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TE15 - Dana Corporation

1. 1 at a E re es sas 1 EPan 4 Pu i t 3 Sensors Valve 2 Gasket Adaptor assy to converter housIng 1 Gn qm NI rr 1 9 Eockwasper seen ee er ee erlegen 9 mr 6 Eockwasper DRE 6 Pils SR mo 10 10 05 2006 8 83 15 GROUP FLANGE GRPTE15131 rev FEBO6 8 84 05 2006 TE15 INPUT FANGE GROUP Item TE15 1 2 3 4 Description 05 2006 8 85 TE15 GROUP FLANGE CC d SE X RM N 3 N j ZN N GRPTE15141 FEBO6 8 86 05 2006 TE15 OUTPUT FANGE GROUP Item TE15 1 2 3 4 Description 05 2006 8 87 9 TE15 ASSEMBLY INSTRUCTIONS TE15 05 2006 9 88 This page intentionally left blank This page intentionally left blank This page intentionally left blank This page intentionally left blank This page intentionally left blank This page int
2. 10 149 DISASSEMBLY of DISCONNECT ASSEMBLY Figure 267 Remove oil seal Figure 268 Remove snap ring Figure 269 Gently tap shaft from disconnect housing TE15 Figure 272 Remove shaft spring and ball Figure 270 Remove plug Figure 271 Remove shift fork lock screw 10 150 DISASSEMBLY of DISCONNECT ASSEMBLY Figure 273 Remove shift hub and disconnect fork Figure 274 Remove oil seal TE15 05 2006 10 151 DISASSEMBLY amp REASSEMBLY of DISCONNECT SHAFT r Figure 275 Figure 276 Using a puller remove bearing from shaft Using a puller remove bearing from shaft TE15 05 2006 10 152 REASSEMBLY of DISCONNECT ASSEMBLY Figure 277 Figure 280 Install
3. Figure 44 1 Figure 47 Open FWD 2 front bearing snap ring and pry L Remove input shaft front bearing drum from front cover Figure 45 Figure 48 Tap on input shaft with a soft hammer to remove input If needed using a puller remove front cover sleeve 3 shaft Figure 46 Figure 49 Remove input shaft front bearing retaining ring Remove input flange oil seal TE15 05 2006 10 107 Figure 50 If needed install front cover sleeves 3 and torque as specified Figure 51 Install input flange oil seal n Figure 52 Install input shaft front bearing TE15 REASSEMBLY of the FRONT COVER ASSEMBLY 05 2006 Figure 53 Install input shaft front bearing retaining ring ee 10 108 DISASSEMBLY of the INPUT SHAFT ASSEMBLY Figure 54 Figure 57 Remove gear retaining ring Remove input shaft bearing retaining snap ring Figure 55 Figure 58 Remove input shaft sensor gear Remove input gear Figure 56 Figure 59 Remove input shaft sensor gear locating snap ring By means of a puller remove bearing TE15 05 2006 10 109 REASSEMBLY of the INPUT SHAFT ASSEMBLY
4. Figure 196 Remove spring discs TE15 05 2006 10 136 DISASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY rd being disassembled 2 24 j 1 e i X x ET mz ug Figure 199 Figure 202 Using a puller remove rear bearing Using a puller remove inner bearing Figure 200 Figure 203 Using a puller remove gear and hub and outer bearing Remove end plate retaining ring lt Figure 201 Figure 204 Remove bearing spacer Remove end plate TE15 05 2006 10 137 DISASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 205 Remove inner and outer discs Figure 206 Compress return spring discs and remove retaining snap ring Figure 207 Remove snap ring retainer TE15 Figure 208 Remove spring discs Figure 209 Remove spacer Figure 210 Remove piston 10 138 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Rev being reassembled Figure 211 Refer to Cleaning and Inspection pages Install piston inner and outer seal Note Seals must be sized prior to installation in clutch drum Sizing is best accomplished by rotating the clutch piston whilst holding v a round object against the new sealing ring Rotate piston
5. chouette Me 1 23 Snap Ling lien Sear Dean Dua 2 24 Shap rine clutch deiven gear serena ior deeds een ae 2 25 Istae se at re ET EID D cod edad 1 26 n uama maa shana annie a asun hu bau masa una 3 27 ASSY aC li D res 1 28 Seal OUICE uso ee Seren nee aan 1 29 ute DP PISO 1 30 Discs Li r 7 3l Diet OU m 7 32 Plate SCI We y uuu unu re era 1 33 Slap rine end plateis cesis E 2 34 ANSON Discs anan 7 35 Pae ml un dnd 1 36 Sap Hine Teta e uum cra eoo Pede _____ 1 37 s sS ne 1 15 05 2006 8 69 TE15 GROUP FWD AND 2ND CLUTCH SHAFT GRPTE15061 rev FEBO7 8 70 05 2006 TE15 FWD amp 2nd CLUTCH SHAFT GROUP Item Description Qty 1 SS Dvd 2nd ee
6. Figure 92 Figure 95 Install piston return spring discs First spring Install snap ring retainer ring See drawing for disc with large diameter of bevel towards correct installation spacer onap rin Return springs Piston iiis Spacer Bearing washer Snap ring retainer ring Figure 93 Figure 96 Drawing Drawing Figure 94 Figure 97 Compress spring discs and install spring disc Install bearing washer retaining snap ring TE15 05 2006 10 116 REASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY A EN 2 gt Y mir a nn M E ETE E Piu Figure 98 Figure 101 Install inner and outer discs First disc 15 steel Warm bearing cone to 120 C 248 F and install on Alternate friction and steel discs until proper clutch shaft amount are installed Last disc 15 friction disc Figure 99 Figure 102 Install end plate Install spacer Figure 100 Figure 103 Install end plate retaining snap ring Install 2 bearing locating rings in hub and gear and install into clutch drum Align splines on hub gear with internal teeth of friction discs DO NOT FORCE THIS OPERATION Gear splines must be flush with inner teeth of all inner discs TE15 05 2006 10 117 REASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 104
7. 1 20 Plate Pwd 2nd shaft front Dearing eld 2 nee aa 1 21 Ball Fwd amp 2nd shaft front bearing end plate retalning 1 22 Front Deanne icone tro odi Dtm ea 1 23 SG AN ek hae tice EHE 3 24 Rine Front pedane Tela Sean 2 25 ASSY aC ib el aig 1 26 EICH LG cie ea ats 1 27 Scale mer ha dnos 1 28 IBI S NIIT UTILE 7 20 Cl OU NEA 7 30 ute end 1 31 Sap Time SCI End ce 1 32 JASS Disc rip ee unuman eine een etree 7 33 SDAPLINS e Spune TE LIND Dubusia ds ads Di eed 1 34 soy Oye ISI pipes ree 2 35 SECHS RES VIT SANI T Du suu 2 15 05 2006 8 71 TE15 GROUP LOW SHAFT AT GTZ Zt N ll 2 f D NC zi e Pk 5 Dx 2 7 DW Zm 7 N LLL T I 2 V
8. Figure 13 Figure 16 Remove rear cover to transmission case screws Remove gasket Figure 14 Figure 17 Remove idler shaft rear bearing retaining snap ring Remove ball Figure 15 Install 2 aligning studs By means es Figure 18 of a special too See Special Tools Section From the front remove 274 clutch hub retaining snap ring remove rear cover TE15 05 2006 10 101 DISASSEMBLY of the TRANSMISSION Figure 19 Remove 2 clutch hub Figure 20 Remove 4 clutch hub retaining snap ring Figure 21 Remove 4 clutch hub TE15 Figure 22 1 Remove idler shaft nut and install hook Gently L tap low clutch loose and install hook on idler shaft Use a hoist to lift idler shaft whilst gently pushing low clutch shaft aside Figure 23 1 Remove low clutch shaft assy L Figure 24 Remove low amp 4 drive gear retaining ring 10 102 DISASSEMBLY of the TRANSMISSION age 0 Figure 25 Remove low amp 4 drive gear Figure 26 1 Remove Rev amp 3rd clutch drum assy from L transmission case Figure 27 Using a special tool tap bearing cup from transmission case TE15 Figure 28 Remove front output flange nut washer amp o ring Figure 29 Remove rear output flange nut washer amp o ring Figure 30 R
9. LLI wa Wd40002 1 16 Wd 07 dWNd Wa 0007 ulu1901 44987 YO M e nu 1990 6 ISd0Z1 0 1 DNDDVtD 3AIVA ALAS 1 54006 80171038 34055344 ha 9 AXI LL C I LZ p 391 9 30055344 IN3WLAYAWOD 80174440 09193135 QuvMuO3 WvaDvIQ NOISSINSNVAL S131 dNNS TIO 6 37 NOLLAN ED ISOH 31009 lt gt 05 2006 ISOH YALYSANOD INOYOL 2115591 9115691 MO uonesnugn TE15 Transmission Operation 6 3 5 FORWARD 4TH CONTINUED TE15 05 2006 LOW HIGH 6 38 LHS JONVY NOILdO LOINNODSIG LNdLNO DNNVYGAH NOILdO 405201 ree 4 6 39 83021081502 dW0S10 NOLLYIIKENT 25 4 2 ORG X e yaHLVAYE QN 8 88 2 Qut 151 2 V 2 Mu 8 8 uv D x 3508 9 ultu 1901 18982 HO 198000 9 02 dnd LLI 73 AUT 4 e n C Wo 5144 s an lt gt 05 2006 10901 6 15901 01 DNDDVtD 3AIVA ALAS 1 ISOH YALYSANOD INOYOL 03123135151 3SU3A3U 2115591 9115691 MO
10. 1 2 DE ON desc 1 3 EX UK EDISION 2 59 9960 en 1 4 vcra uie ET 1 5 i C eji E EI 7 6 IBI QUIM ne ener ere Serer UL 7 7 Pites C u Do 1 9 Siapa sc Tute ren phi uuu n um uyu sm Pede ee I 9 PUSSY DISCS DIMIO umu id 7 10 SDAP T INS SDI iii I BO N ocio doe riot upas asua han eed fence are ee yee 1 11 1 12 dp fH tr uu ama bdo c at cL en ely ea as M iwa dM oM 1 13 Beans Citic driven Seren Energie 1 14 beans C CPP CM cert aati a eee 1 15 Snap ring driven gear unse 2 16 ne 2nd seat loca user Seren nern 1 17 Retainer 2nd gear local ns o 1 18 Shap rine Sear o u Z bum vie 1 19 Bearne 2nd Sait
11. Figure 141 Warm bearing inner race to 120 C 248 F and install on clutch shaft Figure 142 Install 2 bearing locating rings in hub and gear and install into clutch drum Align splines on hub gear with internal teeth of friction discs DO NOT FORCE THIS OPERATION Gear splines must be flush with inner teeth of all inner discs r 2 Figure 143 Warm outer bearing to 120 C 248 F and install in gear TE15 Figure 144 Install bearing retaining snap ring Figure 145 Warm bearing inner race to 120 C 248 F and install on shaft Figure 146 Install bearing outer race 10 126 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 147 Figure 150 Install ball Install sealing rings 3 Figure 148 Install spacer Figure 149 Install retaining snap ring TE15 05 2006 10 127 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY 2nd being reassembled Figure 151 Refer to Cleaning and Inspection pages Install piston inner and outer seal Note Seals must be sized prior to installation in clutch drum Sizing is best accomplished by rotating the clutch piston whilst holding a round object a
12. NOISSINSNVAL S131 Transmission Operation ee en T LLI ep tc 3905 T E INIWNLAVANO 40178340 cO uonesnugn TE15 Transmission Operation 6 3 5 REVERSE 1ST CONTINUED LOW HIGH TE15 05 2006 6 40 Transmission Operation 6 3 7 REVERSE 2ND LHS JONVY NOILdO 405201 NOILdO LOINNODSIG LNdLNO DNNVYGAH S u3H1V3dd uly 4 aM AW 5 y Que 151 9 Hl QN 1144000 1 16 Wd 07 dd Wa 0007 ulu1901 44987 YO LLJ 73 Be e Ya 22001 6 54011 01 INYA ALAWS 1 C 10027 54026 3NWA YOL o3 34155304 391 9 30055344 IN3WLAYAWOD 80174440 3123135 3593 39 WvaDvIQ NOISSINSNVAL S131 dNNS TIO 6 41 NOLLAN ED ISOH 31009 lt gt 05 2006 ISOH YALYSANOD INOYOL 2115591 9115691 MO uonesnugn TE15 Transmission Operation 6 3 7 REVERSE 2ND CONTINUED LOW HIGH TE15 05 2006 6 42 Transmission Operation 6 3 8 REVERSE 3RD LHS JONVY NOILdO 405201 NOILdO LOINNODSIG LNdLNO DNNVYGAH RRR _ 5 Que 15 V QN QM AW V J
13. LLI wa C 3123135 Pl 3583 38 WvaDvIQ NOISSINSNVAL S131 S u3H1V3dd uly 1144000 1 16 Wd 07 dWNd Wa 0007 ulu1901 44987 YO e Ya 10001 6 15901 01 DNDDVtD 3AIVA ALAS 1 10027 54026 YOLIN 39195394 391 9 30055344 IN3WLAYAWOD 80174440 dNNS TIO 6 43 NOLLAN ED ISOH 3100 lt 05 2006 ISOH YALYSANOD INOYOL 2115591 9115691 MO uonesnugn TE15 Transmission Operation 6 3 8 REVERSE 3RD CONTINUED LOW HIGH TE15 05 2006 6 44 ion Operat ission 6 3 8 REVERSE 4TH Transm LHS JONVY NOILdO LOINNODSIG LNdLNO DNNVYGAH NOILdO 405201 43A02 TOULNOD d dns 110 er Que 151 y Hi amd M g g dWNd a Lu XLT V Fen ibd 5 e Wn 54006 80171038 34055344 X E a uIu1901 449880 Wd40002 1 16 Wd 07 LO Y cO NOLLAN u3H1V3dd uly C ISOH cO 8 431002 LO 10901 6 15901 01 DNDDVtD 3NWA ALAVS 1 ISOH OC YALYSANOD INOYOL 391 9 30055344 IN3WLAYAWOD 80174440 09199195 3583 A30 2115591 9115691 MO
14. 80171038 34055344 YALYSANOD INOYOL 03153135 9115591 UYBIH INAWLYYdWOD 80178340 ainssal MO NOISSINSNVAL S131 uonesnugn TE15 Transmission Operation 6 3 3 FORWARD 2ND CONTINUED TE15 05 2006 LOW HIGH 6 34 Transmission Operation 6 3 4 FORWARD 3RD LHS JONVY NOILdO 405201 NOILdO LOINNODSIG LNdLNO DNNVYGAH 43A02 TOULNOD S u3H1V3dd Que 15 uv QM AX J Hl ANZ y LLI 7 7 Wd40002 1 16 Wd 07 dWNd Wa 0007 ulu1901 44987 YO Q D M e nu 1990 6 540 051 SNDDVID 1 20077 15406 HOLVINDIY 340553484 s 391 9 30055344 IN3WLAYAWOD 80174440 03153135 WvaDvIQ rnvsdAH NOISSINSNVAL S131 dNNS TIO 6 35 NOLLAN ED ISOH 100 lt gt 05 2006 ISOH YALYSANOD INOYOL 2115591 9115691 MO uonesnugn TE15 Transmission Operation 6 3 4 FORWARD 3ND CONTINUED TE15 05 2006 LOW HIGH 6 36 Transmission Operation 6 3 5 FORWARD 4TH LHS JONVY NOILdO LOINNODSIG LNdLNO DNNVYGAH NOILdO 405201 43A02 TOULNOD S u3H1V3dd uly 2 2 Que 15 QM AX J V N330
15. Warm outer bearing cone to 120 C 248 F and install in gear Figure 105 Warm front taper bearing cone to 120 248 F and install on clutch drum shaft TE15 05 2006 10 118 DISASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 106 Figure 109 Remove end plate retaining ring Remove spring retaining retainer ring Figure 107 Figure 110 Remove end plate Remove snap ring retainer Figure 108 Figure 111 Remove inner and outer discs Remove clutch piston return spring discs TE15 05 2006 10 119 DISASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 112 Remove clutch piston spacer Figure 113 Remove clutch piston TE15 05 2006 10 120 DISASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Fwd being disassembled Figure 114 Figu
16. Se 2 24 eto pat EE 2 22 Plus pO Pee Tene MO 1 26 Dore Front Cover tO franSMiIsSiOM CaS uu unun mau bore tu ba a haba 10 27 Screw Front COVER transm 1Ss1on 4 28 Lockwasher Front cover to transmission case 18 20 Screw Pront coyor tO transmission ee eilig 4 30 DIS utut tse utet tetuer una 3 3l Llu ss System een een ids 1 15 05 2006 8 61 TE15 GROUP TRANSMISSION CASE 25 13 P 17 Em p LER gt gt A Je ro Ne N 1015 N 0 18 SES Sc RES gt P OP s 16 x AIR 2 d 13 14 AN J Ww E GRPTE15021 rev 6 TE15 05 2006 8 62 TRANSMISSION CASE GROUP Item Description Qty 1 Ass C SION Case SC PUDE od SSD 1 2 Assy Trans mits SUCUON AU DG een desde 1 3 unumanpas 1 4 Plate suc uon Wbe Te lan hr as uman bm m mna eines 1 5 C D CI aH ET 2 6 CDs Suc 1 7 LV MdL MM dE 4 9 l be a Ua MN emt M
17. lt pana gt SPICER Off Highway Products service Manual Transmission TE15 8 speed Long Drop TSM 0227 May 2006 TOWING OR PUSHING Before towing the vehicle be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing AN Note BECAUSE OF THE DESIGN OF THE HYDRAULIC SYSTEM THE ENGINE CANNOT BE STARTED BY PUSHING OR TOWING Copyright DANA CORPORATION 1990 Unpublished material All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION TE15 05 2006 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF HIGWAY PRODUCTS product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechanic studies the instructions in this manual carefully and uses it as a reference when performi
18. EE T TT 1 3 SPINE 1 4 CGO iss pili e e 1 5 S aps TE errr oe uu baka 1 6 GE l MD m 1 7 m d PI EE 1 9 Ball Beanin E ner 1 9 SITIS 1 10 Ji sho om M m 1 11 be 1 12 C I Ci TP e 2 13 Lok wasper 4 14 C ISO I M etd 2 15 EDER aD Societas ce e HE oar T een 1 16 eae p Sal u uuu muna Sasa 1 17 O amu 1 18 Si Cale DEN CAD ticle hee erat eee ta 1 15 05 2006 8 75 TE15 GROUP OUTPUT SHAFT WITH FRONT DISCONNECT GRPTE15091 rev FEBO6 8 76 05 2006 TE15 OUTPUT SHAFT WITH FRONT DISCONNECT GROUP 10 t amp t9 2 02 02 F2 F2 F2 F2 F2 bD DD RR om TOON WON ADA NA WHO 15 Description Assy Output shaft amp bushinz
19. M L N N N From cooler Output speed PS sensor SHE 1 18 x AJE 7 7 N B x EN 1 2 EH 3 Bs Drum speed sensor A lt H 2 7 J es A ok aiy T 1 2 TRE V X EEG lll S m Oil level check ports MSP 4 Drain plug LEFT VIEW TE15 05 2006 7 54 TE15 Troubleshooting guide 7 4 CHECK POINTS continued e 2 E u From Conve DX 0 750 16 UNF 2B FIL Ye ME J a IN Breather TOP VIEW BOTTOM VIEW 05 2006 Transmission oil filler plug 1 00 NPTF 7 55 Troubleshooting guide 7 4 CHECK POINTS continued See also Convention table in numnering ports 1 2 Pressure B sensor gt l E 1 3 Selector LI 2 4 Solenoid E 4 Pressure a sensor Fwd Rev Solenoid c 2 4 Selector Fwd Neu Rev Selector TE15 05 2006 7 56 Troubleshooting guide 7 6 SPEED SENSOR STATIC STANDALONE TEST In order to be able to sense the currents a series resistor of e g 200 2 must be used This resistor i
20. 11 Snap Lone eC TUECTCBUD ido 1 12 Horaco T Vern 1 13 DEJES 1 14 Iste E ront De ac na We unas uuu 1 15 SNAP INS DO TRITT OTT OT 1 16 Re STI Ou aza esse P uu ltd amna 2 17 Sp TMS SPEINS Tet IOP en hee Luc nen toe 1 15 05 2006 8 79 TE15 GROUP HIGH amp LOW RANGE SHIFT CONTROL GRPTE15111 rev FEBO6 8 80 05 2006 TE15 HIGH amp LOW RANGE SHIFT CONTROL GROUP Item Description Qty 1 one as liyuna I MILI I MINUM Bee 1 2 e 1 3 unupi TT EU OU OTT TETUR 1 1 mr 1 5 BIS T 1 6 SS 1 7 Housms 1 9 Pie ze era 1 9 ON er a sree rere 1 10 CANS CTO ua E E 2 11 Fo ES dS L T Rod 2 15 05 2006 8 81 TE15 GROUP ELECTRIC CONTROL VALVE GRPTE15121 rev JAN06 TE1
21. Cause 1 Low oil level 2 Suction screen clogged 3 Defective charging pump 7 3 3 Overheating Cause 1 Worn oil sealing rings converter 2 Worn charging pump 3 Low oil level 4 Dirty oil cooler 9 Restriction in cooler lines 7 3 4 Noisy converter Cause 1 Worn charging pump 2 Worn or damaged bearings to 7 3 5 Lack of power Cause 1 Low engine RPM at converter stall 2 See Overheating and make same checks TE15 Remedy Fill to proper level Clean valve spool and housing Replace pump Replace sealing rings N gt 5 Clean bleed valve thoroughly Remedy 1 Fill to proper oil level 2 Clean suction screen 3 Replace charging pump Remedy 1 Remove disassemble and rebuild assy Replace charging pump Fill to proper level Clean cooler Change cooler lines N Remedy 1 Replace charging pump 2 A complete disassembly will be necassary determine which bearing is faulty Remedy 1 Tune engine check governor 2 Make corrections as explained in Overheating 05 2006 7 51 Troubleshooting guide 7 4 NUMBERING OF PORTS FOR HYDRAULIC CIRCUIT DIAGRAMS CONVENTION TABLE in numbering of ports for Hydraulic Circuit Diagrams CHECK PORTS CHECK PORTS pee sweep O O TO Lockcup valve drain 40 2ndlath mod pressure 80 _ HE 5 s on Transmission cuum s on Remote Filter on Remote Fi
22. Sat uu au aA Bo a UTE Was Mer EAU etes ES Gear Ow Wal Se nee TN Be E E E A E fce lute quus etr AAA C j I M Meer EBcKkwasher C TO T TE me ASME di NIMM II ee Ms Ro tt tc rt Foke Diseonneet Q Lockwasher btt FORK d eate t o Ed viste ____ SEAL E m Sia Ul un eier ld 05 2006 8 77 TE15 GROUP 4TH CLUTCH SHAFT GRPTE15101 rev JAN06 8 78 05 2006 TE15 4th CLUTCH SHAFT GROUP Item Description Qty 1 A eoe cb idee s kas sam 1 2 AS eC p s piman 1 3 SEAL OU ee en 1 4 sumere uter DUSQUIE 2 uuu 1 5 I K ea ee ee ee en a RIEN 7 6 DN SO S 7 7 PE CIC det 1 9 Siapa ili CMCC ES EO ES I 9 caa DISC TR 9 10 bY Oe el Wee E 1
23. rnvsdAH NOISSINSNVAL S131 uonesnugn TE15 Transmission Operation 6 3 8 REVERSE 3RD CONTINUED LOW HIGH TE15 05 2006 6 46 Transmission Operation 64 GEAR CLUTCH LAYOUT TE15 05 2006 6 47 7 TROUBLESHOOTING GUIDE TE15 05 2006 7 48 Troubleshooting guide The following information is presented as an aid to isolate and determine the specific problem area in a trans mission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and correct functioning of the other components of the group Therfore to properly diagnose a suspected problem in the transmission it is necessary to consider the trans mission fluid charging pump torque converter transmission assembly oil cooler filter connecting lines and controls including the engine as a complete system By analysing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system 7 1 The Transmission TE15 powershift transmission troubles fall into four general categories 1 Mechanical problems 2 Hydraulical problems 3 Electrical problems 4 Controller problems In addition to the mechanical and electrical components all of
24. 4 128 14 173 191 113 104 153 168 180 198 224 268 159 175 216 237 223 245 302 332 200 220 271 298 315 347 427 470 282 310 382 420 Torque specifications for plugs Torque specifications for plugs Torque specifications for plugs NPFT O ring ports METRIC O ring plugs Pipe plugs NOM SIZE F Nm NOM SIZE Ni NOM SIZE 5 em E ma 5 Im 9 11 91 100 123 136 82 90 11 10 128 141 174 194 115 127 156 1721 716 x 20 7 10 0 14 M4 x 1 5 12 15 16 20 1 4 x 18 15 20 20 27 12 x 20 10 13 14 18 M16 x 1 5 20 25 27 34 3 8 x 18 25 30 34 41 3 4 x 16 20 25 18x 14 30 35 16 x 1 45 90 26 64 p n NI CET Wx ES 8 1 pa 65 75 8 10 112 140 158x12 15 85 102 115 78x 12 75 85 102 115 Torque specifications NFPT Elastic Stop Nuts NOM SIZE Nm Permanent plugs 1002 150 200 42 610 NON SIZE LBF FT 125x18 20 250 407 474 M18 x 4 5 6H 34 41 25 30 1 50 x 18 300 350 271 339 M26 x 1 5 6H 61 68 45 50 1 79 x 12 400 450 203 271 Torque specifications for plugs TE15 05 2006 3 9 Technical specifications 3 4 PRESSURE amp TEMPERATURE SPECIFICATIONS Normal operating temperature 70 120 158 248F measured at temperature check port to cooler port 71 Maximum allowed transmission temperature 120 248 F Transmission regulator pressure neu
25. 6 30 LHS JONVY NOILdO 405201 NOILdO LOINNODSIG LNdLNO DNNVYGAH 43A02 TOULNOD S u3H1V3dd uly Que 151 AX LLJ 7 7 Wd40002 1 16 Wd 07 dWNd Wa 0007 ulu1901 44987 YO ol SIX AX D M e Ya y ISdOZI OEL SNDOYED 5 1 154076 3NWA Wo1v1n53U 34055344 9 009193155 151 WvaDvIQ rnnvsdAH NOISSINSNVAL S131 Transmission Operation o T lt INVI 24055344 LL LNIWLEVdWOD 40178340 dNNS TIO 6 31 NOLLAN ED ISOH w100 lt gt 05 2006 ISOH YALYSANOD INOYOL 2115591 9115691 MO uonesnugn TE15 Transmission Operation 6 3 2 FORWARD 15 CONTINUED TE15 05 2006 LOW HIGH 6 32 Transmission Operation 6 3 3 FORWARD 2ND LHS JONVY NOILdO 405201 NOILdO LOINNODSIG LNdLNO DNNVYGAH Que 151 QM AX 2 LLJ wa Xl LATA C C73 e Ya 6 33 dNNS TIO NOLLAN MA u3H1V3dd NIJ ISOH Wd40002 1 16 Wd 07 dWNd Wa 0007 ulu1901 44987 YO 400 lt gt 05 2006 15901 01 DNDDVtD 3AIVA ALAS 1 ISOH 54006
26. I TT 2 15 05 2006 8 63 15 GROUP REAR COVER Q Q Q 6656999997 Qo m 006006 o e 90 9 n Qu N N GRPTE15031 rev 6 8 64 05 2006 TE15 REAR COVER GROUP Item Description Qty 1 CoO I uuu DELI 1 2 Gasket Rear cover to TranstisSIOD Case eei e rede 1 3 C TOS me mm 2 4 I ock Ww as her Mounino ser Wien atem n Ve m munasha AEQ D cest 23 5 js pee EET 2 6 SEHE gt 2 7 li uoce en reer an mu 1 15 05 2006 8 65 TE15 GROUP FWD AND REV SHAFT GRPTE15041 rev 6 8 66 05 2006 TE15 FWD amp REV SHAFT GROUP Item 1 2 3 4 TE15 Description Gear Clutch hub Gera Clutch hub High range gear amp clutch hub Gera Drive low amp 4th 05 2006 8 67 TE15 We T 0 x TE15 GROUP REV AND 3RD CLUTCH SHAFT TR E LMS AN S 4 1 amp Sa S EMI HR 3772 JJ sum Sa M ds AN 5 I T IS S IINR I N mb 7 05 2006 GRPTE15051 6 8 68
27. REV amp 3rd CLUTCH SHAFT GROUP Item Description Qty 1 AS eS Solo hill ou cioe 1 2 SOC DIE ION 1 3 SEAL OU TTE T 1 4 merae uter PIS LOM 1 5 IBS im T 7 6 P iC E m 7 7 di NIC i EE 1 9 Sapa ii c Tute Doe TIO pO uuu m uum stie ee mman 1 9 caa TR 7 10 Oye Xe emt Eon er 1 11 SID Tine S Tet aS 1 12 IS Dili rens pari exu ec atiis 1 13 1 14 beatis een 1 15 Bermo cuspide Rede 1 16 A neue obsedit deme Serena 1 17 Spacer Fllen scar messe eiserne 1 18 Beine e ECA L ate Ae 1 19 Plate Rey hich shaft Dear uu uuu nunus da I 20 Ball Rev amp high shaft front bearing end plate retainIing 1 21 Ring Front Dearie Te ansehen 2 22
28. amount are installed Last disc 1s friction disc Figure 177 Figure 180 Install end plate Install bearing retaining snap ring Figure 178 Figure 181 Install end plate retaining snap ring Install sealing rings 2 TE15 05 2006 10 133 DISASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Rev being disassembled Figure 182 Figure 185 Remove sealing rings 3 Remove front bearing end plate lock ball Figure 183 Figure 186 Remove front bearing retaining snap ring Remove front bearing outer race Figure 184 Figure 187 Remove front bearing end plate Using a puller remove front bearing inner race TE15 05 2006 10 134 DISASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 188 Figure 191 Remove bearing retaining snap ring Remove end plate retaining snap ring Figure 189 Figure 192 Using a puller remove gear and hub and outer bearing as Remove end plate an assy Figure 190 Figure 193 Using a puller remove inner bearing Remove inner and outer discs TE15 05 2006 10 135 DISASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 194 Figure 197 Compress return spring discs and remove snap Remove spacer ring Figure 195 Figure 198 Remove spring retainer Remove piston
29. cleaning fluid to flush out particles repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearing to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate drying process 2 1 2 HOUSINGS Clean interior and exterior of housings bearing caps 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 evapo ration of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS All parts cleaned must be thoroughly dried immediately by using moistere free compressed air or soft lint less absorbant wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping 2 2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 2 2 1 BEARINGS Carefully inspect all rollers cages and c
30. new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or spline twisted and that shafts are true 2 2 4 HOUSINGS COVERS ETC Inspect housings covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures 2 3 LEGEND SYMBOLS Smontaggio di sottogruppi Disassembly of assembly groups Montaggio di sottogruppi Reassemble to from assembly group Sostituire con ogni montaggio Renew at each reassembly Smontaggio di particollari ingombranti Remove obstruction parts Togliere mettere la sicura Unlock lock e g split pin locking plate etc Montaggio di particollari ingombranti Reinstall remount parts which had obstructed disassembly Mettere la sicura incollare mastice liquido Lock adhere liquid sealant Attenzione indicazione importante Attention important notice Evitare danni ai materiali danni ai pezzi Guard against material damage damage to parts Controllare regolare p e coppie misure pressione etc Check adjust e g torque dimensions pressures etc Marchiari prima dello smontaggio per il montaggio Mark before disassembly observe marks when reasembl T Attrezzature speciali
31. oil seal Install plug use a small amount of Loctite Figure 278 Figure 281 Install Spring ball and shaft Install shaft in disconnect housing Figure 279 Install shift fork lock screw use a small amount of Loctite Figure 282 Install retaining ring TE15 05 2006 10 153 REASSEMBLY of DISCONNECT ASSEMBLY Figure 283 Install oil seal TE15 05 2006 10 154 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 284 Figure 287 Install o ring suction tube and torque screws as required Install shift hub Figure 285 Figure 288 Install oil baffle Install sleeve Figure 286 Figure 289 Install low range gear Install high range gear TE15 05 2006 10 155 x FE y 5 AMD mot Bun E i w Vy an 4 CN k Qo Tr Figure 290 1 Figure 293 _ Install front caged roller assy 1 Install new o ring on front disconnect housing and shims see procedure Figure 291 ba Figure 294 Install output shaft assy f Install fron
32. radiator if necessary 7 2 4 Hydraulic checks Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of flow it is imporatant to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and the converter and its fluid circuit lines must be fully charged filled at all times N Note THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF 82 93 C 180 200 F To OBTAIN CORRECT FLUID LEVEL AND PRESSURE READINGS Do NOT 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 converter at stall refer to 7 2 1 stall test Caution N BE CAREFULL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND CONVERTER AT STALL RPM 7 2 5 Controller APC200 Please refer to functional description TE15 05 2006 7 50 Troubleshooting guide 7 3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles 7 3 1 Low clutch pressure Cause 1 Low oil level 2 Clutch pressure regulating valve stuck open 3 Faulty charging pump 4 Broken or worn clutch shaft or piston sealing rings 5 Clutch piston bleed valve stuck open 7 3 2 Low charging pump output flow
33. reassembled Figure 131 Refer to Cleaning and Inspection pages Install piston inner and outer seal Note Seals must be sized prior to installation in clutch drum Sizing is best accomplished by rotating the clutch piston whilst holding a round object against the new sealing ring Rotate piston until seal ring is flush with outer diameter of the piston x P Figure 132 Install spacer TE15 Figure 133 Install piston return spring discs First spring disc with large diameter of bevel towards spacer Piston spacer N haft Figure 134 Drawing 10 124 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 135 Install snap ring retainer ring Install inner and outer discs First disc is steel Figure 138 Alternate friction and steel discs until proper amount are installed Last disc is friction disc Snap ring Return springs E Snap ring retainer Figure 136 Figure 139 Drawing Install end plate Figure 137 Figure 140 Compress spring discs and install spring disc Install end plate retaining snap ring retaining snap ring TE15 05 2006 10 125 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY
34. that is coming from the solenoid is measured with a pressure sensor This is used as a feedback signal for the activation of the solenoids and as a check for the regulated pressure 6 2 3 ELECTRIC SOLENOID CONTROLS 8 SPEED RANGE SHIFT DIAGRAM FORWARD REVERSE NEUTRAL X 7 Selector solenoid 0 Proportional solenoid L Low range shift position H High range shift position TE15 05 2006 6 28 Transmission Operation 6 3 POWERFOWS ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 6 3 1 NEUTRAL RANGE SHIFT es HYDRAULIC OUTPUT DISCONNECT OPTION lt CA D gt 5 S 1 a i rm LO H z 3 2 LOCK UP OPTION CONTROL COVER OPERATOR COMPARTMENT PRESSURE GAUGE co ou Ba 2 Lc Lu LL co gt N c c Hm ac CN lt sun a HB 220 m gt 5 1 S mcm 5 Dom 5 5 05 e OOLER 2 LUBRICATION Low pressure EB High pressure c 2 o gt 2 HOSE HOSE TE15 05 2006 6 29 Transmission Operation 6 3 1 NEUTRAL CONTINUED TE15 05 2006
35. until seal ring is flush with outer diameter of the piston Figure 212 Install spacer TE15 Figure 213 Install piston return spring discs First spring disc with large diameter of bevel towards spacer Piston spacer N haft Figure 214 Drawing 10 139 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 215 Figure 218 Install snap ring retainer Install inner and outer discs First disc is steel Alternate friction and steel discs until proper amount are installed Last disc is friction disc Snap ring Return springs BN rr Snap ring retainer ring Figure 216 Figure 219 Drawing Install end plate Figure 217 Figure 220 Install snap ring Install end plate retaining snap ring TE15 05 2006 10 140 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 221 Figure 224 Warm inner bearing to 120 C 248 F and install bearing Install retaining ring Figure 222 Check if 2 bearing locating rings Figure 225 are in gear hub and install gear hub Warm bearing inner to 120 C 248 F and install inner race Fig
36. which must be in proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components 7 2 The input shaft and directional clutches 7 2 1 Stall test A stall test identifies transmission converter or engine problems Use the following procedure 1 Put the vehicle against a solid barrier such as a wall and or apply the parking brake block the wheels 2 Put the directional control lever in FORWARD or REVERSE as applicable 3 Select the highest speed With the engine running slowly increase engine speed to approximately one half throttle and hold until transmission converter outlet oil temperature reaches the operating range 70 C 158 F 4 Once the oil temperature reaches 70 C 158 F check max stall speed at full throttle in all gears The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be equal in all gears Between gears allow the converter outlet temperature to cool down to 70 C 158 F by selecting neutral If max stall speed measured is below specifications it could indicate an engine or converter problem If max stall speed measured is above specifi
37. you to put the shift lever in FORWARD The automatic transmission calibration procedure starts This is indicated on the APC200 display cll ac c1 stands for clutch 1 being forward while 1 stands for mode 1 of the calibration When all clutches have been calibrated the APC200 displays dant At this point the automatic calibration has completed successfully The normal duration of a complete transmission calibration is around 15 minutes To exit the automatic calibration mode you should need to switch off the ignition key the vehicle 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 REMARK 1 If you get any different information on the APC200 display as described above there can be two possible reasons e the calibration conditions are not fulfi lled temperature is too low parking brake switched off the vehi cle is moving engine rpm is too high or too low e a calibration error has occurred during the calibration message starting with an E For possible messages see chapter 4 4 5 TE15 05 2006 4 17 Maintenance REMARK 2 By selecting REVERSE on the shift lever while the automatic calibration is performing the procedure will abort the automatic calibration immediately and restart the APC200 You can use this as an emergency procedure when something goes wrong during th
38. 2 Install low shaft speed sensor gear screws and torque to specified torque E k E Fa 2 Figure 313 Install low shaft sealing ring 10 159 REASSEMBLY of TRANSMISSION CASE ASSEMBLY A UU Figure 314 Figure 317 Install transmission cover rear gasket Remove aligning studs install screws and torque as specified Figure 315 Use a small amount of grease to install idler shaft locating ball Figure 318 Install idler shaft spacer Figure 316 Figure 319 Install two aligning studs and gently tap rear cover into Install 1 screw and shaft nut as shown and lift idler shaft place TE15 05 2006 10 160 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 320 Install shaft rear locating snap ring F 31 Figure 321 Torque idler shaft nut to specified torque Figure 322 Install idler shaft gasket and bearing cap 15 Figure 323 Install screws and torque as specified Figure 324 Install low shaft rear bearing outer race Figure 325 See shim procedure for proper shimming of low shaft rear bearing cap 10 161 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 326 Figure 329 Add shims as required Install speed sensors 3 and screws Torque to specified torque Figure 327 Figure 330 Install ne
39. 5 05 2006 8 82 ELECTRIC CONTROL VALVE GROUP 10 t amp t9 9 09 09 F2 F2 F2 F2 F2 FN ES WNW WN PRR Un QA N 9 TE15 Description Qty A et On OPS A unu area 1 DIS Oh po s ice ue na E p 2 nupumpuni MI UN DM UO 2 CDU utei cen 2 DESI RH 2 lll DT 2 Ok HO T t THEE 3 O lll Seu amta ERES 6 O 3 EES XO e110 doe 1 OS P HT 1 ESA 1 RD T TE 1 lll EN 1 Nd UE Pere De Ser ere usata a 1 rs 1 1 SCHON e EE UE pautas 16 O SPORT ETT UT IT Tnm THEE 1 Poe Pr yasni mam 3 adap MM IM RIAM RIED RIPE 1 PI itm aue deditus 1 Usi HE
40. Figure 60 Figure 63 Warm bearing to 120 C 248 F and install bearing Install input shaft sensor gear locating snap ring Figure 61 Figure 64 Install input gear Install input shaft sensor gear Figure 62 Figure 65 Install input gear retaining snap ring Install input shaft sensor gear snap ring TE15 05 2006 10 110 DISASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 66 Figure 69 Remove low clutch shaft sealing ring Remove low shaft clutch assy sensor gear Figure 67 Figure 70 Remove low shaft rear bearing cup Using a puller remove low shaft clutch assy rear bearing cone Figure 68 Figure 71 Remove low shaft clutch assy sensor gear screws Turn assy and using a puller remove low shaft clutch assy front bearing cone TE15 05 2006 10 111 DISASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 72 Figure 75 Using a puller remove high range gear hub and bearing Remove backing ring Figure 73 Figure 76 Remove bearing washer Remove inner and outer discs Figure 74 Figure 77 Remove backing ring retaining snap ring Remove low clutch gear hub inner bearing cone TE15 05 2006 10 112 DISASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 78 Figure 81 Remove bearing washer Remov
41. GE CLUTCHES Once a directional clutch is engaged power is transmitted to the range clutches Operation and actuation of the range clutches is similar to the directional clutches The engagement of the range clutches is modulated 6 1 3 THE OUTPUT SECTION With a range clutch engaged power is finally transmitted to the output shaft Output rotation is the same as the engine rotation when the reverse clutch is engaged RANGE CLUTCHES OUTPUT SHAFT The Control valve TE15 05 2006 6 27 Transmission Operation 6 2 THE TRANSMISSION CONTROLS REFER TO HYDRAULIC DIAGRAM The transmission is controlled by the control valve The control valve assembly is mounted directly on top of the transmission The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutches 6 2 1 OPERATION OF THE VALVE Regulated pressure 18 bar 261 PSI is directed to the 5 proportional solenoids Each electronic controlled modulation solenoid is current controlled Meaning that no current corresponds to no pressure while full current corresponds to full pressure and all variations inbetween When actuating the electronic controlled modulation solenoid from 0 mA to 1000 mA the output pressure will result in a curve from 0 to 18 bar 0 261 PSI for each directional range clutch 6 2 2 PRESSURE SENSORS Each pressure
42. 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 repeat until the APC200 display shows a temperature above 60 C When the temperature is above 60 C the temperature indication on the display starts blinking Now you can switch to the automatic calibration by pressing the M button for several times until the APC200 displays tran REMARK During this warm up procedure it is possible that the converter out temperature of the transmission exceeds the maximum limit This is a consequence of heating up the transmission using this quick procedure When this occurs the engine speed will be limiting 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 you can resume the heating up procedure if the transmission temperature has not reached 60 C yet TE15 05 2006 4 19 Maintenance 4 4 5 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS This chapter gives an overview of the most common calibration condition messages Normally you will be able to repair the cause of a calibration condition message yourself However you will
43. M M NIME 1 9 1 10 Sleeve Pressure amp IubricatiOn BUDE 2 11 tdt a 1 12 TE 1 13 Pin Transmission case to rear COVer dOWEel En 2 14 P pe rm 1 15 Ct pressure DUDO E 2 16 Ni Ik ie dr masse 1 17 Plug levels Ioc Kup uit nou Su 3 18 PIS utc uL ditm abu 1 19 PUSSY unc tO SCHE C area ea 1 20 CUA SKE Ps SUCHOR EN 1 21 IUBE CoA ci DM NINE EID MEL EI E MI 1 22 ASS Ore MENT re mn E een 1 23 Orne SNe Ionen te Pee 1 24 SUP DOES Seed en 1 22 banc um uyu 1 26 DOSE ha kun ba 1 27 Bushine Reduccino DIG sauces 1 28 By E am T
44. N CONNECTION Current Input Current Output 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 Deutz 2 pin connector DTO4 2P The two pins are numbered 1 amp 2 NOTE THE SENSOR WIRES HAVE A POLARIT Y BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR TE15 05 2006 5 23 6 TRANSMISSION OPERATION TE15 05 2006 6 24 Transmission Operation 6 1 THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies 1 LLL The idler shaft The input shaft and directional clutches The range clutches The output section EZ The transmission control valve oF O N TE15 05 2006 6 25 Transmission Operation 6 1 7 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES The turbine shaft driven from the turbine transmits power to the directional clutch 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
45. Pagina T Special tool P Page Carricare riempire olio lubrificante Filling topping up refilling e g oil cooling water etc Rispettare direzione di montaggio Note direction of installation Scarricare olio lubrificante Drain off oil lubricant Controllare esaminare controllo visuale Visual inspection Tendere Tighten clamp tightening a clamping device Eventualimente riutilizzable sostituire se necessario Possibly still serviceable renew if necessary 05 2006 Insere pressione nel circuito idraulico Apply pressure into hydraulic circuit Pulire To clean 3 TECHNICAL SPECIFICATIONS TE15 05 2006 3 6 Technical specifications Z lt SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 BELGIUM O 3 1 IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number 3 2 WEIGHT DIMENSIONS OIL CAPACITY Weight dry 381 Kg 840 Ib Max Length 730 mm 28 74 Max With 554 mm 21 817 Max Heigth 775 mm 30 517 Cil capacity 18 9 liter 5 US Gallon without cooler and hydraulic lines Consult Operator s manual on applicable machine for system capacity TE15 05 2006 Technical specifications Torque specifications for lubricated or plated threads GRADE 8 8 GRADE 10 9 GRADE 12 9 COARSE THREAD COARSE THREAD COARSE THREAD NOM SIZE LBF FT LBF FT LBF FT Nm us sm ew
46. SIT sui RI EET ER 1 2 yuyun un ry Te ene a 1 3 1 4 Ring Input shaft front bearing 2 5 Gear Input sabbia Dhuha 1 6 A IS tne E nce ea 3 7 1 9 veaks Hanse DI bapa ahua ee 1 9 S TONE COVED GC BUDE 1 10 AS ee 1 11 ASQ uc I Sp C 1 12 O Ill D ete 2 13 bris Gy a EA E E EE 2 14 C I MED NEM 5 15 Po QUI AG NC eat Tm 5 16 SIS egeo sa libe 5 eet 2 17 CON Veter HDOUSINT u SDS 2 18 I LUE E 3 19 Racca mes abenteuer 1 20 Gaskets FO COW 1 21 Pin Eront cover Een een MN MM EMI AN MIU 2 22 1 23
47. ap ring retainer Install inner and outer discs First disc is steel Alternate friction and steel discs until proper amount are installed Last disc is friction disc Snap ring Return springs Snap ring retainer ring 1 1 1 Figure 236 Figure 239 Drawing Install end plate Figure 237 Figure 240 Install snap ring Install end plate retaining snap ring TE15 05 2006 10 144 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 241 Figure 244 Warm inner bearing to 120 C 248 F and install inner Warm outer bearing to 120 C 248 F and install outer bearing bearing Figure 242 Figure 245 Install spacer Warm clutch shaft bearing to 120 C 248 C and install bearing on shaft Figure 243 Check if 2 internal bearing locating rings are in place and install gear and hub TE15 05 2006 10 145 DISASSEMBLY of the IDLER SHAFT ASSEMBLY Figure 246 Using a puller remove bearing Figure 247 Using a puller remove bearing inner cone Figure 248 Turn shaft and using a puller remove bearing TE15 Figure 249 Remove snap ring Figure 250 Remove idler shaft gear Fi
48. arin Cap Sr Wen ee teen use a nase 5 21 Plug Rear Deana nen dui MN MM MINUM PIN ML 1 22 ORTS bor yapu deem aa a 1 23 Ormes REI Deak D e unu ae sea es coetu 1 24 EL UU D T 1 22 Rines 1 26 Cj Me 2 27 Ban shi We na huuu Rode 1 28 ASS C oM dd eta 1 20 PCC GO an oca ese oc 1 30 SUDO ORL Sec 1 31 Capcir w enS Poed SeS O 1 32 Spp dc del THIS iki zu uay 2 33A Bearne 2 2 re Mai erinnere AR 33B ACTIN cdDo gt fce i 33C IV 33D Cap Van u ture eere edu ee maka Glenna d AR AR As required TE15 05 2006 8 73 TE15 GROUP IDLER SHAFT GRPTE15081rev 06 8 74 05 2006 TE15 IDLER SHAFT GROUP Item Description Qty 1 lois uli e TE ER 1 2
49. cations it could indicate slipping clutches CAUTION DO NOT OPERATE THE CONVERTER AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TIME SHIFT TO NEU TRAL FOR 15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPERATURE IS REACHED EXCESSIVE TEMPERATURE 120 250 F MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES FLUID CONVERTER AND SEALS TE15 05 2006 7 49 Troubleshooting guide 7 2 2 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 7 2 3 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 Check the parking brake and inching pedal for correct adjustment Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points The controls are actuated electrically Check the wiring and electrical components Be sure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain proper cooling and operating temperatures for the engine and transmission Air clean the
50. e calibration procedure Note by aborting the automatic calibration the calibration is not fi nalized and needs to be done from the beginning 4 4 4 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 The paragraph how to enter the calibration mode see 1st paragraph also displays how the HEAT mode can be activated Once you see on the display tran you can press the M button once to go into the heat mode The APC200 will display Nr NE To trigger the HEAT mode push the S button The APC200 will display the sump temperature CUCU This means the actual sump temperature of the transmission is 20 C FULL forward 15 Sec 15 NENNEN TE15 05 2006 4 18 Maintenance 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 throttle Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever
51. e piston return spring discs Figure 79 Figure 82 Remove spring retaining snap ring retainer Remove piston spacer Figure 80 Figure 83 Remove snap ring Remove piston TE15 05 2006 10 113 DISASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 84 Remove drum retaining ring Figure 85 Tap gently on shaft to separate drum from shaft Figure 86 Remove o ring TE15 05 2006 10 114 REASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY Figure 87 Install o ring Figure 88 Install drum on shaft Figure 89 Install drum retaining ring TE15 05 2006 E 1 Figure 90 Refer to Cleaning and Inspection pages piston inner and outer seal Note Seals must be sized prior to installation in clutch drum Sizing 15 best accomplished by rotating the clutch piston whilst holding a round object against the new sealing ring Rotate piston until seal ring is flush with outer diameter of the piston Install piston in clutch drum Use caution as not to damage newly installed seal rings Bip Figure 91 Install spacer 10 115 REASSEMBLY of the LOW CLUTCH SHAFT ASSEMBLY
52. emove High Low range shift fork lock screw 10 103 DISASSEMBLY of the TRANSMISSION Figure 31 1 Remove High Low range shift fork cap L screws and remove High Low range shift fork assy Figure 32 1 Remove disconnect housing cap screws and m remove disconnect assy and shims Figure 33 Remove rear output cap screws and remove rear output cap TE15 Figure 34 es Using a special tool push output shaft from transmission case Figure 35 1 From the front remove output shaft assy L Figure 36 E v Remove caged roller assy 10 104 DISASSEMBLY of the TRANSMISSION Figure 37 Remove trust washer and bearing cone Figure 38 Remove caged roller bearing assy Figure 40 Remove shift hub sleeve Figure 41 Remove Low gear Figure 39 Remove High gear TE15 Figure 42 Remove oil baffle 10 105 DISASSEMBLY of the TRANSMISSION Figure 43 Remove suction tube cap screws tube and o ring TE15 05 2006 10 106 ze DISASSEMBLY of the FRONT COVER ASSEMBLY
53. entionally left blank This page intentionally left blank This page intentionally left blank DISASSEMBLY amp REASSEMBLY of the TRANSMISSION TE15 05 2006 10 98 DISASSEMBLY of the TRANSMISSION Figure 1 Front view of the TE15 8 speed transmission Figure 2 Remove input flange nut washer amp o ring Figure 3 Remove 2 valve to transmission housing cap screws Install aligning studs and remove remaining screws TE15 Figure 4 1 E Remove valve assy and valve gasket Figure 5 Remove plate screws and valve plate Figure 6 Remove 2 front cover plugs 10 99 DISASSEMBLY of the TRANSMISSION La Figure 7 Remove 2 front cover to transmission case screws and install aligning studs Remove remainder of the screws Figure 8 1 Use a hoist to secure the front cover and pry the L cover from the transmission case whilst holding the 2 amp 4 clutch front bearing retaining snap rings open in turn Figure 9 mel Remove 4 gear clutch drum and pilot bearing TE15 Figure 10 Remove speed sensor and screw 3 Figure 11 Remove low shaft bearing cap screws Carefully pry bearing cap from rear cover and remove shims Figure 12 Remove idler shaft bearing cap screws and remove idler shaft bearing cap and gasket 10 100 DISASSEMBLY of the TRANSMISSION
54. for gravity drain io trans M Check point D x Converter temperature Suction fine trom transmission Red line 250 F 14219 m N Rouen ae a Check point C converter N Sump 1o pump outlet pressure Converter Gravity draln must have Outlet OF temp 180 200 F continuous slope from 82 9 94 5 C converter to transmission Transrtussion neutral Operating specifications 25 PS 1729 kPa minimum pressure at 2000 RPM engine iine apersting rsqurements Matric dimensions shown speed and maximum of 70 PSI 1 Pressure Lines Suitable tor cperation trom in brackets 1 14030 kPa outlet pressure ambient o 250 F 12136 continunes coeratiac Ne a Tos ae Ceara at temperature Must withstand 200 POI 2068 kPa Note Do not deviste any line size governed speed Conkinuous pressure with BOO PSI 4137 kFaj Hfermitent sures Rei Spec No JS 30083 Hose Specification 2 Suction be protected from collapse nibIwoven sten wire Ref SAE No JST 10974 Hydraulic Hose Spectication Suitable lor aperaton Mort amten to E11 C ContinuGus operating temoerasture X Gravity Drain ine S ntable tor operation from fo 250 F 112118 contnucus operating temperature Rel SAE J5 00i Hydraulic Hose Specification 4 dose Lines most condom to S A E Spec 21019 Test Procedure for High Teng Tra
55. gainst the new sealing ring Rotate piston until seal ring is flush with outer diameter of the piston Figure 153 Install piston return spring discs First spring disc with large diameter of bevel towards spacer x Piston spacer N haft Figure 154 Drawing Figure 152 Install spacer TE15 05 2006 10 128 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 155 Figure 158 Install snap ring retainer Install inner and outer discs First disc is steel Alternate friction and steel discs until proper amount are installed Last disc is friction disc Snap ring Return springs 1 Snap ring retainer us Figure 156 Figure 159 Drawing Install end plate Figure 157 Figure 160 Install snap ring Install end plate retaining snap ring TE15 05 2006 10 129 DISASSEMBLY of 4th CLUTCH SHAFT ASSEMBLY Figure 161 Figure 164 Remove sealing rings 2 Remove end plate retaining ring Figure 162 Figure 165 Remove front bearing retaining ring Remove end plate Figure 163 Figure 166 Using a puller remove front bearing from shaft Remove inner and o
56. gure 251 Remove spacer 10 146 REASSEMBLY of the IDLER SHAFT ASSEMBLY Figure 252 Figure 255 Install spacer Warm bearing to 120 C 248 F and install bearing on shaft Figure 253 Figure 256 Install idler shaft gear Turn shaft and warm bearing assy to 120 C 248 F and install on shaft Figure 254 Install snap ring TE15 05 2006 10 147 DISASSEMBLY amp REASSEMBLY of OUTPUT SHAFT ASSEMBLY Output shaft being disassembled Output shaft being reassembled Figure 257 Figure 260 Using a puller remove bearing Install thrust washer Figure 258 Figure 261 Remove thrust washer Warm bearing to 120 C 248 F and install on shaft Figure 259 Figure 262 Remove output shaft bushing Install output shaft bushing TE15 05 2006 10 148 DISASSEMBLY amp REASSEMBLY of HIGH LOW RANGE SHIFT ASSEMBLY Disassembly Figure 263 Remove plug Figure 264 Remove shaft spring and ball TE15 Reassembly Figure 265 Install spring ball and shaft Figure 266 Install plug
57. h a fixed amplitude changing between 7 and 14 mA Power Pressure sensor Sensors must be supplied with 5Vdc and put out between 5 amp 95 of the supplied current related to 1 bar 0 25V and 31 bar 4 75V pressure Remark max 10mA supply current Sensor is equiped with a 3 pin connector Ground Temperature sensor in speed sensor resistance versus temp see table T amb Resistance Q 50 TE15 05 2006 3 11 Technical specifications TE15 C270 C320 EXTERNAL PLUMBING DIAGRAM Fiter Assembly N jg teer inia pressure Mate EN Line from pump must be connected s io in side of Rhet Ae Cooler a FERN b 3 Lue N JAn v or Check point G Sf UCo0ler temperature Pal z Check point Cooler pressure Ling from pump to fier and filer to reg valve SN NN Y hy if mii 1 g 2 J Og opening Check point B converter inet pressure E amp E ul 0 75 r Clutch pressure fine kom Reg Valve to Conn Valve 05 _ eee Pressure reg valve 1 Check point clutch pressure F 240 280 PSI 16550 19310 Pal s E ale ub E es MY x om c ging pump Tati instak breather and 4 adapter in highest gh Png converter drain location V EN 4 Select lowest connection
58. have to contact the OEM of the machine when a calibration error appears 4 4 5 1 Calibration condition messages The APC200 expects the shift lever Put the shift jever back in NEUTRAL to be in NEUTRAL but finds it in i another position FORWARD or REVERSE THE APC200 expects the partking Put the parking brake ON P brake to be ON while it is OFF The APC200 has detected output Verify that the parkiing brake is ON and working speed properly If this is already the case you will be obliged to keep the machine at standstill by using the footbrake E PY im 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 If the vehicle is equiped with throttle by wire the to the limit that is necessary for engine RPM will be automatically adapted In the oS calibration other case the driver has to change the throttle pedal position until the display looks as follows Engine RPM is to high according to the limit that is necessary for pn calibration J d mM After being to low or to high the engine RPM is coming back into the correct bounderies for calibration When during the automatic Use the M button on the APC200 to go back to transmission calibration the the HEAT mode and the S button to trigger this temperature becomes to low the mode Now you have t
59. ili E Tt 2 P 2 b k 5 JBN 15071 rev FEBOG 8 72 05 2006 TE15 LOW SHAFT GROUP Item Description Qty 1 A EOS Hall er Ree epee RUE UMEN d MEE MUN 1 2 1 3 SEAL OU reed 1 4 Scale De RC uter DIS ON 1 5 ae 10 6 utere er ma etes cess eer 10 7 BTE re ON enter een euere 1 9 Et bnd plate NNE 1 9 PAGS Vi TI 7 10 LORS podes 1 11 Wache ede 1110 cede an en ec ap E ae 1 12 IS ee a PE esee UN 1 13 Retainer prine tI 1 14 easet ae 1 15 Low sear Dean uni 1 16 Rine SLC SAT SCN sa ee 1 17 bearns Low speed elutehshalt 1 18 beaunss ow Spec ass lal OC a ates annie erstehen 1 19 SCH AS Ca ane eer Men inu 5 20 Lockwasher Be
60. is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure 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 valve or holes in the clutch piston into the transmission sump These bleed valves will only allow quick escape of oil when the pressure to the piston is released The engagement of all range and directional clutches is modulated and electronically controlled This means that clutch pressure is built up gradually This will enable the unit to make forward reverse shifts while the vehicle is still moving and will allow smooth engagement of drive amp DIRECTIONA CLUTCHES 15 05 2006 6 26 Transmission Operation 6 1 2 THE RAN
61. is safety nor the safe operation of the machine will be jeopardised by the spare part service procedure or tool selected IMPORTANT IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS CAUTIONS AND NOTICES THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE CAUTIONS AND NOTICES ARE NOT EXHAUSTIVE BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS CAUTION WHEN MAINTENANCE WORKS REQUIRE WELDING DISCONNECT BOTH CONNECTORS FROM THE APC200 AND FROM THE VALVE UNIT BEFORE ANY WELDING IS STARTED TE15 05 2006 1 2 2 CLEANING and inspection TE15 05 2006 2 3 Cleaning and Inspection amp Legend symbols 2 1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES FIRE HAZARDS AND INHALA TION OF VAPOURS WHEN USING SOLVENT TYPE CLEANERS 2 1 1 BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant Immerse again in
62. lter rmm ewe on Transmission 19 49 SAHR Brake Release 20 AwHydrDiscommed 2WD S0 VFSist 21 FomPump Dan SSS FomRewo S 24 SAHRbkeReeme 25 Rame ShR ______ s emm after Total Neutral 27 Power Brake Supply 57 PitPresue 28 ClutchRetumline 58 Pressure Check Range Clutches 29 From Pump for Brake Release 59 Pressure Check Direct Clutches lt 30 Locupappy 60 GI 27778 Peswemenserigh _ PeswemenserrFWD TE15 05 2006 7 52 Troubleshooting guide 7 4 CHECK POINTS Charge pump suction port 1 312 12 UNF Converter drain 1 000 NPTF Mechanical front external disconnect FRONT VIEW Turbine speed sensor Output speed sensor Mechanical High Low range shift Plug Magnetic drain 750 NPTF Nu 4 p REAR VIEW TE15 05 2006 7 53 Troubleshooting guide 7 4 CHECK POINTS continued
63. matic transmission calibration procedure 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 hrs of transmission operation When an overhaul of the transmission is done When the transmission is repaired When the APC200 is replaced 4 4 2 RUNNING THE AUTOMATIC CALIBRATION 4 4 2 1 HOW TO ENTER THE CALIBRATION MODE 13 secomals The automatic calibration mode is entered by pressing S button on the APC200 display for 15 seconds during POWER UP of the APC200 See above figure TE15 05 2006 4 16 Maintenance 4 4 3 PERFORMING AN AUTOMATIC CALIBRATION Before the automatic calibration can be started a number of conditions need to be fulfi lled The parking brake on the vehicle has to be activated The transmission temperature needs to be above 607 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 200 rpm during the complete calibration If the APC200 has control over the engine the engine speed will be adapted automatically If all the conditions mentioned above are met the actual automatic calibration can be performed starting from the following display on the APC200 To trigger the automatic calibration procedure push the S button once You will get this APC200 display readout bo F The APC200 asks
64. method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for cleaning 3 Replace oil filter element 4 The oil cooler must be thoroughly cleaned The cooler should be back flushed with oil and compressed air until all foreign material has been removed Flushing in direction of normal oil flow will not adequately clean the cooler If necessary cooler assembly should be removed from machine for cleaning using oil compressed air and steam cleaner for that purpose DO NOT use flushing compounds for cleaning purposes A IMPORTANT DO NOT USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES 5 Reassemble all components and use only type oil recommended for lubrication section Fill transmission through filler opening until fluid comes up to the oil level check port Run engine 2 minutes at 500 600 R P M to prime torque converter and hydraulic lines Recheck level of fluid in transmission with engine running at idle 500 600 Add quantity necessary to bring fluid level to oil level check port Recheck with hot oil 180 200 F 82 93 C 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary TE15 05 2006 4 15 Maintenance 4 4 PROCEDURE FOR PERFORMING AUTOMATIC CALIBRATION 4 4 1 INTRODUCTION The APC200 firmware contains an auto
65. ng maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAY PRODUCTS approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment SPICER OFF HIGHWAY PRODUCTS does not warrant repair or replacement parts nor failures resulting from the use of parts which are not supplied or approved by SPICER OFF HIGHWAY PRODUCTS IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS TE15 05 2006 1 SAFETY PRECAUTIONS TE15 05 2006 SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instructions must be carefully ob served 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 parts must be replaced by spare parts which have the same part number or with equivalent parts DO NOT USE A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly anyone who intends to use a spare part service procedure or tool which is not recommended by SPICER OFF HIGHWAY PRODUCTS must first determine that neither h
66. nsmission Oti Hose 5 See Lubrication Specifications T5806 89 4 MAINTENANCE TE15 05 2006 4 13 Maintenance 4 1 OIL SPECIFICATION 4 1 1 RECOMMENDED LUBRICANTS Only viscosity at 40 C 104 F 33 38 cSt 100 C 212 F T 8 3 SUMP PREHEATERS Preheat the transmission fluid to the mimimum temperature for the oil viscosity used before engine startup NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hrs for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated detioration or contamination Judgement must be used to determine the required change intervals for extreme conditions Drain and refill system as follows drain with oil at 65 93 150 200 F 1 Drain transmission 2 Remove and discard filter Install new filter 3 Refill transmission to FULL mark 4 Run engine at 500 600 RPM to prime convertor and lines 5 Recheck level with engine running at 500 600 add oil to bring level to LOW mark When oil temperature is hot 82 2 93 3 180 200 F make final oil level check and adjust if necessary to bring oil level to FULL mark Note N IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION ON NEW REBUILT OR REPAIRED UNIT EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids Ap
67. o warm up the transmission APC200 display indicates the again until the temperature is above 60 C 140 actual transmission temperature F Then go back to the automatic tuning mode by the M button and trigger this one again to continue calibration 4 4 5 2 Calibration errors 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 TE15 05 2006 4 20 5 INSTALLATION DETAILS TE15 05 2006 5 21 Installation Details 5 1 EXTERNAL PLUMBING FILTER TO FILTER FROM FILTER CONVERTER PUMP PRESSURE REGULATOR SUCTION LINE CLUTCH PRESSURE GRAVITY DRAIN COOLER 6 gt Q AKG LO O 9 1 1 COOLER amp FILTER LINES SPECIFICATIONS Minimum 19 mm 75 inch internal diameter for lines and fittings 25 4 1 for 28 GPM pump Suitable for operation from ambient to 120 C 248 F continuous operating temperature Must withstand 30 bar 435 psi continuous pressure and with 45 bar 652 psi intermittent surges Conform SAE J1019 and SAE J517 100RI TE15 05 2006 0 22 5 2 SPEED SENSOR PIN NUMBER FUNCTIO
68. propriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metals analysis can provide useful inforamtion but a transmission should not be removed from service based solely on this analysis FILTERS Service oil filter element intervals 100hrs first time Then every 500 hrs under normal envirronmental and duty cycle conditions 4 2 MAINTENANCE INTERVALS 4 2 1 DAILY Check oil level daily with engine running at idle 600 and oil at 82 93 C 180 200 F Maintain oil level at full mark DEXRON is a registered trademark of GENERAL MOTORS CORPORATION TE15 05 2006 4 14 Maintenance 4 2 2 CLUTCH CALIBRATION EVERY 2000HRS PERFORM AUTOMATIC CLUTCH CALIBRATION 4 3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whenever repair or overhaul of one unit is performed the balance of the system must be 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
69. re 117 Remove sealing rings 3 Remove FWD 2 shaft front bearing plate ball i Li E 1 Figure 115 Figure 118 Remove FWD 2 shaft front bearing retaining ring Remove FWD 2 shaft front bearing outer race Figure 116 Figure 119 Remove FWD 2 shaft front bearing end plate Using a puller remove FWD 2 shaft front bearing inner race TE15 05 2006 10 121 DISASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 120 Remove front bearing retaining snap ring Figure 121 Using a puller remove gear and hub Figure 122 Remove end plate retaining ring TE15 Figure 123 Remove end plate Figure 124 Remove inner and outer discs Figure 125 Using a puller as shown pull bearing inner race from shaft 05 2006 10 122 DISASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Figure 126 Figure 129 Compress return disc springs and remove spring Remove clutch piston spacer retaining retainer ring Figure 127 Figure 130 Remove snap ring retainer Remove clutch piston Figure 128 Remove clutch piston return spring discs TE15 05 2006 10 123 REASSEMBLY of FORWARD 2nd CLUTCH SHAFT ASSEMBLY Fwd being
70. read ears of fwd front bearing Using a sliding hammer pull 2 and 4 clutch forward retaining ring and lightly tap on cover until retaining ring snaps into place Figure 345 Figure 348 Using spreading pliers spread ears of 4 front bearing Install plugs 2 and torque as specified retaining ring and tap cover into place Figure 346 Figure 349 Place screws and torque as specified Install front input flange o ring washer and nut and torque as specified TE15 05 2006 10 165 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 350 Install 2 aligning studs and install control valve plate gasket Figure 351 Install control valve plate Figure 352 Install screws and torque as specified TE15 Figure 353 Install control valve gasket and control valve Figure 354 Install screws and torque as specified 10 166
71. s integrated 1n the controller but when the sensor is to be used it must be connected externally The idea 1s 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 I mA current level or 2 6 3 0V for the 14mA I mA current level If the teeth can be moved slowly distinct toggling between the two levels should be noticed Sensor 200 Ohm 1 Watt TE15 05 2006 7 57 Troubleshooting guide 7 8 PRESSURE SENSOR STANDALONE TEST In order to be able to test the pressure sensor without the transmission controller you have to perform a test as per procedure below A The supply current cannot exceed 10mA otherwise the sensor will be damaged Be sure the supply voltage does not exceed 5Vdc Connect the sensor to an external power supply of 5V DC Measure the DC voltage between the output andground In normal atmospheric circumstances 1 bar the voltage should be 0 25 5 of supplied 5Vdc 5V TE15 05 2006 7 58 SECTIONAL VIEW amp PARTS IDENTIFICATION TE15 05 2006 8 59 TE15 GROUP INPUT SHAFT AND FRONT COVER 25 5 T NN AC e a Sar lt gt a 9 Axe 97 SS 26 RNG EP 714 T 2 Q NE 18 gt go gt lt 17 lt SSS IC o N GRPTE15011rev FEBO6 TE15 05 2006 8 60 INPUT SHAFT amp FRONT COVER GROUP Item Description Qty 1
72. t disconnect capscrews and torque as required k gt Figure 292 Figure 295 Install output shaft front bearing outer race Install rear caged roller assy 1 15 05 2006 10 156 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 296 Figure 299 Install thrust washer Install rear output shaft cap capscrews and torque as specified Figure 297 Figure 300 Install output shaft rear bearing inner race Measure output shaft rolling torque procedure Figure 298 Figure 301 Install rear output shaft cap Install shift fork TE15 05 2006 10 157 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 302 Figure 305 7 Install shift rail assy Install REV 3 clutch drum assy Figure 303 Apply a thin coat of Loctite and install lock screw and torque Figure 306 From the rear Install hub and secure with snap ring Figure 304 Figure 307 Install capscrews and torque Install low front bearing cup Into transmission case TE15 05 2006 10 158 REASSEMBLY of TRANSMISSION CASE ASSEMBLY N Figure 308 Install low clutch assy into transmission case Figure 311 Install low shaft speed sensor gear Figure 309 ba Install idler shaft Figure 310 Warm low shaft rear bearing cone to 120 C 248 F and install TE15 Figure 31
73. tral port 31 16 55 bar 240 PSI or 19 31 280 PSI depending on converter type Pump flow at 2000 RPM in neutral 91 l min minimum 20 0 GPM or 106 l min 28 GPM depending on converter and pump type Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 4th clutch port 44 forward clutch port 45 reverse clutch port 46 Clutch pressure is 16 55 bar 240 PSI or 19 31 bar 280 PSI depending on converter type when clutch is activated Safety valve cracking pressure 8 96 bar 12 07 bar 130 PSI 175 PSI To cooler converter out pressure port 32 1 72 bar min 25 PSI at 2000 RPM and max 4 83 bar 70 PSI at no load governed speed pressures and flows to be measured with oil temperature of 82 93 C 180 200F Refer to section troubleshooting for check port identification TE15 05 2006 3 10 Technical specifications 3 5 ELECTRICAL SPECIFICATIONS e Proporsional valves Fwd Rev 1st 3rd 2nd 4th coil resistance 7 25 Q at 20 C 68 F Operation temperature between 40 C 40 F and 120 248 F The valves are equiped with a DEUTSCH D T04 2P connector Total neutral and 1st 3rd 2nd 4th range solenoid coil resistance 12V 7 1 Q at 20 C 68 F 24V 28 5 Q at 20 C 68 F Speed sensor type magneto resistive sensor Sensor signal generates a square current wit
74. ups for wear chipping or nicks to determine fitness of bearings for further use DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed TE15 05 2006 2 4 Cleaning and Inspection amp Legend symbols 2 2 2 OIL SEALS GASKETS ETC Replacement of spring load oils seals O rings metal sealing rings gaskets and snap rings is more eco nomical when the unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the as sembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lips of seals seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with a coat of chassis grease to stabilise rings in their grooves for ease of assembly of mating members Lubricate all O rings and seals with recommended type Automatic Transmission Fluid before assembly 2 2 3 GEARS amp SHAFTS If Magna Flux process is available use process to check parts Examine teeth on all gears carefully for wear pitting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with
75. ure 223 Figure 226 Warm outer bearing to 120 C 248 F and install Install bearing outer race bearing in gear hub TE15 05 2006 10 141 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY Figure 227 Figure 230 Install front bearing end plate lock ball Install sealing rings 3 Figure 228 Install front bearing end plate Figure 229 Install end plate retaining snap ring TE15 05 2006 10 142 REASSEMBLY of Rev 3rd CLUTCH SHAFT ASSEMBLY rd being reassembled Figure 231 Refer to Cleaning and Inspection pages Install piston inner and outer seal Note Seals must be sized prior to installation in clutch drum Sizing is best accomplished by rotating the clutch piston whilst holding a round object against the new sealing ring Rotate piston until seal ring is flush with outer diameter of the piston Figure 232 Install spacer TE15 05 2006 Figure 233 Install piston return spring discs First spring disc with large diameter of bevel towards spacer Piston spacer haft Figure 234 Drawing 10 143 Figure 235 Figure 238 Install sn
76. uter clutch discs TE15 05 2006 10 130 DISASSEMBLY of 4th CLUTCH SHAFT ASSEMBLY Figure 167 Figure 170 Remove spring retainer snap ring Remove piston Figure 168 Remove spring discs Figure 169 Remove spacer TE15 05 2006 10 131 REASSEMBLY of 4th CLUTCH SHAFT ASSEMBLY Figure 171 Figure 173 Refer to Cleaning and Inspection pages Install piston return spring discs First spring disc Install piston inner and outer seal with large diameter of bevel towards spacer Note Seals must be sized prior to installation in clutch drum Sizing is best accomplished by rotating the clutch piston whilst holding a round object against the new sealing ring Rotate piston until seal ring is flush with outer Piston diameter of the piston NS spacer ie haft Figure 174 Drawing Figure 172 Figure 175 Install spacer Install snap ring TE15 05 2006 10 132 REASSEMBLY of 4th CLUTCH SHAFT ASSEMBLY Figure 176 Figure 179 Install inner and outer discs First disc 15 steel Turn shaft and warm bearing to 120 C 248 F and Alternate friction and steel discs until proper install bearing
77. w o ring on low shaft bearing cap Install rear output flange o ring washer and nut and install cap Figure 328 Figure 331 Install screws and torque as specified Torque rear output flange nut to specified torque TE15 05 2006 10 162 REASSEMBLY of TRANSMISSION CASE ASSEMBLY yp 1 l E 4 3x 2 _ 2 xmv Ld Figure 332 Install front output flange o ring washer and nut Figure 333 Torque front output flange nut to specified torque gt Figure 334 Install 2 clutch hub TE15 ay 2 5 Figure 335 Install 2 clutch hub retaining ring M Figure 336 Install spacer Figure 337 Install snap ring 10 163 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 338 Install 4 clutch hub Figure 339 Install snap ring Figure 340 1 Install 4 clutch assy into transmission case 1 15 Ed 3 Eo G Figure 341 ba Install 24 clutch assy into transmission case Figure 342 Install 2 aligning studs and using a light coat of grease place gasket N Figure 343 Install input shaft assy in front cover 10 164 REASSEMBLY of TRANSMISSION CASE ASSEMBLY Figure 344 Figure 347 Using spreading pliers sp
78. ww ms 1 1 8 8 x 1 25 00 25 221 258 90 25 258 295 135 40 15 295 369 0 50 443 479 00 65 119 554 65 75 Max I 1180 210 1280 320 525 600 1900 1050 11850 2100 13249 3699 9 7 B 1 9 11 12 15 6 118 14 8 184 1 25 GRADE 8 8 GRADE 10 9 GRADE 12 9 i SE m TET 1 1 90 116 112 184 10x1 M10x1 M12 x 1 29 M12x 1 5 M14 x 1 5 M16 x 1 5 M18 x 1 5 9 5 quu 128 qux 2 2 mee _ 4 105 101 105 62 169 91 53 8x2 207 22 1280 300 304 315 3 428 347 376 1470 510 I 9 128 14 i 215 228 216 227 1293 308 258 27 350 370 3 302 332 140 450 439 476 1595 645 503 559 683 758 413 443 560 600 586 623 795 845 681 736 1923 998 I M24 x 2 909 968 690 770 130 804 990 1090 045 959 1145 1295 4 2 199 221 236 300 320 19 330 433 448 369 398 900 540 931 590 720 800 167 84 1040 1140 002 992 1195 1345 9 MAT x 1 5 189 848 1070 1150 1129 1202 1530 1630 1309 1420 1775 1925 TE15 05 2006 3 8 Technical specifications Torque specifications for lubricated or plated threads Torque specifications for lubricated or plated threads GRADE 5 GRADE 8 NOM SIZE NOM SIE ew oe es a m 1 4 5 16 3 8 116 1 2 916 5 8 3

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