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1. TOP VIEW lifting eyes M16 x 2 thd port 42 l check port 2nd clutch pressure WER port 31 M10 x 1 thd check port clutch pressure o ring port ISO 6149 1 M10 x 1 thd o ring port ISO 6149 1 port port 35 check port solenoid pressure check port pump pressure M10 x 1 thd M10 x 1 thd o ring port ISO 6149 1 o ring port ISO 6149 1 port 43 ort 34 check port 3rd clutch pressure p M10 x4 thd check port lube pressure o ring port ISO 6149 1 a o ring port ISO 6149 1 port 41 port 11 check port 1st clutch pressure check port transmission out temperature M10 x 1 thd M10 x 1 thd o ring port ISO 6149 1 port 37 o ring port ISO 6149 1 check port safety valve pressure M10 x 1 thd o ring port ISO 6149 1 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 37 SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP HYDROSTATIC OIL PUMP CASE TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 38 SECTIONAL VIEWS AND PARTS IDENTIFICATION ETE IN E fe TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 39 SECTIONAL VIEWS AND PARTS IDENTIFICATION GRO
2. 14 Apply Loctite 243 to thread of accumulator nipple and tighten to 30 35 Ibs ft 41 47 N m 15 Tighten accumulator to 30 35 Ibs ft 41 47 N m 16 Tighten air breather to 25 30 lbs ft 34 41 N m 17 Tighten wiring harness nut to 4 6 lbs ft 6 8 N m 56 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual DISASSEMBLV AND REASSEMBLV ANWWARNING Use caution when installing snap rings Failure to complv can cause personal injurv FIGURE 4 Control valve assembiv removed NOTE Use caution to not lose the safetv valve spring and pop pet FIGURE 1 Remove filter element NOTE Itis recommended a small pan be used to catch the re maining oil FIGURE 6 Remove control valve to case gasket FIGURE 3 Remove control valve screws and lock washers 16 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 57 DISASSEMBLY OF TRANSMISSION CASE FIGURE 10 Use an impact wrench if available to loosen output flange nut output flange nut If impact wrench is not available use flange retainer bar to If impact wrench is not available use flange retaine
3. REAR VIEW port 21 from pump port 11 M48 x 2 thd to cooler o ring port ISO 6149 1 M26 x 1 5 thd connector AW accumulator volume 0 75 filler hole preload 12 6 bar oil level glass full e O O 5 SIE Ar oil level glass low FRONT VIEW air breather M48 x 2 thd o ring port ISO 6149 1 Magnetic drain plug M22 x 1 5 thd TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 35 CHECK POINTS RIGHT VIEW accumulator volume 0 75 prelaod 12 6 bar LEFT VIEW connector filter 36 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual CHECK POINTS
4. 54 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manua ASSEMBLY INSTRUCTIONS All lead in chamfers for oil seals piston rings and o rings must be smooth and free from burrs Inspect at assembly Lubricate all piston ring grooves and o rings with oil before assembly Apply a thin coating of grease between seal lips on lip type seals prior to assembly After assembly of parts using Loctite there must not be any free or excess material which might enter the oil circuit 1 Tighten oil filter to 22 28 lbs ft 30 38 N m 2 Add some grease to o ring before assembly 3 Add some grease to piston rings before assembly Slots of piston rings is not allowed to pass bores in housings 4 Teflon seals must be sized prior to assembly Add some grease to inner and outer diameter of clutch drum be fore assembly 5 1st clutch 9 separator plates with inner splines 8 friction plates friction material on both sides with outer splines 2 1 side friction plates friction material on 1 side with outer splines Start with one 1 side friction plate metal against piston then alternately separator and friction plate End with one 1 side friction plate metal side against end plate or disc spring Be sure disc spring is mounted as shown Clearance min Clearance 2 68mm max Clearance 5 87mm If clearance is more than 4 74 mm add one separ
5. 3 7 U e O OfO O of PUMP PRESSURE AND COOLER LINE SPECIFICATIONS e Minimum 15 mm 59 internal diameter for lines and fittings e Suitable for operation from ambient to 248 F 120 C continuous operating temperature e Must withstand 20 bar 290 PSI continuous pressure and with 40 bar 580 PSI intermittent surges e CONFORM SAE J1019 AND SAE J517 100RI O SUCTION LINE SPECIFICATIONS Minimum 32 mm 1 25 internal diameter for lines and fittings Suitable for operation from ambient to 248 F 120 C continuous operating temperature Must withstand 20 bar 290 PSI continuous pressure and with 40 bar 580 PSI intermittent surges Conform SAE J1019 and SAE J517 100RI 16 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual INSTALLATION DETAILS SPEED SENSOR LOCATION Speed Sensor Speed Sensor Motor 1 Motor 2 Speed Senor Output TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 17 OPERATION OF THE TRANSMISSION THE TRANSMISSION ASSEMBLV The transmission is composed of four main assemblies 1 The transmission charging pump mounted on the engine 2 The range clutches 3 The output section 4 The transmission control valve Do 9000 MOTOR II NE EC PRA 1 T 000 0000 o MOTORI THE TRANSMISSION CHARGING PUMP The transmission charging pump is direct driven by
6. FIGURE 102 Install one 1 half disc with friction material away from piston FIGURE 103 Install one 1 steel disc Alternate friction and steel discs until proper amount of discs is installed 76 Dana Holding Corporation FIGURE 104 Install one 1 half disc with friction material away from piston FIGURE 105 Install modulation spring with large diameter to wards the backing plate FIGURE 106 Install backing plate TSM 0221E 2 3 Transmission Service Manual REASSEMBLY 2ND CLUTCH FIGURE 107 Install backing plate retaining ring FIGURE 110 Warm bearings up to 248 F 120 C and install gear on shaft NOTE Clutch pack must be checked for clutch disc clearance See item 6 on page 54 Do not force the operation in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage FIGURE 108 k FIGURE 111 Install outer bearing thrust washer FIGURE 112 Install 2nd clutch shaft rear bearing retaining snap ring TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 17 REASSEMBLY 2ND CLUTCH FIGURE 113 Install 2nd clutch shaft rear bearing and tap be aring into place FIGURE 114 Install 2nd clutch shaft sealing rings FIGURE 115 Tap 2nd clutch shaft front bearing into place warming up to 248 F 120 C 78 Dana Holding Corporation TSM 0221E 2 3 Tr
7. lt pana gt SPICER Off Highway Products service Manual Transmission 2 3 TSM 0221 March 2013 CONTENTS TOWING OR PUSH STARTING eee 5 FOREWORD Se ee 6 SAFETY PRECAUTIONS aalge jasni ao O S OKI 7 CLEANING AND INSPECTION anna 8 EN 8 BEAR ww 8 UN 8 o en er O A 8 BEARING a a E 8 OIE SFAI S GASKETS EE 8 OPAR E EE 9 HOUSINGS COVERS EE 9 TECHNICAL SPECIFICATIONS u e N oti o ei dii 10 IDENTIFICATION OF THE UNIT ee sooo sr a e a 10 WEIGHT DIMENSIONS amp OIL CAPACITY EEN 10 PRESSURE AND TEMPERATURE SPECIFICATIONS i 11 EEFCTRICAL SPECIFICATIONS S00 0 a ae oe ee dd 11 HYDRAULIC COOLER LINE SPECIFICATIONS ss 12 SUCTION LINE SPECIFICATION ee 12 MAINTENANCE ee 13 DIL SPE IFICA TON l i A e 13 MAINTENANCE INTERVALS i la cae aK 13 ACCUMULATOR CHEO K EE 14 SERVICING MACHINE AFTER COMPONENTS OVERHAUL pe 15 INSTALLATION DETAILS EE 16 a adit 16 PUMP PRESSURE AND COOLER LINE SPECIFICATIONS ss 16 SUCTION LINE SPECIFICATIONS a cai 16 SPEED SENSOR LOCATION Pm nn eee 17 OPERATION OF THE TRANSMISSION ee 18 THE TRANSMISSION ASSEMBLY sse 18 THE TRANSMISSION CHARGING PUMP 00000000 vanno 18 THE RANGE CUTRE cardio ia 19 THE GU o le 20 THE TRANSMISSION CONTROL VALVE REFER TO HYDRAULIC DIAGRAM 7 770 21 POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS ee 23 23 NEUTRAL ACTIVATED SOLENOIDS ss 23 NEUTRAL CONTINUE de lee ecc kaa 24 EE A eel 25 1ST GEAR ACTIVATED SOLENOIDS ss 25 IST GEAR CONTINUED asi a aloe 26 AND
8. 2397 2729 3249 3699 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 96 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual PIPE PLUGS PIPE PLUGS THREAD SIZE lbs ft N m M10 x 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 lbs ft N m
9. REASSEMBLY 2ND GLUTG WEE 75 DISASSEMBLY SAD CLUTCH ur een meta 79 RIEASSEMBLX SRD CLUTCH srt ii 83 REASSEMBLY OF TRANSMISSION GAGE eri a l b ist 8 TORQUE SPEGIFICA WR ei LE 95 LUBRICATED OR PEATED SGREW nee A destained Sege 95 CEOARSE PNEH a me E i a 95 EINE PIPE Pla ia ode ita Sai in g ent ila ita ta ek i asa 95 COARSE PITON a ia 96 FINE PITO stas A 96 PIPE PLUGS do ee a io 97 SPECIAL TOOLS sn EE 98 ASEIY 20 GEAR RETAINER NUT SOGKE WEE 98 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual TOWING OR PUSH STARTING Before towing the vehicle be sure to disconnect both front and rear drivelines to avoid damage to the transmission during towing TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 5 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and in structions on the maintenance and repair of the SPICER OFF HIGHWAY product Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight outlav in personal attention and cost required to provide regular and proper lubrication inspection at stated inter vals and such adjustments as mav be indicated will be reimbursed manv times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation troubleshooting and adjustments it is urged that the mechanic studie
10. 1 16 27 5 7 7 9 1 8 27 L 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 94 61 3 4 14 40 45 94 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 5 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 0221E 2 3 Transmission Service Manual Dana Holding Corporation 9 SPECIAL TOOLS ASHY 20 GEAR RETAINER NUT SOCKET j4 0 0 ra 7 00 60 00 D77 00 0 10 98 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual
11. A is between 10 5 8 14 5 bar System pressure ACCUMULATOR EFFECT a gt A ENGINE ON ENGINE OFF Time pa BB Pressure A pre charge pressure of accumulator If no pressure port is available approximate the pre charge pressure by monitoring the pressure gauge in the vehicle cab during the test NOTE It is recommended the accumulator is tested after the unit is rebuilt or repaired 14 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission and its 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 whene ver repair or overhaul of one unit is performed the balance of the system must be considered before the job can be considered complete After the overhauled or repaired transmission has been installed in the machine the oil cooler and connecting hydraulic system must be thoroughly cleaned This can be accomplished in several manners and a degree of jud gement 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 cleaning 3 Replace oil filter element 4 The oil cooler must be t
12. All pressures and flows to be measured with oil temperature of 180 200 F 82 93 C Refer to TROUBLESHOOTING p 32 for check port identification ELECTRICAL SPECIFICATIONS Solenoid Forward Reverse 1st 2nd 3rd and modulation Coil resistance 12V 28 Q 2 Q Coil resistance 24V 93 Q 6 Q Speed sensor Type Inductive Sensing distance 0 0 6 mm 0 0 024 Coil resistance 1050 Q 100 O TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation TECHNICAL SPECIFICATIONS HYDRAULIC COOLER LINE SPECIFICATIONS Lines and fittings Minimum 59 15 mm internal diameter Continuous Operating Temperature Ambient to 248 F 120 C 20 bar 290 PSI continuous pressure and 40 bar 580 PSI intermittent surges Conformance SAE J1019 and SAE J517 100RI Continuous Pressure SUCTION LINE SPECIFICATIONS Lines and fittings Minimum 1 25 32 mm internal diameter Continuous Operating Temperature Ambient to 248 F 120 C 20 bar 290 PSI continuous pressure and 40 bar 580 PSI intermittent surges Conformance SAE J1019 and SAE J517 100RI Continuous Pressure 12 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual MAINTENANCE OIL SPECIFICATION Automatic Transmission Fluid ATF oil which only meets following specifications e ATF Elfmatic G3 e Texaco Texamatic 7045 e Shell Donax TA e Pennzoil MAINTENANCE IN
13. EA a a a e nit cee ly 27 2ND GEAR ACTIVATED SOLENOIDS ae ea ee ee 27 2ND GEAR CONTINUED an nm A O A 28 OD EAR Se ee 29 3RD GEAR ACTIVATED SOLENOIDS geet 29 dc Eee e TE 30 GEAR AND CLUTCH LAYOUT a Sa let E E EE Eaa eai 31 TROUBLESHOOTING ssssssossssssessssescscsessssescscscsssesseacacscsessasseecacscsesseaeaeecacsssesssessearansesesenaraeessaees 32 TROUBLESHOOTING PROCEDURE ca neusten eb ret tute leticia citados 33 TRANSMISSION PRESSURE CHECKS i 33 TROUBLESHOOTING PROCEDURE 0 34 TRANSMISSION PRESSURE CHECKS i 34 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 3 CHECK POINT Sii os 35 BETA i A EEA MA A 35 FRONI VIEW tad Ee 35 RIGHT MIEW a e g dt ee 36 PERI VE Ve eo 36 POPNE VI a Oe A A ee ee 3 SECTIONAL VIEWS AND PARTS IDENTIFICATION Lee eee ana MA nnnnnnnnnn nun 38 GROUPB HAYDROSTATIC OIL PUMP CASE EE 38 GROUP TRANSMISSION CASE smn ee 40 GROUP SRD SHAFT AND GEAR MOTOR E 42 GROUP SAD SHAFTAND GEAR MOTOR 2 E 44 GROUP T1S1 SHARTAND GEARS EE 46 GROUP OUTPUTSRAFT Se a a a a e Ea E E 48 GROUP CONTROL VALVE AND MOUNTING PARTS L rninn 50 GROUP CONTROL NAL B sas ca a 52 ASSEMBLY INSTRUCTIONS i aeaa ans 54 FRONT VIEW A a atti ea R 56 EEC 56 DISASSEMBLY AND REASSEMBLY ssnnunnnsnnonnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnan 57 DISASSEMBLY LOW HIST GEUTCH sun ee a 64 REASSEMBEY LOW IST BEUTER me a see ea 67 DISASSEMBLY 2ND CEUTO HY net ed ee 71
14. NOTE Clutch pack must be checked for clutch disc clearance See item 5 on page 54 Do not force the operation in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage fa ln FIGURE 71 Install clutch gear inner bearing retaining ring FIGURE 74 Install outer bearing thrust washer TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 69 REASSEMBLY LOW 1ST CLUTCH FIGURE 76 Install low shaft front bearing inner race 70 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual DISASSEMBLY 2ND CLUTCH DISASSEMBLY 2ND CLUTCH FIGURE 77 Remove clutch shaft piston rings li _ d FIGURE 78 Remove clutch shaft rear bearing W s D Li LA FIGURE 79 Remove clutch shaft rear bearing retaining ring TSM 0221E 2 3 Transmission Service Manual FIGURE 82 Clutch gear and outer bearing removed Dana Holding Corporation 71 DISASSEMBLY 2ND CLUTCH FIGURE 83 Remove clutch gear inner bearing FIGURE 86 Remove backing plate FIGURE 87 Remove modulation spring FIGURE 85 Remove backing plate retaining ring FIGURE 88 Remove one 1 outer half disc 12 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY 2ND CLUTCH FIGURE 92 Remove belleville washer disc springs See note in Figure 56 FIGURE 93 Remove clutch piston
15. checking the transmission clutches charging pump and hydraulic circuit for pressure and rate of oil flow it is important to make the following transmission fluid check Check oil level in the transmission The transmission fluid must be at the correct full level All clutches and 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 C TO OBTAIN COR RECT FLUID LEVEL AND PRESSURE READINGS NEVER MAKE THESE CHECKS WITH COLD OIL TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 33 TROUBLESHOOTING PROCEDURE TROUBLESHOOTING PROCEDURE Refer to the following troubleshooting guide for the diagnosis of tvpical transmission troubles TRANSMISSION PRESSURE CHECKS LOW CLUTCH PRESSURE LOW CHARGING PUMP OUTPUT CAUSE REMEDV Low oil level Fill to proper level Defective charging pump Replace pump OVERHEATING CAUSE REMEDV Worn charging pump Replace charging pump Low oll level Fill to proper level Dirtv oil cooler Clean cooler Restriction in cooler lines Change cooler lines 2ND SLIPPING CLUTCH CAUSE REMEDY 2nd clutch is slipping during shifting Check accumulator 34 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual CHECK POINTS
16. should be exercised to avoid skin rashes fire hazards and inhalation of vapours when using solvent type cleaners BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubri cant 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 bearing to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate drying process HOUSINGS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the 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 Care should be exercised to avoid inhalation of vapours and skin rashes when using alkali cleaners All parts cleaned must be thoroughiv dried immediately by using moistere free compressed air or soft lintless ab sorbant wiping rags free of abrasive materials such as metal fillings contaminated oil or lapping compound INSPECTION The import
17. 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 en gine and transmission Air clean the radiator if necessary HYDRAULIC CHECKS Also before checking the transmission clutches 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 e All clutches 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 C TO OBTAIN COR RECT FLUID LEVEL AND PRESSURE READINGS NEVER MAKE THESE CHECKS WITH COLD OIL Transmission problems can be isolated by the use of pressure tests In addition charging pressure and transmis sion lubrication pressure can also be measured Priorto checking any part of the system for hydraulic function pressure testing the following mechanical and elec trical checks should be made e The controls are actuated electrically Check the wiring and electrical components e Be sure 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 Also before
18. the engine which is supplying oil to the control valve NOTE The transmission charging pump is customer mounted and is not supplied bv Dana Off Highwav 18 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual OPERATION OF THE TRANSMISSION THE RANGE CLUTCHES The range clutches 1st 2nd amp 3rd 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 inter nal splines are alternated until the required total is achieved A back up plate is then inserted and secured with a retainer ring A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch To engage the clutch a solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts Oil sealing rings are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the piston and discs against the back up plate The discs with splines on the outer dia meter 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 rel
19. 298 282 310 382 420 FINE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 lbs ft Nem lbs 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 0221E 2 3 Transmission Service Manual Dana Holding Corporation LUBRICATED OR PLATED SCREW COARSE PITCH TVPEOF BOLT SIZE OF BOLT Grade 8 8 Grade 10 9 Grade 12 9 lbs ft Nem lbs ft Nem lbs 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 M14 x2 81 92 110 125 111 129 150 175 133 155 180 210 M16x2 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 M24x3 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
20. EAR ACTIVATED SOLENOIDS CON ONG 1S TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 29 POWER FLOWS SOLENOIDS 8 HYDRAULIC CIRCUITS 3RD GEAR CONTINUED OE 5 EB x 5 ir l a gt 5 2 e aS E SVA S d MODULATION SOLENOID 3FD GEARSELECTED 243 TRANSMISSION HYDRAULIC DIAGRAM SOLENOID PRESSURE B 8 sS w s FE S WV ERS F 2 2 a tal a a i a gt m OE 2 e A dy E c fu E s O Gs 3 S sz E 2 2 a FE m ges O fi 30 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual GEAR AND CLUTCH LAYOUT GEAR AND CLUTCH LAYOUT lt K TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 31 TROUBLESHOOTING The following information is presented as an aid to isolating and determining the specific problem area in a tran smission that is not functioning correctiv When troubleshooting a transmission problem it should be kept in mind that the transmission is only the central unit of a group of related powertrain components Proper operation of the transmission depends on the condition and correct functioning of the other components of the group Therefore to properly diagnose a suspected pro blem in the transmission it is necessary to consider the transmission fluid charging pump transmission assembly oil cooler filter connecting li
21. Ez gt 3 E fa SES j o 5 u B MODULATION 1ST GEAR SELECTED SAFTY VALVE 243 TRANSMISSION HYDRAULIC DIAGRAM SOLENOID PRESSURE CONTROL VALVE 3 NE Ek gt s a z u ATA MAD 1 L u D 5 S E ES CE Soz S SSE 7 F PE S OS FE O Es 26 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS 2ND GEAR oo oo Oo MOTORI li Sall I TAR er oo o s zi 90009 o MOTOR 2ND GEAR ACTIVATED SOLENOIDS TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 2 POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS 2ND GEAR CONTINUED d OE as U E SE Ben 5 du sE LOPS 2 E o SE 3 E a 2 E 5 3 J MODULATION 2ND GEARSELECTED SAFTY VALVE 2 3 TRANSMISSION HYDRAULIC DIAGRAM SOLENOID PRESSURE HIGH PRESSUFE CONTROL VALVE REGULATOR VALVE14 2 23 1bar BV PASSVALVE SCREEN Th HOSE Dar HOSE al PRESSURE E TEMPERATURE GAUGE AIR BREATHER TON FILTER Es OIL SUMP ACCUMULATOR PRELOAD 12 6 bar VOLUME0 75 L OPERATORCOMPARIMENT PRESSURE GAUGE 28 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS 3RD GEAR MOTOR II MOTOR 3RD G
22. SPECTION GEARS amp SHAFTS If Magna Flux process is available use process to check parts Examine teeth on all gears carefully for wear pit ting chipping nicks cracks or scores If gear teeth show spots where case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts and quills to make certain they are not sprung bent or spline twisted and that shafts are true HOUSINGS COVERS ETC Inspect housings covers and bearing caps to ensure they are thoroughly clean and mating surfaces bearing bo res etc are free from nicks or burrs Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 9 TECHNICAL SPECIFICATIONS SPICER OFF HIGHWAY TEN BRELE3 B 8200 BELGIUM IDENTIFICATION OF THE UNIT 1 Model and type of the unit 2 Serial number WEIGHT DIMENSIONS amp OIL CAPACITY WEIGHT DIMENSIONS OIL CAPACITY Weight dry 285
23. TERVALS DAILY Check oil level daily with engine running at idle 750 RPM and oil at 180 200 F 82 93 C Maintain oil level at FULL mark NORMAL DRAIN PERIOD Normal drain period and oil filter change are for average environment and duty cycle conditions Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated de terioration and contamination For extreme conditions judgement must be used to determine the required change intervals e Every 1000 hours change oil filter e Every 1000 hours drain and refill system as follows Drain with oil at 150 200 F 65 93 C 1 Drain transmission 2 Remove and discard filter 3 Install new filter 4 Refill transmission to FULL mark 5 Run engine at idle 750 RPM to prime lines 6 Recheck level with engine running at 500 600 RPM and add oil to bring level to LOW mark When oil tempe rature 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 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 13 MAINTENANCE ACCUMULATOR CHECK 1 Start the engine when transmission oil is at maximum 86 F 30 C and wait until system pressure is reached 2 Turn engine off and keep monitoring system pressure 3 Check if pressure
24. THE TRANSMISSION O O O 0101 EX O N gt d O JK a OW On te rod 22 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual POWER FLOWS SOLENOIDS 8 HYDRAULIC CIRCUITS NEUTRAL oo oooo 20084 000 E je e ooo Zoe MOTORI NEUTRAL ACTIVATED SOLENOIDS TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 23 POWER FLOWS SOLENOIDS 8 HYDRAULIC CIRCUITS NEUTRAL CONTINUED d U te IH S Es Oe TE 3 5 z Os i D A S ES S d SAFTY VALVE NEUTRAL SELECTED 2 3 TRANSMISSION HYDRAULIC DIAGRAM a E S E u S 8 l E OE H SCH SES sl HS x E HOSE E PUMP TEMPERATURE GAUGE AIR BREATHER N ALTER L OILSUMP ACCUMULATOR PRELOAD 126 bar VOLUME0 75 L OPERATORCOMPARTMENT PRESSURE GAUGE 24 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS 1ST GEAR OTOR Il MOTOR 1ST GEAR ACTIVATED SOLENOIDS TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 25 POWER FLOWS SOLENOIDS amp HYDRAULIC CIRCUITS 1ST GEAR CONTINUED 98 E U BG Ee 2
25. TORQUE SPECIFICATIONS p 95 EN FIGURE 193 Tighten output shaft flange nut to 250 300 lbs FIGURE 196 Install valve to case gasket ft 339 407 N ml See item 11 on page 54 TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 93 REASSEMBLY OF TRANSMISSION CASE FIGURE 200 Position new sealing ring in accumulator Install accumulator with Loctite 243 to filter adapter and tighten to 45 50 Ibs ft 61 68 N ml See item 13 on page 54 M D D Ce A gt e P La FIGURE 198 Use alignment studs to install valve assembly to housing AN Use caution as not to damage safety valve spring and pop lat pet FIGURE 201 Install new oil filter Tighten filter to 22 28 Ibs ft 30 38 N m See item 1 on page 54 FIGURE 199 Install screws 16 and lock washers Tighten to specified torque See TORQUE SPECIFICATIONS p 95 94 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual TORQUE SPECIFICATIONS LUBRICATED OR PLATED SCREW COARSE PITCH TYPE OF BOLT SIZE OF BOLT Grade 5 Grade 8 lbs ft Nem lbs 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
26. UP TRANSMISSION CASE 40 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SECTIONAL VIEWS AND PARTS IDENTIFICATION TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 41 SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP 3RD SHAFT AND GEAR MOTOR 1 2 42 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SECTIONAL VIEWS AND PARTS IDENTIFICATION TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 43 SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP 3RD SHAFT AND GEAR MOTOR 2 22 A Ya A N SA e N N ns N A N N 44 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SECTIONAL VIEWS AND PARTS IDENTIFICATION TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 45 SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP 1ST SHAFT AND GEARS 46 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SECTIONAL VIEWS AND PARTS IDENTIFICATION ITEM DESCRIPTION Assembly 1st shaft hub drum and plug Piston Clutch gt GT TEE A S Seal Clutch piston inner A AI fl TS gt gt gt CAC bom T E I boom ON E Sam OC Z see E CI ON T EE 7 nn E CAC ON E Semo omenen 9 DEn gt A 1 2 mom a C z mme zs E zs DE flo Mo 7 pmo z oom z ao 0 ema TSM 0221E 2 3 Transm
27. ance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 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 automatic transmission fluid and wrap in clean lintless cloth or paper to protect them until installed OIL SEALS GASKETS ETC Replacement of spring load oils seals o rings metal sealing rings gaskets and snap rings is more economical when the unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling un der of lips of seals seriously impairs its efficiency When assembling new metal type sealing rings these should be lubricated with a coat of chassis grease to stabi lise rings in their grooves for ease of assembly of mating members Lubricate all o rings and seals with recommen ded type automatic transmission fluid before assembly 8 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual CLEANING AND IN
28. ansmission Service Manual DISASSEMBLY 3RD CLUTCH DISASSEMBLY 3RD CLUTCH PP FIGURE 120 Remove 3rd clutch gear and outer bearing FIGURE 117 Remove 3rd clutch shaft rear bearing FIGURE 118 Remove spacer TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 79 DISASSEMBLY 3RD CLUTCH FIGURE 122 Remove clutch gear inner bearing FIGURE 125 Remove modulation spring FIGURE 123 Remove backing plate retaining ring FIGURE 126 Remove one 1 outer half disc FIGURE 124 Remove backing plate FIGURE 127 Remove inner and outer discs 80 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY 3RD CLUTCH 2 i ma uu FIGURE 128 Remove one 1 outer half disc FIGURE 129 Compress clutch piston belleville washer FIGURE 132 Remove clutch piston spring and remove spring snap ring ANWARNING Use caution when installing snap rings Failure to complv can cause personal injurv FIGURE 133 Remove 3rd clutch shaft front bearing FIGURE 130 Remove belleville washer disc springs See note in Figure 56 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 81 DISASSEMBLY 3RD CLUTCH FIGURE 134 Remove 3rd clutch shaft front bearing thrust washer 82 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY 3RD CLUTCH REASSEMBLY 3RD CLUTCH i A i
29. ator plate upon last separator plate 6 2nd clutch 5 separator plates 4 friction plates and two 1 side friction plates Assembly see item 5 Clearance min Clearance 1 47mm max Clearance 3 78mm If clearance is more than 3 53mm add one separator plate upon last separator plate 7 3rd clutch 4 separator plates 3 friction plates and two 1 side friction plates Assembly see item 5 Clearance min Clearance 1 18mm max Clearance 3 27mm lf clearance is more than 3 24mm add one separator plate upon last separator plate ANWARNING Installation force of disc springs is 4410N 1 8 Clutch spring concave side of first disc spring to be placed against clutch piston wear sleeve Remaining springs to be stacked alternatelv reversed as shown 9 Be sure shielded and sealed bearings are mounted as shown 10 Seals must be pressed in perpendicular upon axis from bearing side 11 Tighten output flange nut to 250 300 Ibs ft 339 407 N m 12 Tighten gear retaining nut to 125 147 Ibs ft 170 200 N m 13 Apply Loctite 243 to thread of filter adaptor and tighten adaptor to 45 50 lbs ft 61 68 N m TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 55 ASSEMBLY INSTRUCTIONS FRONT VIEW REAR VIEW
30. ch shaft rear bearing snap ring Fi FIGURE 27 Remove 1st clutch shaft rear bearing inner race FIGURE 30 Remove low clutch shaft seal rings TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 61 DISASSEMBLY OF TRANSMISSION CASE FIGURE 31 Remove retainer nut Use special tool ASHY 20 Gear Retainer Nut Socket p 98 A FIGURE 32 Retainer nut removed A FIGURE 33 Remove output drive gear 62 Dana Holding Corporation Na MAL Zem A ili lt Ei 1 Ko FIGURE 36 Lift 1st shaft to be able to remove 2nd and 3rd a i gt a clutch TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY OF TRANSMISSION CASE 5 n di 1 FIGURE 40 If output shaft rear bearing has to be replaced remove bearing retaining ring FIGURE 38 Remove oil baffle lt FIGURE 39 Remove 1st shaft rear bearing outer race from transmission case TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 63 DISASSEMBLY LOW 1ST CLUTCH DISASSEMBLY LOW 1ST CLUTCH I a FIGURE 41 Using puller remove low shaft front bearing in ner race ie FIGURE 42 Low shaft front bearing inner race removed DE FIGURE 43 Remove front bearing retainer ring 64 Dana Holding Corporation FIGURE 44 Remove clutch gear outer bearing thrust washer mam FIGURE 45 Remove clutch gear and outer bearing FIGURE 46 Clutch gear and oute
31. eased a return spring will push the piston back and oil will drain back via the shift spool or holes in the clutch piston into the transmission sump 0000 MOTORII B o Wl el Pree MOTORI TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 19 OPERATION OF THE TRANSMISSION THE OUTPUT SECTION With a range clutch engaged power is transmitted from the motor s to the output shaft oo oooo MOTORI 8 Eu WMD JU Ces 000 LL 000 290 MOTORI 20 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual OPERATION OF THE TRANSMISSION THE TRANSMISSION CONTROL VALVE REFER TO HVDRAULIC DIAGRAM The transmission is controlled bv the control valve The control valve assembiv is mounted directiv on the top of the transmission housing The function of the control valve assembiv is to direct oil under pressure to the desired clutch OPERATION OF THE VALVE The control valve receives oil from the transmission charging pump In the control valve a pressure regulating valve maintains the oil pressure for actuating the range clutches This requires a small portion of the total volume of oil used in the svstem The remaining volume of oil is directed through the oil cooler and returns to the transmission for positive lubrication The 1st clutch can be closed by activating the 1st solenoid The 1st solenoid will then allow pilot pressure to mo
32. egulator and filter bypass LT CI CN y moo CA mmm mm E ows o p Z E r 7 cr r T me p omme CI oem CI 1 om ooo p CC p A 2 EC ewone A po o o Seam 1 m po QO O OOI OJI O N N N N N N NI N N N N a a oy NJ Bi wo bM i ch IO 010 ns Oil BR OINI O TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 53 ASSEMBLY INSTRUCTIONS LA SI O Co lt CO u
33. horoughly 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 co oler 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 the oil type defined on page 13 Fill the transmission through filler opening until fluid comes up to FULL mark on transmission Remove filler plug and fill oil up to the FULL mark Run engine two minutes at 700 800 RPM to prime the hydraulic lines and the oil cooler Recheck level of fluid in transmission with engine running at idle 700 800 RPM Add quantity necessary to bring fluid level to LOW mark Recheck with hot oil 180 200 F 82 2 93 3 C Adjust oil level to FULL mark 6 Recheck all drain plugs lines connections etc for leaks and tighten where necessary TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 15 INSTALLATION DETAILS EXTERNAL PLUMBING From transmission out to cooler Transmission cooler Oil pump From cooler to transmission in O J O AO o f O O O O O O O O ES
34. i i d FIGURE 138 Install clutch piston wear sleeve e ca See item 8 on page 54 FIGURE 139 Install piston return springs First spring with larger diameter of bevel towards wear slee ve See Figure 106 Alternate seven 7 springs See note Figure 56 FIGURE 135 Refer to CLEANING AND INSPECTION p 8 The bleed hole in the piston must be clean and free of any fo reign material Install clutch piston outer seal Size as descri bed in Figure 59 FIGURE 136 Install clutch piston inner seal and size as de scribed in Figure 59 u FIGURE 140 Compress spring to install spring retainer ring FIGURE 137 Position piston in low clutch drum as shown NOTE Use caution as not to damage inner and outer piston sealing Be sure ring is in full position in groove rings TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 83 REASSEMBLY 3RD CLUTCH spacer piston AT Ia i FIGURE 143 Install one 1 outer half disc with friction mate rial down FIGURE 141 Install one 1 outer half disc with friction mate rial away from piston FIGURE 144 Install modulation spring with large diameter up to the backing plate FIGURE 142 Install one 1 steel disc Alternate friction and steel discs until proper amount of discs are installed First and last disc are steel FIGURE 145 Install backing plate 84 Dana Hold
35. ing Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY 3RD CLUTCH il FIGURE 146 Install backing plate retaining ring FIGURE 149 Install 3rd clutch gear outer bearing retaining ring mes NOTE Clutch pack must be checked for clutch disc clearance See item 7 on page 54 FIGURE 151 Install 3rd clutch shaft rear bearing FIGURE 148 Warm bearings up to 248 F 120 C and install gear on shaft Do not force the operation in this step Gear splines must be aligned with internal teeth of all friction discs Failure to comply may cause equipment damage TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 85 REASSEMBLY 3RD CLUTCH BE la FIGURE 152 Install 3rd clutch shaft sealing rings FIGURE 153 Install 3rd clutch shaft front bearing thrust wa sher FIGURE 154 Install 3rd clutch shaft front bearing 86 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY OF TRANSMISSION CASE REASSEMBLY OF TRANSMISSION CASE TN d de FIGURE 158 Position oil baffle into transmission case FIGURE 156 Install output shaft rear bearing outer race re taining ring FIGURE 159 Install oil baffle screws and lock washers Tighten screws to specified torque see TORQUE SPECIFI CATIONS p 95 la FIGURE 157 Position new output shaft rear oil seal in tran N k d smission case FIGURE 160 Install low shaft gear bearing outer
36. ission Service Manual Dana Holding Corporation 47 Z e I L O Z LLI p I Cc L a O Z L o gt 1 L Z I e LLI ge GROUP OUTPUT SHAFT TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 48 SECTIONAL VIEWS AND PARTS IDENTIFICATION TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 49 Z e I L O Z LLI p I Cc L a O Z lt U gt 1 L Z I e LLI ge GROUP CONTROL VALVE AND MOUNTING PARTS Ono 9 o gt 0 0 745 TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 50 SECTIONAL VIEWS AND PARTS IDENTIFICATION Lock washer Control valve to adaptor plate screw Lock washer Control valve to transmission 16 case screw TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 51 Z e I L e Z LLI Q dp I ma L a a Z L o gt l L Z e I O LLI ge GROUP CONTROL VALVE 7 fi OD 0 30 D de N ong ji i OD 9 TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 92 SECTIONAL VIEWS AND PARTS IDENTIFICATION ITEM DESCRIPTION Body Spool Spool Pressure reducer y Spool Pressure reducer EOI hlllf mra Spring Lube r
37. kg 627 Ib Maximum length 576 8 mm 22 71 inches Maximum height 713 0 mm 28 07 inches Oil capacity 11 2 9 US Gallon without cooler and hydraulic lines 10 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual TECHNICAL SPECIFICATIONS PRESSURE AND TEMPERATURE SPECIFICATIONS Normal operating temperature 158 248 F 70 120 C measured at temperature check port converter out port 71 Maximum allowed transmission temperature 248 F 120 C Regulator Pressure Vehicle in Neutral amp Port 31 At 700 RPM engine 17 bar 247 PSI minimum At 2200 RPM engine 23 1 bar 835 PSI maximum Pump flow At 750 RPM engine 10 7 l min minimum 2 8 GPM At 2000 RPM engine 34 2 l min minimum 9 0 GPM At 2200 RPM engine 49 4 l min minimum 13 GPM Clutch pressures 1st clutch port 41 2nd clutch port 42 3rd clutch port 43 At 700 RPM 14 2 bar 206 PSI minimum if clutch activated At 2200 RPM 18 3 22 3 bar 265 323 PSI minimum if clutch activated 0 0 2 bar 0 3 PSI minimum if clutch released Solenoid pressure 8 5 11 5 bar 123 167 PSI Filter bypass valve set at 4 1 4 5 bar 59 65 PSI Lube pressure Port 33 0 8 1 1 bar 12 16 PSI at 22 6 I min 6 GPM pump flow Safety valve cracking pressure 6 5 10 bar 94 145 PSI Cooler bypass 4 1 6 4 bar 59 93 PSI
38. nes and controls including the engine as a complete 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 The 2 3 transmission troubles fall into three general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical problems In addition to the mechanical and electrical components all of which must be in the proper condition and functio ning 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 pres sures to engage and hold the clutches from slipping and to cool and lubricate the working components 32 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual TROUBLESHOOTING PROCEDURE TROUBLESHOOTING PROCEDURE TRANSMISSION PRESSURE CHECKS Transmission problems can be isolated by the use of pressure tests In addition charging pressure and transmis sion lubrication pressure can also be measured MECHANICAL AND ELECTRICAL CHECKS Prior to checking any part of the system for hydraulic function pressure testing the following mechanical and elec trical checks should be made e The controls are actuated electrically Check the wiring and electrical components e Be sure all components of
39. ngs 2 TSM 0221E 2 3 Transmission Service Manual REASSEMBLY OF TRANSMISSION CASE FIGURE 179 Install output shaft gear retaining ring FIGURE 182 The use of two 2 aligning studs will facilitate aligning the transmission case to the motor case FIGURE 180 Install output shaft gear bearing inner race war ming up to 248 F 120 C FIGURE 183 Align clutch shaft bearings with bearing bores in the case housing Tap lightly in place Use caution as not to damage oil sealing rings Remove aligning studs FIGURE 181 Position new gasket on motor case A thin coat of chassis grease will hold the gasket in place FIGURE 184 Install dowel pins 2 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 91 REASSEMBLY OF TRANSMISSION CASE fi ya FIGURE 185 Install case to case screws and lockwashers FIGURE 188 Install rear output flange o ring washer and Tighten screws to specified torque See TORQUE SPECIFI locknut CATIONS p 95 FIGURE 189 Tighten output shaft flange locknut to 250 300 lbs ft 339 407 N m See item 11 on page 54 FIGURE 187 Install output front spacer FIGURE 190 Install output front spacer 92 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual REASSEMBLY OF TRANSMISSION CASE FIGURE 192 Install front output flange o ring washer and FIGURE 195 Install cover screws and lock washers Tighten locknut to specified torque See
40. nner seal and size as descri bed in Figure 59 TSM 0221E 2 3 Transmission Service Manual FIGURE 61 Position piston in low clutch drum as shown Use caution as not to damage inner and outer piston sealing rings FIGURE 62 Install clutch piston wear sleeve See item 8 on page 54 FIGURE 63 Install piston return springs First spring with larger diameter of bevel towards wear slee ve See Figure 65 Alternate thirteen 13 springs See note Fi gure 56 Dana Holding Corporation 67 REASSEMBLY LOW 1ST CLUTCH i gt FIGURE 64 Compress spring to install spring retainer ring FIGURE 66 Install one steel clutch plate Alternate friction and steel discs until the proper amount of discs are installed NOTE NOTE Be sure ring is in full position in groove First and last disc are steel NAAN Se spacer piston FIGURE 67 Install one 1 outer half disc with friction material down FIGURE 65 Install one 1 outer half clutch disc with friction h material away from piston FIGURE 68 Install modulation spring with large diameter up towards the backing plate 68 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY LOW 1ST CLUTCH FIGURE 69 Install backing plate FIGURE 70 Install backing plate retaining ring FIGURE 73 Warm bearings up to 248 F 120 C and install gear on shaft
41. purpose Accordingly anyone who intends to use a spare parts service procedure or tool which is not recommended by SPICER OFF HIGHWAY PRODUCTS must first determine that neither his safety nor the safe operation of the ma chine will be jeopardized by the spare part service procedure or tool selected IMPORTANT This manual contains various cautions and notes that must be carefully observed in order to reduce the risk of personal injury during service or repair or the possibility that improper service or repair may damage the unit or render it unsafe It is also important to understand these cautions and notes are not exhaustive because it is impossible to warn about all the possible hazardous consequences that might result from failure to follow these instructions WARNING under no circumstances should this plate be removed It holds shifting spools under heavy spring load and could cause personal injury A WARNING under no circumstances should welding soldiering or any mechanical work be carried out on this accumulator TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 7 CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned Care
42. r bar to prevent companion flange from turning prevent companion flange from turning L FIGURE 8 Remove output flange rear o ring washer and FIGURE 11 Remove output flange front o ring washer and nut nut FIGURE 9 Remove output spacer FIGURE 12 Remove output spacer 58 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY OF TRANSMISSION CASE FIGURE 17 Using prv slots provided prv transmission case from motor case tapping on the output shaft FIGURE 15 Support transmission case with a chain hoist Remove transmission case to motor case screws and lock FIGURE 18 Lift transmission case from motor case All washers drums and shafts remain in motor case TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 59 DISASSEMBLY OF TRANSMISSION CASE pn A FIGURE 22 Baffle plate screws and spacers removed FIGURE 20 Use bearing puller to remove output gear and FIGURE 23 Remove suction tube screws and lock washers rear bearing inner race FIGURE 24 Remove suction tube and o ring FIGURE 21 Remove baffle plate mounting screws and lock washers 60 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY OF TRANSMISSION CASE e FIGURE 25 Remove output shaft front bearing locating ring FIGURE 28 Remove snap ring retainer FIGURE 26 Remove output shaft and front bearing FIGURE 29 Remove low clut
43. r bearing removed TSM 0221E 2 3 Transmission Service Manual DISASSEMBLY LOW 1ST CLUTCH FIGURE 47 Remove clutch gear inner bearing FIGURE 48 Remove inner bearing retaining ring mn LI FIGURE 49 Remove backing ring plate retaining ring TSM 0221E 2 3 Transmission Service Manual FIGURE 51 Remove modulating spring Nu FIGURE 52 Remove one 1 outer half disc Dana Holding Corporation 69 DISASSEMBLY LOW 1ST CLUTCH a PE FIGURE 56 Remove belleville washer disc springs NOTE Do not mix disc springs with anv other disc springs as thev are matched spring packs FIGURE 54 Remove outer half disc FIGURE 55 Compress clutch piston belleville washer spring and remove snap ring FIGURE 58 Remove clutch piston Use caution when installing snap rings Failure to complv can cause personal injurv 66 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY LOW 1ST CLUTCH REASSEMBLY LOW 1ST CLUTCH FIGURE 59 Refer to CLEANING AND INSPECTION p 8 The bleed hole in the piston must be clean and free of any fo reign material Install clutch piston outer seal NOTE Ring must be sized before installing in the clutch drum Sizing is best accomplished by rotating clutch piston whi le holding a round object against the new sealing ring Rotate piston until seal is flush with outer diameter of pi ston FIGURE 60 Install clutch piston i
44. race See item 10 on page 54 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 8 REASSEMBLY OF TRANSMISSION CASE FIGURE 161 Position new output shaft front oil seal in motor FIGURE 164 Install 3rd driven gear with counter bore up case See item 10 on page 54 Y ty re FIGURE 166 Install output drive gear with counter bore up jo d FIGURE 163 Install 2nd and 3rd shaft assembly into motor case at the same time 88 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual REASSEMBLY OF TRANSMISSION CASE a FIGURE 167 Install output shaft and secure with output shaft FIGURE 170 Install baffle plate screws spacers and lock front bearing retaining ring washers gt FIGURE 171 Tighten screws to specified torque See TORQUE SPECIFICATIONS p 95 FIGURE 169 Install suction tube screws and lock washers TFT Tighten to specified torque See TORQUE SPECIFICATIONS FIGURE 172 Install output shaft gear p 95 TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 89 REASSEMBLY OF TRANSMISSION CASE FIGURE 174 Tighten gear retaining nut to 125 147 Ibs ft 170 200 N m See item 12 on page 63 using ASHY 20 Gear Retainer Nut Socket p 98 FIGURE 175 Install retaining ring 90 Dana Holding Corporation FIGURE 177 Install low shaft gear bearing inner race war ming up to 248 F 120 C FIGURE 178 Install piston ri
45. s the instructions in this manual carefully and uses it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only SPICER OFF HIGHWAV PRODUCTS appro ved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may en danger proper operation and performance of the equipment SPICER OFF HIGHWAY PRODUCTS does not warrant repair or replacement parts nor failures resulting form the use of parts which are not supplied by or ap proved by SPICER OFF HIGHWAY PRODUCTS IMPORTANT ALWAVS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS 6 Dana Holding Corporation TSM 0221E 2 3 Transmission Service Manual SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instructions must be carefully ob served Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced by a spare part which has the same part num ber or with an equivalent part DO NOT USE A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the
46. ve the 1st shift spool Due to this movement of the 1st shift spool the 1st clutch will be fed with oil pressure When the 2nd solenoid is activated pilot pressure will move to the 2nd shift spool and the 2nd clutch will be fed with oil pressure When the 3rd solenoid is activated pilot pressure will move to the 3rd shift spool and the 3rd clutch will be fed with oil pressure The shift spools of 1st and 3rd are located opposite each other separated by areturn spring This ensures that only 1st or 3rd can be selected MODULATION OF THE CLUTCHES Modulation means when a clutch is activated pressure is built up gradually during closing This results in a smooth engagement of the drive The modulation is achieved by activating the modulation solenoid which results by filling the clutch over a restriction Once the clutch is closed the modulation solenoid is switched off and the clutch re ceives the full pressure ELECTRONIC SOLENOID CONTROLS Activated Soleniods Activated Clutches 2nd 2nd 2ND SOLENOID gt MODULATION SOLENOID S 3RD SOLENOID gt 1ST SOLENOID gt TSM 0221E 243 Transmission Service Manual Dana Holding Corporation 21 OPERATION OF
47. wear sleeve FIGURE 91 Compress clutch piston belleville washer spring a and remove spring retaining snap ring FIGURE 94 Remove clutch piston Use caution when installing snap rings Failure to complv can cause personal injury TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 73 DISASSEMBLY 2ND CLUTCH FIGURE 95 Remove clutch shaft front bearing 74 Dana Holding Corporation TSM 0221E 243 Transmission Service Manual REASSEMBLY 2ND CLUTCH REASSEMBLY 2ND CLUTCH i FIGURE 99 Install clutch piston wear sleeve Lin il gt See item 8 on page 54 FIGURE 96 Refer to CLEANING AND INSPECTION p 8 The bleed hole in the piston must be clean and free of any fo reign material Install clutch piston outer seal Size as descri bed in Figure 59 FIGURE 100 Install piston return springs First spring with larger diameter of bevel towards wear slee ve See Figure 106 Alternate seven 7 springs See note Figure 56 FIGURE 97 Install clutch piston inner seal and size as descri bed in Figure 59 FIGURE 101 Compress spring to install spring retainer ring FIGURE 98 Position piston in low clutch drum as shown NOTE Use caution as not to damage inner and outer piston sealing Be sure ring is in full position in groove rings TSM 0221E 2 3 Transmission Service Manual Dana Holding Corporation 75 REASSEMBLY 2ND CLUTCH spacer AT Ia

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