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Report this Document Download Now Save Save Dana 36000 Service Manual For Later 100 (32) 100 found this document useful (32 votes) 12K views 156 pages Dana 36000 Service Manual Uploaded by tripleo8131 Description: Full description Save Save Dana 36000 Service Manual For Later 100 100 found this document useful, Mark this document as useful 0 0 found this document not useful, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 156 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. In order to view the files contained in this library, Adobe Acrobat Reader must be installed on your computer. Adobe Acrobat Reader can be downloaded for free by clicking here. Password required.) Off-Highway Steering Components for Agriculture. Please try again.Please try again.Please try again. 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Dana Spicer Transmission Repair Manual -Dana Spicer Transmission Repair Manual Dana Spicer T12015 PowershiftTransmission service - Manuals.us Dana Spicer T12015 Powershift Transmissionservice. All Spicer service manuals are in PDF format. If you need assistance give us a call. We are here to help. If you need assistance feel free to contact us. We are here to assist you in any way we can. The world Leader in Spicer Truck Transmissions, Differentials, Transfer Cases and Power Take Off (PTO) Units and Parts in Rebuilt, New and Good Used Takeouts. Learn more - opens in a new window or tab This amount is subject to change until you make payment. For additional information, see the Global Shipping Programme terms and conditions - opens in a new window or tab This amount is subject to change until you make payment. If you reside in an EU member state besides UK, import VAT on this purchase is not recoverable. 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User Agreement, Privacy, Cookies and AdChoice Norton Secured - powered by Verisign. Something went wrong.Learn more - opens in a new window or tab This amount is subject to change until you make payment. For additional information, see the Global Shipping Program terms and conditions - opens in a new window or tab This amount is subject to change until you make payment. For additional information, see the Global Shipping Program terms and conditions - opens in a new window or tab Learn more - opens in a new window or tab Learn more - opens in a new window or tab Learn more - opens in a new window or tab Learn more - opens in a new window or tab Learn more - opens in a new window or tab See the seller's listing for full details. Contact the seller - opens in a new window or tab and request postage to your location. Please enter a valid postcode. Please enter a number less than or equal to 49. If you don't follow our item condition policy for returns, you may not receive a full refund. Refunds by law: In Australia, consumers have a legal right to obtain a refund from a business if the goods purchased are faulty, not fit for purpose or don't match the seller's description. More information at returns. All Rights Reserved. Something went wrong. View cart for details.User Agreement, Privacy, Cookies and AdChoice Norton Secured - powered by Verisign. Or Click Here to know the steps to enable javascript in browser. Enter your email address below in order to get paid out via PayPal when a sale occurs. We take care of everything; you just share and make money! We only use your email to create an affiliate tracking account so we can pay you directly via PayPal. By entering your email address, you agree to the PayLoadz Terms of Service. Download Dana Service Manual TE13-17.OF THE DESIGN OF THE HYDRAULIC SYSTEM, THE ENGINE CANNOT BE STARTED BY PUSHING OR Copyright DANA CORPORATION 1990. Limited Distribution. Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated, will be reimbursed many times in low cost operation and trouble-free service. In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and adjustments, it is urged that the mechanic studies the instructions in this manual carefully and uses it as a reference when performing maintenance and repair operations. Whenever repair or replacement of component parts is required, only SPICER OFF-HIGHWAY PRODUCTS approved parts as listed in the applicable parts manual should be used. Use of ?will-fit? or non-approved parts may endanger proper operation and performance of the equipment. SPICER OFF-HIGHWAY PRODUCTS does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied or approved by SPICER OFF-HIGHWAY PRODUCTS.Some of these procedures require the use of tools specifically designed for the purpose. Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended by SPICER OFF-HIGHWAY PRODUCTS, must first determine that neither his safety nor the safe operation of the machine will be jeopardised by the spare part, service procedure or tool selected.CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS, AND INHALATION OF VAPOURS WHEN USING SOLVENT TYPE CLEANERS. 1.1.1 BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.Dry bearings using moisture-free compressed air. Be careful to direct air stream across bearing to avoid spinning.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.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. 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 under of lips of seals seriously impairs its efficiency. When assembling new metal type sealing rings, these should be lubricated with a coat of chassis grease to stabilise rings in their grooves for ease of assembly of mating members. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with 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. 1.2.4 HOUSINGS, COVERS, etc. Inspect housings, covers and bearing caps to ensure that they are thoroughly clean and that mating surfaces, bearing bores, etc.Check all parts carefully for evidence of cracks or conditions which would cause subsequent oil leaks or failures. 1.3 LEGEND SYMBOLS Smontaggio di sottogruppi Sostituire con ogni montaggio Disassembly of assembly groups Renew at each reassembly Montaggio di sottogruppi Togliere - mettere la sicura Reassemble to from assembly group Unlock - lock e.g. split pin, locking plate, etc. Smontaggio di particollari ingombranti Mettere la sicura, incollare (mastice liquido) Remove obstruction parts Lock - adhere (liquid sealant) Montaggio di particollari ingombranti Evitare danni ai materiali, danni ai pezzi Reinstall - remount parts which had obstructed disassembly Guard against material damage, damage to parts Attenzione, indicazione importante Marchiari prima dello smontaggio (per il montaggio) Attention.Controllare regolare p.e. coppie, misure, pressione etc. Carricare riempire (olio - lubrificante) Check - adjust e.g. torque, dimensions, pressures etc. Filling - topping up - refilling e.g. oil, cooling water, etc. Consult Operator?s manual on applicable machine for system capacity. Refer to section troubleshooting for check port identification. Conform SAE J1019 and SAE J517,100RI. NORMAL OIL CHANGE INTERVAL Drain and refill system every 1000 hrs for average environmental and duty cycle conditions. Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated detioration or contamination. Judgement must be used to determine the required change intervals for extreme conditions. EXTENDED OIL CHANGE INTERVAL Extended oil service life may result when using synthetic fluids. Appropriate change intervals should be determined for each transmission by measuring oil oxidation and wear metals over time, to determine a baseline. Wear metals analysis can provide useful inforamtion but a transmission should not be removed from service based solely on this analysis. Maintain oil level at full mark. 3.2.2 NORMAL DRAIN PERIOD Normal drain period and oil filter element change are for average environment and duty cycle condition. Severe or sustained high operating temperature or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For extreme conditions judgement must be used to determine the required change intervals. Every 500 hours Change oil filter element. Note IT IS RECOMMENDED THAT OIL FILTER BE CHANGED AFTER 100 HOURS OF OPERATION ON NEW, REBUILT OR REPAIRED UNIT. 3.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL The transmission, torque converter, and its allied hydraulic system are important links in the driveline between the engine and the wheels. The proper operation of either unit depends greatly on the condition and operation of the other. Therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered complete. After the overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement must be exercised as to the method employed. The following are considered the minimum steps to be taken: 1. Drain entire system thoroughly. 2. Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine for cleaning. 3. Replace oil filter element. 4.The oil cooler must be thoroughly cleaned. The cooler should be ?back flushed? with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air, and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes. IMPORTANT DO NOT USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES. 5.Reassemble all components and use only type oil recommended for lubrication section. Fill transmission through filler opening until fluid comes up to the oil level check port. Recheck level of fluid in transmission with engine running at idle (500-600 R.P.M.). Add quantity necessary to bring fluid level to oil level check port. Note two (2) kits have two (2) intermediate drive plates and one (1) drive plate and weld nut assembly. Two (2) kits with three intermediate drive plates.Each kit will include the following parts: ? 3 Intermediate drive plates. ? 1 Backing ring. ? 6 Mounting screws. ? 6 Lockwashers. ? 1 Instruction sheet. Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter. Align intermediate drive plates and backing plate with holes in torque converter assembly.Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. FLYWHEEL HOUSING MOUNT DIAL INDICATOR HERE ENGINE FLYWHEEL PILOT BORE FLYWHEEL FIG. 1 FLYWHEEL HOUSING 5. Rotate the transmission torque converter to align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step No. 3. Locate transmission on flywheel housing. Aligning drive plate to flywheel and transmission to flywheel housing guide studs. Install transmission to flywheel housing screws. Tighten screws to specified torque. Remove transmission to engine guide studs. Install remaining screws and tighten to specified torque. Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel housing circumference in line with the drive plate screw access hole. A screwdriver or pry bar used to hold the drive plate against the flywheel will facilitate installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven (7) flywheel to drive plate attaching screws. Snug screws but do not tighten. After all eight (8) screws are installed. Torque each one 35 to 39 N.m. (26- 29ft.lbs.). This will require tightening each screw and rotating the engine flywheel until the full amount of eight (8) screws have been tightened to specified torque. 8. Measure engine crankshaft end play after transmission has been completely installed on engine flywheel. Make sure the position sign on the sensor points as shown below in the direction of the movement of the gearteeth (Teeth rotation as shown). The sensor has an integrated AMP superseal 2 pin connector. The two pins are numbered 1 and 2. Following table shows the relation between wire colour, pin number and connection. COLOUR BROWN BLUE PIN NUMBER 1 2 FUNCTION Current input Current output CONNECTION Hot wire Ground wire Note THE SENSOR WIRES HAVE A POLARITY.This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter. This element receives fluid at its outer diameter and discharges it at its centre. The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. This recirculation will make the converter to multiply torque. The torque multiplication is function of the blading (impeller, turbine and reaction member) and the converter output speed (turbine speed). The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. The hydraulic pump is connected with the pump drive gear. This pump drive gear is driven by the impeller hub gear. These clutches consist of a drum with internal splines and a bore to receive a hydraulic actuated piston. The piston is oil tight by the use of sealing rings. The steel discs with internal splines, and friction discs with external splines, are alternated until the required total is achieved. A back-up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts. Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft to the desired clutch. Pressure of the oil forces the piston and discs against the back-up plate. The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil will drain back via the shift spool, the bleed valve or holes in the clutch piston into the transmission sump. These bleed valves will only allow quick escape of oil when the pressure to the piston is released. (The engagement of all range and directional clutches is modulated and electronically controlled.). This means that clutch pressure is built up gradually. Operation and actuation of the directional clutches is similar to the range clutches. The engagement of the directional clutches is modulated. 5.1.4 The output section With a directional clutch engaged, power is finally transmitted to the output shaft. This unit has a microprocessor that receives certain inputs (gear selector position, speed senors,.), which are processed and will give output signals to the control valve. Between each electronic controlled modulation valve and pressure intensifier is placed an accumulator to dampen any hydraulic vibration. In neutral position, the total neutral solenoid is not activated and no pressure is supplied to the electronic controlled modulation valves and to the pressure intensifiers. Total neutral solenoid will be activated only when forward or reverse direction is requested. When forward is selected, total neutral solenoid and forward electronic modulation valve are activated. The forward clutch is fed with modulated pressure supplied through the forward pressure intensifier. When reverse is selected, total neutral solenoid and reverse electronic modulation valve are activated. The reverse clutch is fed with modulated pressure supplied through the reverse pressure intensifier. Pressure switch The control valve also has a pressure switch installed between the total neutral shift spool and the pressure intensifiers supply. This switch will verify that pressure to the various pressure intensifiers is supplied only when the total neutral solenoid is activated. When troubleshooting a ?transmission? problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therfore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines and controls, including the engine as a complete system. Transmission fluid is the ?life blood? of the transmission.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.In addition, converter charging pressure and transmission lubrication pressure can also be measured. 6.2.3 Mechanical and electrical checks Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical checks should be made. Check the parking brake and inching pedal for correct adjustment. ? Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. ? The controls are actuated electrically. Check the wiring and electrical components. ? Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary. 6.2.4 Hydraulic checks Also, before checking the transmission clutches, torque converter, charging pump and hydraulic circuit for pressure and rate of flow, it is imporatant to make the following transmission fluid check. Check oil level in the transmission. The transmission fluid must be at the correct (full level). ? All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at ?stall? (refer to 6.2.1 ?stall test?). Caution: BE CAREFULL THAT THE VEHICLE DOES NOT MOVE UNEXPECTEDLY WHEN OPERATING THE ENGINE AND RPM. The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor. If the teeth can be moved slowly, distinct toggling between the two levels should be noticed. Inspect at assembly. Add grease to ?O? ring before assembly.