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TSM-0228 - TE13 & TE17 Full Flow Service Manual_nuovo.book

Contents

1. 86 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Transmission Assembly Instructions Alllead in chamfers for oil seals piston rings and o rings must be smooth and free from burrs Inspect at assembly e Lubricate all piston ring grooves and o rings with oil before assembly e Apply a thin coating of grease between seal lips on lip type seals prior to assembly Useonly pre coated pipe plugs On uncoated pipe plugs apply a light coat of Loctite 592 e After assembly of parts using Loctite there must not be any free or excess material which might enter the oil circuit Pump must be filled up with oil prior to assembly Apply a light coat of Loctite 262 or 270 to all thru hole stud holes p Tighten oil filter to 22 28 Ibs ft 30 38 Nem Teflon seals must be sized prior to assembly Add some grease to seal b diameter of clutch hub before assembly 1st Clutch b TE13 4 separator plates with inner splines 3 friction plates friction material on both sides with outer splines 2 friction plates friction material on one side with outer splines TE17 5 separator plates with inner splines 4 friction plates friction materia
2. 45 GEAR amp CLUTC HLAYOUT tud pena en voa uds i cuentos ba cu eni iays 46 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 3 TROUBLESHOOTING gt u u ni Eee Sa uama 47 TRANSMISSION PROBLEMS PR 47 TROUBLESHOOTING PROCEDURES Co eser tra Oo sas eMe 47 INPUT SHAFT AND DIRECTIONAL CLUTCH PROBLEMS 47 TRANSMISSIOBNLPRESSURE epu 2 canada ese caes opu eet eso ptos 47 MECHANICAL AND ELEGTRICAE CHECKS fp 48 HYDRAULIC CHECK O M UL D MED LEE NEUE 48 TROUBLESHOOTING GUIDE 49 LOVCEUTCEUPIBESSUBE o aaa a Md 49 EOW CHARGING PUMP OUTPUT uuu nscale asec 49 OVE REE A TIR e 22 215 0 uiia xi Iu 49 NOISY CONVERTER AE Lu C A Lie a Lo ue 49 LACK OF POWER 99 c usa ama se ea ete a 49 CHECK PONTS cc EE 50 FRONTE VIEU ss EC E 50 A n AA PW LI MI au eee M er 50 eon E I D Me LL de E
3. 6521 OLX SE 2615 901 go 717 OLX SE 4615 160 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Oil Baffle Seal Driver Oil Baffle Seal Driver TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 161 Output Shaft Lifting Hook Output Shaft Lifting Hook Made from Nut Dana P N 231639 NOTE Remove nylon from nut 162 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual x L E g 02 gt as 5 A 2nd Rev Shaft Lifting Hook 25 NN S SS 2 ALLE 163 na Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Filter Adaptor Tool Filter Adaptor Tool 40 6H7 2x 164 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual
4. 224 FATWA SSVd A8 H31H3ANOO9 JATA ALS 1 8310009 d31ddANO9 ANOYOL 3onvo 3anivd3dlNal 155484 INAWLEVd NOD dO1Vd3dO 3193155 3583 34 JAVA 1104 NOISSINSNVd1 2131 O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Reverse 2nd Speed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 42 Power Flows Activated Solenoids amp Hydraulic Circuits Reverse 2nd Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 43 10 183408 HILMO HILMO 10110 uomo HILMO a ut Ish amd Nu uv boe d 10916 116 D lt 9 JAWA 108100 000 UWA 1 26 NIN did ule J C CIM a CIM 9 11659 Jd uBiH 9 11959 14 M07 p gt Svd Ad 2 an uon eaniqmq H 00 3 wmwvgami U01003 38165384 290 206 3NWASSVd A8 14301 300901 41100 310801 390v9 39119 34155384 IN3IN LHVdIWO9 d01Vd43d0
5. AL3HVS U31U3ANOO 1 d31ddANO9 30801 380 831000 380 351 9 3anivd3dlNal 39055394 dO1Vd3dO 3193155 046 04 JAVA 1103 NOISSINSNVd1 2131 ejnsseJd uBiH eJnsseJd uoneouqn JAVA 9 ps A8 dri TSM 0228 TE13 amp 17 Full Flow Control Valve Service Manual Dana Holding Corporation 38 Power Flows Activated Solenoids amp Hydraulic Circuits Forward Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 39 ircuits O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Reverse 1st Speed NOILLVOIYEM HOLNTO aNg dNNS 10 191 Aa uv N33H2S hd HOLATO HILMO HOLATO HOLATO gt v sr xr NC CC 9162 ZEL gez 126 NIN e a Gr E 7 lt gt CIM E CIM 2 CIM N 09 1951 55 AAS uoneouqn 2 1 SSvd Ad HALT P dari 2 _ ufi 2 N 046 18 04 15 HOSN3S
6. BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 2 BACKING RING Each kit includes 2 Intermediate Drive Plates 1 Drive Plate amp Weld Nut Assembly 1 Backing Ring 10 Mounting Capscrews 10 Lockwashers Instruction Sheet N BOLT CIRCLE DIAMETER INTERMEDIATE DRIVE PLATES 3 BACKING RING Each kit includes 3 Intermediate Drive Plates 1 Backing Ring 10 Mounting Capscrews 10 Lockwashers Instruction Sheet 11 380 288 9 mm diameter 11 380 288 9 mm diameter 4 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual 13 120 332 2 mm diameter 13 500 342 9 mm diameter 13 120 332 2 mm diameter 13 500 342 9 mm diameter Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter Align intermediate drive plates and backing ring with holes in torque converter assembly Two dimples 180 apart in backing ring must be facing outward toward engine flywheel hollow side facing torque converter assembly Install capscrews and lockwashers Tighten capscrews to 30 37 Ibs ft 40 50 Nem NOTE Assembly of all plates must be completed within 15 minutes from when screws are installed If a screw is removed for any reason it must be replaced The adhesive left in the tapped holes must be removed with the proper tap and cleaned with solvent Dry the hole thoroughly and use a new screw for reinstallation Dana H
7. 51 PAIGE VIE cmm 51 59 sas a re et EM p cue I E uL I UU 52 BOTFON VIEW tec 52 Salze dus ITE o3 FULL EEOW VAEVE CONMEPONEBUIS ect a 54 SPEED SENSOR STATIC STANDALONE TEST 55 EXPLODED VIEWS uwawan uya 56 CONVERTER ROUSING GROUP J ana S O RET 56 TRANSMISSION CASE 8 REAR COVER GROUP _ 58 TORQUE CONVERTER GROUP aka uyak 60 P UNP DRIVEGPOUP d 62 5 55 0 64 INPUT SHAFT amp TST GROUP loca ortu cuis aue 0 66 REVERSE G2ND GROUP Kr EM 68 LIBE GIOUP Em 70 CRARGING PUMP GROUP 72 CONTROLVALVEGROUP PARTI Du nva ev tu ena praese Dev roca saya 74 REGULATOR BODY ASSEMBLE 76 FULL FLOW VALVE ASSEMBLY GROUP stands ovt vac v dax tius ou eva kae edes vare 78 CONTROL VALVE GROUP PARTIE uuu u w 80 SHIFPING COVER GROUP 28 uuu u
8. 03194135 4 ori vadAH JAVA 1104 NOISSINSNVu1 2131 O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Reverse 3rd Speed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 44 Power Flows Activated Solenoids amp Hydraulic Circuits Reverse 3rd Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 45 Gear 8 Clutch Layout Gear amp Clutch Layout 46 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual TROUBLESHOOTING The following information is presented as an aid to isolate and determine the specific problem areas in a transmission that is not functioning correctly When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and cor rect functioning of the other components of the group Therefore to properly diagnose a suspected problem in the transmission it is necessary to consider the transmission fluid charging pump torque converter transmission assem bly oil cooler filter connecting lines and controls including the engine as a c
9. Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury Indicates a situation which if not avoided may result NOTICE in damage to components TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 9 SPECIFICATIONS Identification Tag The nameplate contains both the model and serial number of the unit SPICER OFF HIGHWAY TEN BRIELE 3 B 8200 BELGIUM General Specifications Weight dry 1257 lbs 570 kg Length maximum 41 14 1045 mm Width maximum 27 28 693 mm Height maximum 32 53 826 mm Oil Capacity 6 6 US gallons 25 liters Without cooler and hyaraulic lines Consult equipment operator s manual for complete system capacity 10 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Hydraulic Cooler Lines Specifications Hydraulic Cooler Lines Specifications Lines and Fittings Minimum 0 75 19 mm internal diameter Continuous Operating Temperature ambient to 248 F 120 C 435 PSI 30 bar continuous pressure and 652 PSI 45 bar intermittent surges Conformance SAE J1019 and SAE J517 100RI Continuous Pressure Pressure and Temperature Specifications Normal Operating 158 248 F 70 120 C Temperature Measured at temperature check port for cooler Maximum Temperature 248 F 120 C Vehicle in Neu
10. lt gt SPICER Off Highway Products Service Manual Transmission TE13 amp TE17 3 Speed Short Drop with Full Flow Control Valve TSM 0228 April 2013 CONTENTS TOWING OR PUSHING uuu poeta oss 7 INTRODUCTION 9 memi pM 9 SAFEN PRECAUTIONS 42825 8501 55553658 1 5 9 SPECIFICATIONS 10 IDENTIFICANON RR 10 GENERAL SPEGIBICATIONS Eee 10 HYDRAULIC COOLER LINES SPEGIFICATIONS aed 11 PRESSURE AND TEMPERATURE SPECIFICATIONS 0 11 ELECTRICAL SPECIFICATIONS unu t uu 12 MAINTENANGE cm 13 SUMP PREREATERO 542002 42 13 alil ER 13 CALIBRATION aS 13 EB IM 13 RECOMMENDED CUBRICANTS u aka Qu PD E ae 13 MAINTENANCE INTERVALS Rn 13 SERVICING MACHINE AFTER COMPONENT OVERHAUL 14 AUTOMATIC CALIBRATION PROCEDURE u 15 15 ENTERING AUTOMATIC CALIBRATION MODE 15 PERFORMING AUTOMATIC CALIBRATION 16 HEATING UP THE TRANSMISSION BY USI
11. 1 2 RE eunsseuJd uBiH 2 eunsseJd h A 42 SSvd A8 P 83174 uoneougn a 086 181 x 2 0 uosN3s aNg ij 3dnivu3dW3l toe 5 086 18 QHe ISL JeQ 6116 082 3unsS3ud GD 3unSS3Hd VILN383 IQ 289 6 E JAYA SSvd A8 HAIHAANOO 300801 U U emm 841002 O gt O gt I 2 0 O U gt lt 721 gt LL gt 3nouoL 9 3anivd3diNal 39055394 INAWLEVd 40174340 03193135 1 JAVA TIN NOISSINSNVd1 2131 Neutral 2nd 1 3 Dana Holding Corporation TE13 amp TE17 Full Flow Control Valve Service Manual 0228 TSM ircuits O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Neutral 3rd 1 H01019 aNg 090 HOLATO 15 d 3SOH YOSNAS 831000 HOLATO HOLATO Add N ert 46 15 3193155 86 1 A38 N QMd H
12. 20000 1 Supply Voltage 4 5 5 5V Maximum Current 10 Pressure Sensor Pressure Range 14 5 450 PSI 1 31 bar 1 296 full scale 450 PSI 31 bar range 14 5 363 PSI 1 25 bar 2 596 full scale 450 PSI 31 bar range 363 450 PSI 25 31 bar Temperature Sensor Ambient Temperature C Resistance 12 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual MAINTENANCE Sump preheaters Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up Filters Service oil filter elements the first time at 100 hours and then every 1000 hours under normal environmental and duty cycle conditions Clutch Calibration Perform automatic clutch calibration every 2000 hours Lubricants Recommended Lubricants Only Dextron III is approved Viscosity at 104 F 40 C 33 38 cSt at 212 F 100 C 7 8 cSt Maintenance Intervals Daily Check oil level daily with engine running at idle 600 RPM and oil at 180 200 F 82 93 C Maintain oil level at full mark Normal oil change interval Drain and refill system every 1000 hours for average environmental and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement must be used to determine the required change intervals for extreme conditions
13. FIGURE 112 Install one outer half disc with friction material down 112 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of 1st clutch drum and turbine shaft FIGURE 113 Install end plate FIGURE 115 Warm lower thrust washer to 248 F 120 C and install thrust washer FIGURE 118 Install 1st clutch gear in clutch drum Align splines on clutch gear with internal teeth of steel discs NOTE Do not force this operation Gear splines must be in full position with internal teeth of all inner discs TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 113 Reassembly of 1st clutch drum and turbine shaft FIGURE 122 Install bearing needle in shaft FIGURE 121 Warm bearing to 248 F 120 C and install bearing on shaft 114 Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of REV clutch drum H FIGURE 128 Remove inner and outer discs FIGURE 125 Clutch gear and bearing removed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 115 Disassembly of REV clutch drum imam E Ll d z P f w 3 129 Use a bearing puller to remove clutch inner FIGURE 132 Compress spring to remove spring retainer snap earing ring FIGURE 130 Inner bearing removed F
14. is displayed on the screen press the M button once to go into the HEAT mode The 200 will display To trigger the HEAT mode push the S button The APC200 will display the sump temperature This means the actual sump temperature of the transmission is 20 Perform the following steps in order to heat up the transmission 1 Make sure the parking brake is active and works properly 2 Putthe transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throt tle 3 Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with the shift lever Keep the engine at full throttle 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 140 60 When the tem perature is above 140 F 60 the temperature indication on the display starts blinking Now switch to automatic calibration by pressing the M button several times until the APC200 displays tran During this warm up procedure it is possible for the converter out temperature of the transmission to exceed the maxi mum limit This is a consequence of heating up the transmission using this quick procedure When this occurs the engine speed will be limited to half throttle when the
15. 0 INWA SSvd A8 0 1 d31009 d3183ANO9 3nouoL OD 39nv9 390v9 54 4 1N3N1dVdNO9 dO1Vd43dO 031937135 JAVA TINS NOISSINSNVd1 2131 TSM 0228 TE13 8 TE17 Full Flow Control Valve Service Manual O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Forward 2nd Speed Dana Holding Corporation 36 Power Flows Activated Solenoids amp Hydraulic Circuits Forward 2nd Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 37 ircuits O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Forward 3rd Speed 41108 10 4 HOLATO HOLATO HOLATO HOLATO HOLATO Que 191 au gt 019162 1161 1081NO2 00 2 26 NIN e ar m lt 7 Ad3d N QNd N 04 15 Fi FI m e 461 916 980 do1v 10938 34055344 OM 38155384 IVILN3H3210 Jed 6 rm 3AWA SSVd A8
16. 10 11 DESCRIPTION HOUSING CONVERTER ASSY INCLUDES ITEMS 2 4 PLUG INCLUDES ITEM 2A O RING PART OF ITEM 2 PLUG EXPANSION PLUG INCLUDES ITEM 3A O RING PART OF ITEM 3 PLUG INCLUDES ITEM 4A O RING PART OF ITEM 4 GASKET CONVERTER HOUSING TO TRANSMISSION CASE CAPSCREW LOCKWASHER PLUG EXPANSION COVER O RING CAPSCREW N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual QTY 21 25 ITEM 12 12A 13 14 15 16 17 19 20 20A 21 22 23 24 SPEED SENSOR ASSY INCLUDES 12A O RING NOT USED ON THIS MODEL SWITCH TEMPERATURE NOT USED ON THIS MODEL OIL FILTER ASSY FILTER ADAPTER AIR BREATHER O RING SUCTION TUBE ASSY SUCTION TUBE CLAMP N I SCREW Lockwasher Not Used On This Model Not Used On This Model QTY Dana Holding Corporation 57 O x gt 9 C 4 E 9 0 Transmission Case amp Rear Cover Group E 2 00 2 2 K Q 4 e 4 TSM 0228 13 8 17 Full Control Valve Service Manual Dana Holding Corporation 58 Transmission Case amp Rear Cover Group ITEM DESCRIPTION QTY CASE TRANSMISSIONWITH EXTRA SUMP GASKET TRANS CASE REAR COVER 3
17. 34055384 IILN3U3HIQ 84 ET 3NWASSVd A8 3AWA 1 4 8410002 Y3LYJANO9 310801 351 9 1553 1 3 131923155 15015 MO 13 1103 NOISSINSNVYL 2131 TSM 0228 13 amp TE17 Full Flow Control Valve Service Manual O 9 E 4 O 2 op O D du U gt 4 lt 0 gt LL gt n Forward 1st Speed Dana Holding Corporation 34 Power Flows Activated Solenoids amp Hydraulic Circuits Forward 1st Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 35 dNNS 110 N33H9S gt HALMI HILMO H3HIV3u8 Que 181 IEO lt uidi 9162 161 3NWA 1081500 0270 106 NIN ay s did 21 8 A nss d ufi am O m SSvd Ad 8319 eunsseJd uoneouqn mg ued m HOSNAS 3 3uniyu3aWal gi IQ AATVA 3use3ud GD 38168384
18. From Cooler 4 holes M10 x 1 5 Thread Temperature Checkport for Cooler 18 NPFT 31 Pressure Regulator Sump Temperature 0 Sensor TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Check Points Left View Speed Sensor Engine Speed Air Breather Speed Sensor Port 34 Drum Speed Lube Pressure Port 45 Pump Gear FWD Clutch Pressure 4 4 Mounting holes M20 x 2 5 thread 30mm deep Right View Speed Sensor Port 11 Port 33 Turbine Speed To Cooler Pressure from Cooler Port 34 Lube Pressure e 9 12 Port 43 9 3rd Clutch Pressure Speed Sensor Output Speed Port 37 Safety Valve Pressure 4 Mounting holes M20 x 2 5 Thread 30mm deep TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 51 Check Points Top View Lirung Eye Locations Port 35 Pump Pressure Filler Hole Bottom View Port 32 To Cooler Port 46 Rev Clutch Pressure Port 12A From Cooler Port 46 Rev Clutch Pressure Port 45 Fwd Clutch Pressure 52 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Checkports Checkports System Pressure 1st Clutch Pressure Regulated Pressure 33 43 41 31 67 66 42 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation
19. Min clearance 1 76 mm 0 069 Max clearance 4 81 mm 0 189 TE17 Min clearance 2 99 mm 0 118 Max clearance 6 44 mm 0 254 The friction and separator plates for FWD REV 1st amp 2nd 3rd are not the same NEVER mix plates with plates from other clutches Rev Clutch TE13 8 separator plates with inner splines 8 friction plates friction material on both sides with outer splines TE17 10 separator plates with inner splines 1Ofriction plates friction material on both sides with outer splines Start with one separator plate then alternate friction and separator plates ending with a friction plate Clearance TE13 Min clearance 2 29 mm 0 090 Max clearance 5 14 mm 0 202 TE17 Min clearance 3 52 mm 0 139 Max clearance 6 77 mm 0 267 The friction and separator plates for FWD REV 1st amp 2nd 3rd are not the same NEVER mix plates with plates from other clutches TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 89 Transmission Assembly Instructions HEAVY SPRING LOAD INSTALLATION FORCE OF DISC SPRING IS 6015Nm HEAVY SPRING LOAD INSTALLATION FORCE OF COIL SPRING IS 1420 Nm Be sure shielded and sealed bearings are mounted as shown 3rd clutch spring discs concave side of fi rst spring disc is to be placed against clutch piston wear sleeve Seals must be pressed perpendicular upon shaft axis from baring side Tighten air breather t
20. 1 22 E seq JATVA 39155394 ze D 15538 TILLN3U333I 189 9 6 E ANWASSVd Ad JAYA 13 9 U3183ANO9 1 380 831009 380 e d31H3ANOO 310801 39199 39nv5 34055 44 03193135 18814 58 1N3IALHVdIAOO HO1VH330 SATIVA 1104 NOISSINSNVUL 2131 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 40 Power Flows Activated Solenoids amp Hydraulic Circuits Reverse 1st Speed Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 41 4405 10 33805 18 c EE _ A c uidi 9162 JMA 0 L26 a e 15 a rg eC h E eunsseJd 4 um gt lt z eunsseJd h passa ann 52 Nm 09 191 uoneouqn a 8 ASY N OMG 2 HOSNJS Nc uniyuadWal CHE ISL 08 151 Jed 6 6 6 80 3A VA d s rm HOLWINOSY 3805534 Y 34088384
21. 27 7 10 9 14 1 4 18 15 20 20 27 5 16 24 3 5 4 7 3 8 24 5 8 7 11 3 8 18 25 30 34 41 1 2 14 30 35 41 47 1 2 20 10 13 14 18 3 4 10 40 45 54 61 3 4 14 40 45 54 61 7 16 20 7 10 9 14 9 16 18 12 15 16 20 3 4 16 20 25 27 34 7 8 14 30 35 41 47 11 16 12 45 50 61 68 15 16 12 65 75 88 102 1 11 1 2 50 55 68 75 1 1 4 11 1 2 60 65 81 88 1 5 8 12 75 85 102 115 1 7 8 12 75 85 102 115 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 157 SPECIAL TOOLS Drum Holder eGy X 80 N3XJH8 N3330H LAG 9 TOOL AYIN 2 0904 A35 0298 3 5 LVN 202104121057 9 z E 1 00 ru Z S Seve V M X 8 O N3X3MH8 N3 30H HN LAG 9 TOOL AYIN Z 0994 TLNO 0298 395 LVN VOZ LOZL31OSV 1 1 00 S0 0 20009290 L 8 091 719 313 0 SP IAQNVH 4 of X 9N 9 40 5 1432905 9 7021041 41057 09 X 8100 8 902104
22. 299 Tighten to specified torque in sequence shown above FIGURE 296 Install new control valve outer gasket TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 149 Heassembly of transmission a i ON 36 5 a p A 4214725R FIGURE 300 Install separator plate with a new gasket on each side FIGURE 303 Tighten to specified torque in sequence shown above transmission 1 n i E E rd zt 1 i gt 2 c 2523 T0 Pe THE e ri t 3 NS Y ES e E ae Ecc Ex FIGURE 302 Install control valve assembly bolts lockwashers FIGURE 305 Install new sealing ring on stator support and and capscrews Tighten to specified torque install stator support 150 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control
23. 8 ELM 4 11 EY T 1 4 V Y E T FIGURE 61 Stator support and gasket removed s t F 2 L 3 E E 28 ka i T ac ira 1 1 elie 7 1 4 FIGURE 64 Remove lock nut from forward and 3rd shaft assembly Te lt TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 103 Disassembly of Transmission FIGURE 65 Fit special tool see Drum Holder on page 158 to FIGURE 68 Remove 2 gear from transmission case prevent gear from dropping when transmission is turned FIGURE 66 Remove 2nd gear retaining ring FIGURE 70 Remove 1st clutch drum and turbine shaft as an FIGURE 67 Pull up 2nd gear slightly to allow FWD 3rd clutch assembly drum and shaft assembly to be removed 104 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of Transmission Te E a OON c ee FIGURE 72 Remove 1st clutch drum retaining ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 105 Disassembly amp reassembly of rear cover Disassembly amp reassembly of rear cover bre o FIGURE 76 Install oil baffle and lockwashers and
24. APC200 has engine control or forcing neutral when the APC200 has no engine control To solve this simply leave the transmission in neutral for a minute and throttle the engine to around 1300 rpm This will allow the heat in the converter to be evacuated After one or two minutes resume the heat ing up procedure if the transmission temperature has not reached 60 C yet FULL IDLE forward neutral TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 17 Automatic Calibration Procedure CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS This chapter gives an overview of the most common calibration condition messages Many calibration condition mes sages can be corrected however if any calibration error messages appear contact the OEM of the machine Calibration Condition Messages The APC200 expects the shift lever to be in NEUTRAL but finds it in another position FORWARD or REVERSE Put the shift lever back in NEUTRAL C THE APC200 expects the parking brake to be ON while it is OFF Put the parking brake ON Verify that the parking brake is ON and working properly If this is already the case keep the machine at standstill by The APC200 has detected output using the brake speed Once the machine has been stopped the APC200 will ask the driver to shift to FORWARD before continuing the calibration Li e mm Engine RPM is to low according to t
25. BACKING 10 6 TE17 INCL ITEMS2THRUS5 N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 85 INSTALLATION DIAGRAMS Transmission Assembly Instructions
26. Every 1000 hours e Change oil filter element Drain oil at 150 200 F 65 93 and refill system as follows Drain transmission Remove and discard filter Install new filter Refill transmission to FULL mark Run engine at 500 600 RPM to prime converter and lines A E E Hecheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil temperature is hot 180 200 F 82 2 93 3 C make final oil level check and adjust if necessary to bring oil level to FULL mark NOTE It is recommended that oil filter be changed after 100 hours of operation on new rebuilt or repaired unit Extended oil change interval Extended oil service life may result when using synthetic fluids Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time to determine a baseline Wear metal analysis can provide useful information but a transmission should not be removed from service based solely on this analysis 13 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Servicing Machine After Component Overhaul Servicing Machine After Component Overhaul The transmission torque converter and its allied hydraulic system are important links in the driveline between the engine and the wheels The proper operation of either unit depends greatly on the condition and operation of the other Therefore whe
27. FIGURE 200 Compress spring and remove spring retainer snap ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 129 Disassembly of FWD clutch drum 113 1 TM FIGURE 204 Remove clutch piston inner seal 130 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of FWD clutch drum Reassembly of FWD clutch drum FIGURE 208 i i o FIGURE 209 Compress spring and spring retainer Install retainer snap ring Be sure snap ring is in full position in groove FIGURE 206 See Cleaning and Inspection on page 91 Install clutch piston outer seal ring and size as explained NOTE Ring mustbe sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until seal is flush with outer diameter of piston t 5 FIGURE 210 Install inner bearing snap ring FIGURE 207 Install clutch piston spring spacer TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 131 Reassembly of FWD clutch drum FIGURE 211 Install one steel disc Alternate friction and steel FIGURE 214 Install FWD clutch gear with inner and outer discs until the corect amount of discs are installed First and last bearing in clutch drum Warm the
28. FINE PITCH TYPE OF BOLT SIZE OF BOLT Grade 8 8 Grade 10 9 Grade 12 9 lbs ft Nem lbs ft Nem lbs ft Nem M8 x 1 17 20 23 28 25 28 34 39 30 34 41 46 M10 X 1 35 42 47 57 52 60 71 81 62 69 84 94 M10 x 1 25 32 40 44 54 49 57 67 77 58 66 79 89 M12 x 1 25 60 68 82 92 89 96 120 130 105 116 143 158 M12 x 1 5 58 65 78 88 86 94 117 127 101 112 138 153 M14 x 1 5 94 105 128 143 142 153 193 208 162 184 220 250 M16 x 1 5 159 169 215 228 216 227 293 308 258 273 350 370 M18 x 1 5 221 236 300 320 319 330 433 448 369 398 500 540 M18 x 2 207 221 280 300 304 315 413 428 347 376 470 510 M20 x 1 5 302 332 410 450 439 476 595 645 503 559 683 758 M22 x 1 5 413 443 560 600 586 623 795 845 681 736 923 998 M24 x 1 5 531 590 720 800 767 841 1040 1140 882 992 1195 1345 M24 x 2 509 568 690 770 730 804 990 1090 845 955 1145 1295 M27 x 1 5 789 848 1070 1150 1129 1202 1530 1630 1308 1420 1175 1925 156 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Pipe Plugs Pipe Plugs THREAD SIZE Ibs ft Nem 10 1 6 7 8 10 M14 x 1 5 7 9 10 12 M18 x 1 5 25 30 34 41 M22 x 1 5 35 44 48 60 M26 x 1 5 45 50 61 68 M33 x 2 83 103 112 140 THREAD SIZE Ibs ft 1 16 27 5 7 7 9 1 8
29. PIN DOWEL 4 4 CAPSCREW 26 5 LOCKWASHER 26 ASSY SPEED SENSOR INCLUDING ITEM 6 O RING SPEED SENSOR PART OF ITEM 6 7 PLUG INCLUDING ITEM 8 1 8 O RING PART OF ITEM 7 1 9 O RING FILTER ADAPTER 2 10 ASSY SPEED SENSOR 2 INCLUDING ITEM 10 10 O RING SPEED SENSOR 1 PART OF ITEM 10A 11 BUSHING SPEED SENSOR 1 FOR 71T OUTPUT GEAR 11A BUSHING SPEED SENSOR 1 FOR 92 TEETH GEAR 12 SCREW PART OF ITEM 6 3 AND 10 13 CAPSCREW 4 14 ASSY REAR COVER PLUGS 1 INCL ITEMS 15 THRU 19 PLUG M22X1 5 INCL ITEM 16 amp PART OF ITEM 14 3 16 O RING PART OF ITEM 15 4 EXPANSIONPLUG PART OF 4 ITEM 14 18 PLUG INCLUDING ITEM 19 amp 3 PART OF ITEM 14 N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ITEM 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 DESCRIPTION O RING PART OF ITEM 18 SPACER OIL BAFFLE SPACER OIL BAFFLE BAFFLE OIL COVER OIL BAFFLE BAFFLE OIL CAPSCREW CAPSCREW LOCKWASHER PLUG MAGNETIC DRAIN COVER SPLIT FLANGE SHIPPING O RING CAPSCREW LOCKWASHER O RING O RING SCREW N I PLAIN WASHER PLAIN WASHER BRACKET Dana Holding Corporation 59 Torque Converter Group Torque Converter Group 60 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ITEM
30. SPEED 45 DEGREES 4209832 DEUTZ 2 PINS 45 DEGREES 4209855 DEUTZ 5 PINS ENGINE SPEED 55 DEGREES TEMPERATURE On the sensor body there is a small plastic triangular position sign Make sure the position sign on the sensor points as shown below in the direction of the movement of the gear teeth teeth rotation as shown or 180 rotated Position sign 2 1 22 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Speed Sensor Locations The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 14 mA The sensor has an integrated AMP super seal 2 pin connector The two pins are numbered 1 and 2 Following table shows the relation between wire color pin number and connection Speed Sensor Locations Speed Sensor Turbine Speed Speed Sensor I p Output Speed 2 Speed Sensor Speed Sensor Engine Speed Drum Speed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 23 24 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual TRANSMISSION OPERATION The transmission is composed of five main assemblies Converter pump drive section and pressure regulating valve Input shaft and directional clutches Range clutches Output section Control valve Converter Pum
31. Valve Service Manual Reassembly of transmission Ec E 5 5 M D FIGURE 309 Install idler gear bolts and lockwashers Tighten to specified torque 209 FIGURE 311 Install bolts and lockwasher Tighten to specified FIGURE 308 Install idler gear washer bearing as torque assembly TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 151 Reassembly of transmission INS 2 Es T FIGURE 315 Install adaptor plate and new gasket E FIGURE 316 Install adaptor plate capscrews and tighten to specified torque cmm FIGURE 314 Install charging pump capscrews Tighten to specified torque FIG URE 317 Install adaptor plate cover and new gasket 152 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission ai ND FIGURE 318 Install adaptor plate cover bolts and lockwashers FIGURE 321 Install oil filter and tighten to 22 28 Ibs ft 30 38 Tighten to specified torque N m lt ew gasket FIGURE 322 See Cleaning and Inspection on page 91 After installing new seal ring on baffle plate use a special tool see Converter Lifting Hook on page 159 and install converter assembly in housing FIGURE 319 Install filter adaptor a
32. function pressure testing the following mechanical and electrical checks should be made e Check the parking brake and inching pedal for correct adjustment 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 Besure that all components of the cooling system are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if necessary he engine must be operating correctly Be sure that it is correctly tuned and adjusted to the correct idle and maximum no load governed speed specifications Hydraulic Checks Also before checking the transmission clutches torque converter charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid checks e 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 NOTE The transmission fluid must be at operating temperature of 180 200 F 82 93 to obtain correct fluid level and pressure readings NEVER attempt to make these checks with cold oil To raise the oil temperature to this specification
33. it is necessary to either operate work the vehicle or run the engine with the converter at stall see Stall Test on page 47 Be careful the vehicle does not move unexpectedly when operating the engine and converter at stall rpm 48 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Troubleshooting Guide Troubleshooting Guide Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles Low Clutch Pressure my 0 Low Charging Pump Output Overheating Restriction in cooler lines Noisy Converter Worn charging pump Replace charging pump Worn or damaged bearings A complete disassembly will be necessary to determine which bearing is faulty Defective charging pump Replace pump Lack of Power Low engine RPM at converter stall Tune engine check governor See Overheating section above and make same checks Make corrections as explained in Overheating TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 49 Check Points Check Points Front View Split Flange for Dipstick Diameter 25 Rear View Port 41 1st Clutch Pressure Port 67 1st 3rd Reg Pressure Port 66 Fwd Rev Reg Pressure Port 42 2nd Clutch Pressure 8 Mounting holes M20 x 2 5 thread 30mm deep 50 Dana Holding Corporation Plug Magnetic drain M22 x 1 5 UNI Port 12B
34. vehicle has to be activated e The transmission temperature needs to be above 60 C See the next paragraph how to use the HEAT mode to do this in a time effective way The engine speed has to be kept at around 800 rpm x 200 rpm during the complete calibration If the APC200 has control over the engine the engine speed will be adapted automatically 1 If all the conditions mentioned above met the actual automatic calibration can be performed starting from the following display on the APC200 2 To trigger the automatic calibration procedure push the S button once The APC200 display readout will show bo F 3 The APC200 asks for the shift lever to be put in FORWARD The automatic transmission calibration procedure starts This is indicated on the APC200 display cil ceni ac stands for clutch 1 being forward while 1 stands for 1 of the calibration 4 When all clutches have been calibrated the APC200 displays dant 5 Atthis point the automatic calibration has completed successfully The normal duration of a complete transmission calibration is around 15 minutes 6 Toexit the automatic calibration mode switch off the vehicle ignition key Make sure that the APC200 has powered down wait for 2 seconds Now restart the vehicle and the new tuning results will be activated automatically Troubleshooting If anything different than described above appears o
35. 121057 H33 y 02104131057 IW IdSONISILSSASE 20010413105 Sn8S5NIGI3 T39 2 202104131057 578434 ON 1 3AVN Ql 1SM IN3NOdAOO 99 45j N3 30H HN LAC TOOL AYAN 21615 800107 11057 97 06 007 111 d 18 m 5 o Z 920 06 59 0 7 0 TSM 0228 TE13 amp 17 Full Flow Control Valve Service Manual Dana Holding Corporation 158 Converter Lifting Hook Converter Lifting Hook 212 00 40 00 106 00 R1 X 1 2 5 00 TN 165 00 50 00 50 00 HBe 1 131 00 i 50 00 48 00 10 00 4 1 70 00 10 00 174 00 19 00 T i G i 70 00 50 00 10 00 1 XR N 155 00 I 11 00 ZAUR a 128 00 P d TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 159 Case Lifting Hook Case Lifting Hook 262
36. 13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 67 Reverse amp 2nd Group Reverse amp 2nd Group 68 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reverse amp 2nd Group QTY ITEM 10 11 12 13 13A 14 15 16 DESCRIPTION RING PISTON BEARING HK3026 BUSHING SNAP RING NOT USED ON THIS MODEL PLATE END 2ND DISC CLUTCH OUTER HALF 2ND DISC CLUTCH INNER 2ND DISC CLUTCH OUTER 2ND SNAP RING EXTERNAL SPACER CLUTCH PISTON SPRING SPRING RETURN SPACER ASSY CLUTCH PISTON 2ND INCL ITEM 13A amp 14 SCREEN PART OF ITEM 13 SEAL OUTER 2ND PART OF ITEM 13 RING PISTON 56 X 2 5 ASSY REV 2ND SHAFT DRUM TUBE amp PLUG N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED QTY ITEM 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual DESCRIPTION RING PISTON ASSY CLUTCH PISTON REV INCL ITEM 1 4 14 RETAINER SPRING DISC CLUTCH OUTER REV DISC CLUTCH INNER REV SEAL LIP END PLATE RING RETAINING BEARING CLUTCH DRIVEN GEAR RING SNAP REAR BEARING WASHER BEARING SUPPORT SNAP RING EXTERNAL SPECIAL BEARING BALL RETAINING RING RING PISTON NOT USED ON THIS MODEL SPRING BELLEVILLE GENERA TION II PLATE END REV 10 10 Dana Hold
37. 31H3ANOO 39095399 119935414 848 JAVA SSVd A8 U3183ANOO 300801 0 JAVA 1103 NOISSIWSNVuL 21 31 5 0 JAVA AL33VS dNNS TIO div N3auos lt gt gt d x 9162 0720 ulu 1 L26 NIN eunsseJd ainsseid uoneougn JAVA SSvd A8 HALTS 48455 00 do1v1n938 39155394 F 2 390v9 39055394 INAWLEVd dO1Vd3dO TSM 0228 13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 32 Power Flows Activated Solenoids amp Hydraulic Circuits Neutral Continued TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 33 dNNS 110 gt HOLNTO HILMO HOL TIO HOLM HILMO 15 p ES 2 SES MEM 9162 116 JAYA 108LNOO 0072 126 NIN e 9 n N Qo Lr ms rg lt ued CIM p 4 a A3g N OMd ainsseid an 2 Ssvd A8 Hard uoneouqn mg 0 uosN3s 4 3univu3aWal Ge B 481 516 490 3A IVA go1v 10938 39155399
38. 4444811 LI FIGURE 257 Fit special tool to prevent gear from dropping when transmission is turned See Drum Holder on page 158 q 1 1 4 4 EIN REN FIGURE 254 Install input shaft rear bearing retaining snap ring bine 142 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission FIGURE 258 Install oil baffle plate mounting spacers Longest FIGURE 261 Raise 2nd gear up to allow 3rd FWD shaft in the middle assembly to be installed FIGURE 259 Install oil baffle using Loctite 243 on bolts and tighten to specified torque FIGURE 263 Remove special tool FIGURE 260 Install 2nd clutch gear TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 143 Heassembly of transmission FIGURE 264 Install gear retaining nut FIGURE 267 Using aligning studs install converter housing on transmission case FIGURE 265 Block gears from turning and tighten to specified torque FIGURE 268 Tap down dowel pins into converter housing and transmission case FIGURE 266 Install new converter housing gasket and o ring FIGURE 269 Install bolts and lockwashers Tighten to specified torque 144 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission Align splines on
39. 53 Full Flow Valve Components Full Flow Valve Components FWD REV gt SELECTOR VALVE 1ST 3RD SELECTOR VALVE 3RD 1ST PROPORTIONAL VALVE 3RD 1ST PRESSURE SENSOR FWD REV PROPORTIONAL VALVE 2ND PROPORTIONAL VALVE 2ND PRESSURE SENSOR Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Speed Sensor Static Standalone Test Speed Sensor Static Standalone Test In order to be able to sense the currents a series resistor of e g 200 W must be used This resistor is integrated in the controller but when the sensor is to be tested it must be connected externally The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor The voltage reading should be either 1 2V 1 6V for the 7 1mA current level or 2 6 3 0V for the 14mA 1mA cur rent level If the teeth can be moved slowly distinct toggling between the two levels should be noticed sensor 200 Ohm 1 Watt TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 55 EXPLODED VIEWS Converter Housing Group 5 e Le 72 Z S TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 56 Converter Housing Group DESCRIPTION ITEM 2A 2B 4
40. C CIRCUITS 30 NEUTRAL TST er rc c 30 aspa maaa aa 31 LD 22 8 an noe 622858 asap omuia tcu debate nue Ce ea eats 32 NEUTRAL CONTINUED 33 FORWARD 34 FORWARD IST SPEED CONTINUED 582 35 FORWARD 2ND SPEE D 2 ice E 36 FORWARD 2ND SPEED 37 FORWARD SAD GREED 38 FORWARD SHDOPEEDI GONTINUED 39 um u ymi au an 40 REVERSE 191 SPEED CONTINUED uu Guy aaa e 41 REVERSE DM ee err ee re ere ene ete er te eer eee ere eres 42 REVERSE 2ND SPEED CONTINUED 85 09 2 Gt 43 HEVERSE GROSE EED ioi canet oue icis tc MeL er 44 REVERSE SRD SPEED CONTINUED Z Z ca ua 54 08 58 65500688
41. CRIPTION QTY 1 BODY FULL FLOW VALVE 1 16 PLUG EXPANSION 3 SOLENOID VALVE INCLUD PLUG O RING INCLUDING ING ITEMS 3 amp 4 ITEM 18 3 O RING PART OF ITEM 2 3 18 O RING PART OF ITEM 17 3 4 O RING PART OF ITEM 2 6 19 SPRING ACCUMULATOR 3 5 2 20 SPOOL ACCUMULATOR 3 ASSEMBLY SOLENOID 24V 6 INCL ITEMS 7 THRU 10 1 21 PIN ACCUMULATOR STOP 3 SENSOR VALVE PRES 7 O RING PART OF ITEM 6 1 22 2 PLUG O RING INCLUDING 8 O RING PART OF ITEM 6 1 23 9 9 O RING PART OF ITEM 6 1 24 O RING PART ITEM23 9 10 O RING PART OF ITEM 6 1 25 O RING POLYACRYLATE 1 ASSEMBLY SOLENOID 24V 11 INCL ITEMS 12 THRU 15 1 26 COVER SPLIT FLANGE 1 12 O RING PART OF ITEM 11 1 27 WASHER SPRING LOCK 4 13 O RING PART OF ITEM 11 1 28 2 rcc 14 O RING PART OF ITEM 11 1 29 PLUG EXPANSION 4 15 O RING PART OF ITEM 11 1 N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 79 Control Valve Group Part II Control Valve Group Part 09 Z9 ON YS Oo 9 E gt m d Dur o Da oa 5 26 0 2 70 k 80 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Control Valve Group Part II ITEM DESCRIPTION QTY 1 ASSY REGULATOR BODY 1 2 GASKET CONTROL VAL
42. DESCRIPTION QTY ITEM DESCRIPTION QTY TORQUE CONVERTER ASSY 1 GASKET TORQUE INCL ITEMS 2 THRU 5 VERTER PART OF ITEM 1 2 GEAR TORQUE CONVERTER LOCKWASHER PART OF PART OF ITEM 1 ITEM 1 3 SCREW PART OF ITEM 1 8 6 NOT USED ON THIS MODEL 5 5 NOT SOLD SEPARATELY NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 61 Pump Drive Group Pump Drive Group C UC 2 ET p V LA M EN NN M S MN N lt amp N lt N 62 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Pump Drive Group ITEM DESCRIPTION 1 NOT USED ON THIS MODEL 2 NOT USED ON THIS MODEL 3 GEAR PUMP DRIVE IDLER 66T 4 GEAR PUMP DRIVE 61T 5 BEARING 6311 C3 SUPPORT PUMP DRIVE BEAR ING N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED QTY ITEM 10 11 12 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual DESCRIPTION QTY SNAP RING 4 NOT USED ON THIS MODEL PLUG 2 CAPSCREW 8 WASHER SEAL 4 LOCKWASHER 4 Dana Holding Corporation 63 Gear Group TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 64 ITEM A O N N S S NOT SOLD SEPARATELY DESCRIPTION GEAR CLUTCH 1ST GEAR GEAR CLUTCH 2ND GEAR CLUTCH 3RD GEAR
43. Dana Holding Corporation 75 9 lt 2 O aa O 9 D Regulator Body Assembly 2 N y 7 451 TSM 0228 TE13 8 TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 76 Regulator Body Assembly ITEM 7 8 DESCRIPTION BODY REGULATOR VALVE SPRING SPOOL PRESSURE REGULA TOR PLUG M22 X 1 5 INCLUDING ITEM 5 O RING PART OF ITEM 4 SPRING SAFETY VALVE SPOOL CONV BYPASS SPRING CONV BYPASS N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual QTY ITEM 9 10 11 12 13 14 15 DESCRIPTION QTY PLUG O RING ISO 6149 1 SENSOR TEMPERATURE 1 O RING POLYACRYLATE 1 COVER SPLIT FLANGE 1 WASHER SPRING LOCK 4 SCREW HEXAGON HEAD 4 CAP PLUG EXPANSION 1 Dana Holding Corporation 77 Full Flow Valve Assembly Group Full Flow Valve Assembly Group 226 TA 02 7 87 S 910 2 2449 25 amp Z OMe x C gt A Q 2 qo e 7 gt JD SN J 5 10 7 29 2 _ Pd C 24 4 A KN ff 8 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Full Flow Valve Assembly Group ITEM DESCRIPTION QTY ITEM DES
44. GEAR Dana Holding Corporation Charging Pump Group Charging Pump Group 72 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual 8 9 DESCRIPTION CHARGING PUMP NOT USED ON THIS MODEL CAPSCREW LOCKWASHER ADAPTOR CHARGING PUMP SAE C GASKET ADAPTOR SCREW ADAPTER TO CHARGING PUMP LOCKWASHER COVER SHIPPING SAE C N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Charging Pump Group ITEM 10 11 12 13 14 15 16 DESCRIPTION GASKET SHIPPING COVER LOCKWASHER NOT USED ON THIS MODEL NOT USED ON THIS MODEL O RING 50 X 2 5 O RING 30 X 3 Dana Holding Corporation m x U U gt O Control Valve Group Part Joy TSM 0228 TE13 amp 17 Full Flow Control Valve Service Manual Dana Holding Corporation 74 Control Valve Group Part DESCRIPTION ITEM 4 5 GASKET CONTROL VALVE GASKET DISTRIBUTION PLATE TO REAR COVER PLATE SEPERATOR ASSY CONTROL VALVE LOCKWASHER N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual QTY 1 16 ITEM 10 DESCRIPTION QTY SCREW 6 SCREW 10 LOCKWASHER 18 CAPSCREW 18 BRACKET 4
45. IGURE 131 Remove inner bearing snap ring FIGURE 134 Remove return spring spacer 116 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of REV clutch drum FIGURE 136 Remove clutch piston inner seal TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 117 Disassembly of 2nd clutch drum Disassembly of 2nd clutch drum FIGURE 140 Remove inner and outer discs FIGURE 137 Remove end plate retainer ring FIGURE 141 Remove one outer half disc FIGURE 142 Compress spring and remove spring retainer snap ring FIGURE 139 Remove one outer half disc 118 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of 2nd clutch drum FIGURE 143 Remove Belleville spring 5 assembly and make FIGURE 146 Remove inner piston ring sure to keep them in the same position FIGURE 147 ET FIGURE 145 Remove clutch piston assembly 1 busning Mom TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 119 Reassembly of 2nd clutch drum Reassembly of 2nd clutch drum 3 FIGURE 152 See Cleaning and Inspection on page 91 Install clutch piston outer sealing ring and size as explained FIGURE 149 Warming up to 248 F 120 C install bushing on haft Ring must be sized
46. NG THE HEAT MODE 17 CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS 18 DRIVE PLATE INSTALLATION erect Qua unde Sov 19 TRANSMISSION TO ENGINE INSTALLATION 20 EXTERNAL PLUMBING INSTALLATION 21 COOLER EINE SPEGIFIOATIONS Dee Ee deco bo teme 21 SPEED SENSOH INSTALLATION ook te cosas usse 22 SPEED SENSOR INSTALLATION aa S Gss ye Rosi 22 SPEED SENSOR LOCATIONS 10024284 4 dopo x eva Re Ru dE n DU NONE 23 TRANSMISSION OPERATION u il un ss ass 25 CONVERTER PUMP DRIVE SECTION amp PRESSURE REGULATING VALVE 25 RANGE CGEUDHECHES T S 26 INPUT SHAFT AND DIRBEGTIONAL CGDUTGOFHES u 27 OUTPLITCSEGTIOD a 27 TRANSMISSION CONTROLS Da Za 28 THE VALVE __ _ _ _ _ 28 ELECTHIC SOLENOID GONTBROLS Qamkuna awa 29 POWER FLOWS ACTIVATED SOLENOIDS HYDRAULI
47. REV 1st amp 2nd 3rd are not the same NEVER mix plates with plates from other clutches ard Clutch b TE13 4 separator plates with inner splines 3 friction plates friction material on both sides with outer splines 2 friction plates friction material on one side with outer splines TE17 4 separator plates with inner splines 3 friction plates friction material on both sides with outer splines 2 friction plates friction material on one side with outer splines Start with one side friction plate metal against piston Then alternately separator and friction plates End with a one side friction plate metal against the end plate Clearance TE13 Min clearance 1 09 mm 0 043 Max clearance 2 70 mm 0 106 TE17 Min clearance 1 09 mm 0 043 Max clearance 2 70 mm 0 106 The friction and separator plates for FWD REV 1st amp 2nd 3rd are not the same NEVER mix plates with plates from other clutches 88 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Transmission Assembly Instructions Fwd Clutch TE13 9 separator plates with inner splines 9 friction plates friction material on both sides with outer splines TE17 11 separator plates with inner splines 11 friction plates friction material on both sides with outer splines Start with one separator plate then alternate friction and separator plates ending with a friction plate Clearance TE13
48. REV CLUTCH N I NOT ILLUSTRATED QTY ITEM NJ TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual DESCRIPTION GEAR FWD CLUTCH SHAFT OUTPUT 71T GEAR GEAR QTY Dana Holding Corporation 65 Input Shaft amp 1st Group Input Shaft amp 1st Group 66 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Input Shaft amp 1st Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY SEAL OIL BAFFLE INNER ASSY CLUTCH PISTON PART ITEM 3 1ST INCL ITEMS 17 amp 17A SPACER CLUTCH PISTON 2 SNAP RING 1 19 SPRING 1 ASSY OIL BAFFLE AND 3 SEAL INCLUDING ITEM 1 1 20 SPRING PISTON RETURN 1 4 O RING 1 21 SPRING RETAINER 1 5 RING SNAP DIA 60 1 22 SNAP RING EXTERNAL 4 6 BEARING TORQUE CON 1 23 DISC CLUTCH OUTER 2 VERTER NU212 ECJ HALF 7 RING PISTON 1 24 DISC CLUTCH OUTER 4 8 SUPPORT STATOR 1 25 DISC CLUTCH INNER 5 8A BUSHING 26 PLATE END 1 9 LOCKWASHER 8 27 USED THIS MODEL 10 CAPSCREW 8 28 SNAP RING 1 11 GASKET STATOR SUPPORT 1 29 WASHER THRUST 78X55X5 1 12 RING PISTON 1 30 BEARING NEEDLE ROLLER 2 13 RING PISTON 1 31 BEARING K55X60X17XFV1C 2 14 BEARING BALL 1 32 SPACER 1 15 ASSY SHAFT AND HUB 15 1 33 BEARING 6311 C3 1 16 RING PISTON 56 X 2 5 1 34 SNAP RING 1 17 SEAL OUTER PART OF ITEM 4 35 WASHER THRUST 4 18 WS 81111 17A SCREEN PART OF ITEM 18 1 N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE
49. RTER HOUSING 4 4 STUD CALD 21 ALIGNING STUDS 21 0 FLYWHEEL DRIVE _ SG PLATE Remove drive plate locating stud SPECIAL STUD WASHER AND SELF LOCK NUT FURNISHED Install drive plate attaching screw and washer onug FLYWHEEL HOUSING BY ENGINE MANUFACTURER screw but do not tighten Some engine flywheel housings have a hole located on the flywheel hous ing circumference in line with the drive plate screw access hole A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws Rotate the engine flywheel and install the remaining seven 7 flywheel to drive plate attaching screws Snug screws but do not tighten After all eight 8 screws are installed tighten each capscrew to 26 29 165 ft 35 39 Nem This will require tightening each screw and rotating the engine flywheel until the full amount of eight 8 screws have been tightened to specified FLYWHEEL IMPELLER COVER SS INTERMEDIATE DRIVE PLATES 22 9 torque FIG 4 9 Measure engine crankshaft end play after transmis _____ ____________ TO BE INSTALLED sion has been completely installed on engine fly i WITH SIDE wheel This value must be within 0 001 0 025 mm TOWARD ENGINE of the end play r
50. TORQUE TE17 TRANSMISSION FULL FLOW VALVE HYDRAULIC DIAGRAM TEMPERATURE GAUGE OPERATOR COMPARTMENT LLI RS wa Dana Holding Corporation e lt e gt SAFETY VALVE 4 9 bar oc Lu EE ui g 2 2 1 lt m cc Lu LL a a 2ND CLUTCH 00 3RD CLUTCH 15 CLUTCH SENSOR FWD CLUTCH FWD N REV pagum MEN Sr gt lt h CONTROL VALVE 77 lt o sE m SCREEN FILTER lt gt S cN cN e e 8 gt SE lt 5 EE EE PEL NN 2 OIL SUMP Low pressure o 2 o 2 I EH Lubrication TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ts 4405 10 x 3905 gt HOLNTO HOLNTO Que 15 au Na d 4 Z 0160 16 1OH1NOO 4 02 2 0 16 NIN e s Xr q in x ES
51. VE 2 3 PLATE SEPERATOR 1 4 ASSY FULL FLOW VALVE 24V 1 N S S NOT SOLD SEPARATELY NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ITEM 5 6 DESCRIPTION QTY LOCKWASHER 2 SCREW 1 CAPSCREW 1 Dana Holding Corporation 81 Shipping Cover Group Shipping Cover Group Nz NO Ger FOS 22 x pu 1 I pl N 1 m V uM a 2 23 W M TES N d v W V v V Vw Y N N VW S N NN SN Vai NS N SW NN N NS X NS SN Ws XA IN SM l o 1 1 A lt a lt 27 82 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Shipping Cover Group DESCRIPTION QTY LOCKWASHER 4 SCREW 4 ITEM DESCRIPTION QTY 1 COVER SHIPPING SAE C 1 GASKET SHIPPING COVER SAE N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ITEM 3 Dana Holding Corporation 83 Drive Plate Group Drive Plate Group 84 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Drive Plate Group ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 NOT USED ON THIS MODEL 4 CAPSCREW 10 2 PLATE DRIVE 5 5 LOCKWASHER 1 KIT ASSY DRIVE PLATE 3 RING
52. a Sasan 82 DRIVE PEATE GROUP ce 84 INSTALLATION DIAGRAMS uuu ce ce eaters 86 TRANSMISSION ASSEMBLY INSTRUCTIONS uui sss 86 CLEANING AND INSPECTION 2 5 44525522 22525554 8545 22 262 91 e zc 91 Sim A LN Lee NERO DES 91 HOUSINGS 5 58 42 84 551488 185221 340 555 55 42 58 25584 54 4558485 a 91 INSPECTION a 91 BEARING m E 91 SEALS GASKETS AND RETAINING RINGS 91 AND 552515 4 91 HOUSINGS COVERS AND CARS 92 4 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual 6 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual TOWING OR PUSHING Before towing the vehicle be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid dam age to the transmission during towing NOTE Because of the design of the hydraulic system the engine cannot be started by pushing or towing TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 7 8 Dana Holding Cor
53. allow smooth engagement of drive 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 bleed holes in the clutch piston into the transmission sump These bleed holes will only allow quick escape of oil when the pressure to the piston is released 26 Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Input Shaft and Directional Clutches Input Shaft and Directional Clutches Once a range clutch is engaged power is transmitted to the directional clutches Operation of the directional clutches is similar to the range clutches Output Section With a directional clutch engaged power is finally transmitted to the output shaft Output rotation is same as the input
54. alve Service Manual Disassembly of 3rd clutch drum FIGURE 178 Remove inner thrust bearing FIGURE 179 Use bearing puller to remove thrust bearing FIGURE 182 Remove end plate spacer FIGURE 183 Remove half disc with friction material down to FIGURE 180 Remove thrust bearing snap ring inner disc TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 125 Disassembly of 3rd clutch drum FIGURE 184 Remove inner and outer disc FIGURE 187 Remove Belleville spring 5 assembly and make sure to keep them in the same position FIGURE 186 Compress spring and remove snap ring FIGURE 190 Remove clutch piston assembly 126 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of 3rd clutch drum FIGURE 191 Remove inner piston ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 127 Disassembly of FWD clutch drum Disassembly of FWD clutch drum FIGURE 197 Remove inner and outer discs FIGURE 194 Clutch gear and bearing removed 128 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of FWD clutch drum FIGURE 198 Use bearing puller to remove clutch inner bearing FIGURE 201 Spring and spring retainer removed FIGURE 203 Remove clutch piston assembly
55. anual Disassembly of Transmission Jie FIGURE 23 Remove control valve assembly bolts lockwashers FIGURE 26 Remove regulator valve screws and lockwashers and capscrews transmission FIGURE 28 Remove gaskets and separator plate FIGURE 25 Remove separator plate and upper and lower gaskets TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 97 Disassembly of Transmission FIGURE 32 Using external snap ring pliers open snap ring on 2nd REV shaft and using hoist remove rear cover dia p uma ES FIGURE 30 Remove flange o ring washer and nut FIGURE 34 Remove rear cover gasket FIGURE 31 Remove bolts and lockwashers from rear cover 98 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of Transmission FIGURE 38 Bearing gear and washer removed FIGURE 36 Remove bearing retaining ring FIGURE 39 Remove seal rings from 2nd REV shaft Wall n NI j al FIGURE 37 Use bearing puller to remove bearing gear washer TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 99 Disassembly of Transmission FIGURE 41 Remove gear washer and bearing from 2nd REV shaft 1 271 1 1 E FIGURE 45 Remove oil baffle bolts a
56. before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until seal is flush with outer diameter of piston FIGURE 153 Install spacer clutch piston spring FIGURE 151 Install inner piston sealing ring FIGURE 154 Install Belleville spring 5 assembly 120 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of 2nd clutch drum FIGURE 158 Install one outer half disc with friction material down FIGURE 156 Install one outer half disc with friction material away from piston FIGURE 159 Install end plate FIGURE 157 Install one steel disc Alternate friction and steel FIGURE 160 Install end plate retaining ring discs until proper amount of discs are installed First and last discs are steel TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 121 Reassembly of REV clutch drum Reassembly of REV clutch drum FIGURE 161 Install piston inner seal on shaft FIGURE 165 Compress return spring and install snap ring FIGURE 162 See Cleaning and Inspection on page 91 Install clutch piston outer seal ring and size as explained NOTE Ring must be sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate
57. clutch gear up to 248 F 120 discs are steel C and align the splines on clutch gear with internal splines of steel discs DO NOT FORCE THIS OPERATION Gear splines must be in full position with internal teeth of all inner discs uium FIGURE 213 Install end plate retaining ring 132 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of 3rd clutch drum Reassembly of 3rd clutch drum P E s n FIGURE 217 See Cleaning and Inspection on page 91 Install clutch piston outer seal Seal must be sized FIGURE 220 Compress spring and install clutch piston spring retainer snap ring Be sure ring is in full position in groove E en NOTE Ring mustbe sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until seal is flush with outer diameter of piston M FIGURE 221 Install one outer half disc with friction material away from piston FIGURE 218 Install clutch piston spring spacer TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 133 Reassembly of 3rd clutch drum FIGURE 222 Install one steel disc Alternate friction and steel FIGURE 225 Install end plate retaining ring discs until proper amount of discs a
58. clutch gear with internal teeth of steel discs DO NOT FORCE THIS OPERATION Gear splines must be in full position with internal teeth of all inner discs i t E A ES _ 4 ji tif P j Uu Ve _ cari 4 4 FIGURE 274 Warm bearing to 248 F 120 C and install z i bearing with snap ring groove down M La Em FIGURE 271 Install output shaft gear assembly 18 LU MR Er m FIGURE 272 Warm gear 44 to 266 F 130 C and install on 2nd REV clutch shaft FIGURE 275 Install bearing retaining snap ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 145 Reassembly of transmission i a E KAERRA g d n era L F i 4 uie FIGURE 276 Install clutch shaft sealing rings bearing EE de wn 3 FIGURE 277 Warm oear ard FWD clutch shaft 5 1 7 FIGURE 278 Install bearing spacer FIGURE 281 Install clutch shaft sealing rings 146 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission FIGU Install new gasket and clutch pressure 5 o rings tighten up to specified torque into o ring grooves ik FIGURE 286 Us
59. connected with the pump drive gear This pump drive gear is driven by the impeller hub gear Since the impeller hub gear is connected with the impeller cover the pump speed is in direct relation with the engine speed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 25 Range Clutches Range Clutches The turbine shaft driven from the turbine transmits power to the range clutches 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 external splines and friction discs with internal splines are alter nated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the oppo site direction as long as no pressure is present in that specific clutch To engage a clutch the current of the electronic controlled modulation solenoid should go from 0 to 1000 mA in order to change the pressure to the clutch from 0 to maximum pressure The oil under pressure will go through tubes and pas sages to the selected clutch shafts 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
60. e 5 Grade 8 Ibs ft Nem Ibs ft Nem 9 11 12 2 14 9 11 13 14 9 17 6 16 20 21 7 27 1 28 32 38 0 43 4 26 29 35 2 39 3 37 41 50 2 55 6 41 45 56 61 58 64 79 87 64 70 87 95 90 99 122 134 91 100 123 136 128 141 174 191 129 141 174 191 180 198 224 268 223 245 302 332 315 347 427 470 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation Lubricated Plated Screws COARSE PITCH TYPE OF BOLT Grade 8 8 Grade 10 9 Grade 12 9 Ibs ft Nem Ibs ft Nem Ibs ft Nem M5 x 0 8 3 7 4 4 5 6 5 2 5 9 7 8 5 9 7 4 8 10 M6 x 1 5 9 7 4 8 10 8 9 11 1 12 15 9 6 11 8 13 16 M8 x 1 25 14 8 18 4 20 25 22 1 25 8 30 35 25 8 29 5 35 40 M10 x 1 5 29 5 36 9 40 50 44 3 47 9 60 65 47 9 55 3 65 75 M12 x 1 75 50 55 68 75 74 81 100 110 85 96 115 130 M14x2 81 92 110 125 111 129 150 175 133 155 180 210 M16 x 2 125 140 170 190 177 203 240 275 207 236 280 320 M20 x 2 5 236 266 320 360 332 369 450 500 387 443 525 600 M24 x 3 420 479 570 650 590 664 800 900 664 774 900 1050 M30 x 3 5 848 959 1150 1300 1180 1328 1600 1800 1364 1549 1850 2100 M36 x 4 1475 1660 2000 2250 2028 2323 2749 3149 2397 2729 3249 3699
61. e two guide studs to assist the fitting of the rear 243 cover FIGURE 284 Install 2 suction tube bolts using Loctite 243 and FIGURE 287 Use spreading type snap ring pliers spread ears tighten to specified torque on 2nd REV shaft rear bearing retaining snap ring Holding snap ring open tap transmission case into place TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 147 Heassembly of transmission FIGURE 288 Tap dowel pins into rear cover and transmission FIGURE 291 Install output flange case FIGURE 292 Install o ring washer and nut FIGURE 289 Install rear cover to transmission case bolts and lockwashers Torque to specified torque p il EN eg FIGURE 293 Tighten nut to 250 300 Ibs ft 339 407 FIGURE 290 Pull Rev 2nd shaft to secure snap ring 148 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission FIGURE 294 Install new control valve inner gasket FIGURE 297 Use two 2 aligning studs and install control valve assembly Z TT Th UO FIGURE
62. ean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lint free absor bent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound Inspection The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts show ing indication of wear or stress will eliminate costly 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 or paper to protect them until installed OIL SEALS GASKETS AND RETAINING RINGS Heplacement of spring loaded oil seals gaskets and retaining rings are more economical wh
63. ecorded in Step 2 POM FIG 5 Does not apply to units having 3 intermediate drive plates See Figure 4 TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 20 EXTERNAL PLUMBING INSTALLATION Cooler Line Specifications e Minimum 19 mm 75 inch internal diameter for lines and fittings 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 From Transmission Out to Cooler From Cooler to Transmission In oo 50 TSM 0228 13 8 TE17 Full Control Valve Service Manual Dana Holding Corporation 21 SPEED SENSOR INSTALLATION GEAR ROTATION SENSOR WITH POSITION SIGN POINTING IN THE DIRECTION GEAR TEETH MOVEMENT 180 ROTATED SCREW 9 11 ff 12 15 INSTALL CLIP UNDER ANGLE X SEE TABLE TEIS I7 4209851 DEUTZ 2 PINS DRUM SPEED 45 DEGREES OUTPUT
64. en the unit is disassem bled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particu larly when being installed Cutting scratching or curling under the lip of the seal seriously impairs its efficiency At reas sembly lubricate rings and seals with Multipurpose Lithium Grease Grade 2 for axles and Automatic Transmission Fluid for transmissions GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use this process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 91 Inspection HOUSINGS COVERS AND CAPS Inspect housings covers and caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures 92 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Cont
65. g Hook on page 159 to lift converter and oil baffle from converter housing as an assembly FIGURE 8 Pry torque converter bearing from converter assembly as shown FIGURE 6 Converter housing oil baffle and sealing ring removed FIGURE 7 Remove torque converter bushing 3 10 Remove torque converter capscrews lockwashers 94 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of Transmission FIGURE 14 Remove filter adapter and gasket ur E 2 FIGURE 12 Oil baffle and sealing ring removed FIGURE 15 Remove charging pump cover bolts and lockwashers k Remove filter element TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 95 Disassembly of Transmission FIGURE 17 Remove charging pump adaptor capscrews and FIGURE 20 Remove pump assembly and o ring lockwashers ee m JUNE MT FIGURE 21 Remove aux pump drive cover plate bolts and FIGURE 18 Remove charging pump adaptor and gasket lockwashers OF a 2 1 E 3 C ac i ae FIGURE 19 Remove pump lockwashers FIGURE 22 Remove aux pump drive cover plate and gasket 96 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service M
66. he limit that is necessary for calibration mim When during the automatic transmission calibration the temperature becomes to low the APC200 display indicates the actual transmission temperature rri Engine RPM is to high according to the limit that is necessary for calibration DJ After being to low or to high the engine RPM is coming back into the correct boundaries for calibration Use the M button on the APC200 to go back to the HEAT mode and the S but When during the automatic transmission ton to trigger this mode Then warm up calibration the temperature becomes to the transmission again until the temper low the APC200 display indicates the ature is above 140 F 60 C Then go actual transmission temperature back to the automatic tuning mode by the M button and trigger this one again to continue calibration 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 18 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual DRIVE PLATE INSTALLATION Proper identification is determined by measuring the bolt circle diameter see dimension A in the illustration below and then ordering the appropriate drive plate kit from the table DRIVE PLATE AND WELD NUT ASSEMBLY 1
67. ing Corporation 69 Forward amp 3rd Group Forward amp 3rd Group 70 Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual 10 11 11 12 13 14 15 16 17 18 DESCRIPTION LOCK NUT RING RETAINING BEARING 6311 C3 SNAP RING EXTERNAL WASHER THRUST 78X55X5 THRUST BEARING NOT USED ON THIS MODEL BEARING NEEDLE ROLLER 60 55 30 SNAP RING WASHER THRUST WS 81111 PLATE END FWD PLATE END 3RD DISC CLUTCH OUTER HALF 3RD DISC CLUTCH INNER 3RD DISC CLUTCH OUTER 3RD ASSY SPRING DISC INCLUDING 5 WASHERS SPACER CLUTCH PISTON SPRING 3RD RING PISTON 56 X 2 5 ASSY CLUTCH PISTON 3RD INCL ITEMS 18 amp 19 N S S NOT SOLD SEPARATELY N I NOT ILLUSTRATED TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual ITEM 18A 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Forward amp 3rd Group ITEM DESCRIPTION SCREEN PART OF ITEM 18 AND 22 SEAL OUTER FWD AND 3RD PART OF ITEM 18 OR 22 ASSY SHAFT HUB DRUM AND PLUGS FWD amp 3RD RING PISTON ASSY CLUTCH PISTON FWD SPACER CLUTCH PISTON SPRING SPRING PISTON RETURN RETAINER SPRING DISC CLUTCH INNER FWD DISC CLUTCH OUTER FWD SEAL LIP RING SNAP HEAR BEARING WASHER BEARING SUP PORT BEARING RETAINING RING RING PISTON BEARING CLUTCH DRIVEN
68. l decrease pressure from 31 to 0 bar thus releasing the 1st clutch in a controlled manner At the same time the 2nd proportional valve is activated and will provide a pressure curve from O to 31 bar which will provide clutch overlap When the shift is finalized the 1st 3rd selector valve is deacti vated When 3rd clutch is selected the 1st 3rd selector valve is not activated The 2nd proportional valve will decrease pres sure from 31 to 0 bar thus releasing the 2nd clutch in a controlled manner At the same time the 1st 3rd proportional valve is activated and will provide a pressure curve from O to 31 bar which will provide clutch overlap Pressure Sensor The control valve also has a pressure sensor installed to monitor overlap on range clutches 28 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Transmission Controls Electric Solenoid Controls Gear Selector Valve Proportional Valve Clutches ____ 2d Neutral 1 1st 3rd 1st 3rd 1st 2nd FWD REV 190874 REV 2nd FWD REV 2nd REV 1st 3rd FWD REV 1st 3rd TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 29 Power Flows Activated Solenoids amp Hydraulic Circuits Power Flows Activated Solenoids amp Hydraulic Circuits Neutral 1st 30 e on LL lt cc CONVERTER
69. l on both sides with outer splines 2 friction plates friction material on one side with outer splines Start with one side friction plate metal against piston Then alternate separator and friction plates End with a one side friction plate metal against the end plate Clearance TE13 Min clearance 1 09 mm 0 043 Max clearance 2 70 mm 0 106 TE17 Min clearance 1 63 mm 0 064 Max clearance 3 46 mm 0 136 The friction and separator plates for FWD REV 1st amp 2nd 3rd are not the same NEVER mix plates with plates from other clutches TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 87 Transmission Assembly Instructions 2nd Clutch p TE13 5 separator plates with inner splines 4 friction plates friction material on both sides with outer splines 2 friction plates friction material on one side with outer splines TE17 6 separator plates with inner splines 5 friction plates friction material on both sides with outer splines 2 friction plates friction material on one side with outer splines otart with one side friction plate metal against piston Then alternately separator and friction plates End with a one side friction plate metal against the end plate Clearance TE13 Min clearance 1 63 mm 0 064 Max clearance 3 46 mm 0 136 TE17 Min clearance 1 82 mm 0 072 Max clearance 3 87 mm 0 152 The friction and separator plates for FWD
70. ly the parking brake and block the wheels 2 Putthe 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 158 F 70 C 4 Once the oil temperature reaches 158 F 70 C check maximum 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 158 F 70 by selecting neutral If maximum stall speed measured is below specifications it could indicate an engine or converter problem If maximum stall speed measure is above specifications it could indicate slipping clutches Transmission Pressure Checks Transmission problems can be isolated by the use of pressure tests When the stall test indicates slipping clutches then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure In addition converter charging pressure and transmission lubrication pressure can also be measured TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 47 Troubleshooting Procedures Mechanical and Electrical Checks Prior to checking any part of the system for hydraulic
71. n the APC200 display there can be two possible reasons e The calibration conditions are not fulfilled temperature is too low parking brake switched off the vehicle is moving engine rpm is too high or too low Acalibration error has occurred during the calibration This message starts with an E see CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS on page 18 By selecting REVERSE on the shift lever while the automatic calibration is performing the procedure will abort the auto matic calibration immediately and restart the APC200 This feature can be used when something goes wrong during the calibration procedure NOTE By aborting the automatic calibration the calibration is not finalized and needs to be done from the beginning 16 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Automatic Calibration Procedure HEATING UP THE TRANSMISSION BY USING THE HEAT MODE The HEAT mode allows to select forward reverse while the parking brake is activated without forcing neutral and will disable the inching and declutch function During the heat mode the highest gear is forced even when the shift lever is in a lower gear This combination allows the driver to heat up the transmission by going into stall HEAT mode can be activated in the same way automatic calibration mode is entered see ENTERING AUTOMATIC CALIBRATION MODE on page 15 Once tran
72. nd lockwashers FIGURE 43 Using the special tool see Output Shaft Lifting Hook on page 162 lift the output shaft assembly from case 2 FIGURE 46 Remove oil baffle 100 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of Transmission yi Tu ce EE FIGURE 49 Remove lower oil baffle plate FIGURE 52 Remove pump drive idler gear bolts and lockwashers TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 101 Disassembly of Transmission FIGURE 53 Remove pump drive idler gear and bearing as an assembly FIGURE 57 Remove pump drive gear bearing as FIGURE 54 Remove pump drive gear bolts and lockwashers assembly FIGURE 58 Remove pump drive gear bolts and lockwashers Dg FIGURE 55 Remove pump drive gear and bearing as assembly 102 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of Transmission FIGURE 59 Remove pump drive gear and bearing as an FIGURE 62 Remove converter housing to transmission case assembly bolts and washers FIGURE 63 Remove converter housing with a special tool see Case Lifting Hook on page 160 from transmission case 1 1 T a 7 T i 5 L 2 m Ia Do n B il a L Li i 4 a 1 3 uU Y
73. nd n Wawa SiS FIGURE 320 Install filter adaptor with Loctite 243 Tighten to specified torque using special tool ASO TE 8003100 see Filter Adaptor Tool on page 164 g FIGURE 323 Install baffle retaining ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 153 Heassembly of transmission FIGURE 325 Install drive plate bolts and lockwashers Tighten to specified torque 4 UI EL a Ce ine 1 8 2 A 8115 E 795 5 x b M RT E i NE 4 ac 1 1 MM e i FIGURE 326 Install speed sensor in converter housing and transmission case NOTE The other end of the speed sensor has to be connected to the transmission to function 154 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual TORQUE SPECIFICATIONS Lubricated or Plated Screws COARSE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 Ibs ft Nem Ibs ft Nem 8 10 10 8 13 6 9 11 12 2 14 9 12 16 16 3 21 7 26 30 35 2 40 7 23 25 31 2 33 9 33 36 44 7 48 8 37 41 50 2 55 6 52 57 70 5 77 3 57 63 77 85 80 88 108 119 82 90 111 122 115 127 156 172 113 124 153 168 159 175 216 237 200 220 271 298 282 310 382 420 FINE PITCH TYPE OF BOLT SIZE OF BOLT Grad
74. nd or property damage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part NEVER use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of unique tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither their safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various precautions that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may also damage the unit or render it unsafe It is important to understand that these precautions are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions Indicates an imminently hazardous situation which DANGER if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury
75. never 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 be accomplished in several manners and a degree of judgement must be exercised as to the method employed The following are considered the minimum steps to be taken 1 Drain entire system thoroughly 2 Disconnect and clean all hydraulic lines Where feasible hydraulic lines should be removed from machine for clean ing 3 Replace oil filter element 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 IMPORTANT NEVER use flushing compounds for cleaning purposes 5 Reassemble all components and use only type oil See chapter 4 1 1 Recommended lubricants Fill the transmission through filler opening until fluid comes up to FULL mark on transmission dipstick Remove filler plug and fill oil until FULL mark e Run engine two minutes at 500 600 RPM to prime torque converter and hydraulic line
76. o 25 30 Ibs ft 34 41 Nem Tighten nut to 200 250 Ibs ft 271 340 Nem Tighten nut to 200 250 Ibs ft 271 340 Nem V V V WV NW Seals must be pressed perpendicular upon shaft axis from converter side 90 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual CLEANING AND INSPECTION DANGER Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type and alkali cleaners Cleaning Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials Thoroughly dry all cleaned parts immediately by using moisture free compressed air or soft lint free absorbent wiping rags free of abrasive materials such as metal filings contaminated oil or lapping compound BEARINGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearings to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate the dry ing process HOUSINGS COVERS AND CAPS Cl
77. olding Corporation 19 TRANSMISSION TO ENGINE INSTALLATION 1 Remove all burrs from flywheel mounting face and FLYWHEEL H OUSING nose pilot bore Clean drive plate surface with sol vent Dry thoroughly MOUNT DIAL INDICATOR HERE 2 Check engine flywheel and housing for conformance to standards SAE 3 per SAE J 927 and J 1033 tol ENGINE erance specifications for pilot bore size pilot bore runout and mounting face flatness Measure and record engine crankshaft end play PILOT BORE 3 Install two 2 50 63 5 mm long transmission to fly wheel housing guide studs in the engine flywheel housing as shown Rotate the engine flywheel to align a drive plate mounting screw hole with the fly wheel housing access hole 4 Install a 4 00 101 6 mm long drive plate locating stud 3750 24 fine thread in a drive plate nut Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step 3 5 Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in Step 3 Locate transmission on flywheel housing 6 Align drive plate to flywheel and transmission to fly wheel housing guide studs Install transmission to flywheel housing screws Tighten screws to specified torque Remove transmission to engine guide studs Install remaining screws and tighten to specified torque CONVE
78. omplete system By analyzing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction which may occur in the system Transmission Problems TE13 amp TE17 power shift with torque converter transmission troubles fall into four general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems 4 Controller problems In addition to the mechanical and electrical components all of which must be in the proper condition and functioning correctly the correct functioning of the hydraulic circuit is most important Transmission fluid is the life blood of the transmission It must be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation to engage and hold the clutches from slipping and to cool and lubricate the working components Troubleshooting Procedures Input Shaft and Directional Clutch Problems Stall Test Do not operate the converter at stall condition longer than 30 seconds at one time shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached Excessive temperature 250 F 120 C maximum will cause damage to transmission clutches fluid converter and seals A stall test to identifies transmission converter or engine problems Use following procedure 1 Putthe vehicle against a solid barrier such as a wall and or app
79. p Drive Section amp Pressure Regulating Valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication This element can be compared to a centrifugal pump that picks up fluid at its centre and discharges it at the outer diameter The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque con verter This element receives fluid at its outer diameter and discharges it at its centre The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation will make the con verter to multiply torque The torque multiplication is function of the blading impeller turbine and reaction member and the converter output speed turbine speed The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM stall Therefore we can say that as the turbine shaft is decreasing in speed the torque multiplication is increasing The hydraulic pump is
80. piston until seal is flush with outer diameter of piston FIGURE 166 Install one steel disc Alternate friction and steel discs until proprer amount are installed First and last discs are steel FIGURE 163 Install clutch piston spring spacer 122 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of REV clutch drum FIGURE 167 Install new seal into backing plate and install plate FIGURE 170 Install reverse clutch gear with inner and outer bearing in clutch drum Warm the clutch gear up to 248 F 120 C and align the splines on clutch gear with internal teeth of steel discs DO NOT FORCE THIS OPERATION Gear splines must be in full position with internal teeth of all inner discs d zit w p s 1 Y i i i 1 FIGURE 171 Install outer bearing snap ring FIGURE 169 Install inner bearing retaining ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 123 Disassembly of 3rd clutch drum Disassembly of 3rd clutch drum FIGURE 175 Remove thrust bearing and spacer FIGURE 176 Remove 3rd clutch gear FIGURE 173 Remove 3rd shaft front bearing FIGURE 177 Remove 3rd clutch gear needle bearing FIGURE 174 Remove thrust bearing snap ring 124 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control V
81. poration TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual INTRODUCTION Foreword This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Spicer products Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight out lay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals adjustments as indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjust ments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when perform ing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana Spicer approved parts as listed in the appli cable service parts list should be used Use of will fit or non approved parts may endanger proper operation and per formance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts which are not supplied or approved by Dana IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS Safety Precautions To reduce the chance of personal injury a
82. re installed First and last disc are steel FIGURE 226 FIGURE 223 Install one outer half disc with friction material down FIGURE 227 Warm thrust washer to 248 F 120 C and install thrust washer FIGURE 224 Install end plate 134 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of 3rd clutch drum FIGURE 231 Install outer thrust bearing and thrust washer FIGURE 229 Install needle bearing FIGURE 230 Install 3rd clutch gear in clutch drum Align splines on clutch gear with internal teeth of steel discs DO NOT FORCE THIS OPERATION Gear splines must be in full position with internal teeth of all inner discs FIGURE 233 Warm bearing up to 248 F 120 C and install bearing TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 135 Reassembly of 3rd clutch drum FIGURE 234 Install bearing retaining ring 136 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of output shaft Disassembly of output shaft FIGURE 235 Use a bearing puller as shown to remove speed sensor gear bearing and spacer Be careful not to damage teeth on speed sensor gear FIGURE 236 FIGURE 237 Use a bearing puller and remove bearing TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 137 Reas
83. rol Valve Service Manual DISASSEMBLY amp REASSEMBLY Getting Started NCAUTION Cleanliness is of extreme importance in the repair and over haul of the transmission Before conducting repairs the exterior of the unit must be thoroughly cleaned to prevent dirt and foreign debris from entering the transmission NCAUTION When maintenance work requires welding disconnect both connectors from the APC200 and from the control valve unit before any welding is started NOTE CLUTCH RETURN SPRING PACKS ARE CERTIFIED ACCORDING TO COMPRESSION WEIGHT SPECIFICATIONS AND ARE PRE PACKED IN QUANTITIES TO REPAIR ONE 1 SPECIFIC CLUTCH The disc spring packs are to be used as complete assem blies and care should be taken not to intermix the individ ual disc springs with disc springs in another clutch or disc spring pack Each disc spring assembly is made up of selected springs to precisely match each part within this assembly Failure to replace all piston return springs can result in unequal deflection within the spring pack The result of this imbalance may adversely affect overall life of springs Disassembly of Transmission emove oil baffle retaining ring FIGURE 4 R FIGURE 1 Front view of the TE17 transmission 3 speed TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 93 Disassembly of Transmission FIGURE 5 Use special tool see Converter Liftin
84. rotation when the forward clutch is engaged TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 27 Transmission Controls Transmission Controls The transmission is controlled by the control valve refer to hydraulic diagrams for additional information The control valve assembly is mounted directly on the side of the rear cover The function of the control valve assembly is to direct oil under pressure to the desired directional and speed clutches Operation of the Valve Regulated pressure 377 450 PSI 26 31 bar is directed to the proportional valve and selector valves to activate the required clutches When activated the proportional valve will give an output pressure curve from 0 450 PSI 0 31 bar proportional to a cur rent from 0 mA to 1000 mA Dampers are used to dampen any hydraulic vibration Directional Selection When a direction forward or reverse is selected the required selector valve is activated for forward or reverse and the proportional valve will provide a pressure rise from 0 to 31 bar feeding the directional clutch with modulated pressure Range Selection When 1st clutch is selected the 1st 3rd selector valve is activated and the 1st 3rd proportional valve will provide a pres sure rise from 0 to 31 bar feeding the 1st clutch with modulated pressure When 2nd clutch is selected the 1st 3rd proportional valve wil
85. s e Recheck level of fluid in transmission with engine running at idle 500 600 RPM Add quantity necessary to bring fluid level to LOW mark on dipstick e HRHecheck with hot oil 180 200 F 82 2 93 3 C Adjust oil level to FULL mark on dipstick Hecheck all drain plugs lines connections etc for leaks and tighten where necessary Perform automatic calibration 14 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Automatic Calibration Procedure Automatic Calibration Procedure Introduction The APC200 firmware contains an automatic transmission calibration procedure which is able to optimize the shift quality of the transmission An automatic calibration has to be done When the vehicle is build at the OEM Every 2000 hours of transmission operation When an overhaul of the transmission is done When the transmission is repaired When the APC200 is replaced ENTERING AUTOMATIC CALIBRATION MODE The automatic calibration mode is entered by pressing the S button on the APC200 display for 15 seconds during power up Gade fl during power up keep for 15 seconds TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 15 Automatic Calibration Procedure PERFORMING AUTOMATIC CALIBRATION Before the automatic calibration can be started a number of conditions need to be fulfilled The parking brake on the
86. sembly of output shaft Reassembly of output shaft FIGURE 241 Warm bearing to 248 F 120 C and install bearing bearing FIGURE 240 Install spacer 138 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of pump drive Disassembly of pump drive FIGURE 242 Remove pump drive snap ring FIGURE 243 Remove bearing and support TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 139 Reassembly of pump drive Reassembly of pump drive FIGURE 245 Install snap ring 140 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of transmission Reassembly of transmission FIGURE 249 Install new gasket FIGURE 246 Install new oil seal FIGURE 247 Install new oil seal in baffle with special tool PN ASO 1700300 see Oil Baffle Seal Driver page 161 FIGURE 251 Install torque converter gear capscrews and lockwashers and tighten to specified torque FIGURE 248 Install oil seal baffle and new o ring on torque converter TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 141 Reassembly of transmission FIGURE 252 Install torque converter bearing Fe Va et FIGURE 253 Install torque converter bushing 977 845 e L 114141
87. tighten to specified torque FIGURE 75 Install rear oil baffle 106 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of 1st clutch drum and turbine shaft Disassembly of 1st clutch drum and turbine shaft FIGURE 82 Remove upper thrust bearing washer FIGURE 79 Using a bearing puller to remove bearing needle out shaft ri aerem Lt 3 ial FIGURE 83 Remove clutch gear y FIGURE 80 Use a bearing puller to remove bearing from shaft FIGURE 84 Remove needle bearings and spacer FIGURE 81 Remove snap ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 107 Disassembly of 1st clutch drum and turbine shaft FIGURE 86 Remove end plate retaining ring Do not bend or disform teeth FIGURE 90 Remove 1 one outer half disc FIGURE 87 Remove clutch disc end plate 108 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Disassembly of 1st clutch drum and turbine shaft FIGURE 91 Using a bearing puller to remove lower thrust FIGURE 94 Remove spring retainer and spring washer FIGURE 96 Remove clutch piston assembly FIGURE 93 Compress piston return spring and remove spring retainer snap ring TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 109 Disassembly of 1st clutch drum and t
88. tral amp Port 31 Regulator Pressure At 600 RPM minimum 377 PSI 26 bar minimum At 2650 RPM 450 PSI 31 bar maximum At 2200 RPM 24 3 GPM 92 1 l min minimum 1st clutch Port 41 2nd clutch Port 42 3rd clutch Port 43 Forward clutch Port 45 Clutch Pressure Reverse clutch Port 46 At 2200 RPM 377 435 PSI 26 30 bar clutch activated 0 3 PSI 0 0 2 bar clutch released Filter Bypass Valve Set at 65 2 PSI 4 5 bar Port 33 Lube Pressure 22 5 32 6 PSI 1 55 2 25 bar at 16 9 GPM 64 l min converter flow 1500 RPM Safety Valve 108 7 PSI 7 5 b Cracking Pressure Port 32 Pressure between 43 5 50 7 PSI 3 3 5 bar when transmission is stalled at full throttle and engaged in Fwd 3rd gear Converter Out Pressure All pressures and flows to be measured with oil temperature 180 200 F 82 93 C TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 11 Electrical Specifications Electrical Specifications FWD REV 1st 3rd 2nd Coil Resistance 7 250 at 68 F 20 FWD N REV 1st 3rd Coil Resistance 28 50 at 68 F 20 Proportional Valves Selection Valves Type Magneto resistive sensor Sensing Distance 0 0 07 0 1 8 mm Sensor Signal Generates a square current with a fixed amplitude changing between 7 and 14 mA Speed Sensor Material Silicon Tops e r Resistance 77 F 25
89. urbine shaft FIGURE 97 Remove inner piston ring from shaft FIGURE 100 Use bearing puller to remove bearing from shaft FIGURE 99 Remove lower sealing ring from turbine shaft 110 Dana Holding Corporation TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Reassembly of 1st clutch drum and turbine shaft Reassembly of 1st clutch drum and turbine shaft FIGURE 104 Install piston inner seal on shaft FIGURE 101 Warm bearing to 248 F 120 C and install on shaft FIGURE 105 See Cleaning and Inspection on page 91 Install clutch piston outer seal and install piston in clutch drum FIGURE 102 Install lower seal ring on shaft Ring mustbe sized before installing in clutch drum Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring Rotate piston until seal is flush with outer diameter of piston FIGURE 103 Install upper seal ring on shaft N EO FIGURE 106 Install return spring spacer TSM 0228 TE13 amp TE17 Full Flow Control Valve Service Manual Dana Holding Corporation 111 Reassembly of 1st clutch drum and turbine shaft FIGURE 110 Install one outer half disc with friction material away from piston FIGURE 111 Install one steel disc Alternate friction and steel discs until proper amount of discs are installed First and last disc are steel FIGURE 109 Install retaining ring

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