINE CONV...

Страница 19: ...al CONNECTION POINTS FRONT VIEW 1 Port 22 Drain Connection Ø38 Split Flange 2 1 3125 O ring Port 3 1 NPTF Threads Optional Dipstick 4 Port 80 Suction Line Ø50 8 Split Flange 5 Ø26 12 26 44 6 Mounting Holes 6 Breather 7 Port 16 Pressure Regulator In Ø38 Split Flange 5 2 1 7 6 4 3 ...

Страница 20: ... 1 Valve connector Deutch HD34 18 14 PE 2 Port 23 Pressure Regulator OUT Ø38 Split Flange 3 Port 83 Lube IN Ø38 Split Flange REAR VIEW 1 Ø26 12 26 44 6 Mounting Holes 2 Oil Level Glasses 3 Oil Level Check 4 3 4 14 NPTF Drain Plug 5 Port 22 Transmission Drain Ø38 Split Flange 1 3 2 1 2 3 4 5 ...

Страница 21: ... M14 x 1 5 6 Port 36 Solenoid pressure M14 x 1 5 7 Port 31 Regulated pressure M14 x 1 5 8 Port 37 Converter in pressure M14 x 1 5 9 Port 34 Lube pressure M14 x 1 5 10 Port 44 4th clutch pressure M14 x 1 5 11 Port 46 Rev clutch pressure M14 x 1 5 12 Port 45 Fwd clutch pressure M14 x 1 5 13 14 Pole deutz connector HD34 18 14PN mating parts specs connector deutz HD36 18 14SN contact female deutz 0462...

Страница 22: ... 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 Function Connection 1 Current Input Hot Wire 2 Current Output Ground Wire The sensor wires have a polarity Be sure to correctly observe sensor polarities as wrong connections will deactivate the sen sor Speed Sensor Speed ...

Страница 23: ...ition of clamp must be 180 in relation to position sign on speed sensor clamp must be fixed Item Description Qty 1 Support speed sensor 1 2 Screw 1 3 O ring DIA 15x1 8 1 4 Assy speed sensor AMP 1 Transmission model ASSY Part Nr Connector Type X Position 6000 4209752 AMP 2 pins Drum speed 180 1 ...

Страница 24: ...24 Dana Incorporated TSM 0238 6000 Transmission Service Manual OPERATION OF THE TRANSMISSION 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 25: ... 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 end plate The discs with tee...

Страница 26: ...l RANGE CLUTCHES Once a directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the directional clutches is similar to the range clutches The engagement of the directional and range clutches is modulated 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 27: ...238 6000 Transmission Service Manual OUTPUT SECTION With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the opposite to input rotation when the forward clutch is engaged 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 28: ...ated until the required total is achieved After inserting the last disc a series of springs and pins are assembled in such a manner that these springs rest on theeth of the piston A heavy backup plate is then inserted and secured by a snap ring A hub with ID and OD splines is inserted into the splines of the discs with theeth on the inner diameter and the splined shaft extending through the clutch...

Страница 29: ... Activated Proportional valve Activated Clutches Forward 4 Fwd 4th Forward 4th Forward 3 Fwd 3rd Forward 3rd Forward 2 Fwd 2nd Forward 2nd Forward 1 Fwd 1st Forward 1st Neutral 4 4th 4th Neutral 3 3rd 3rd Neutral 2 2nd 2nd Neutral 1 1st 1st Reverse 4 Rev 4th Reverse 4th Reverse 3 Rev 3rd Reverse 3rd Reverse 2 Rev 2nd Reverse 2nd Reverse 1 Rev 1st Reverse 1st ...

Страница 30: ...CLUTCH 2ND CLUTCH 3RD CLUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV...

Страница 31: ...UTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 ba r PRESSURE REDUCE R 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 32: ...CH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 ba r PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND PROP 3RD 4TH FWD REV FWD REV ...

Страница 33: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 34: ...UTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FW D REV FWD REV ...

Страница 35: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 35 Dana Incorporated TSM 0238 6000 Transmission Service Manual FORWARD 1ST SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 36: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 37: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 37 Dana Incorporated TSM 0238 6000 Transmission Service Manual FORWARD 2ND SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 38: ...UTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 ba r PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 39: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 39 Dana Incorporated TSM 0238 6000 Transmission Service Manual FORWARD 3RD SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 40: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 41: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 41 Dana Incorporated TSM 0238 6000 Transmission Service Manual FORWARD 4TH SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 42: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 43: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 43 Dana Incorporated TSM 0238 6000 Transmission Service Manual REVERSE 1ST SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 44: ...UTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCE R 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 45: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 45 Dana Incorporated TSM 0238 6000 Transmission Service Manual REVERSE 2ND SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 46: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 47: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 47 Dana Incorporated TSM 0238 6000 Transmission Service Manual REVERSE 3RD SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 48: ...LUTCH 4TH CLUTCH REV CLUTCH FWD CLUTCH Lubrication Low pressure 0 6 bar High pressure 0 20 bar Drain SCREEN FILTER AIR BREATHER PUMP OIL SUMP PRESSURE REGULATOR VALVE 12 4 15 2 bar PRESSURE REDUCER 8 5 11 bar Ø 0 8 SAFETY VALVE 7 6 9 0 bar CONVERTER REGULATOR 3 8 4 0 bar TORQUE CONVERTER LUBRICATION HOSE HOSE HOSE HOSE HOSE HOSE COOLER 1ST 1ST 2ND 3RD 4TH 2ND 3RD 4TH FWD REV FWD REV ...

Страница 49: ...POWER FLOWS SOLENOIDS AND HYDRAULIC CIRCUITS 49 Dana Incorporated TSM 0238 6000 Transmission Service Manual REVERSE 4TH SPEED CONTINUED 1ST 4TH REV IDLER 2ND FWD 3RD ...

Страница 50: ...e 1 Put the vehicle at standstill apply the parking brake and block the wheels 2 Select Manual Mode Drive 3 Put the directional control lever in FORWARD or REVERSE as applicable 4 Select the highest speed 5 With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission con verter outlet oil temperature reaches the operating range Always check th...

Страница 51: ...rrect full level All clutches and the converter and its fluid circuit lines must be fully charged filled at all times 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 The transmission fluid must be at operating temperature of 82 93 C 180 200 F to obtain correct fluid level and pressure readings NEVER...

Страница 52: ...r on Transmission 46 REV Clutch 86 17 Air Hydr Disconnect 4WD 47 Disconnect Clutch 87 18 To Pump 48 Clutch Return Line 88 19 Air Hydr Inching 49 SAHR Brake Release 89 20 Air Hydr Disconnect 2WD 50 VFS 1st 90 21 From Pump 51 VFS 2nd 22 Drain 52 VFS 3rd 23 From Regulator 53 VFS High 24 SAHR brake Release 54 VFS FWD 25 Range Shift 55 VFS REV 26 Diff Lock 56 System Pressure after Total Neutral 27 Powe...

Страница 53: ...4 x 1 5 6 Port 36 Solenoid pressure M14 x 1 5 7 Port 31 Regulated pressure M14 x 1 5 8 Port 37 Converter in pressure M14 x 1 5 9 Port 34 Lube pressure M14 x 1 5 10 Port 44 4th clutch pressure M14 x 1 5 11 Port 46 Rev clutch pressure M14 x 1 5 12 Port 45 Fwd clutch pressure M14 x 1 5 13 14 Pole deutz connector HD34 18 14PN mating parts specs connector deutz HD36 18 14SN contact female deutz 0462 20...

Страница 54: ...place pump Broken or worn clutch shaft or piston sealing rings Replace sealing rings Cause Remedy Low oil level Fill to proper level Suction screen plugged Clean suction pump Defective charging pump Replace pump Cause Remedy Worn oil sealing rings Remove disassemble rebuild converter assembly Worn charging pump Replace charging pump Low oil level Fill to proper level Dirty oil cooler Clean cooler ...

Страница 55: ...en the sensor is tested separately resistor must be integrated in sensor connector as per below schematic 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 By slowly moving gear teeth or a metal part in front of the se...

Страница 56: ...56 Dana Incorporated TSM 0238 6000 Transmission Service Manual ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS 8 2 2 7 8 13 9 2 9 1 8 2 2 11 2 11 ...

Страница 57: ...r and again use the one notch snap ring 3 If the one notch snap ring still not seat properly in the ring groove repeat step 2 using the two notch snap ring and start with the one notch washer thickest When the ring fit in the ring groove check the clutch to support the clutch endplay Endplay can be 0 0000 line to line to a maximum of 0 102 mm 0 004 loose endplay After selection of proper snap ring...

Страница 58: ...ice Manual 0 2 2 Torque to 200 250 lbs ft 271 340 Nm 9 1 WARNING HEAVY SPRING LOAD Use the correct tools to assemble and disassemble this item 9 2 Only use the specified lifting locations to lift the transmission or subassemblies WARNING HEAVY SPRING LOAD 9 1 9 2 2 2 CAUTION ...

Страница 59: ...bs ft 339 407 Nm 8 2 Apply Loctite 577 when threads are without coating 8 13 Apply Loctite 638 10 3 Shim bearings to produce 6 8 lbs inch 0 68 0 90 Nm preload 10 14 Shim bearings to produce 6 10 lbs inch 0 68 1 13 Nm preload 12 1 Seals must be pressed in perpendicularly on shaft axis from this side 8 3 12 1 2 4 8 2 2 3 10 14 10 3 2 4 8 13 8 13 ...

Страница 60: ...SEMBLY INSTRUCTIONS Dana Incorporated TSM 0238 6000 Transmission Service Manual 2 2 Torque to 200 250 lbs ft 271 340 Nm 12 1 Seals must be pressed in perpendicularly on shaft axis from this side 2 2 8 3 12 1 ...

Страница 61: ...ana Incorporated TSM 0238 6000 Transmission Service Manual 2 21 Torque to 20 25 lbs ft 27 34Nm 9 1 WARNING HEAVY SPRING LOAD Use the correct tools to assemble and disassemble this item WARNING HEAVY SPRING LOAD 2 21 9 1 CAUTION ...

Страница 62: ...62 ASSEMBLY INSTRUCTIONS Dana Incorporated TSM 0238 6000 Transmission Service Manual 8 2 Apply Loctite 577 when threads are without coating 8 2 8 2 ...

Страница 63: ...RUCTIONS 1 Install adaptor valve on transmission by twelve 12 screws and torque 59 N m 2 Install new gasket and valve body 3 Install thirteen 13 bolts and hand tighten in the numerical sequence indicated on the drawing 4 Then torque all thirteen 13 bolts twice to 50 56 N m in the correct sequence 8 4 1 5 9 13 10 6 2 3 7 11 12 ...

Страница 64: ... separator outer to reach the overall dimension The sequence to assemble the shim separators Assembly must be packed securely for transport and must be forseen by partnumber on top 1 1 2 3 1 4 SHIM POSITION BOTTOM SEPARATOR TOP QUANTITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 SHIM X 2 SHIMS X X 3 SHIMS X X X 4 SHIMS X X X X 5 SHIMS X X X X X 3 NOTE One to five shims could be required to reach ...

Страница 65: ...r to reach the overall dimension The sequence to assemble the shim separators Assembly must be packed securely for transport and must be forseen by partnumber on top 1 1 2 3 1 4 SHIM POSITION BOTTOM SEPARATOR TOP QUANTITY 1 2 3 4 5 6 7 8 9 10 11 12 13 1 SHIM X 2 SHIMS X X 3 SHIMS X X X 4 SHIMS X X X X 5 SHIMS X X X X X 3 NOTE One to five shims could be required to reach the proper thickness of the...

Страница 66: ...er to reach the overall dimension The sequence to assemble the shim separators Assembly must be packed securely for transport and must be forseen by partnumber on top 1 1 2 3 1 4 SHIM POSITION BOTTOM SEPARATOR TOP QUANTITY 1 2 3 4 5 6 7 8 9 10 11 1 SHIM X 2 SHIMS X X 3 SHIMS X X X 4 SHIMS X X X X 5 SHIMS X X X X X 3 NOTE One to five shims could be required to reach the proper thickness of the clut...

Страница 67: ...cedure is aligned with DIN standard In any case DIN 472 regulation prevails Snap ring replacement is mandatory if they are removed wi thout pre setted plier d1 2019 End bolt A CAUTION CAUTION 1 Measure the shaft diameter of circlip or snapring d1 2 Pre set the caliber at value Dmax Dmax d1 x 1 01 3 Fix it with the screw on caliber see picture Point A 4 Put the snap ring into the plier 5 Open it un...

Страница 68: ...orated TSM 0238 6000 Transmission Service Manual SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP 3RD 4TH CLUTCH 8 7 6 1 5 4 3 2 30 31 32 20 18 16 14 35 22 23 21 25 24 9 12 10 17 15 11 13 19 36 36 37 33 34 26 27 28 29 ...

Страница 69: ...KEYED 147 148 A R 13 WASHER KEYED 145 146 A R 14 WASHER KEYED 143 144 A R 15 WASHER KEYED 141 142 A R 16 WASHER KEYED 139 140 A R 17 RING RETAINING EXTERNAL TYPE A R 18 RING SNAP A R 19 RING SNAP A R 20 RING SNAP A R 21 PISTON CLUTCH 1 22 RING PISTON OUTER 1 23 SPRING PISTON RING EXPANDER OUTER 1 24 RING PISTON 1 25 SPRING PISTON RING EXPANDER INNER 1 26 HUB CLUTCH 1 28 SNAP RING INTERNAL 1 27 WAS...

Страница 70: ... AND REVERSE CLUTCH Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP FORWARD AND REVERSE CLUTCH 8 7 6 1 5 4 3 2 30 31 32 20 17 16 14 35 22 23 21 25 24 9 12 10 18 15 11 13 19 36 36 37 33 34 26 27 28 29 ...

Страница 71: ...ER KEYED 147 148 A R 13 WASHER KEYED 145 146 A R 14 WASHER KEYED 143 144 A R 15 WASHER KEYED 141 142 A R 16 WASHER KEYED 139 140 A R 17 RING RETAINING EXTERNAL TYPE A R 18 RING SNAP A R 19 RING SNAP A R 20 RING SNAP A R 21 PISTON CLUTCH 1 22 RING PISTON OUTER 1 23 SPRING PISTON RING EXPANDER OUTER 1 24 RING PISTON INNER 1 25 SPRING PISTON RING EXPANDER INNER 1 26 HUB CLUTCH 1 28 SNAP RING INTERNAL...

Страница 72: ...GROUP 1ST 2ND CLUTCHES Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP 1ST 2ND CLUTCHES 3 10 35 34 33 34 19 6 7 4 5 24 1 2 32 31 18 16 14 22 12 23 11 17 13 15 21 20 8 9 28 30 29 27 26 25 ...

Страница 73: ...R 1 11 RING RETAINING EXTERNAL TYPE A R 12 RING SNAP A R 13 SPACER A R 14 SPACER A R 15 WASHER KEYED A R 16 WASHER A R 17 WASHER A R 18 WASHER A R 19 PISTON CLUTCH 1 20 RING PISTON 1 21 SPRING PISTON RING EXPANDER OUTER 1 22 RING PISTON INNER 1 23 SPRING PISTON RING EXPANDER INNER 1 24 HUB CLUTCH 1 25 WASHER CLUTCH HUB 1 26 RING RETAINING 1 27 RING RETAINING EXTERNAL TYPE 1 28 ASSY CLUTCH PACK SHI...

Страница 74: ...74 GROUP FORWARD REVERSE SHAFT Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP FORWARD REVERSE SHAFT 6 2 3 4 5 7 1 8 16 14 10 9 11 13 15 12 ...

Страница 75: ... DESCRIPTION QTY 1 SHAFT INPUT AND REVERSE 1 2 SPACER 1 3 INPUT GEAR 50T 1 4 SPACER 1 5 BEARING BALL 1 6 BALL 1 7 NUT NYLON INSERT 1 8 BEARING BALL 1 9 INPUT BRG CAP OPEN 1 10 OIL SEAL 1 11 BEARING CAP GASKET 1 12 CAPSCREW 4 13 Not used in this model 14 O RING 1 15 WASHER FLANGE 1 16 NUT FLANGE 1 ...

Страница 76: ...76 GROUP 1ST 3RD 2ND 4TH SHAFT Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP 1ST 3RD 2ND 4TH SHAFT 10 6 7 5 8 9 2 4 5 1 3 ...

Страница 77: ...38 6000 Transmission Service Manual ITEM DESCRIPTION QTY 1 SHAFT 1ST 3RD AND 2ND 4TH 2 2 ASSEMBLY TAPERED BEARING 2 3 PIN BEARING LOCK 2 4 SNAP RING 2 5 SPACER 2 6 GEAR OUTPUT 1 7 WASHER 2 8 CYLINDRICAL ROLLER BEARING 2 9 NUT NYLON INSERT 2 10 GEAR OUTPUT 1 ...

Страница 78: ...UP BASE PARTS Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP BASE PARTS 4 3 10 8 9 29 16 23 14 25 21 21A 18 19 28 4 24 2 1 4 3 24A 22 20 20 17 21 21A 21 17 21A 26 14 12 13 11 6 7 3 5 27 15 ...

Страница 79: ...4TH CLUTCH CO VER 1 7 ASSY OIL SUMP SCREEN BAFFLE 1 8 CAPSCREW 3 9 GASKET OIL SUMP FRAME 1 10 ASSY OIL SUMP 1 11 WASHER 2 12 GASKET OIL SUMP 1 13 MAGNET SUMP 2 14 PLUG 2 15 AIR BREATHER 1 16 FITTING ELBOW 90 DEGREE STREET 1 17 COVER SPLIT FLANGE 2 18 COVER SPLIT FLANGE 1 19 O RING 1 20 O RING 2 21 CAPSCREW 12 21A LOCKWASHER 12 22 PLUG 2 23 PLUG 1 24 PLUG 1 24A O RING 1 25 PLUG 1 27 FITTING PIPE CA...

Страница 80: ...80 ASSY CONTROL VALVE Dana Incorporated TSM 0238 6000 Transmission Service Manual ASSY CONTROL VALVE 11 10 9 6 7 2 1 4 8 3 5 ...

Страница 81: ...0238 6000 Transmission Service Manual ITEM DESCRIPTION QTY 1 ADAPTOR VALVE 1 2 CONTROL COVER GASKET 1 3 O RING 6 4 CAPSCREW 12 5 GASKET CONTROL VALVE 1 6 ASSY CONTROL VALVE 1 7 O RING 6 8 CAPSCREW 13 9 LOCKWASHER 13 10 CAPSCREW 1 11 LOCKWASHER 1 ...

Страница 82: ...82 ASSY CONTROL VALVE 2 Dana Incorporated TSM 0238 6000 Transmission Service Manual ASSY CONTROL VALVE 2 3 7 7 2 14 11 12 4 7 8 13 9 6 15 10 1 5 ...

Страница 83: ...TH VARIABLE RE STRICTIONS 1 2 ASSEMBLY SOLENOID PLATE 1 3 PLATE SPACER 1 4 SCREW M8X100 22 5 CAPSCREW 3 6 CAPSCREW 11 7 LOCKWASHER 36 8 GASKET PLATE SPACER TO PLATE SOLENOID 1 9 GASKET SPOOL BODY TO PLATE SPACER 1 10 GROUP WIRING HARNESS 1 11 LOCKWASHER 12 12 CAPSCREW 12 13 COVER SPLIT FLANGE 3 14 O RING 3 15 COVER PROTECTION 1 ...

Страница 84: ...CTITE NO 5205 BETWEEN ADAPTER AND VALVE 10 APPLY LOCTITE NO 243 OR 245 SOLENOID 3RD CLUTCH WIRE COLOR WHITE SOLENOID FWD CLUTCH WIRE COLOR BLACK SOLENOID 1ST CLUTCH WIRE COLOR YELLOW SOLENOID 2ND CLUTCH WIRE COLOR GREEN SOLENOID REV CLUTCH WIRE COLOR BLUE SOLENOID 4TH CLUTCH WIRE COLOR ORANGE ...

Страница 85: ...e Manual ASSY SOLENOID PLATE ITEM DESCRIPTION QTY 1 PLATE SOLENOID NON TOTAL NEUTRAL 1 2 SCREW 3 3 CLAMP SOLENOID 1 4 SOLENOID 24V 6 5 RING SNAP 6 6 SCREW M5 6 7 DISC FILTER 6 8 PLUG RESTRICTION DIA 0 8 1 9 STRAP 2 4 X 200 MM 4 10 SCREW M5 1 11 CLAMP WIRING 1 12 LOCKWASHER 1 ...

Страница 86: ...ana Incorporated TSM 0238 6000 Transmission Service Manual ASSY CONTROL VALVE WITH VARIABLE RESTRICTIONS 29 15 20 3 4 5 39 2 28 32 31 33 17 12 13 6 7 1 38 25 27 14 26 8 24 20 9 31 10 33 16 34 10 19 28 38 36 35 21 14 8 9 28 23 22 17 18 28 39 37 32 11 30 ...

Страница 87: ...RALLEL PIN 4 16 SPOOL FWD N REV 1 17 SPOOL ACCUMULATOR 6 18 COVER SAFETY VALVE 1 19 PLUG RESTRICTION 5 16 24UNF DIA 032 FWD REV 2 20 PLUG RESTRICTION 5 16 24UNF DIA 045 3RD 4TH 2 21 PLUG RESTRICTION 5 16 24UNF DIA 042 1ST 2ND 2 22 GASKET COVER DIRECTION SPOOLS 1 23 COVER DIRECTION SPOOLS 1 24 SEAT SAFETY VALVE 1 25 SAFETY VALVE SPACER 1 26 BALL 1 27 SPRING SAFETY VALVE 1 28 SCREW 28 29 PLUG SCREW ...

Страница 88: ...88 FLANGE CROSS SERRATED 155KV70 Dana Incorporated TSM 0238 6000 Transmission Service Manual FLANGE CROSS SERRATED 155KV70 1 ITEM DESCRIPTION QTY 1 FLANGE CROSS SERRATED 155KV70 1 ...

Страница 89: ...FLANGE CROSS SERRATED 180KV70 89 Dana Incorporated TSM 0238 6000 Transmission Service Manual FLANGE CROSS SERRATED 180KV70 1 1 ITEM DESCRIPTION QTY 1 FLANGE CROSS SERRATED 180KV70 2 ...

Страница 90: ...90 GROUP FORWARD SHAFT Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP FORWARD SHAFT 1 8 9 14 13 10 11 12 6 2 3 4 5 7 ...

Страница 91: ...vice Manual ITEM DESCRIPTION QTY 1 SHAFT INPUT AND REVERSE 1 2 SPACER 1 3 INPUT GEAR 50T 1 4 SPACER 1 5 BEARING BALL 1 6 BALL 1 7 NUT NYLON INSERT 1 8 BEARING BALL 1 9 SPACER 1 10 NUT FLANGE 1 11 REV BRG CAP 1 12 BEARING CAP GASKET 1 13 CAPSCREW 4 14 Not Used On This Model ...

Страница 92: ...92 GROUP OUTPUT SHAFT Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP OUTPUT SHAFT 9 6 7 5 4 8 13 14 15 16 11 10 2 12 1 5 4 8 9 6 7 12 14 11 10 15 16 13 3 ...

Страница 93: ... 4TH 41T 1 3 GEAR 1ST AND 3RD 54T 1 4 CUP BEARING 2 5 CONE BEARING 2 6 ASSY BRG CAP AND OIL SEAL 2 7 SEAL OIL PART OF ITEM 6 1 8 O RING BEARING CAP 2 9 SHIM BEARING CAP 004 A R 10 SHIM BEARING CAP 007 A R 11 SHIM BEARING CAP 010 A R 12 SCREW BEARING CAP 12 13 Not Used On This Model 14 O RING FLANGE 2 15 WASHER FLANGE 2 16 NUT FLANGE 2 ...

Страница 94: ...94 GROUP IDLER SHAFT Dana Incorporated TSM 0238 6000 Transmission Service Manual GROUP IDLER SHAFT 2 4 3 1 5 6 7 8 10 12 9 11 13 14 15 17 16 ...

Страница 95: ...RONT BEARING 1 5 BAFFLE REAR BEARING OIL 1 6 CUP REAR BEARING 1 7 CONE REAR BEARING 1 8 GEAR IDLER 46T 1 9 SHIM RETAINING PLATE 004 A R 10 SHIM RETAINING PLATE 007 A R 11 SHIM RETAINING PLATE 010 A R 12 SHIM RETAINING PLATE 020 A R 13 PLATE GEAR RETAINER 1 14 CAPSCREW RETAINING PLATE 3 15 PLATE IDLER SHAFT LUBE 1 16 SCREW IDLER SHAFT LUBE PLATE CAP 2 17 Not Used On This Model ...

Страница 96: ...96 Dana Incorporated TSM 0238 6000 Transmission Service Manual ...

Страница 97: ...ansmission Service Manual DISASSEMBLY ASSEMBLY DISASSEMBLY FIGURE 1 Cover photo FIGURE 2 Remove 13x cap screws washers size 5 8 FIGURE 3 Remove valve using 2x eyebolt M14 and 2x gui de pins FIGURE 4 Remove gasket FIGURE 5 Remove 6x O rings ...

Страница 98: ... TSM 0238 6000 Transmission Service Manual FIGURE 6 Remove 12x cap screws size 8 FIGURE 7 Remove adaptor plate FIGURE 8 Remove gasket FIGURE 9 Remove 6x O rings FIGURE 10 Remove 26x cap screws washers size 9 16 FIGURE 11 Remove cover ...

Страница 99: ... to eyes wear eye protection equipment MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p 64 WARNING CAUTION FIGURE 14 Remove snap ring Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to eyes wear eye protection equipment MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p 64 FIGUR...

Страница 100: ...move discs shims FIGURE 18 Remove snap ring Removal of the snap rings can cause personal injuries You must wear appropriate safety equipment To avoid injury to eyes wear eye protection equipment MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p 64 FIGURE 19 Remove spacer WARNING CAUTION ...

Страница 101: ... tool AS0010012800 see drawing AS0010012800 p 153 push belleville washers down and re move snapring FIGURE 21 Remove snapring spacer Belleville washers and spacer FIGURE 22 Remove piston use two guide pins FIGURE 23 Remove clutch assembly using special tool TG1500106700 see drawing TG1500106700 p 149 ...

Страница 102: ...isassembled is the 4th clutch NOTE All clutch parts removed must be kept together The clutch retainer ring washer taper bearings drum and clutch support must be kept together for proper reas sembly Mark each part removed to match with the clutch support These parts must be reassembled on the same support they were removed from If taper bearings clutch support or clutch drum are to be replaced reas...

Страница 103: ...ated TSM 0238 6000 Transmission Service Manual FIGURE 28 Remove cover FIGURE 29 Remove gasket FIGURE 30 Remove 3x cap screw size 9 16 FIGURE 31 Remove baffle FIGURE 32 Remove gasket FIGURE 33 Remove 20x cap screws washers size 9 16 ...

Страница 104: ...na Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 34 Remove cover FIGURE 35 Remove gasket FIGURE 36 Remove 4x cap screws size FIGURE 37 Remove Reverse cap FIGURE 38 Remove gasket FIGURE 39 Loosen nylon nut ...

Страница 105: ...00 Transmission Service Manual FIGURE 40 Remove nylon nut spacer and O ring FIGURE 41 Remove flange FIGURE 42 Remove 4x cap screws size FIGURE 43 Remove input cap FIGURE 44 Remove gasket FIGURE 45 Prevent gear from moving and tap on forward shaft ...

Страница 106: ...ssion Service Manual FIGURE 46 Remove input shaft FIGURE 47 Remove gear and spacer FIGURE 48 Remove spacer FIGURE 49 Tap out bearing ball FIGURE 50 Remove bearing ball NOTE Forward and reverse shafts are disassembled in a similar manner FIGURE 51 Loosen nut ...

Страница 107: ...M 0238 6000 Transmission Service Manual FIGURE 52 Remove nut spacer and O ring FIGURE 53 Remove output flange FIGURE 54 Remove 6x cap screw size FIGURE 55 Remove front output cap FIGURE 56 Loosen nut FIGURE 57 Remove nut spacer and O ring ...

Страница 108: ...ansmission Service Manual FIGURE 58 Remove flange FIGURE 59 Remove 6x cap screws size FIGURE 60 Remove rear output cap shims FIGURE 61 Remove output shaft bearing assembly FIGURE 62 Remove small output gear bearing cone FIGURE 63 Remove big output gear ...

Страница 109: ...ana Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 64 Remove bearing cup FIGURE 65 Remove 3x cap screws size 7 8 FIGURE 66 Remove spacer and shims FIGURE 67 Remove gear FIGURE 68 Remove 2x cap screws side ...

Страница 110: ...IGURE 69 Remove lube plate FIGURE 70 Remove idler shaft prevent shaft from drop ping FIGURE 71 Remove bearing cone FIGURE 72 Prevent gear from moving and tap out 1 3 shaft FIGURE 73 Remove 2x spacers and gear FIGURE 74 Tap out bearing NOTE 2 4de shaft is removed in a similar way ...

Страница 111: ...DISASSEMBLY 111 Dana Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 75 Remove bearing cup FIGURE 76 Remove bearing cup ...

Страница 112: ...112 ASSEMBLY Dana Incorporated TSM 0238 6000 Transmission Service Manual ASSEMBLY FIGURE 77 Install bearing cup FIGURE 78 Install bearing cup FIGURE 79 Remove bearing cone idler shaft ...

Страница 113: ...Manual FIGURE 80 Install bearing heat to 120 C Wear protective garments when handling hot objects Use heat resistant gloves to pick up hot objects Keep body parts and clothes away from heat source WARNING FIGURE 81 Lower idler shaft into transmission case eyebolt M12 ...

Страница 114: ... Wear protective garments when handling hot objects Use heat resistant gloves to pick up hot objects Keep body parts and clothes away from heat source FIGURE 83 Install lube plate WARNING FIGURE 84 Install 2x cap screws with Loctite 243 torque to 57 63 ft lbs size FIGURE 85 Install gear groove on top FIGURE 86 Install shims and spacer ...

Страница 115: ...all 3x cap screw torque to 113 124 ft lbs precoated size 7 8 FIGURE 88 Measure rolling torque when using new bea rings rolling torque must be 6 to 10 inch lbs Add shims for less rolling torque remove shims for more rol ling torque FIGURE 89 Remove bearing from 1 3rd shaft and 2 4th shaft ...

Страница 116: ...NG CAUTION FIGURE 92 Press the double taper bearing assembly on the shaft tight against shoulder on shaft These bearings are in matched sets and under on circum stances can any of the four 4 parts de changed or mixed up with another bearing Install the long spacer on the 2nd 4th shaft against the double taper bearing Position the 1st 3rd gear in the transmission case with long hub of gear to ward ...

Страница 117: ...ansmission Service Manual FIGURE 94 Remove bearing FIGURE 95 Install bearing heat to 120 C Wear protective garments when handling hot objects Use heat resistant gloves to pick up hot objects Keep body parts and clothes away from heat source WARNING ...

Страница 118: ...s NOTE All clutch supports are assembled and disassembled in a similar way Do not mix parts from different clutches WARNING FIGURE 97 Install clutch support align with 8x cap screws and tap clutch support down before driving the cap screws FIGURE 98 Tighten 8x cap screws to 80 88 ft lbs cap screws should be precoated size ...

Страница 119: ...p FIGURE 100 Tap bearing in position using special tool AS0010004200 see drawing AS0010004200 000 001 p 154 FIGURE 101 Prevent shaft from moving and Install nylon nut torque to 175 200 ft lbs using special tool AS0010005000 see drawing AS0010005000 p 140 FIGURE 102 Install clutch support assembly align with 8x cap screws and tap clutch support down before driving the cap screws ...

Страница 120: ...ighten 8x cap screws to 80 88 ft lbs cap screws should be precoated size NOTE 1 3rd shaft is assembled in a similar way no spacer is in stalled on top of the gear also long hub is placed to the input side of the case Install long spacer underneath small spacer FIGURE 104 Remove bearing ...

Страница 121: ... away from heat source FIGURE 106 Position forward gear with hub to rear side of case position spacer on top of the gear Insert shaft into shaft bore and through the spacer and forward gear Pull the shaft from the other side into position WARNING FIGURE 107 Remove seal FIGURE 108 Install new seal apply Loctite 641 using special tools AS0010006200 see drawing AS0010006200 000 001 p 156 and AS001000...

Страница 122: ...anual FIGURE 109 Install gasket FIGURE 110 Install input cap 4x cap screws torque to 57 63 ft lbs size FIGURE 111 Install flange FIGURE 112 Install O ring washer and nylon nut FIGURE 113 Block input shaft and torque nylon nut to 150 175 ft lbs FIGURE 114 Install spacer ...

Страница 123: ...16 Tap bearing in position using special tool AS0010004200 see drawing AS0010004200 000 001 p 154 FIGURE 117 Prevent shaft from moving and Install nylon nut torque to 175 200 ft lbs using special tool AS0010005000 see drawing AS0010005000 p 140 FIGURE 118 Install clutch support assembly align with 8x cap screws and tap clutch support down before driving the cap screws ...

Страница 124: ...ssion Service Manual FIGURE 119 Tighten 8x cap screws to 80 88 ft lbs cap screws should be precoated size NOTE Reverse shaft is assembled in a similar way FIGURE 120 Position output gears both hubs to the input side of the case FIGURE 121 Remove bearing ...

Страница 125: ... C Wear protective garments when handling hot objects Use heat resistant gloves to pick up hot objects Keep body parts and clothes away from heat source WARNING FIGURE 123 Lower shaft into bore hole through output ge ars FIGURE 124 Install bearing cup using speial tool AS0010009800 see drawing AS0010009800 p 142 ...

Страница 126: ...126 ASSEMBLY Dana Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 125 Remove O ring FIGURE 126 Remove oil seal FIGURE 127 Install oil seal FIGURE 128 Install O ring ...

Страница 127: ...t lbs using special tools AS0010006400 see drawing AS0010006400 000 001 p 157 and AS0010005900 see drawing AS0010005900 000 001 p 155 FIGURE 130 Install bearing cone heat to 120 C Wear protective garments when handling hot objects Use heat resistant gloves to pick up hot objects Keep body parts and clothes away from heat source WARNING ...

Страница 128: ...follow the shimming procedure as followed Do not tighten cap screws Using an inch pound torque wrench on the ou tput flange nut determine the amount of torque required to turn the gear train Tighten cap screws to 57 63 ft lbs It must take 6 to 8 inch lbs more torque to turn the gear train with cap screws torque than when bolts were loose Add or remove shims from bearing cap to adjust preload when ...

Страница 129: ...238 6000 Transmission Service Manual FIGURE 135 Torque nylon nut to 250 300 ft lbs NOTE Repeat for other side FIGURE 136 Remove inner piston ring and expander FIGURE 137 Remove outer piston ring and expander FIGURE 138 Remove bearing cone ...

Страница 130: ...130 ASSEMBLY Dana Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 139 Remove bearing cup FIGURE 140 Remove bearing cup FIGURE 141 Install bearing cup FIGURE 142 Install bearing cup ...

Страница 131: ... 131 Dana Incorporated TSM 0238 6000 Transmission Service Manual FIGURE 143 Install inner piston ring and expander FIGURE 144 Install outer piston ring and expander FIGURE 145 Install piston use two guide pins ...

Страница 132: ...238 6000 Transmission Service Manual FIGURE 146 Install spacer Belleville washers spacer and snapring FIGURE 147 Using special tool AS0010012900 see drawing AS0010012900 p 153 push Belleville washers down and in stall snapring in position ...

Страница 133: ...106500 p 144 FIGURE 149 Install bearing FIGURE 150 Install washer and snap ring when using new bearings follow shimming procedure below Personal injury can result when installing snap ring The ap propriate safety equipment must be worn To avoid injury to your eyes wear protective glasses during this procedure MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p 64 WARNING ...

Страница 134: ...ping outer cone and rotating drum assembly on support Select a snap ring and washer that snaps into position and measure the load on the bearing Value must be between 000 to a maxi mum 002 loose end play Adjust snap ring and washer if ne eded See chart for snap ring and washer thickness FIGURE 152 Install hub assembly ...

Страница 135: ...ing the correct procedure shown in p 64 WARNING CAUTION FIGURE 154 Installing clutch discs Complete discs packs are supplied with an adjusted total thickness pre shimmed Keep discs as ordered in the pack from bottom to top Start installing the bottom steel disc next to the piston alternate friction and steel discs In case clutch discs are mixed up fol low the assembly instructions at Clutch packs ...

Страница 136: ... PROCEDURE Set the pliers following the correct procedure shown in p 64 NOTE 1st 2nd 3rd 4th forward and reverse are assembled in a si milar manner The 1st and 2nd clutches are larger than the others using special tool TG1500106700 see drawing TG1500106700 p 149 to lift Forward reverse 3th and 4th clutch Clutch being assembled is the 1th clutch Different amounts of discs are mounted check parts li...

Страница 137: ...sket FIGURE 158 Install cover use 2x guide pins FIGURE 159 Install 20x cap screws washers torque to 23 25 ft lbs cap screws should be precoated size 9 16 FIGURE 160 Install baffle gasket FIGURE 161 Install 3x cap screws apply Loctite 243 torque to 23 25 ft lbs size 9 16 FIGURE 162 Install gasket ...

Страница 138: ... pins FIGURE 164 Install 18x cap screws washers torque to 23 25 ft lbs cap screws should be precoated size 9 16 FIGURE 165 Install gasket FIGURE 166 Install cover use 2x guide pins FIGURE 167 Install 26x cap screws washers torque to 23 25 ft lbs cap screws should be precoated size 9 16 FIGURE 168 Install 6x O rings gasket ...

Страница 139: ... adaptor plate use 2x guide pins FIGURE 170 Install 12x cap screws apply Loctite 243 tor que to 41 46 ft lbs size 8 FIGURE 171 Install 6x O rings gasket FIGURE 172 Install valve using 2x eyebolts M14 use 2x gui de pins FIGURE 173 Install 13x cap screws washers torque to 41 46 ft lbs size 5 8 ...

Страница 140: ...140 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual SPECIAL TOOLS AS0010005000 AS0010005000 000 001 ...

Страница 141: ...SPECIAL TOOLS 141 Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010005000 000 002 TOOL00000516_A ...

Страница 142: ...142 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010009800 AS0010009800 000 001 ...

Страница 143: ...SPECIAL TOOLS 143 Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010009800 000 002 ...

Страница 144: ...144 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106500 TG1500106500 000 001 ...

Страница 145: ...SPECIAL TOOLS 145 Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106500 000 002 ...

Страница 146: ...146 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106500 000 003 ...

Страница 147: ...SPECIAL TOOLS 147 Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106500 000 004 ...

Страница 148: ...148 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106500 000 005 ...

Страница 149: ...SPECIAL TOOLS 149 Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106700 TG1500106700 000 001 ...

Страница 150: ...150 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106700 000 002 ...

Страница 151: ...SPECIAL TOOLS 151 Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106700 000 003 ...

Страница 152: ...152 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual TG1500106700 000 004 ...

Страница 153: ...SPECIAL TOOLS 153 Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010012800 AS0010012900 ...

Страница 154: ...154 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010004200 000 001 ...

Страница 155: ...SPECIAL TOOLS 155 Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010005900 000 001 ...

Страница 156: ...156 SPECIAL TOOLS Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010006200 000 001 ...

Страница 157: ...SPECIAL TOOLS 157 Dana Incorporated TSM 0238 6000 Transmission Service Manual AS0010006400 000 001 ...

Страница 158: ...ine service parts ordering visit www danaaftermarket com Copyright 2020 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or otherwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES ...

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