TSM 0064
TSM 0064
TSM 0064
Powershift Transmission
TE27 & TE32 4-Speed Long Drop
with Full Flow Control Valve
TSM-0064
August 2012
CONTENTS
CONTENTS .................................................... i
Towing or Pushing ........................................... 1
Introduction ..................................................... 2
Foreword
.......................................................... 2
Safety Precautions
SPECIFICATIONS
........................................... 2
.......................................... 3
................................... 77
.............. 3
Maintenance
................................................... 6
Sump preheaters
............................................. 6
Filters ............................................................... 6
Clutch Calibration ............................................ 6
Lubricants ........................................................ 6
Servicing Machine After Component Overhaul 7
Automatic Calibration Procedure ..................... 8
TROUBLESHOOTING
...................................... 42
.................................... 43
EXPLODED VIEWS
........................................ 53
........................... 85
.............................................. 93
.................................... 95
INSTALLATION DIAGRAMS
...........................97
................ 97
................ 102
TORQUE SPECIFICATIONS
..........................175
SPECIAL TOOLS
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
............................................178
Dana Holding Corporation
TOWING OR PUSHING
Before towing the vehicle, be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing.
NOTE:
Because of the design of the hydraulic system, the engine cannot be started by pushing or towing.
TSM-0064 - TE27/32 4-Speed LD with 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 outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and
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 adjustments, it is urged that mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only Dana Spicer approved parts, as listed in the applicable service parts list, should be used. Use of will fit or non-approved parts may endanger proper operation and performance 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 and/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.
DANGER
WARNING
CAUTION
NOTICE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
SPECIFICATIONS
Identification Tag
The nameplate contains both the model and serial number of the unit.
General Specifications
Weight (dry)
Length (maximum)
Width (maximum)
27.7"/ 703 mm
Height (maximum)
49.6"/ 1260 mm
Oil Capacity
Without cooler and hydraulic lines. Consult equipment operators manual for complete system capacity.
Continuous Pressure
Conformance
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
158248F / 70120C
Measured at temperature check port converter out
(port 71 or port 32*)
Maximum Temperature
248F / 120C
Regulator
Pressure
Pump Flow
At 1900RPM
31.5 GPM / 119.3 l/min minimum
Clutch Pressure
Lube Pressure
Port 34
5880 PSI / 4.05.5 bar
at 2200 RPM
Safety Valve
Cracking Pressure
Port 33
72.5 PSI / 5 bar minimum
2000 RPM and maximum 123.3 PSI / 8.5 bar
at no load governed speed
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Electrical Specifications
Electrical Specifications
Proportional Valves
Selection Valves
FWD/N/REV - 1st/3rd
Coil Resistance: 12V - 7.1: at 68F / 20C
Coil Resistance: 24V - 28.5: at 68F / 20C
Speed Sensor
Temperature Sensor
Material: Silicon
Resistance: 77F / 25C = 2000: + 1%
Pressure Sensor
TSM-0064 - TE27/32 4-Speed LD with 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 104F [40C] = 33 - 38 cSt; at 212F [100C] = 7-8 cSt.
Maintenance Intervals
Daily
Check oil level daily with engine running at idle (600 RPM) and oil at 180-200F [82 - 93C].
Maintain oil level at full mark.
1.
Drain transmission.
2.
3.
4.
5.
6.
Recheck level with engine running at 500 - 600 RPM and add oil to bring level to LOW mark. When oil temperature
is hot 180-200F [82.2-93.3C] 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-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
2.
Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine for cleaning.
3.
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:
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.
Run engine two minutes at 500 - 600 RPM to prime torque converter and hydraulic lines.
Recheck level of fluid in transmission with engine running at idle (500 - 600 RPM).
6.
Recheck all drain plugs, lines, connections, etc for leaks and tighten where necessary.
7.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
The transmission temperature needs to be above 60C. See the next paragraph how to use the HEAT-mode
to do this in a time effective way.
The engine speed has to be kept at around 800 rpm ( 200 rpm) during the complete calibration. If the APC200
has control over the engine, the engine speed will be adapted automatically.
1.
If all the conditions mentioned above are 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:
3.
C1 stands for clutch 1 being forward, while M1 stands for mode 1 of the calibration.
4.
5.
At this point, the automatic calibration has completed successfully. The normal duration of a complete transmission
calibration is around 15 minutes.
6.
To exit 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 on the APC200 display, there can be two possible reasons:
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).
A calibration error has occurred during the calibration. This message starts with an E (see CALIBRATION
CONDITION MESSAGES AND CALIBRATION ERRORS, on page 11).
By selecting REVERSE on the shift lever, while the automatic calibration is performing, the procedure will abort the automatic calibration immediately and restart the APC200. 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.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
To trigger the HEAT-mode, push the S-button. The APC200 will display the sump temperature:
2.
Put the transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throttle.
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!
4.
Keep the gearbox in neutral at full engine throttle for about 15 seconds again.
5.
6.
Go back to point 2 and repeat until the APC200 display shows a temperature above 140F [60C]. When the temperature is above 140F [60C], 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 maximum 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 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 heating up procedure if the transmission temperature has not reached 60C yet.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
10
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.
11
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
BOLT CIRCLE
DIAMETER
"A"
BOLT CIRCLE
DIAMETER
"A"
INTERMEDIATE
DRIVE PLATES (3)
INTERMEDIATE
DRIVE PLATES (2)
BACKING RING
BACKING RING
1.
Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter.
2.
Align intermediate drive plates and backing ring with holes in torque converter assembly.
3.
Two dimples 180o apart in backing ring must be facing outward toward engine flywheel (hollow side facing torque
converter assembly).
4.
Install capscrews and lockwashers. Tighten capscrews to 30-37 lbs. ft. (40-50 Nm).
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.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
12
FLYWHEEL H OUSING
MOUNT
DIAL INDICATOR
HERE
2.
ENGINE
FLYWHEEL
PILOT BORE
FLYWHEEL
suitable for operating from ambient to 120C continuous operating temperature, must withstand 25 bar
continuous pressure, with 50 bar intermittent surges.
Reference SAE spec J-517, 100RI hydraulic hose
specification. All hose lines used must be conform to
SAE spec J-1019 tests and procedures for high temperature transmission oil hose. All hose lines and fitting have a 19 mm inside diameter unless noted.
*
13
FIG. 1
CONVERTER HOUSING
FLYWHEEL HOUSING
4"STUD
21/2"ALIGNING
STUDS
DRIVE
PLATE
FLYWHEEL
FLYWHEEL HOUSING
FLYWHEEL
IMPELLER
COVER
INTERMEDIATE
DRIVE PLATES
FIG. 3
FIG.4
PLATES TO BE INSTALLED
WITH CONCAVE SIDE
TOWARD ENGINE FLYWHEEL.
FIG. 5
Does not apply to units having 3 intermediate drive plates. See Figure 4.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Minimum 1" [25.4 mm] internal diameter for lines and fittings.
Suitable for operation from ambient to 248F [120C] continuous operating temperature.
Must withstand 435 PSI [30 bar] continuous pressure and with 652 PSI [40 bar] intermittent surges.
to remote filter 2
from pump 2
Remote Filter 2
to remote filter 1
from pump 1
Remote Filter 1
Cooler
from cooler to
transmission
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
14
The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 mA and 14
mA. The sensor has an integrated AMP superseal 2-pin connector. The two pins are numbered 1 and 2.
The following table shows the relation between wire color, pin number and connection.
Pin / Color
Function
Connection
1 / Brown
Current Input
Hot Wire
2 / Blue
Current Output
Ground Wire
CAUTION
The sensor wires have a polarity. Be sure to correctly observe
sensor polarities as wrong connections will deactivate the sensor!
15
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
16
17
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
TRANSMISSION OPERATION
FWD
REV
3RD
2ND
1ST
4TH
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
18
FWD
REV
3RD
2ND
1ST
4TH
CONVERTER SECTION
19
CONTROL VALVE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FWD
REV
3RD
2ND
1ST
4TH
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
20
Range Clutches
Range Clutches
Once a directional clutch is engaged, power is transmitted to the range clutches. Operation and actuation of the directional clutches is similar to the range clutches. The engagement of the directional clutches is modulated. For the 1st
clutch assembly, there is an extra bleed hole to allow full drain when the pressure to the piston is released.
FWD
REV
3RD
2ND
1ST
4TH
Output Section
With a range clutch engaged, power is finally transmitted to the output shaft. Output rotation is the same to input rotation when the forward clutch is engaged.
FWD
REV
3RD
2ND
1ST
4TH
21
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Transmission Controls
Transmission Controls
Refer to the Hydraulic Diagrams starting on page 24.
The transmission is controlled by a TCON ECU. This unit has a microprocessor that receives certain inputs (gear selector position, speed senors, etc.) which are processed and will give output signals to the control valve.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
22
23
Transmission
Gear
Activated
Selector Valve
Activated
Proportional Valve
Activated
Clutches
Forward 4
FWD
FWD/REV, 2nd/4th
Forward, 4th
Forward 3
FWD
FWD/REV, 1st/3rd
Forward, 3rd
Forward 2
FWD, 2nd/4th
FWD/REV, 2nd/4th
Forward, 2nd
Forward 1
FWD, 1st/3rd
FWD/REV, 1st/3rd
Forward, 1st
Neutral 4
2nd/4th
4th
Neutral 3
1st/3rd
3rd
Neutral 2
2nd/4th
2nd/4th
2nd
Neutral 1
1st/3rd
1st/3rd
1st
Reverse 4
REV
FWD/REV, 2nd/4th
Reverse, 4th
Reverse 3
REV
FWD/REV, 1st/3rd
Reverse, 3rd
Reverse 2
REV, 2nd/4th
FWD/REV, 2nd/4th
Reverse, 2nd
Reverse 1
REV, 1st/3rd
FWD/REV, 1st/3rd
Reverse, 1st
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
Neutral Selected
24
FWD
REV
3RD
2ND
1ST
4TH
25
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
26
FWD
REV
3RD
2ND
1ST
4TH
27
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
28
FWD
REV
3RD
2ND
1ST
4TH
29
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
30
FWD
REV
3RD
2ND
1ST
4TH
31
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
32
FWD
REV
3RD
2ND
1ST
4TH
33
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
34
FWD
REV
3RD
2ND
1ST
4TH
35
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
36
FWD
REV
3RD
2ND
1ST
4TH
37
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
38
FWD
REV
3RD
2ND
1ST
4TH
39
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
HOSE
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
HOSE
35A
FILTER 2
34A
71
LUBRICATION
RANGE
CLUTCHES
OIL SUMP
HOSE
34A
FILTER 1
31A
HOSE
PRESSURE
REGULATOR
VALVE 22 bar
PRESSURE
GAUGE
AIR
BREATHER
SAFTY VALVE
CRACKING
9 bar
TORQUE
CONVERTER 37
PUMP 2
52,4 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
34
COOLER
HOSE
32
TEMPERATURE
GAUGE
OPERATOR COMPARTMENT
SCREEN
PUMP 1
100,7 L/min @ 2170 rpm
BY-PASS VALVE
4,1-4,5 bar
31
41
Drain
High pressure
Low pressure
Lubrucation
FWD/REV
46
46
0.9
FWD/N/REV
REV
CLUTCH
FWD
CLUTCH
0.9
45
45
1ST/3RD
PRESSURE
SENSOR
41
41
0.9
1ST/3RD
1ST
CLUTCH
3RD
CLUTCH
0.9
43
43
2ND/4TH
PRESSURE
SENSOR
42
42
0.9
2ND/4TH
2ND
CLUTCH
0.8
4TH
CLUTCH
0.9
44
44
40
FWD
REV
3RD
2ND
1ST
4TH
41
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ut
Inp
u
utp
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
42
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 correct 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 assembly, oil cooler, filter, connecting lines, 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.
Transmission Problems
TE27/30 (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
CAUTION
NEVER 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 250F [120C] maximum will
cause damage to transmission clutches, fluid, converter, and seals.
Put the vehicle against a solid barrier, such as a wall and/or apply the parking brake, block the wheels.
2.
Activate calibration mode during power up and holding the S button for 15 seconds.
3.
4.
43
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Troubleshooting Procedures
5.
6.
Once the oil temperature reaches 158F [70C] check maximum stall speed at full throttle in all gears.
7.
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 158F [70C] by selecting neutral.
8.
Exit the stall mode with the M button or switch off the ignition.
If maximum stall speed measured is below specifications, it could indicate an engine or converter problem.
If maximum stall speed measured is above specifications, it could indicate slipping clutches.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
44
Troubleshooting Procedures
Mechanical and Electrical Checks
Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical
checks should be made:
Check the parking brake and inching pedal for correct adjustment.
Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points.
The controls are actuated electrically. Check the wiring and electrical components.
Be sure that all components of the cooling system are in good condition and operating correctly. The radiator
must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air
clean the radiator, if necessary.
The 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 check:
Check oil level in the transmission. The transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times.
CAUTION
The transmission fluid must be at operating temperature of 180 - 200F
[82 - 93 C] 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 it is necessary to either operate (work) the vehicle or run the engine with
the converter at stall ((see Stall Test, on page 43)).
DANGER
Be careful the vehicle does not move unexpectedly
when operating the engine and converter at stall rpm.
45
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Troubleshooting Guide
Troubleshooting Guide
Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
Cause
Remedy
Replace pump
Cause
Remedy
Replace pump
Overheating
Cause
Remedy
Clean cooler
Noisy Converter
Cause
Remedy
Replace pump
Lack of Power
Cause
Remedy
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
46
Check Points
Check Points
Front View
Rear View
Plug16B From
Remote Filter 1
Port 32 Pressure Check Port to
Cooler / Converter Out
M12x1.5 o-ring port
Port 41
Pressure Check Port
1st Clutch
M10x1 o-ring port
Temperature
Sensor
47
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Check Points
Right View
Port 11 to Cooler
Drum Speed
Sensor
Output Speed
Sensor
Metric Flange
for Dipstick
Dia. 25.4 mm
Left View
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
48
Check Points
Top View
Port 13B to
Remote Filter
from Pump 2
Port 13A to
Remote Filter
from Pump 1
Lifting Eyes
M20 x 2.5 THD
28mm Deep
49
Air Breather
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Checkports*
Checkports*
31A
System Pressure
41B
42B
43B
44B
45B
46B
66
67
68
31A
45B
66
46B
68
67
43B
41B
44B
42B
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
50
FWD/REV
Selector Valve
FWD/REV
Proportional Valve
2nd/4th
Proportional Valve
3rd/1st
Proportional Valve
4th/2nd
Selector Valve
4th/2nd
Pressure Sensor
51
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
52
EXPLODED VIEWS
Converter Housing Group
13
33
38 37
32
30
29
42
34
43
35
40
31
41
21
14
1
15
19
18
17
18
42
43
40
41
18
16
35 13
36
22
23
19
20
45
10
21
6
12
19
44
37
38
20
11
39
39
7
5
4
10
11
12 9
41
40
27
25
43
42
27
26
28
24
53
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
23
O-ring
Not Illustrated
24
Pin - Dowel
Plug - Expansion
25
Capscrew
14
Plug
26
Capscrew
O-ring
27
Lockwasher
23
Tube
28
Gasket - Converter-ToTransmission-Case
Tube
29
Bushing
Tube
30
Breather - Air
Clip
31
Plug
10
O-ring
32
Sensor - Speed
11
Capscrew
33
O-ring
12
Lockwasher
34
Sensor - Speed
13
Tube
35
O-ring
14
Sleeve
36
Plug
15
Sleeve
37
16
Sleeve
38
O-ring
17
Sleeve
39
Capscrew
12
18
Washer
40
Lockwasher
12
19
Capscrew
41
Plug
20
Lockwasher
42
O-ring
21
Plug
43
22
Plug
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
54
16
14
12
19
26
27
32
33 34
17
13
15
29
31 30
28
38
9
10
42
24
43
40
39
1
35
41
8 7
22
25
Y
X
23
36
37
W
Y
X
21
11
W
20
Y
X
W
21
55
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Case - Transmission
QTY
ITEM
DESCRIPTION
23
O-ring
24
Sensor - Speed
25
O-ring
26
27
28
29
Capscrew
30
Lockwasher
Plug
31
Nut
10
O-ring
32
O-ring
11
O-ring
33
Lockwasher
12
34
13
Plug
35
Baffle
14
Sensor - Temperature
36
15
Pin
37
16
Capscrew
37
38
Washer - Seal
17
Capscrew
39
Capscrew
18
Lockwasher
44
39A
Spacer - Baffle
19
40
20
41
O-ring
21
42
Capscrew
22
Sensor - Speed
43
Lockwasher
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
56
2
15
16
4
5
14
9
6
8
7
11
12
10
13
57
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Ring - Piston
10
Baffle - Oil
11
Seal - Oil
Snap Ring
12
Ring - Piston
13
14
O-ring
15
Snap Ring
Lockwasher
16
Turbine Shaft
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
58
7
1
7
1
10
5
8
11
6
12
7
1
59
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
10
Washer - Plain
11
Washer - Seal
12
Snap Ring
Lockwasher
13
14
Snap Ring
15
Bearing - Ball
Snap Ring
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
60
16
17
10
15
14
18
3
19
9
6
5
4
11
20
21
22
23
12
13
24
7
25
27
61
26
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Member - Reaction
QTY
ITEM
DESCRIPTION
15
O-ring
Snap Ring
16
Screw
17
Turbine
18
Bearing
Hub - Turbine
19
Snap Ring
Snap Ring
20
Cover - Impeller
Snap Ring
21
Capscrew
10
22
O-ring
Locktab
23
Spacer
10
Impeller
24
Snap Ring
11
O-ring
25
Shaft - Input
12
Screw
32
26
Screw
13
Lock washer
32
27
Bearing - Ball
14
Hub - Impeller
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
62
1
d
RE
&
2n
FW
2
3
th
3r
63
4
or
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
64
10
24
11
14
16
13
18
15
17
18
7
8
9
22
21
20
19
23
25
65
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Piston
14
Bearing - Rear
15
Bearing
16
Ring - Retaining
Screen*
17
Ring - Piston
11
18
Ring - Retaining
11
19
Bearing
Plate - End
20
Spacer
Seal
21
Snap Ring
Snap Ring
22
Retainer - Oil
10
Washer - Belleville
(Not as illustrated)
23
Snap Ring
11
Ring - Retaining
24
12
25
13
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
66
13
16
14
17
2
15
18
4 3
19
1
27
28
6
7
21
8
9
24
23
22
20
67
19
29
26
25
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Piston
16
Washer
17
Snap Ring
18
Snap Ring
Screen*
19
Ring - Piston
11
20
Bearing
11
21
22
Spacer
Plate - End
23
Snap Ring
Snap Ring
24
O-ring
10
Washer - Belleville
15
25
Plug
11
26
O-ring
12
Retainer - Spring
27
Capscrew
13
Ring - Retainer
28
Lockwasher
14
Bearing
29
O-ring
15
Bearing
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
68
69
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
1
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
70
30
27
28
29
36
17
18
19
20
21
1
4
2
37
3
&
2N
RE
13
38
15 14
12
23
32
22
11
33
34
35
10
16
7
5
6
71
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Piston
ITEM
DESCRIPTION
20
Seal
21
Snap Ring
22
Washer - Belleville
15
Screen*
23
Washer - Belleville
24
Bearing
25
Bearing
Ring - Retaining
26
Ring - Retaining
27
Ring - Retaining
28
Bearing
10
Plate - End
29
Ring - Retaining
11
Snap Ring
30
Ring
12
Piston
31
13
32
14
33
Snap Ring
15
Screen*
34
Retainer
16
Ring - Retaining
35
Snap Ring
17
11
36
Ring - Piston
18
11
37
19
Plate - End
38
QTY
QTY
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
72
15
8
27
26
25
16
28
6
11
12
9
23
10
24
21
22
17
32
31
30
18
19
20
29
13
73
14
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Piston
ITEM
DESCRIPTION
17
Ring - Piston
18
Cap - Bearing
19
O-ring
Screen*
20
Plug
11
21
O-ring
11
22
O-ring
Plate - End
23
Capscrew
Snap Ring
24
Lock washer
Washer - Belleville
25
Bearing
10
26
Spacer - Bearing
11
Retainer - Spring
27
Snap Ring
12
Ring - Retainer
28
Snap Ring
13
Bearing
29
Bearing
14
Washer
30
Bearing
15
Bearing
31
Spring - Disc
16
Retainer - Oil
32
Nut
QTY
QTY
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
74
1
4
2
3
15
17
14
16
18
13
19
11
12
9
10
8
6
75
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Piston
ITEM
DESCRIPTION
11
Retainer - Spring
12
Spring
13
Ring - Retainer
Screen*
14
Bearing
11
15
Snap Ring
16
Snap Ring
10
17
Hub
Plate - End
18
Snap Ring
Snap Ring
19
Ring - Piston
10
QTY
QTY
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
76
3r
77
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
1
ITEM
DESCRIPTION
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
1
78
10
9
7
11
12
16
13
14
14
15
15
13
17
9
5
3
4
79
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Shaft - Output
QTY
ITEM
DESCRIPTION
10
Shims
AR
Bearing
11
Capscrew
11
Bearing
12
Lock washer
11
Snap Ring
13
O-ring
Snap Ring
14
Washer - Flange
Spacer
15
Locknut
Cap - Shimming
16
Flange - Companion
O-ring
17
Flange - Companion
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
80
14
15
16
17
19 18
3
1
13
2
21
9
12
11
12
8
6
20
81
10
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
12
Clamp - Suction
Gasket - Valve-To-ConverterHousing
13
O-ring
O-ring
14
Screw
Pump - Hydraulic
15
Lock washer
Shaft - Gear-To-Pump
16
Cap - Flange
Snap Ring
17
O-ring
Screw
18
Capscrew
19
Lock washer
Adapter - Suction
Transmission Case Side
20
Capscrew
10
Capscrew
21
O-ring
11
Hose - Suction
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
82
29
28
26
27
14
8
15
1716
18
2
2
23
5
7
2
1
2
19
19A
13
21
22
12
11 10
20
4A
25
3
24
30
83
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
16
O-ring
Plug - Expansion
22
17
O-ring
Plug - Expansion
18
O-ring
Plug - Expansion
19
Spool
4A
Plug - Orifice
19A
Valve - Solenoid
20
Spring - Accumulator
O-ring
21
Plug
O-ring
22
O-ring
Capscrew
23
Solenoid Assembly
24
Plug
10
O-ring
25
O-ring
11
O-ring
26
Plug
10
12
O-ring
27
O-ring
10
13
O-ring
28
Lock washer
16
14
Solenoid Assembly
29
Capscrew
16
15
O-ring
30
Gasket
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
84
4
7
5
4
7
5
85
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
Filter
QTY
ITEM
DESCRIPTION
O-ring
Adapter - Filter
Capscrew
Lockwasher
Cover
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
86
3
2
1
4
8
6
7
5
10
87
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
Screw
12
Lock washer
12
Hose
10
Plug
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
QTY
88
89
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Flange - Companion
Washer - Flange
O-ring
Nut - Flange
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
90
LO
PU
T
OU
91
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
92
13
9
10
6
12
11
2
6
14
1
3
4
5
93
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Shaft - Idler
Capscrew
Bearing - Ball
Lock washer
Bearing
10
Retainer - Oil
11
Plug - Expansion
Snap Ring
12
O-ring
13
Snap Ring
O-ring
14
Bearing - Needle
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
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3
4
95
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
Capscrew
Dipstick
Lock washer
O-ring
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
96
INSTALLATION DIAGRAMS
Transmission Assembly Instructions
10
6
2
3R D
FWD
11
3
R EV
2ND
1S T
12
4TH
97
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
All lead-in chamfers for oil seals, piston rings, and o-rings must be smooth and free from burrs. Inspect at
assembly.
Apply a thin coating of grease between seal lips on lip type seals prior to assembly
Use only pre-coated pipe plugs. On uncoated pipe plugs, apply a light coat of LOCTITE 592.
After assembly of parts using LOCTITE, there must not be any free or excess material which might enter the
oil circuit.
Refer to the picture on previous page to match step number to the transmission area where the step is performed.
11
1
Apply a light coat of LOCTITE 262 or 270 to all thru holes stud holes.
12
2
Teflon seals must be sized prior to assembly. Add grease to seal diameter of clutch hub before assembly.
Forward and Reverse Clutch
13
3
TE32:
11 separator discs with outer splines
11 friction discs (friction material on both side) with inner splines.
Clearance - Min. 0.23" [6.0 mm] / Max. 0.25" [6.4 mm]
TE27:
8 separator discs with outer splines
8 friction discs (friction material on both sides) with inner splines.
Clearance - Min. 0.23" [6.0 mm] / Max. 0.25" [6.4 mm]
Choose an end plate with suitable thickness to obtain this clearance.
CAUTION
The separator discs in the Fwd/Rev clutches and in the 1st and 2nd clutches look
similar to each other but are not the same. NEVER mix them.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
98
14
4
TE32:
11 separator discs with outer splines
11 friction discs (friction material on both side) with inner splines.
Clearance - Min. 0.17" [4.35 mm] / Max. 0.19" [4.75 mm]
TE27:
10 separator discs with outer splines
10 friction discs (friction material on both sides) with inner splines
Clearance - Min. 0.17" [4.35 mm] / Max. 0.19" [4.75 mm]
Choose an end plate with suitable thickness to obtain this clearance.
2nd Clutch
15
5
TE32:
7 separator discs with outer splines
7 friction discs (friction material on both side) with inner splines.
Clearance - Min. 0.10" [2.75 mm] / Max. 0.12" [3.15 mm]
TE27:
6 separator discs with outer splines
6 friction discs (friction material on both sides) with inner splines
Clearance - Min. 0.10" [2.75 mm] / Max. 0.12" [3.15 mm]
Choose an end plate with suitable thickness to obtain this clearance.
3rd Clutch
16
6
TE32:
12 separator discs with inner splines
11 friction discs (friction material on both side) with outer splines
2 one-sided friction discs (friction material on one side) with outer splines
Clearance - Min. 0.14" [3.5 mm] / Max. 0.16" [3.9 mm]
TE27:
9 separator discs with inner splines
8 friction discs (friction material on both side) with outer splines
2 one-sided friction discs (friction material on one side) with outer splines
Clearance - Min. 0.14" [3.5 mm] / Max. 0.16" [3.9 mm]
99
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
16
67
TE32:
11 separator discs with inner splines
10 friction discs (friction material on both side) with outer splines
2 one-sided friction discs (friction material on one side) with outer splines
Clearance - Min. 0.12" [3.1 mm] / Max. 0.14" [3.5 mm]
TE27:
11 separator discs with inner splines
10 friction discs (friction material on both side) with outer splines
2 one-sided friction discs (friction material on one side) with outer splines
Clearance - Min. 0.12" [3.1 mm] / Max. 0.14" [3.5 mm]
16
68
16
69
Seals must be pressed in perpendicular upon shaft axis from bearing side.
16
10
6
16
11
6
16
12
11
6
16
13
11
6
16
14
11
6
16
15
11
6
16
17
11
6
16
17
18
11
6
16
18
11
6
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
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13
14
15
16
18
17
101
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Install two (2) aligning studs. Install new gasket and valve body.
2.
Install fourteen (14) bolts and hand-tighten in the numerical sequence indicated on the drawing below.
3.
4.
Then torque all bolts twice to 1518 lbs. ft. [2025 Nm] in the correct sequence.
5.
16
15
13
14
7
6
10
12
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
11
102
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. NEVER SPIN BEARINGS WHEN DRYING. Bearings may be rotated slowly by hand to facilitate the drying process.
Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
BEARINGS
Carefully inspect all rollers, cages, and cups for wear, chipping, or nicks to determine fitness of bearings for further use.
NEVER 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.
103
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
CAUTION
Cleanliness is of extreme importance in the repair and overhaul 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.
CAUTION
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 PREPACKED IN QUANTITIES TO REPAIR ONE (1) SPECIFIC CLUTCH.
The disc spring packs are to be used as complete assemblies and care should be taken not to intermix the individual 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.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 10: Use special tool to lift impeller cover assembly. (See
Impeller Cover Lifting Hook, on page 179,)
105
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
106
107
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 23: Remove pump drive blanking cover plate bolts (if
fitted).
FIGURE 28: Remove pump drive idler gear, bearing, and support
assembly.
FIGURE 25: Remove stator support assembly bolts and
lockwashers.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
108
109
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
NOTE:
Reverse/ 2nd and 4th clutch drum will remain in the converter housing.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
110
FIGURE 41: Remove inner snap ring from 2nd clutch hub.
FIGURE 44: Remove bolts from 3rd clutch shaft rear bearing.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 45: Remove 3rd clutch shaft rear bearing cap and
o-ring.
FIGURE 46: Remove 3rd clutch shaft rear bearing cap snap ring.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 43: Remove snap ring from 4th clutch hub and remove
hub.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
111
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 47: Remove 1st clutch shaft rear bearing cap bolts.
FIGURE 48: Remove 1st clutch shaft rear bearing cap o-rings
and spring disc.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
112
FIGURE 54: Use special tool to remove nut from 1st shaft.
(See Shaft Nut Socket, on page 180.)
FIGURE 57: Remove snap ring from 3rd shaft bearing.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
113
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 60: Shown are the 1st shaft drum assembly and idler
shaft as an assembly, removed. (See Idler & Low Shaft Lifting
Hook, on page 178.)
FIGURE 64: Remove 1st shaft drum assembly front bearing snap
ring.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
114
FIGURE 65: Remove 1st shaft drum assembly front bearing oil
retainer.
WARNING
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
115
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
116
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 79: Remove rear output flange nut, washer, and o-ring.
FIGURE 82: Push output shaft through bearing and gear from
the rear side.
117
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
118
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
119
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 98: Remove turbine shaft bearing snap ring.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 96: Remove 4th drum shaft assembly using special tool.
(See 4th Drum Lifting Hook, on page 181.)
FIGURE 99: Using a soft hammer, tap turbine shaft and bearing
assembly from converter housing.
FIGURE 97: Using external snap ring pliers, open Rev/2nd drum
shaft assembly bearing snap ring and remove shaft assembly
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
120
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
121
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
FIGURE 108: Remove end plate and seal assembly.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
122
CAUTION
CAUTION
The steel discs in the Fwd/Rev clutches and in the 1st and
2nd clutches look similar to each other but are not the
same. NEVER mix them.
To ensure correct reassembly, be sure to keep the different
types of discs separated and identified.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when removing snap ring.
Force of spring is 2888 Nm. Failure to comply can
cause personal injury.
123
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 122: Install clutch piston inner seal. Rotate piston until
seal is flush with outer diameter of piston.
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
NOTE:
Seal must be sized before installing in clutch drum. Sizing is best
accomplished by rotating clutch piston while holding a round object
against the new seal.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
124
FIGURE 128: Install clutch inner and outer discs into drum. Start
with one steel disc against piston. Alternate friction and steel
discs until proper number of discs are installed. Last disc is
friction disc.
125
WARNING
WARNING
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
WARNING
FIGURE 133: Install clutch piston spacer (wear sleeve).
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
126
FIGURE 137: Install one (1) clutch inner/outer steel disc into
drum. Alternate friction and steel discs until proper number of
discs are installed. First and last discs are steel.
FIGURE 140: Install two (2) bearings in clutch gear and warm
assembly to 248F [120C]. Install clutch gear and hub into clutch
drum. Align splines on clutch hub with internal teeth of friction
discs. Tap gear into position.
CAUTION
CAUTION
NEVER 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.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 139: Install end plate in drum and fit end plate snap
ring.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
127
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
128
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 150: Remove two (2) piston rings.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
129
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when removing snap ring.
Force of spring is 3381Nm. Failure to comply can
cause personal injury.
FIGURE 156: Remove end plate.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
130
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
131
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 170: Install new seal in end plate and install plate.
WARNING
WARNING
FIGURE 169: Install steel discs. Alternate friction and steel discs
until proper number of discs are installed. First and last discs are
steel.
FIGURE 172: Install two (2) bearings in clutch gear and warm
assembly to 248F [120C]. Install clutch gear and hub into clutch
drum. Align splines on clutch hub with internal teeth of friction
discs. Tap gear into position.
CAUTION
CAUTION
NEVER 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-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
132
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 177: Install snap ring over shaft before fitting bearing.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 174: Install bearing inner race.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
133
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 183: Remove 3rd clutch driven gear and bearing.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
134
WARNING
WARNING
135
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
FIGURE 193: Install clutch piston outer seal and install piston
into drum.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
136
FIGURE 199: Install steel discs. Alternate friction and steel discs
until proper number of discs are installed. First and last discs are
steel.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
137
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
CAUTION
CAUTION
NEVER force the operation in this step. Gear splines must
be in full position with internal teeth of all inner discs. Failure
to comply may cause equipment damage.
WARNING
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
138
WARNING
WARNING
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
139
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
140
FIGURE 224: Install one (1) clutch outer half disc (friction
material on one side) steel side down.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
141
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 231: Install bearing snap ring.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 229: Install snap ring over shaft (to be used when
installing drum/shaft in casing).
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
142
WARNING
143
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
144
FIGURE 245: Turn shaft and remove outer bearing race from
shaft.
NOTE:
Bleed hole in the piston must be clean and free of any foreign material. Instructions for cleaning can be found in the Cleaning and
Inspection (see page 103) section of the manual.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
FIGURE 250: Install clutch piston outer seal and install piston
into drum.
145
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 256: Install one (1) steel disc. Alternate steel and friction
discs until proper number of discs are installed.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
146
FIGURE 261: Install clutch driven gear and hub assembly. Align
splines on clutch gear hub with internal splines of friction discs.
CAUTION
CAUTION
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
147
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
148
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 274: Turn shaft and, using a puller, remove bearing inner
race from shaft.
149
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 276: Turn shaft and install idler shaft rear bearing
spacer.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
150
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
FIGURE 283: Using a hydraulic press, remove bearing.
151
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Impeller Disassembly
Impeller Disassembly
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
152
Impeller Reassembly
Impeller Reassembly
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
153
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Impeller Reassembly
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 301: Make sure that hub mounting surface and tapped
holes are cleaned with solvent. Install self-locking screws and
tighten to 5865 lbs ft. [7987 Nm].
NOTE:
Assembly of the hub must be completed within a fifteen-minute
period from the start of screw installation. The special screw is to be
used for one (1) installation only. If the screw is removed for any reason, it must be replaced. The epoxy left in the hub holes must be
removed with the proper tap and the hole must be cleaned with solvent. Holes must be dried thoroughly and a new screw used for
reinstallation.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
154
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
155
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 315: Remove snap ring.
WARNING
Use caution when removing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
156
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 320: Install left and right outer auxiliary pump drive gear
assemblies. Put new o-rings (4) on bolts, install bolts, and tighten
to specified torque. Refer to TORQUE SPECIFICATIONS on
page 175.
157
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 323: From the rear of the housing, tap turbine shaft and
bearing in converter housing. Tap shaft until gear shoulders are
against converter housing.
FIGURE 324: From the front of the housing, install turbine shaft
bearing snap ring. Tap shaft until snap ring is in full position in
groove.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
158
FIGURE 329: Install 4th shaft and drum assembly snap ring.
FIGURE 332: Install inside suction tube bolt and nut.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
159
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 337: Install inside front cap bolts and tighten to specific
torque. Refer to TORQUE SPECIFICATIONS on page 175.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
160
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 341: Insert output shaft and taper bearing from rear of
case and through output gear.
161
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 349: Install new o-ring and oil seal on output front cap.
FIGURE 351: Tap and rotate output shaft to seat taper bearings.
Loosen front bearing cap bolts. Using an torque wrench,
determine the rolling torque of the output shaft and record.
Tighten front bearing cap bolts to specified torque. Refer to
TORQUE SPECIFICATIONS on page 175. Check rolling torque
with bolts tight. Torque must be 4 - 10 lbs. in. (0.46 - 1.1 Nm)
more than when bearing cap bolts were loose. Add or omit shims
on the front bearing cap to achieve the proper preload.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
162
FIGURE 354: Tighten front output flange nut to 250 - 300 lbs. ft.
(339 - 407 Nm).
FIGURE 357: Tighten rear output flange nut to 250 - 300 lbs. ft.
(339 - 407 Nm).
163
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 359: Install idler shaft, oil retainer, and snapring. Refer
to Figure 360.
FIGURE 362: Install 1st clutch shaft oil retainer and snap ring.
Refer to Figure 363.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
164
WARNING
WARNING
165
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
FIGURE 370: Using special tool Idler & Low Shaft Lifting Hook
(see page 178), install idler shaft and 1st clutch assembly.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
166
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 381: Using special tool Shaft Nut Socket (see page
180), torque lock nut to 107118 lbs ft. [145160 Nm].
FIGURE 378: Raise 3rd shaft slightly and install snap ring.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
167
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FIGURE 382: Fit o-ring (2) to idler shaft bearing cap and install
bearing cap.
FIGURE 384: Fit o-ring (2) to 3rd shaft bearing cap and install
bearing cap.
FIGURE 386: Install 1st shaft bearing cap with new o-rings (3)
and spring disc.
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FIGURE 391: Install new converter-housing-to-transmissioncase gasket and new o-rings (3).
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
NOTE:
Turning output shaft will assist in aligning clutch hubs with clutch
assembly.
CAUTION
CAUTION
NEVER use bolts to pull converter and transmission housing
together. Failure to comply may cause equipment damage.
FIGURE 390: Install 2nd clutch hub snap ring, spacer, and snap
ring.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 393: Install aligning studs and install new valve gasket.
169
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WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
FIGURE 411: Install impeller cover screws and lockwashers and
tighten to specified torque. Refer to TORQUE SPECIFICATIONS
on page 175.
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WARNING
Use caution when installing snap ring.
Failure to comply can cause personal injury.
173
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TORQUE SPECIFICATIONS
Lubricated or Plated Screws
COARSE PITCH
TYPE OF BOLT
SIZE OF BOLT
Grade 5
Grade 8
lbs. ft.
Nm
lbs. ft.
Nm
.2500
8 - 10
10.8 - 13.6
9 - 11
12.2 - 14.9
.3125
12 - 16
16.3 - 21.7
26 - 30
35.2 - 40.7
.3750
23 - 25
31.2 - 33.9
33 - 36
44.7 - 48.8
.4375
37 - 41
50.2 - 55.6
52 - 57
70.5 - 77.3
.5000
57 - 63
77 - 85
80 - 88
108 - 119
.5625
82 - 90
111 - 122
115 - 127
156 - 172
.6250
113 - 124
153 - 168
159 - 175
216 - 237
.7500
200 - 220
271 - 298
282 - 310
382 - 420
FINE PITCH
TYPE OF BOLT
SIZE OF BOLT
175
Grade 5
Grade 8
lbs. ft.
Nm
lbs. ft.
Nm
.2500
9 - 11
12.2 - 14.9
11 - 13
14.9 - 17.6
.3125
16 - 20
21.7 - 27.1
28 - 32
38.0 - 43.4
.3750
26 - 29
35.2 - 39.3
37 - 41
50.2 - 55.6
.4375
41 - 45
56 - 61
58 - 64
79 - 87
.5000
64 - 70
87 - 95
90 - 99
122 - 134
.5625
91 - 100
123 - 136
128 - 141
174 - 191
.6250
129 - 141
174 - 191
180 - 198
224 - 268
.7500
223 - 245
302 - 332
315 - 347
427 - 470
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Grade 8.8
Grade 10.9
Grade 12.9
lbs. ft.
Nm
lbs. ft.
Nm
lbs. ft.
Nm
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 x 2
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
FINE PITCH
TYPE OF BOLT
SIZE OF BOLT
Grade 8.8
Grade 10.9
Grade 12.9
lbs. ft.
Nm
lbs. ft.
Nm
lbs. ft.
Nm
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
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Pipe Plugs
Pipe Plugs
177
THREAD SIZE
lbs. ft.
Nm
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.
Nm
1/16 - 27
5-7
7-9
1/8 - 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-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
SPECIAL TOOLS
Idler & Low Shaft Lifting Hook
Bolt M10 x 40
TSM-0064 - TE27/32 4-Speed LD with Full Flow Control Valve Service Manual
Eyebolt M16
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TYP
TYP
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181
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