TÀI LIỆU HỘP SỐ TE17 SERVICE MANUAL

Maintenance & Service Manual TE13 / TE17 Transmission Speed Short Drop SPICER OFF-HIGHWAY COMPONENTS CD-ROM: 8100066 MANUAL: 8100067 Table of Contents FOREWORD SAFETY PRECAUTIONS CLEANING AND INSPECTION TECHNICAL SPECIFICATIONS 2.1 IDENTIFICATION OF THE UNIT 2.2 WEIGHT, DIMENSIONS, OIL CAPACITY 2.3 TIGHTENING TORQUES 2.4 PRESSURE & TEMPERATURE SPECIFICATIONS 2.5 ELECTRICAL SPECIFICATIONS 2.6 HYDRAULIC COOLER LINES SPECIFICATIONS 2 6 MAINTENANCE 3.1 OIL SPECIFICATION 3.2 MAINTENANCE INTERVALS 3.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL INSTALLATION DETAILS 4.1 CONVERTER DRIVE COUPLING 4.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE 4.3 EXTERNAL PLUMBING 4.4 SPEED SENSOR INSTALLATION 5 TRANSMISSION OPERATION 5.1 THE TRANSMISSION ASSEMBLY 5.2 THE TRANSMISSION CONTROLS (REFER TO HYDRAULIC DIAGRAM) 5.3 Electric solenoid controls 5.4 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT 6 Transmission Operation 6.1 THE TRANSMISSION 6.2 THE INPUT SHAFT AND DIRECTIONAL CLUTCHES 6.3 TROUBLESHOOTING GUIDE 6.4 CHECK POINTS 6.5 WIRING 6.6 SPEED SENSOR-STATIC STAND ALONE TEST 2 SECTIONAL VIEWS & PARTS IDENTIFICATION 7.1 DRIVE PLATE GROUP 7.2 SHIPPING COVER GROUP 7.3 TORQUE CONVERTER GROUP 7.4 OUTPUT SHAFT GROUP 7.5 PUMP DRIVE GROUP 10 7.6 GEAR GROUP 12 7.7 CHARGING PUMP GROUP 14 7.8 TRANSMISSION CASE & REAR COVER GROUP 16 7.9 CONVERTER HOUSING GROUP 18 7.10 REVERSE & 2ND GROUP 20 7.11 FORWARD & 3RD GROUP 22 TE13/17 3SD 02/2002 7.12 1ST GROUP 7.13 CONTROL VALVE GROUP 7.14 REGULATOR VALVE GROUP 7.15 MODULATOR VALVE GROUP 24 26 30 32 ASSEMBLY INSTRUCTIONS DISASSEMBLY & REASSEMBLY 10 SPECIAL TOOLS TE13/17 3SD 02/2002 TOWING OR PUSHING Before towing the vehicle, be sure to lift the rear wheels off the ground or disconnect the driveline to avoid damage to the transmission during towing Note: BECAUSE TOWING OF THE DESIGN OF THE HYDRAULIC SYSTEM, THE ENGINE CANNOT BE STARTED BY PUSHING OR Copyright DANA CORPORATION 1990 Unpublished material © All rights reserved Limited Distribution No part of this work may be reproduced in any form under any means without direct written permission of the DANA CORPORATION TE13/17 SD 02/2002 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of the SPICER OFF-HIGWAY PRODUCTS product Extreme care has been exercised in the design, selection of materials, and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such adjustments as may be indicated, will be reimbursed many times in low cost operation and trouble-free service In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and adjustments, it is urged that the mechanic studies the instructions in this manual carefully and uses it as a reference when 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 IMPORTANT ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS TE13/17 SD 02/2002 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 parts must be replaced by spare parts which have the same part number or with equivalent parts DO NOT USE A SPARE PART OF LESSER QUALITY The service procedures recommended in this manual are effective methods for performing service and repair Some of these procedures require the use of tools specifically designed for the purpose Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended by SPICER OFF-HIGHWAY PRODUCTS, must first determine that neither his safety nor the safe operation of the machine will be jeopardised by the spare part, service procedure or tool selected IMPORTANT IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS ‘CAUTIONS AND NOTICES’ THAT MUST BE CAREFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSONAL INJURY DURING SERVICE OR REPAIR, OR THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE IT IS ALSO IMPORTANT TO UNDERSTAND THAT THESE ‘ CAUTIONS AND NOTICES’ ARE NOT EXHAUSTIVE, BECAUSE IT IS IMPOSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS TE13/17 SD 02/2002 CLEANING AND INSPECTION TE13/17 SD 02/2002 1-1 Cleaning and Inspection & Legend symbols 1.1 CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION CARE SHOULD BE EXERCISED TO AVOID SKIN RASHES, FIRE HAZARDS, AND 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 repeat above operation until bearings are thoroughly clean Dry bearings using moisture-free compressed air Be careful to direct air stream across bearing to avoid spinning DO NOT SPIN BEARINGS WHEN DRYING Bearings may be rotated slowly by hand to facilitate drying process 1.1.2 HOUSINGS Clean interior and exterior of housings, bearing caps, etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION CARE SHOULD BE EXERCISED TO AVOID INHALATION OF VAPOURS AND SKIN RASHES WHEN USING ALKALI CLEANERS All parts cleaned must be thoroughly dried immediately by using moistere-free compressed air or soft lintless absorbant wiping rags, free of abrasive materials such as metal fillings, contaminated oil or lapping compound 1.2 INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date 1.2.1 BEARINGS Carefully inspect all rollers: cages and cups for wear, chipping, or nicks to determine fitness of bearings for further use DO NOT REPLACE A BEARING CONE OR CUP INDIVIDUALLY without replacing the mating cup or cone at the same time After inspection, dip bearings in Automatic Transmission Fluid and wrap in clean lintless cloth or paper to protect them until installed TE13/17 SD 02/2002 1-2 Cleaning and Inspection & Legend symbols 1.2.2 OIL SEALS, GASKETS, etc Replacement of spring load oils seals, “O” rings, metal sealing rings, gaskets and snap rings is more economical when the unit is disassembled than premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully, particularly when being installed Cutting, scratching or curling under of lips of seals seriously impairs its efficiency When assembling new metal type sealing rings, these should be lubricated with a coat of chassis grease to stabilise rings in their grooves for ease of assembly of mating members Lubricate all “O” rings and seals with recommended type Automatic Transmission Fluid before assembly 1.2.3 GEARS & SHAFTS If Magna-Flux process is available, use process to check parts Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores If gear teeth show spots where case hardening is worn through or cracked, replace with 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 are free from nicks or burrs 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 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 materiali, danni 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! important notice Mark before disassembly, observe marks when reasembl 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 T = Attrezzature speciali Scarricare olio, lubrificante T = Special tool TE13/17 SD P = Pagina P = Page Drain off oil, lubricant Rispettare direzione di montaggio Tendere Note direction of installation Tighten - clamp ; tightening a clamping device Controllare esaminare controllo visuale Insere pressione nel circuito idraulico Visual inspection Apply pressure into hydraulic circuit Eventualimente riutilizzable (sostituire se necessario) Pulire Possibly still serviceable, renew if necessary To clean 02/2002 1-3 TECHNICAL SPECIFICATIONS TE13/17 SD 02/2002 2-1 REASSEMBLY OF TRANSMISSION CASE Figure 258 Install 2ND/REV clutch assembly Align splines on clutch gear with internal teeth of stel discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs Figure 261 Block gears from turning and tighten to 339-407 Nm [205-300 lbft] Figure 259 Remove special tool Figure 262 Install output shaft gear assembly Figure 260 Install gear retaining nut Figure 263 Install gear (44T) on 2ND/REV clutch shaft TE 13/17 SD 02/02 9-52 REASSEMBLY OF TRANSMISSION CASE Figure 264 Install bearing spacer Figure 266 Install clutch shaft sealing rings Figure 265 Warm bearing to 120° C [248° F] and install bearing with snap ring groove down Figure 267 Install gear (48T) on 3RD/FWD clutch shaft Figure 266 Install bearing retaining snap ring Figure 268 Install bearing spacer TE 13/17 SD 02/02 9-53 REASSEMBLY OF TRANSMISSION CASE Figure 269 Warm bearing to 120° C [248° F] and install bearing Figure 272 Install new gasket and clutch pressure “O” rings into “O” ring grooves Figure 270 Install bearing retaining snap ring Figure 273 Use two guide studs to assist the fitting of the rear cover Figure 271 Install clutch shaft sealing rings Figure 274 Using spreading type snap ring pliers, spread ears on 2nd/REV shaft rear bearing retaining snap ring Holding snap ring open, tap transmission case into place TE 13/17 SD 02/02 9-54 REASSEMBLY OF TRANSMISSION CASE Figure 275 Tap dowel pins into rear cover and transmission case Figure 278 Install output flange Figure 276 Install rear cover to transmission case bolts and lockwashers Torque to specified torque Figure 279 Install “O” ring, washer and nut Figure 277 Tap the end of the turbine shaft to secure snap ring Figure 280 Tighten nut to 339-407 Nm [205-300 lbft] TE 13/17 SD 02/02 9-55 REASSEMBLY OF TRANSMISSION CASE Figure 281 Install control valve spacer plate and new gaskets Figure 284 Install new converter housing gasket Figure 282 Use two (2) aligning studs and install control valve assembly Figure 285 Install new suction tube “O” ring Figure 283 Install bolts and lockwashers and tighten to specified torque Figure 286 Using aligning studs, install converter housing on transmission case TE 13/17 SD 02/02 9-56 REASSEMBLY OF TRANSMISSION CASE Figure 287 Install bolts and lockwashers Tighten to specified torque Figure 290 Install pump drive gear, washer and bearing assembly Figure 288 Install pump drive gear, washer and bearing assembly Figure 291 Install pump drive bolts and lockwashers Tighten to specified torque Figure 289 Install pump drive bolts and lockwashers Tighten to specified torque Figure 292 Install pump drive gear, washer and bearing assembly TE 13/17 SD 02/02 9-57 REASSEMBLY OF TRANSMISSION CASE Figure 293 Install pump drive bolts and lockwashers Tighten to specified torque Figure 296 Install stator support bolts and lockwashers Tighten to specified torque Figure 294 Install new stator support gasket Figure 297 Install idler gear, washer and bearing as an assembly Figure 295 Install new sealing ring on stator support and install stator support Figure 298 Install idler gear bolts and lockwashers Tighten to specified torque TE 13/17 SD 02/02 9-58 REASSEMBLY OF TRANSMISSION CASE Figure 299 Install pump drive cover and gasket Figure 302 Install new charge pump gasket Figure 300 Install bolts and lockwasher Tighten to specified torque Figure 303 Install charging pump Figure 301 Install temperature sensor Figure 304 Install charging pump cap screws Tighten to specified torque TE 13/17 SD 02/02 9-59 REASSEMBLY OF TRANSMISSION CASE Figure 305 Install adaptor plate and new gasket Figure 307 Install adaptor plate cover bolts and lockwashers Tighten to specified torque Figure 306 Install adaptor plate cap screws and tighten to specified torque Figure 308 Install filter adaptor and new gasket Figure 307 Install adaptor plate cover and new gasket Figure 309 Install filter adaptor bolts and lockwashers Tighten to specified torque TE 13/17 SD 02/02 9-60 REASSEMBLY OF TRANSMISSION CASE Figure 310 Install oil filter and tighten to 30-38 Nm [22.1-28 lbft] Figure 312 Install torque converter sleeve Figure 311 Install new seal in bafle plate and install plate on converter Figure 313 Install torque converter sleeve cap screws and lockwashers and tighten to specified torque Figure 311 Install new sleeve gasket Figure 314 Install stator support bearing TE 13/17 SD 02/02 9-61 REASSEMBLY OF TRANSMISSION CASE Figure 314 Install stator support bearing retaining snap ring Figure 317 Install torque converter gear upper retaining snap ring Figure 315 Install torque converter gear lower retaining snap ring Figure 318 Refer to “Cleaning and Inspection” pages After installing new seal ring on baffle plate, use special tool and install converter assembly in housing See chapter 10 Special Tools Section page Figure 316 Install torque converter gear TE 13/17 SD Figure 319 Install oil baffle retaining ring 02/02 9-62 REASSEMBLY OF TRANSMISSION CASE Figure 320 Install drive plate and backing ring Figure 323 Install speed sensor in transmission case (See assembly instructions.) Figure 321 Install drive plate bolts and lockwashers Tighten to specified torque Figure 322 Install speed sensor in converter housing (See assembly instructions.) TE 13/17 SD 02/02 9-63 TE 13/17 SPECIAL TOOLS TE13/17 3SD 02/02 10-1 TE 13/17 SPECIAL TOOLS Special Tool for holding drum in place during disassembly and reassembly Transmission 02/02 10-2 TE 13/17 SPECIAL TOOLS Lifting hook for converter Transmission 02/02 10-3 ... means without direct written permission of the DANA CORPORATION TE13/17 SD 02/2002 FOREWORD This manual has been prepared to provide the customer and the maintenance personnel with information... 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... 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