Dana Service Manual TE13-17
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Maintenance & Service Manual
TE13 / TE17 Transmission 3 Speed Short Drop
SPICER OFF-HIGHWAY COMPONENTS
CD-ROM: 8100066 MANUAL: 8100067
Table of Contents FOREWORD SAFETY PRECAUTIONS CLEANING AND INSPECTION ....................................................................................... 1 2 TECHNICAL SPECIFICATIONS .................................................................................. 1 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 2 3 5 6 6
3 MAINTENANCE ............................................................................................................ 1 3.1 OIL SPECIFICATION ....................................................................................................................... 2 3.2 MAINTENANCE INTERVALS ............................................................................................................ 2 3.3 SERVICING MACHINE AFTER COMPONENTS OVERHAUL ........................................................... 3
4. INSTALLATION DETAILS............................................................................................ 1 4.1 CONVERTER DRIVE COUPLING ...................................................................................................... 4.2 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE ........................................................... 4.3 EXTERNAL PLUMBING .................................................................................................................... 4.4 SPEED SENSOR INSTALLATION .....................................................................................................
2 3 4 5
5 TRANSMISSION OPERATION ..................................................................................... 1 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 ........................................
2 6 6 7
6 Transmission Operation .............................................................................................. 1 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 2 4 6 8 9
7 SECTIONAL VIEWS & PARTS IDENTIFICATION ....................................................... 1
7.1 DRIVE PLATE GROUP ...................................................................................................................... 2 7.2 SHIPPING COVER GROUP .............................................................................................................. 4 7.3 TORQUE CONVERTER GROUP ........................................................................................................ 6 7.4 OUTPUT SHAFT GROUP ................................................................................................................... 8 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
8 ASSEMBLY INSTRUCTIONS ....................................................................................... 1 9 DISASSEMBLY & REASSEMBLY ............................................................................... 1 10 SPECIAL TOOLS ....................................................................................................... 1
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 3 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 3 SD
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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.
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CLEANING AND INSPECTION
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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 do not have ground or polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts may also be cleaned with steam cleaner.
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.
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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 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! 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 3 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
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1-3
2 TECHNICAL SPECIFICATIONS
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2-1
Technical specifications
OFF-HIGHWAY
TEN BRIELE 3 B-8200 BELGIUM
MODEL SERIAL
2.1. IDENTIFICATION OF THE UNIT 1. Model and type of the unit 2. Serial number.
2.2. WEIGHT, DIMENSIONS, OIL CAPACITY Weight (dry): Max. Length: Max. With: Max. Heigth:
570 Kg [1257 lb] 1045 mm [41.14] 693 mm [27.28] 826.4 mm [32.53]
Oil capacity 25 liter [6.6 US Gallon] without cooler and hydraulic lines. Consult Operators manual on applicable machine for system capacity.
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2-2
Technical specifications 2.3 TIGHTENING TORQUES 2.3.1 Torque specifications for lubricated or plated screw threads
NOM. SIZE
GRADE 5 FINE THREAD
COARSE THREAD
LBF - FT
[N.m]
LBF - FT
[N.m]
.2500
9 - 11
[12 - 15]
8 - 10
[11 - 14]
.3125
16 - 20
[22 - 27]
12 - 16
[16 - 22]
.3750
26 - 29
[35 - 39]
23 - 25
[31 - 34]
.4375
41 - 45
[56 - 61]
37 - 41
[50 - 56]
.5000
64 - 70
[87 - 95]
57 - 63
[77 - 85]
.5625
91 - 100
[123 - 136]
82 - 90
[111 - 122]
.6250
128 - 141
[174 - 191]
113 - 124
[153 - 168]
.7500
223 - 245
[302 - 332]
200 - 220
[271 - 298]
NOM. SIZE
GRADE 8 FINE THREAD
COARSE THREAD
LBF - FT
[N.m]
LBF - FT
[N.m]
.2500
11 - 13
[15 - 18]
9 - 11
[12 - 15]
.3125
28 - 32
[38 - 43]
26 - 30
[35 - 41]
.3750
37 - 41
[50 - 56]
33 - 36
[45 - 49]
.4375
58 - 64
[79 - 87]
52 - 57
[71 - 77]
.5000
90 - 99
[122 - 134]
80 - 88
[108 - 119]
.5625
128 - 141
[174 - 191]
115 - 127
[156 - 172]
.6250
180 - 198
[224 - 268]
159 - 175
[216 - 237]
.7500
315 - 347
[427 - 470]
282 - 310
[382 - 420]
NOM. SIZE
GRADE 8.8 or 9.8
GRADE 10.9
COARSE THREAD
COARSE THREAD
LBF - FT
[N.m]
LBF - FT
[N.m]
M8
15 - 18
[20 - 25]
22 - 26
[30 - 35]
M10
30 - 37
[40 - 50]
44 - 48
[60 - 65]
M12
50 - 55
[65- 75]
74 - 81
[100 - 110]
M16
125 - 140
[170 - 190]
177 - 203
[240 - 275]
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2-3
Technical specifications
2.3.2 Elastic stop nut torque
THREAD SIZE
LB - FT
[N . m]
1" - 20
150 - 200
[203.4 - 271.1]
1 1/4" - 18
200 - 250
[271.2 - 338.9]
1 1/2" - 18
300 - 350
[406.8 - 474.5]
1 3/4" - 18
400 - 450
[542.4 - 610.1]
2.3.3 Torque tables for plugs (o-ring ports)
THREAD SIZE
LBF - FT
[N . m]
9/16" - 18
12 - 15
[16 - 20]
3/4" - 16
20 - 25
[27 - 34]
2.3.4 Torque tables for pipe plugs
THREAD NPTF
TORQUE LBF - FT
[N.m]
1/16 - 27
5-7
[7 - 9]
1/8 - 27
7 - 10
[9 - 14]
1/4 - 18
15 - 20
[20 - 27]
3/8 - 18
25 - 30
[34 - 41]
1/2 - 14
30 - 35
[41 - 47]
3/4 - 10
40 - 45
[54 - 61]
1 - 11 1/2
55 - 50
[68 - 75]
1 1/4 - 11 1/2
60 - 65
[81 - 88]
3.3.5 Permanent metric plug torque chart
THREAD SIZE
TORQUE LBF - FT
[N.m]
M18 x 1.5 6H
25-30
[34-41]
M18 x 1.5 6H
45-50
[61-68]
TE13/17 3 SD
02/2002
2-4
Technical specifications 2.4 PRESSURE & TEMPERATURE SPECIFICATIONS Normal operating temperature 70 - 120°C [158 - 248F] measured at temperature check port to cooler (port 71 - **). Maximum allowed transmission temperature 120°C [248 F]. Transmission regulator pressure (*) - (neutral) - port 31 (**). - at 600 RPM min. 26 bar [327 PSI] minimum. - at 2650 RPM : 31 bar [449.6 PSI] maximum. Pump flow (*) - at 2200 RPM in neutral: 92.1 l/min. minimum [24.3 GPM]. Clutch pressures (*) - 1st clutch: port 41 (**). - 2nd clutch: port 42 (**). - 3rd clutch: port 43 (**). - forward clutch: port 45 (**). - reverse clutch: port 46 (**). at 2200 RPM : - 26 - 30 bar [377 - 435.1 PSI] clutch activated. Filter bypass valve set at 4.5 bar(*) [65.2 PSI]. Lube pressure (*) (port 33) - 0.4 - 0.85 bar [5.8 - 12.3 PSI] at 35 l/min. [9.2 GPM] converter flow. Internal total leakage at 1000 engine RPM N0 = 4 L/min. [1.05GPM] N1-3 = 8 L/min [2.11 GPM] Fwd0 / Rev0 = 8 L/min [2.11 GPM] Safety valve : cracking pressure (*) 7.5 bar [108.7 PSI]. To cooler (converter out) pressure (*) (port 32) 3 bar min. (43.5 PSI) at 2200 RPM and max. 6.5 bar (94.27 PSI) at no load governed speed).
(*) (**)
All pressures and flows to be measured with oil temperature of 82 - 93° C ( 180 - 200F). Refer to section troubleshooting for check port identification.
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02/2002
2-5
Technical specifications 2.5 ELECTRICAL SPECIFICATIONS Electronic controlled modulation valves (Fwd/Rev/2nd/1st-3rd). coil resistance : 4.35 ± 0.35 Ω at 25°C [77°F]. Total neutral and 1st/3rd range solenoid: coil resistance : 28 ± 2 Ω at 20°C [68°F]. Speed sensor : - type: magneto resistive sensor. - sensing distance: 0 - 1,8 mm [0 - 0.07]. - Sensor signal: generates a square current with a fixed amplitude changing between 7 and 14 mA.
2.6 HYDRAULIC COOLER LINES SPECIFICATIONS
Minimum 19 mm [0.75] internal diameter for lines and fittings. Suitable for operation from ambient to 120° C [248° F] continuous operating temperature. Must withstand 30 bar [435PSI] continuous pressure and with 45 bar [652PSI] intermittent surges. Conform SAE J1019 and SAE J517,100RI.
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2-6
3 MAINTENANCE
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02/2002
3-1
Maintenance 3.1. OIL SPECIFICATION 3.1.1 RECOMMENDED LUBRICANTS
Dexron* III, viscosity at 40° C [104° F]: 33 - 38 cSt 100° C [212° F]: 7 - 8 cSt
SUMP PREHEATERS Preheat the transmission fluid to the mimimum temperature for the oil viscosity used before engine startup. 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. FILTERS Service oil filter element every 5000 hrs under normal envirronmental and duty cycle conditions. 3.2 MAINTENANCE INTERVALS 3.2.1 DAILY Check oil level daily with engine running at idle (600 RPM) and oil at 82 - 93 °C (180-200 F). 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. Every 1000 hours Drain and refill system as follows (Drain with oil at 65 - 93 °C [150 - 200 F]): 1. Drain transmission. 2. Remove and discard filter. Install new filter. 3. Refill transmission to FULL mark.
* DEXRON is a registered trademark of GENERAL MOTORS CORPORATION T13/17 3 SD
02/2002
3-2
Maintenance 4. Run engine at 500 - 600 RPM to prime convertor and lines. 5. Recheck level with engine running at 500 - 600 RPM and add oil to bring level to LOW mark. When oil temperature is hot 82.2 - 93.3 °C (180- 200 F) 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. 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. Run engine 2 minutes at 500+600 R.P.M. to prime torque converter and hydraulic lines. 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. Recheck with hot oil (180-200 F) 82-93° C. 6.Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.
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3-3
INSTALLATION DETAILS
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4-1
Installation details 4. INSTALLATION DETAILS 4.1 CONVERTER DRIVE COUPLING Measure the A dimension (bolt circle diameter) and order drive plate kit listed below. 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.
ALIGNMENT HOLES
(1) DRIVE PLATE AND WELD NUT ASSEMBLY
A
A BOLT CIRCLE DIA. BACKING RING (2) INTERMEDIATE DRIVE PLATES
BOLT CIRCLE DIA. BACKING RING
(3) INTERMEDIATE DRIVE PLATES
A Dimension (Bolt circle diameter) 13.125 (333.38 mm) diameter
A Dimension (Bolt circle diameter) 13.125 (333.38 mm) diameter
13.500 (342.90 mm) diameter
13.500 (342.90 mm) diameter
Each kit will include the following parts: 2 Intermediate drive plates. 1 Drive plate and weld nut assembly. 1 Backing ring. 6 Mounting screws. 6 Lockwashers. 1 Instruction sheet.
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. Note TWO DIMPLES 180° APART IN BACKING RING MUST BE OUT TOWARD ENGINE FLYWHEEL (HOLLOW SIDE FACING TORQUE CONVERTER ASSEMBLY). INSTALL CAP SCREWS AND LOCKWASHERS. TIGHTEN CAP SCREWS TORQUE 40 - 50 N.M. (30 - 37 LBF. FT.).
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4-2
Installation details 4.2
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and nose pilot bore. Clean drive plate surface with solvent. 2. Check engine flywheel & housing for conformance to standard SAE No. 3 per SAE J927 and J1033 tolerance specifications for pilot bore size, pilot bore runout and mounting face flatness. Measure and record engine crankshaft end play (Fig. 1). 3. Install two 63,50 mm (2.50) long transmission to flywheel housing guide studs in the engine flywheel housing as shown. Rotate the engine flywheel to align a drive plate mounting screw hole with the flywheel housing access hole (Fig. 2). *4. Install a 101,60 mm (4.00) long drive plate locating stud .3750-24 fine thread in a drive plate nut. Align the locating stud in the drive plate with the flywheel drive plate mounting screw hole positioned in step 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.
CONVERTER HOUSING
4"STUD
21/2"ALIGNING STUDS DRIVE PLATE
FLYWHEEL
FIG. 2
*6. Remove drive plate locating stud. 7. Install drive plate attaching screw and washer. 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. This value must be within 0,025 mm (0.001) of the end play recorded in step No. 2. *
FLYWHEEL HOUSING
SPECIAL STUD, WASHER AND SELF LOCK NUT FURNISHED BY ENGINE MANUFACTURER.
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 Fig.4.
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4-3
Installation details 4.3 EXTERNAL PLUMBING
From transmission out to cooler
4.3.1 Cooler & filter lines specifications Minimum 19 mm [.75 inch] internal diameter for lines and fittings. Suitable for operation from ambient to 120° C [248° F] continuous operating temperature. Must withstand 30 bar [435psi] continuous pressure and with 40 bar [652 psi] intermittent surges. Conform SAE J1019 and SAE J517,100RI.
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4-4
Installation details 4.4 SPEED SENSOR INSTALLATION On the sensor body there is a small plastic triangular position sign. Make sure the position sign on the sensor points as shown below in the direction of the movement of the gearteeth (Teeth rotation as shown).
Position sign
Teeth rotation
1.65 (42.0) Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm)
Position sign Support
"O"-ring
Screw Tighten to 5.9 - 7.4 lbf-ft (8 - 10 Nm)
Plug "O"-ring
Sensor installed
Hole plugged
4.4 SPEED SENSOR INSTALLATION (CONTINUED) Position sign
Pin 2 ( - )
Pin 1 ( + )
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. 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. BE SURE TO CORRECTLY OBSERVE SENSOR POLARITIES, AS WRONG CONNECTIONS WILL DEACTIVATE THE SENSOR ! TE13/17 3 SD
02/2002
4-5
TRANSMISSION OPERATION
TE13/17 3 SD
02/2002
5-1
Transmission Operation 5.1
THE TRANSMISSION ASSEMBLY Basically the transmission is composed of five main assemblies: 1. 2. 3. 4. 5.
The converter, pump drive section and pressure regulating valve. The input shaft and directional clutches. The range clutches. The output section. The transmission control valve.
1ST
2ND
3RD
TE13/17 3 SD
02/2002
REV
FWD
5-2
Transmission Operation 5.1.1 The converter, pump drive section and pressure regulating valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque 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. Since the impeller hub gear is connected with the impeller cover, the pump speed is in direct relation with the engine speed.
1ST
TE13/17 3 SD
2ND
REV
3RD
FWD
02/2002
5-3
Transmission Operation 5.1.2 The input shaft and range clutches The turbine shaft driven from the turbine transmits power to the range clutch. 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. This will enable the unit to make forward, reverse shifts while the vehicle is still moving and will allow smooth engagement of drive.
1ST
2ND
3RD
TE13/17 3 SD
REV
FWD
02/2002
5-4
Transmission Operation 5.1.3 The directional clutches Once a range clutch is engaged power is transmitted to the directional clutches (Fwd/Rev). 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. Output rotation is the same as the engine rotation when the forward clutch is engaged.
1ST
2ND
3RD
1ST
REV
FWD
2ND
3RD
TE13/17 3 SD
02/2002
REV
FWD
5-5
Transmission Operation 5.2 THE TRANSMISSION CONTROLS (REFER TO HYDRAULIC DIAGRAM) The transmission is controlled by an APC200 box. 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. Operation of the valve Regulated pressure 26 bar [377PSI] is directed to the total neutral shift spool and the pressure reducer that will decrease the pressure to 12 bar [174 psi]. This reduced pressure will be used to supply the electronic controlled modulation valves, total neutral solenoid and 3rd/1st solenoid. When activated the electronic controlled modulation valves will give an output pressure curve from 0 to 6 bar [0-87PSI]. The pressure intensifiers with a ratio of 5:1 will multiply this pressure curve so that a curve from 0 to 30 bar [435 PSI] is available for each directional and range clutches. 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. Range selection 1st and 2nd clutch are fed with modulated pressure supplied through their respective pressure intensifiers and electronic controlled modulation valves. 3rd clutch is selected when 1st/3rd electronic controlled modulation valve and 1st/3rd solenoid are activated. The pilot pressure of the 1st/3rd solenoid will move the shift spool so that 3rd clutch can be fed with modulated pressure. 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. This information is an input of the APC200 box.
5.3
ELECTRIC SOLENOID CONTROLS Transmission gear
Activated solenoids
Activated clutches
Forward 3 Forward 2 Forward 1
N, FWD, 1st/3rd, 1st/3rd range N, FWD, 2nd N, FWD, 1st/3rd
Forward, 3rd Forward, 2nd Forward, 1st
N, REV, 1st/3rd, 1st/3rd range N, REV, 2nd N, REV, 1st/3rd
Reverse, 3rd Reverse, 2nd Reverse, 1st
Neutral Reverse 3 Reverse 2 Reverse 1
TE13/17 3 SD
02/2002
5-6
TE13/17 3 SD
02/2002
BY-PASS VALVE Pressure difference 3,9 bar
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
A
B
REV CLUTCH
46 bar
A
B
TEMPERATURE CHECK PORT
X
LUBRICATION RANGE CLUTCHES
PRESSURE CHECK PORT
X bar
C
PRESSURE INTENSIFIER RATIO 5:1
B
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
5.4.1 Neutral Selected
5-7
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
43 bar
5.4 POWERFLOWS, ACTIVATED SOLENOIDS AND HYDRAULIC CIRCUIT
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
OPERATOR COMPARTMENT
TE17 TRANSMISSION - HYDRAULIC DIAGRAM NEUTRAL SELECTED
Transmission Operation
Transmission Operation 5.4.1 Neutral (Continued)
1ST
2BD
3RD
TE13/17 3 SD
02/2002
REV
FWD
5-8
TE13/17 3 SD
02/2002
BY-PASS VALVE Pressure difference 3,9 bar
5-9
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
5.4.2 Forward 1st speed
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
OPERATOR COMPARTMENT
TE17 TRANSMISSION - HYDRAULIC DIAGRAM FORWARD 1st SELECTED
Transmission Operation
Transmission Operation 5.4.2 Forward 1st speed (continued)
1ST
FORWARD 1st (POWERFLOW)
TE13/17 3 SD
02/2002
2ND
REV
3RD
FWD
5-10
TE13/17 3 SD
02/2002
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
BY-PASS VALVE Pressure difference 3,9 bar
5-11
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
OPERATOR COMPARTMENT
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
TE17 TRANSMISSION - HYDRAULIC DIAGRAM FORWARD 2nd SELECTED
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
Transmission Operation
5.4.3 Forward 2nd speed
Transmission Operation 5.4.3 Forward 2nd speed (continued)
FORWARD 2nd (POWERFLOW)
TE13/17 3 SD
2ND
REV
3RD
FWD
1ST
02/2002
5-12
TE13/17 3 SD
02/2002
BY-PASS VALVE Pressure difference 3,9 bar
5-13
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
5.4.4 Forward 3rd speed
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
OPERATOR COMPARTMENT
TE17 TRANSMISSION - HYDRAULIC DIAGRAM FORWARD 3rd SELECTED
Transmission Operation
Transmission Operation 5.4.4 Forward 3rd speed (continued)
1ST
FORWARD 3rd (POWERFLOW)
TE13/17 3 SD
02/2002
2ND
REV
3RD
FWD
5-14
TE13/17 3 SD
02/2002
BY-PASS VALVE Pressure difference 3,9 bar
5-15
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
5.4.5 Reverse 1st speed
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
OPERATOR COMPARTMENT
TE17 TRANSMISSION - HYDRAULIC DIAGRAM REVERSE 1st SELECTED
Transmission Operation
Transmission Operation 5.4.5 Reverse 1st speed (continued)
1ST
REVERSE 1st (POWERFLOW)
TE13/17 3 SD
02/2002
2ND
REV
3RD
FWD
5-16
TE13/17 3 SD
02/2002
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
BY-PASS VALVE Pressure difference 3,9 bar
5-17
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
OPERATOR COMPARTMENT
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
TE17 TRANSMISSION - HYDRAULIC DIAGRAM REVERSE 2nd SELECTED
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
Transmission Operation
5.4.6 Reverse 2nd speed
Transmission Operation 5.4.6 Reverse 2nd speed (continued)
REVERSE 2nd
(POWERFLOW)
TE13/17 3 SD
2ND
REV
3RD
FWD
1ST
02/2002
5-18
TE13/17 3 SD
02/2002
BY-PASS VALVE Pressure difference 3,9 bar
5-19
OIL SUMP
SCREEN
Pump flow MIN 92,1 l/min at 2420 RPM Max 137,1 at 2916 RPM
Pressure reducer 12 bar
Pressure regulator valve 25-29 bar
TEMPERATURE GAUGE
3
1
Total neutral
Safety valve 8,5 bar
2
34 bar
A
TORQUE CONVERTER
B
71 C
FWD CLUTCH
32 bar
HOSE
45 bar
A
B
AA C
Torque converter by-pass valve pressure difference 4 bar
COOLER
2nd CLUTCH
HOSE
42 bar
A
B
REV CLUTCH
46 bar
B
TEMPERATURE CHECK PORT
X
A
PRESSURE CHECK PORT
X bar
LUBRICATION RANGE CLUTCHES
PRESSURE INTENSIFIER RATIO 5:1
B
C
ELECTRONIC CONTROLLED MODULATION VALVE 6 TO 0 bar
A
1st CLUTCH
3RD / 1ST
41 bar
3rd CLUTCH
43 bar
5.4.6 Reverse 3rd speed
AIR BREATHER
PUMP
FILTER
31 bar
PRESSURE GAUGE
OPERATOR COMPARTMENT
TE17 TRANSMISSION - HYDRAULIC DIAGRAM REVERSE 3rd SELECTED
Transmission Operation
Transmission Operation 5.4.6 Reverse 3rd speed (continued)
1ST
2ND
REV
3RD
FWD
REVERSE 3rd (POWERFLOW)
TE13/17 3 SD
02/2002
5-20
Transmission Operation 5.5 GEAR AND CLUTCH LAY-OUT
ut
tp Ou ut
Inp
Input engine 1, 2nd and REV clutch shaft 3rd en FWD clutch shaft Output shaft
TE13/17 3 SD
02/2002
5-21
TROUBLESHOOTING GUIDE
TE13/17 3 SD
02/2002
6-1
Troubleshooting guide The following information is presented as an aid to isolate and determine the specific problem area 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. 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. By analysing 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. 6.1 The Transmission TE13/17 powershift transmission with torque converter troubles fall into four general categories: 1. Mechanical problems 2. Hydraulical problems 3. Electrical problems 4. Controller problems In addition to the mechanical and electrical components, all of which must be in 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. 6.2
The input shaft and directional clutches
6.2.1 Stall test A stall test identifies transmission, converter or engine problems. Use the following procedure: 1. Put the vehicle against a solid barrier, such as a wall and/or apply the parking brake, block the wheels. 2. Put the directional control lever in FORWARD (or REVERSE, as applicable). 3. Select the highest speed. With the engine running, slowly increase engine speed to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range. 70°C [158° F] 4. Once the oil temperature reaches 70° C [158° F] check max. stall speed at full throttle in all gears. The figure obtained should be within 50 RPM as mentioned in the vehicle handbook and should be equal in all gears. Between gears allow the converter outlet temperature to cool down. to 70° C [158° F] by selecting neutral. If max. stall speed measured is below specifications, it could indicate an engine or converter problem. If max. stall speed measured is above specifications, it could indicate slipping clutches. CAUTION DO NOT OPERATE THE CONVERTER AT STALL CONDITION LONGER THAN 30 SECONDS AT ONE TIME, SHIFT TO NEUTRAL 15 SECONDS AND REPEAT THE PROCEDURE UNTIL DESIRED TEMPERATURE IS REACHED.
FOR
EXCESSIVE TEMPERATURE 120° C [250° F] MAXIMUM WILL CAUSE DAMAGE TO TRANSMISSION CLUTCHES, FLUID, CONVERTER AND SEALS.
TE13/17 3 SD
02/2002
6-2
Transmission Operation 6.2.2 Transmission pressure checks Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure can also be measured.
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.
Note: THE TRANSMISSION FLUID MUST BE AT OPERATING TEMPERATURE OF CORRECT FLUID LEVEL AND PRESSURE READINGS.
82 - 93° C [180 - 200° F] TO OBTAIN
DO NOT 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 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.
CONVERTER AT STALL
6.2.5 Controller (APC200): Please refer to functional description
TE13/17 3 SD
02/2002
6-3
Transmission Operation 6.3 TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles 6.3.1 Low clutch pressure Cause
Remedy
1. Low oil level. 2. Clutch pressure regulating valve stuck open. 3. Faulty charging pump. 4. Broken or worn clutch shaft or piston sealing rings. 5. Clutch piston bleed valve stuck open.
1. Fill to proper level. 2. Clean valve spool and housing. 3. Replace pump. 4. Replace sealing rings. 5. Clean bleed valve thoroughly.
6.3.2 Low charging pump output flow Cause 1. Low oil level. 2. Suction screen clogged. 3. Defective charging pump.
Remedy 1. Fill to proper oil level. 2. Clean suction screen. 3. Replace charging pump.
6.3.3 Overheating Cause 1. Worn oil sealing rings 2. Worn charging pump. 3. Low oil level. 4. Dirty oil cooler. 5. Restriction in cooler lines.
Remedy 1. Remove, disassemble and rebuild converter assy. 2. Replace charging pump. 3. Fill to proper level. 4. Clean cooler. 5. Change cooler lines.
6.3.4 Noisy converter Cause 1. Worn charging pump. 2. Worn or damaged bearings.
Remedy 1. Replace charging pump. 2. A complete disassembly will be necassary to determine which bearing is faulty.
6.3.5 Lack of power Cause 1. Low engine RPM at converter stall. 2. See Overheating and make same checks.
TE13/17 3 SD
Remedy 1. Tune engine, check governor. 2. Make corrections as explained in Overheating.
02/2002
6-4
Transmission Operation 7.4 CHECK POINTS
Plug - Magnetic drain M22 x 1.5 UNI
FRONT VIEW
Port 12B M10 x 1.5 THD Port 34 Port 42 Port 36 Temperature Checkport ¼ - 18 NPFT
Port 31
Port 41 Port 43 8 Mounting holes M20 x 2.5 THD 30mm DEEP
Plug - Magnetic drain M22 x 1.5 UNI
REAR VIEW
TE13/17 3 SD
02/2002
6-5
Transmission Operation 7.4 CHECK POINTS (continued)
Speed Sensor Turbine Speed
Port 11
Speed Sensor Output Speed Port 37 Split Flange for Dipstick Dia 25 mm
RIGHT VIEW
4 Mounting holes M20 x 2.5 THD 30mm DEEP
Speed Sensor Pump Driven Gear Speed Sensor Clutch Drum Gear
4 Mounting holes M20 x 2.5 THD 30mm DEEP
LEFT VIEW TE13/17 3 SD
02/2002
6-6
Transmission Operation 7.4 CHECK POINTS (continued)
Temp Sensor Inching Rev.
Lifting Eye Location
Port 46
Port 46
Port 35
Temp Sensor Inching Fwd
Filler Hole
TOP VIEW
4 Mounting holes M20 x 2.5 THD 30mm DEEP
Port 32
BOTTOM VIEW
TE13/17 3 SD
02/2002
6-7
Transmission Operation 7.4 CHECK POINTS (continued) (Rear view of control valve)
Port 12B From cooler Port 34 Lube pressure
Port 41 1st clutch pressure Port 43 3rd clutch pressure
Port 36 Solenoid pressure Port 42 2nd clucth pressure
Port 31 Regulator pressure
TE13/17 3 SD
02/2002
6-8
Transmission Operation 7.5 SPEED SENSOR - WIRING SCHEMATIC
VFS Fwd
3 4 14
VFS Rev
Pressure switch
VFS 2nd
15 9
VFS Fwd
VFS 3rd / 1st
10
Solenoid 3rd / 1st
7 8 1 2 5 6 13 14
VFS = Variable Force Solenoid Depending on input current (from 0 to 1000mA), output pressure is regulated from (6 to 0 bar)
Pin
Wire Colour
Function
1-2
Blue
VFS 2nd
3-4
Green
VFS Fwd
5-6
Yellow
VFS 3rd / 1st
7-8
Red
VFS Rev
9-10
Black
Total Neutral
11
White
Pressure switch
12
-
-
13
Orange
Solenoid 3rd / 1st
14
White
Common ground
TE13/17 3 SD
02/2002
6-9
Transmission Operation 7.6 SPEED SENSOR - STATIC STANDALONE TEST In order to be able to sense the currents, a series resistor of e.g. 200 Ω must be used. This resistor is integrated in the controller, but when the sensor is to be used, it must be connected externally. The idea is to connect the sensor to an external power source and measure the DC voltage across the series resistor. The voltage reading should be either 1.2V (from the 7mA ± 1mA current level) or 2.6 - 3.0V (for the 14mA ± 1mA current level). If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
TE13/17 3 SD
02/2002
6-10
TE 13/17 SECTIONAL VIEWS & PARTS IDENTIFICATION
TE13/17 3SD
02/2002
7-1
TE 13/17 DRIVE PLATE GROUP
1 2
3
4
5
TE13/17 3 SD
02/2002
7-2
TE 13/17 DRIVE PLATE GROUP Item 1 2 3 4 5
Description
Qty
Plate - Drive with welded nuts .................................................................................................. 1 Plate - Drive ............................................................................................................................. 2 Ring - Backing ......................................................................................................................... 1 Bolt ....................................................................................................................................... 10 Lockwasher ........................................................................................................................... 10
TE13/17 3 SD
02/2002
7-3
TE 13/17 TORQUE CONVERTER GROUP
3
5 4
1 2
6
TE13/17 3 SD
02/2002
7-4
TE 13/17 TORQUE CONVERTER GROUP Item 1 2 3 4 5 6
Description
Qty
Torque Converter .................................................................................................................................... 1 Sleeve - troque converter ........................................................................................................................ 1 Screw ....................................................................................................................................................... 8 Gasket - Torque converter ....................................................................................................................... 1 Lockwasher ............................................................................................................................................. 8 Snap ring ................................................................................................................................................. 1
TE13/17 3 SD
02/2002
7-5
TE 13/17 OUTPUT SHAFT GROUP
4 3 1
2
7 6 8
9 5
TE13/17 3 SD
02/2002
7-6
TE 13/17 OUTPUT SHAFT GROUP Item 1 2 3 4 5 6 7 8 9
Description
Qty
Flange - Output ....................................................................................................................... 1 O ring .................................................................................................................................... 1 Washer - Flange ...................................................................................................................... 1 Nut - Output shaft .................................................................................................................... 1 Bearing .................................................................................................................................... 1 Bearing .................................................................................................................................... 1 Seal - Output flange ................................................................................................................. 1 Gear - Speed sensor ................................................................................................................ 1 Spacer ..................................................................................................................................... 1
TE13/17 3 SD
02/2002
7-7
TE 13/17 PUMP DRIVE GROUP
4
5
6
7 3
8 9 6 5 7 8
11 10 4
6 12
5
10 12
8
7
10 1
11 10 2
TE13/17 3 SD
02/2002
7-8
TE 13/17 PUMP DRIVE GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12
Description
Qty
Gear - Torque converter ............................................................................................................ 1 Snap ring ................................................................................................................................. 2 Gear - Pump drive idler ............................................................................................................ 2 Gear - Pump drive .................................................................................................................... 2 Bearing .................................................................................................................................... 4 Support - Pump drive bearing ................................................................................................... 4 Snap ring ................................................................................................................................. 4 Shim - Washer ........................................................................................................................ 4 Plug ........................................................................................................................................ 2 Bolt ......................................................................................................................................... 8 Washer - Seal ......................................................................................................................... 4 Lockwasher ............................................................................................................................. 4
TE13/17 3 SD
02/2002
7-9
TE 13/17 GEAR GROUP
1 2
3 EV
4
R D&
2N
T
T
PU
1S
T OU
5 7
6 9
8 WD
F D&
3R
TE13/17 3 SD
02/2002
7-10
TE 13/17 GEAR GROUP Item 1 2 3 4 5 6 7 8 9
Description
Qty
Gear - Rev shaft ....................................................................................................................... 1 Gear - Clutch Rev .................................................................................................................... 1 Gear - Clutch 2nd .................................................................................................................... 1 Gear - Clutch 1st ..................................................................................................................... 1 Gear - Shaft - Output ............................................................................................................... 1 Gear - Forward shaft ................................................................................................................ 1 Gear - Clutch forward ............................................................................................................... 1 Gear - Clutch 3rd ..................................................................................................................... 1 Gear - Shaft 3rd ....................................................................................................................... 1
TE13/17 3 SD
02/2002
7-11
TE 13/17 CHARGING PUMP GROUP
11
9 10 5 6
12
3 1
4 8
7
2 13
TE13/17 3 SD
02/2002
14
7-12
TE 13/17 CHARGING PUMP GROUP 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Pump - Charging ..................................................................................................................... 1 Gasket - Charging pump .......................................................................................................... 1 Capscrew ................................................................................................................................ 4 Lockwasher ............................................................................................................................. 4 Adaptor - Charging pump ......................................................................................................... 1 Gasket - Adaptor ..................................................................................................................... 1 Capscrew ................................................................................................................................ 4 Lockwasher ............................................................................................................................. 4 Cover - Pump adaptor .............................................................................................................. 1 Gasket .................................................................................................................................... 1 Capscew ................................................................................................................................. 2 Lockwasher ............................................................................................................................. 2 Sleeve - Drive gear hub ............................................................................................................ 1 Snapring .................................................................................................................................. 1
TE13/17 3 SD
02/2002
7-13
TE 13/17 TRANSMISSION CASE & REAR COVER GROUP
14
14 15
15
14 8 27 2
20 22
3
6 24 15 14
25
28
23
6 26
1
5
8 6
7
4
13
23 21 17
16 12 11
24
19
10
TE13/17 3 SD
18
9
02/2002
7-14
8
TE 13/17 TRANSMISSION CASE & REAR COVER GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Description
Qty
Case - Transmission ................................................................................................................ 1 Gasket .................................................................................................................................... 1 Pin - Dowel .............................................................................................................................. 1 Bolt ....................................................................................................................................... 26 Lockwasher ........................................................................................................................... 26 Speed sensor .......................................................................................................................... 3 Plug ........................................................................................................................................ 1 Capscrew ................................................................................................................................ 3 Suction tube ............................................................................................................................ 1 O ring .................................................................................................................................... 1 Bolt ......................................................................................................................................... 2 Lockwasher ............................................................................................................................. 2 Cover - Rear ............................................................................................................................ 1 Plug ........................................................................................................................................ 4 Plug ........................................................................................................................................ 3 Spacer - Oil baffle .................................................................................................................... 1 Spacer - Oil baffle .................................................................................................................... 2 Baffle - Oil ............................................................................................................................... 1 Cover - Oil baffle ...................................................................................................................... 1 Baffle - Oil ............................................................................................................................... 1 Capscrew ................................................................................................................................ 3 Capscrew ................................................................................................................................ 3 Lockwasher ............................................................................................................................. 6 Plug - Magnetic drain............................................................................................................... 2 Cover ....................................................................................................................................... 1 O ring .................................................................................................................................... 1 Bolt ......................................................................................................................................... 4 Lockwasher ............................................................................................................................. 4
TE13/17 3 SD
02/2002
7-15
TE 13/17 CONVERTER HOUSING GROUP
5 27 11
16
1
9 10
15
2 3
12
8 8
3
2
4
2 13 14 3 3 3
2
2
21
2
23 24 19
18
22 20
26 21
7
25
17
TE13/17 3 SD
02/2002
7-16
6
TE 13/17 CONVERTER HOUSING GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Description
Qty
Housing - Converter ................................................................................................................. 1 Plug ........................................................................................................................................ 6 Plug ........................................................................................................................................ 7 Plug ........................................................................................................................................ 1 Gasket .................................................................................................................................... 1 Bolt ....................................................................................................................................... 21 Lockwasher ........................................................................................................................... 21 Plug - Core .............................................................................................................................. 2 Cover - Shipping ...................................................................................................................... 1 O ring .................................................................................................................................... 1 Bolt ......................................................................................................................................... 4 Lockwasher ............................................................................................................................. 4 Sensor - Speed ........................................................................................................................ 1 Capscrew ................................................................................................................................ 1 Sensor - Temperature .............................................................................................................. 1 Adaptor - Temperature switch .................................................................................................. 1 Filter ........................................................................................................................................ 1 Adaptor - Filter bypass ............................................................................................................ 1 Spool - Safety valve ................................................................................................................. 1 Adaptor - Filter ........................................................................................................................ 1 Spring - Lube regulator ............................................................................................................. 1 Plug ........................................................................................................................................ 2 Plug ........................................................................................................................................ 1 Gasket -Filter .......................................................................................................................... 1 Screw ...................................................................................................................................... 3 Lockwasher ............................................................................................................................. 3 Breather - Air ........................................................................................................................... 1
TE13/17 3 SD
02/2002
7-17
TE 13/17 REVERSE & 2ND GROUP
15
14 12 10 8 6
13
7
11 9
32 9 11
2 5 3
1
18 19
17
16
12 14
25 23
3 5
24 22
21 4
20
29 27 30
31
9 28
26
TE13/17 3 SD
02/2002
7-18
TE 13/17 REVERSE & 2ND GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Description
Qty
Ring- Piston ............................................................................................................................ 1 Bearing - Needle roller ............................................................................................................. 1 Ring - Snap End plate ............................................................................................................. 2 Spacer - Clutch plate ............................................................................................................... 1 Plate - End .............................................................................................................................. 2 Disc - Clutch outer half ............................................................................................................ 2 Disc - Clutch outer (3 in TE13) ................................................................................................. 4 Disc - Clutch inner (4 in TE13) ................................................................................................. 5 Snap ring ................................................................................................................................. 3 Spring - Retainer ...................................................................................................................... 1 Spring - Piston return spring .................................................................................................... 2 Spacer - Clutch piston pring ..................................................................................................... 2 Piston - Clutch ........................................................................................................................ 1 Seal - Outer ............................................................................................................................. 2 Piston - Ring ........................................................................................................................... 1 Shaft - 2nd / Rev ...................................................................................................................... 1 Ring - Piston ........................................................................................................................... 1 Piston - Clutch ........................................................................................................................ 1 Retainer -Spring ....................................................................................................................... 1 Disc - Clutch outer (8 in TE13) ............................................................................................... 10 Disc - Clutch inner (8 in TE13) ............................................................................................... 10 Seal ........................................................................................................................................ 1 Snap ring ................................................................................................................................. 1 Bearing .................................................................................................................................... 1 Snap ring ................................................................................................................................. 1 Bearing .................................................................................................................................... 1 Washer ................................................................................................................................... 1 Snap ring ................................................................................................................................. 1 Bearing .................................................................................................................................... 1 Retainig ring ............................................................................................................................ 1 Ring - Piston ........................................................................................................................... 3 Spacer - Clutch plate (ONLY USED in TE13) ........................................................................... 1
TE13/17 3 SD
02/2002
7-19
TE 13/17 FORWARD & 3RD GROUP
6
4
7 5
5
3
7 8 6 4 2
12
13
10 14
1 11 25
9 23
4
19 24 22
21 19
2
20
17 29
15 16
31
29
18
30
11 2
2 9
34 32 35 33
27 26 TE13/17 3 SD
02/2002
7-20
TE 13/17 FORWARD & 3RD GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Description
Qty
Locknut ................................................................................................................................... 1 Ring - Retaining ....................................................................................................................... 3 Bearing .................................................................................................................................... 1 Snap ring ................................................................................................................................. 4 Plate - Thrust ........................................................................................................................... 2 Bearing - Thrust ....................................................................................................................... 2 Washer - Thrust ....................................................................................................................... 2 Bearing - Needle roller ............................................................................................................. 1 Snap ring ................................................................................................................................. 2 Spacer ..................................................................................................................................... 1 End plate ................................................................................................................................. 2 Disc - Clutch Outer half ........................................................................................................... 2 Disc - Clutch inner (TE13 uses 2 Discs) .................................................................................. 4 Disc - Clutch outer (TE13 uses 1 Disc) .................................................................................... 3 Spring - Disc ............................................................................................................................ 5 Spacer ..................................................................................................................................... 1 Ring - Piston ........................................................................................................................... 1 Piston - Clutch ........................................................................................................................ 1 Seal - Outer ............................................................................................................................. 2 Assembly - FWD/ 3RD shaft drum & plug ............................................................................... 1 Ring - Piston ........................................................................................................................... 1 Piston - Clutch ........................................................................................................................ 1 Spacer ..................................................................................................................................... 1 Spring - Piston return ............................................................................................................... 1 Retainer ................................................................................................................................... 1 Disc - Clutch inner (TE13 uses 9) .......................................................................................... 11 Disc - Clutch outer (TE13 uses 9) .......................................................................................... 11 Seal ........................................................................................................................................ 1 Bearing .................................................................................................................................... 1 Snap ring ................................................................................................................................. 1 Bearing .................................................................................................................................... 1 Washer - bearing support ........................................................................................................ 1 Bearing .................................................................................................................................... 1 Ring - retaining ........................................................................................................................ 1 Ring - Piston ........................................................................................................................... 3
TE13/17 3 SD
02/2002
7-21
TE 13/17 FORWARD & 3RD GROUP
11 9 4
10
6 8
3
28
7 2
27
5 25 24 23
26 21 19 1
22
22 35
17
20 22
15
30
18
32
16
29
13
34
31
31
33
29 12
14
32 30 22
TE13/17 3 SD
02/2002
7-22
TE 13/17 FORWARD & 3RD GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Description
Qty
Seal - Oil baffle ........................................................................................................................ 1 Snap ring ................................................................................................................................. 1 Baffle - Oil ............................................................................................................................... 1 O ring - Oil baffle ................................................................................................................... 1 Snap ring ................................................................................................................................. 1 Bearing .................................................................................................................................... 1 Ring - Piston ........................................................................................................................... 1 Support - Stator ....................................................................................................................... 1 Bolts ....................................................................................................................................... 8 Lockwasher ............................................................................................................................. 8 Gasket - Stator support ........................................................................................................... 1 Ring - Piston ........................................................................................................................... 1 Ring - Piston ........................................................................................................................... 1 Bearing .................................................................................................................................... 1 Asembly - 1st shaft, drum & plug ............................................................................................ 1 Ring - Piston inner ................................................................................................................... 1 Seal - Outer ............................................................................................................................. 1 Piston - Clutch ........................................................................................................................ 1 Spacer ..................................................................................................................................... 1 Spring ...................................................................................................................................... 1 Retainer - Spring ...................................................................................................................... 1 Snap ring ................................................................................................................................. 4 Disc - Clutch outer half ............................................................................................................ 2 Disc - Clutch outer (TE13 uses 3) ............................................................................................ 4 Disc - Clutch inner (TE13 uses 4) ............................................................................................ 5 Plate - End .............................................................................................................................. 1 Spacer - Clutch plate (Only used in TE13) ............................................................................... 1 Snap ring ................................................................................................................................. 1 Washer - thrust ....................................................................................................................... 2 Bearing - Needle roller ............................................................................................................. 2 Plate - thrust ........................................................................................................................... 2 Bearing - Needle roller ............................................................................................................. 2 Spacer ..................................................................................................................................... 1 Bearing .................................................................................................................................... 1 Snap ring ................................................................................................................................. 1
TE13/17 3 SD
02/2002
7-23
TE 13/17 CONTROL VALVE GROUP
5 6
1 7 8
3
4
2
TE13/17 3 SD
02/2002
7-24
TE 13/17 CONTROL VALVE GROUP Item 1 2 3 4 5 6 7 8
Description
Qty
Group - Control valve (See pages 28 - 29 for parts description) ................................................ 1 Gasket - Rear cover to adaptor plate ....................................................................................... 1 Gasket - Adaptor plate to valve ................................................................................................ 1 Plate - Adaptor ........................................................................................................................ 1 Screw .................................................................................................................................... 20 Lockwasher ........................................................................................................................... 20 Capscrew .............................................................................................................................. 15 Lockwasher ........................................................................................................................... 15
TE13/17 3 SD
02/2002
7-25
TE 13/17 CONTROL VALVE GROUP (CONTINUED)
7 8
6 4 5 4 3 2
1
TE13/17 3 SD
02/2002
7-26
TE 13/17 CONTROL VALVE GROUP (CONTINUED) Item 1 2 3 4 5 6 7 8
Description
Qty
Plate - Distribution ................................................................................................................... 1 Gasket - Distribution plate to regulator valve ............................................................................ 1 Assembly - Regulator valve (See pages 30 - 31 for parts description) ...................................... 1 gasket - Separator plate .......................................................................................................... 2 Plate - Separator ..................................................................................................................... 1 Assembly - Modulator (See pages 32 - 33 for parts description) .............................................. 1 Screw ...................................................................................................................................... 7 Lockwasher ............................................................................................................................. 7
TE13/17 3 SD
02/2002
7-27
TE 13/17 REGULATOR VALVE GROUP
15
16
13 14 10
12 5 6 7 7
6
5 10
8 9
4
10
3 2 2 11
10
1
TE13/17 3 SD
02/2002
7-28
TE 13/17 REGULATOR VALVE GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Description
Qty
Body - Regulator valve ............................................................................................................. 1 Spool - Regulator ..................................................................................................................... 2 Spring - Pressure regulator ...................................................................................................... 1 Cover - Pressure regulator ....................................................................................................... 1 Spool - Pressure intensifier ...................................................................................................... 4 Spring - Pressure intensifier ..................................................................................................... 4 Piston - pressure intensifier ..................................................................................................... 4 Spool - Converter bypass ......................................................................................................... 1 Spring - Lube regulator & filter bypass ..................................................................................... 1 Plug ........................................................................................................................................ 6 Spring - Safety valve ................................................................................................................ 1 Plug - Restriction ..................................................................................................................... 4 Cover ....................................................................................................................................... 1 O ring .................................................................................................................................... 1 Bolt ......................................................................................................................................... 4 Lockwasher ............................................................................................................................. 4
TE13/17 3 SD
02/2002
7-29
TE 13/17 MODULATOR VALVE GROUP
25 20
15
26 16 1
4
24
27
2 3
22 3
10
5
23
2
4
19 18 17 20
8
6
14 9 13
12
21 11 20
6
7 10
TE13/17 3 SD
02/2002
7-30
TE 13/17 MODULATOR VALVE GROUP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Description
Qty
Body - Modulator valve ............................................................................................................. 1 Spool - Accumulator ................................................................................................................ 4 Spring - Accumulator ............................................................................................................... 4 Solenoid .................................................................................................................................. 4 Spool - 1st / 3rd ....................................................................................................................... 1 Spring - Selector valve ............................................................................................................. 2 Spool - Total neutral ................................................................................................................. 1 Spool - Pressure reducer ......................................................................................................... 1 Spring ...................................................................................................................................... 1 Solenoid .................................................................................................................................. 2 Clamp - Pressure switch ......................................................................................................... 1 Stop - Reducer spool ............................................................................................................... 1 Plate - Separator ..................................................................................................................... 1 O ring .................................................................................................................................... 1 Cover - Solenoids right ............................................................................................................. 1 Gasket - Cover solenoids right ................................................................................................. 1 Cover - Solenoids left ............................................................................................................... 1 Gasket - Cover solenoids left ................................................................................................... 1 Wiring harnes .......................................................................................................................... 1 Screw .................................................................................................................................... 17 Pressure Switch ...................................................................................................................... 1 Plug ...................................................................................................................................... 11 Cover ....................................................................................................................................... 1 O ring .................................................................................................................................... 1 Screw ...................................................................................................................................... 4 Lockwasher ............................................................................................................................. 4 Plug ........................................................................................................................................ 1
TE13/17 3 SD
02/2002
7-31
TE 13/17 ASSEMBLY INSTRUCTIONS
TE13/17 3SD
02/2002
8-1
TE 13/17 ASSEMBLY INSTRUCTIONS
5
13 3
4
7 9
6
9
16 2
9 15 11
10
8 2 14
1 12
TE13/17 3 SD
02/2002
8-2
TE 13/17 ASSEMBLY INSTRUCTIONS All lead in chamfers for oil seals, piston rings and O rings must be smooth and free from burs. Inspect at assembly. Add grease to O ring before assembly. Add some grease to piston rings before assembly. Apply a thin coating of grease between seal lips on lip type seals prior to assembly. Use only precoated pipe plugs. On uncoated pipe plugs apply a light coat of Loctite® 592. Pump must be filled up with oil prior to assembly. After assembly of parts using Loctite®, there must not be any free or excess material which might enter the oil circuit. Apply a light coat of Loctite® 262 or 270 to all thru hole stud holes. 1
Tighten oil filter to 22-28 lbs.ft [30-38 Nm].
2
Teflon seals must be sized prior to assembly. Add some grease to seal diameter of clutch hub before assembly.
3
1st Clutch TE17 5 separator plates with inner splines 4 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines. 1st Clutch TE13 4 separator plates with inner splines 3 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines.
CAUTION: THE FRICTION AND SEPARATOR PLATES FOR FWD, REV AND 1ST, 2ND AND 3RD ARE NOT THE SAME.DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES. Start with one side-friction plate, metal against piston. Then alternately separator and friction plates. End with a one-sided friction plate, metal against the end plate. Clearance
TE17
Min. clearance Max. clearance
1.3 mm [0.05] 1.7 mm [0.07]
TE13
Min. clearance Max. clearance
1.0 mm [0.03] 1.4 mm [0.05]
Use one of the 3 different thickness end-plates available to obtain this clearance.
TE13/17 3 SD
02/2002
8-3
TE 13/17 ASSEMBLY INSTRUCTIONS 4
2nd Clutch TE17 5 separator plates with inner splines 4 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines. 2nd Clutch TE13 4 separator plates with inner splines 3 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines.
CAUTION: THE FRICTION AND SEPARATOR PLATES FOR FWD, REV AND 1ST, 2ND AND 3RD ARE NOT THE SAME.DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES. Start with one side-friction plate, metal against piston. Then alternately separator and friction plates. End with a one-sided friction plate, metal against the end plate. Clearance
TE17
Min. clearance Max. clearance
1.3 mm [0.05] 1.7 mm [0.07]
TE13
Min. clearance Max. clearance
1.0 mm [0.03] 1.4 mm [0.05]
Use one of the 3 different thickness end-plates available to obtain this clearance.
5
3rd Clutch TE17 4 separator plates with inner splines 3 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines. 3rd Clutch TE13 3 separator plates with inner splines 2 friction plates (friction material on both sides) with outer splines. 2 friction plates (friction material on one side) with outer splines.
CAUTION: THE FRICTION AND SEPARATOR PLATES FOR FWD, REV AND 1ST, 2ND AND 3RD ARE NOT THE SAME.DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES. Start with one side-friction plate, metal against piston. Then alternately separator and friction plates. End with a one-sided friction plate, metal against the end plate. Clearance
TE17
Min. clearance Max. clearance
1.3 mm [0.05] 1.7 mm [0.07]
TE13
Min. clearance Max. clearance
1.0 mm [0.03] 1.4 mm [0.05]
Use one of the 3 different thickness end-plates available to obtain this clearance. TE13/17 3 SD
02/2002
8-4
TE 13/17 ASSEMBLY INSTRUCTIONS 6
FWD Clutch TE17 11 separator plates with inner splines 11 friction plates (friction material on both sides) with outer splines. FWD Clutch TE13 9 separator plates with inner splines 9 friction plates (friction material on both sides) with outer splines.
CAUTION: THE FRICTION AND SEPARATOR PLATES FOR FWD, REV AND 1ST, 2ND AND 3RD ARE NOT THE SAME.DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES. Start with one separator plate.Then alternately separator and friction plates. End with friction plate against end plate. Clearance
TE17
Min. clearance Max. clearance
3.1 mm [0.12] 3.5 mm [0.14]
TE13
Min. clearance Max. clearance
2.5 mm [0.01] 2.9 mm [0.11]
Use one of the 3 different thickness end-plates available to obtain this clearance.
7
REV Clutch TE17 10 separator plates with inner splines 10 friction plates (friction material on both sides) with outer splines. REV Clutch TE13 9 separator plates with inner splines 9 friction plates (friction material on both sides) with outer splines.
CAUTION: THE FRICTION AND SEPARATOR PLATES FOR FWD, REV AND 1ST, 2ND AND 3RD ARE NOT THE SAME. DO NOT MIX PLATES WITH PLATES FROM OTHER CLUTCHES. Start with separator plate, metal against piston. Then alternately separator and friction plates. End with friction plate against the end plate. Clearance
TE17
Min. clearance Max. clearance
3.1 mm [0.12] 3.5 mm [0.14]
TE13
Min. clearance Max. clearance
2.5 mm [0.01] 2.9 mm [0.11]
Use one of the 3 different thickness end-plates available to obtain this clearance.
TE13/17 3 SD
02/2002
8-5
TE 13/17 ASSEMBLY INSTRUCTIONS CAUTION: 8
INSTALLATION FORCE OF DISC SPRING IS 6015 NM.
CAUTION: 9
INSTALLATION FORCE OF COIL SPRING IS 1420 NM.
10
Be sure that shielded and sealed bearings are mounted as shown.
11
3rd clutch spring discs concave side of first spring disc to be placed against clutch piston wear sleeve. Remaining 5 springs to be stacked alternately reversed as shown in fig 222.
12
Seals must be pressed in perpendicular upon shaft axis from bearing side.
13
Tighten air breather to 34-41 Nm [25-30 Lbs.ft]
14
Tighten nut to 339-407 Nm [250-300 Lbs.ft]
15
Tighten nut to 339-407 Nm [250-300 Lbs.ft]
16
Seals must be pressed in perpendicular upon shaft axis from converter side.
TE13/17 3 SD
02/2002
8-6
TE 13/17 DISASSEMBLY & REASSEMBLY
TE13/17 3SD
02/2002
9-1
DISASSEMBLY OF TRANSMISSION
NOTE: TE17 is being used for this manual. Figure 1 Front view of the TE17 transmission 3 speed.
Figure 4 Remove filter element.
Figure 2 Remove drive plate mounting bolts and washers.
Figure 5 Remove filter adapter bolts and lockwashers.
Figure 3 Drive plate and backing ring removed.
Figure 6 Remove filter adapter and gasket.
TE 13/17 3 SD
02/02
9-2
DISASSEMBLY OF TRANSMISSION
Figure 7 Remove oil baffle retaining ring.
Figure 10 Remove torque converter gear snap ring.
Figure 8 Use special tool to lift converter and oil baffle from converter housing as an assembly.
Figure 11 Torque converter gear removed.
(See Chapter 10 - Special Tools)
Figure 9 Converter housing, oil baffle and sealing ring removed.
TE 13/17 3 SD
Figure 12 Remove torque converter gear lower snap ring.
02/02
9-3
DISASSEMBLY OF TRANSMISSION
Figure 13 Remove stator support bearing retaining ring.
Figure 16 Remove stator support capscrews and lockwashers.
Figure 14 Pry stator support bearing from converter assembly as shown.
Figure 17 Torque converter sleeve and gasket removed.
Figure 15 Stator support bearing removed.
Figure 18 Oil baffle and sealing ring removed.
TE 13/17 3 SD
02/02
9-4
DISASSEMBLY OF TRANSMISSION
Figure 19 Remove charging pump cover bolts and lockwashers.
Figure 22 Remove charging pump adaptor and gasket.
Figure 20 Remove charging pump cover and gasket.
Figure 23 Remove pump cap screws and lockwashers.
Figure 21 Remove charging pump adaptor cap screws and lockwashers.
Figure 24 Remove pump assembly and gasket.
TE 13/17 3 SD
02/02
9-5
DISASSEMBLY OF TRANSMISSION
Figure 25 Remove aux pump drive cover plate bolts and lockwashers.
Figure 28 Support converter housing with a chain hoist and using a soft hammer, tap converter housing from transmission case.
Figure 26 Remove aux pump drive cover plate and gasket.
Figure 29 Remove pump drive idler gear bolts and lockwashers.
Figure 27 Remove converter housing to transmission case bolts and lockwashers.
Figure 30 Remove pump drive idler gear, washer and bearing as an assembly.
TE 13/17 3 SD
02/02
9-6
DISASSEMBLY OF TRANSMISSION
Figure 31 Remove pump drive idler gear bolts and lockwashers.
Figure 34 Remove pump drive gear, washer and bearing as an assembly.
Figure 32 Remove pump drive idler gear, washer and bearing as an assembly.
Figure 35 Remove pump drive gear bolts and lockwashers.
Figure 33 Remove pump drive gear bolts and lockwashers.
Figure 36 Remove pump drive gear, washer and bearing as an assembly.
TE 13/17 3 SD
02/02
9-7
DISASSEMBLY OF TRANSMISSION
Figure 37 Remove stator support bolts and lockwashers.
Figure 40 Remove lock nut from forward and 3rd shaft assembly.
Figure 38 Stator support and gasket removed.
Figure 41 Fit special tool to prevent gear from dropping when transmission is turned. (See chapter 10 - Special Tools page 2)
Figure 39 Remove temperature sensor from housing.
TE 13/17 3 SD
Figure 42 Remove control valve assembly bolts (15) and lockwashers and capscrews (20) and lockwashers. See figure 43 for bolts to be removed.
02/02
9-8
DISASSEMBLY OF TRANSMISSION
Figure 43 Remove only marked bolts. TE 13/17 3 SD
02/02
9-9
DISASSEMBLY OF TRANSMISSION
Figure 44 Use a chain hoist to lift valve assembly from transmission.
Figure 47 Flange, O ring, washer and nut removed.
Figure 45 Remove separator plate and upper and lower gaskets.
Figure 48 Remove bolts and lockwashers from rear cover.
Figure 46 Remove rear output flange, nut, O ring and washer.
Figure 49 Using external snap ring pliers, open snap ring on 2nd/REV shaft and using a hoist remove rear cover.
TE 13/17 3 SD
02/02
9-10
DISASSEMBLY OF TRANSMISSION
Figure 50 Rear cover removed.
Figure 53 Remove bearing retaining ring.
Figure 51 Remove rear cover gasket.
Figure 54 Use a bearing puller to remove bearing, gear and washer.
Figure 52 Remove seal rings from FWD/3rd shaft.
Figure 55 Bearing, gear and washer removed.
TE 13/17 3 SD
02/02
9-11
DISASSEMBLY OF TRANSMISSION
Figure 56 Remove seal rings from 2nd/REV shaft.
Figure 59 Bearing washer and gear removed.
Figure 57 Remove rear bearing retaining ring.
Figure 60 Using special tool lift shaft assembly from case.
Figure 58 Remove gear, washer and bearing from 2nd/REV shaft.
Figure 61 Using special tool lift shaft assembly from case.
TE 13/17 3 SD
02/02
9-12
DISASSEMBLY OF TRANSMISSION
Figure 62 Remove pilot bearing.
Figure 65 Remove 2nd gear from transmission case.
Figure 63 Remove 2nd speed gear retaining ring.
Figure 66 Remove oil baffle bolts and lockwashers.
Figure 64 Pull up 2nd gear slightly to allow FWD/3rd clutch drum and shaft assembly to be removed.
Figure 67 Remove oil baffle (front side).
TE 13/17 3 SD
02/02
9-13
DISASSEMBLY OF TRANSMISSION
Figure 68 Remove oil baffle spacers.
Figure 71 Remove suction tube.
Note: Middle spacers is longer.
Figure 69 Remove bolts and lockwashers from lower oil baffle.
Figure 72 Remove special tool.
Figure 70 Remove lower oil baffle plate.
Figure 73 Remove 1st clutch drum and turbine shaft as an assembly.
TE 13/17 3 SD
02/02
9-14
DISASSEMBLY OF TRANSMISSION
Figure 74 Remove gear.
Figure 75 Remove 1st clutch drum retaining ring.
TE 13/17 3 SD
02/02
9-15
DISASSEMBLY & REASSEMBLY OF REAR COVER
Figure 76 Remove rear oil baffle bolts and lockwashers.
Figure 78 Install rear oil baffle.
Figure 77 Remove rear oil baffle.
Figure 79 Install oil baffle bolts and lockwashers and tighten to specified torque.
TE 13/17 3 SD
02/02
9-16
DISASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 80 Use a bearing puller to remove bearing from shaft.
Figure 83 Remove clutch gear.
Figure 81 Remove snap ring.
Figure 84 Remove needle bearings and spacer.
Figure 82 Remove upper thrust bearing, washer and plate.
Figure 85 Remove lower thrust bearing, washer and plate.
TE 13/17 3 SD
02/02
9-17
DISASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 86 Remove retaining snap ring.
Figure 89 Remove 1 (one) outer half disc.
Figure 87 Remove backing plate retaining ring.
Figure 90 Remove inner and outer clutch discs.
CAUTION: Do not bend or disform teeth.
Figure 88 Remove clutch disc backing plate.
TE 13/17 3 SD
Figure 91 Remove 1 (one) outer half disc.
02/02
9-18
DISASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 92 Compress piston return spring and remove spring retainer snap ring.
Figure 95 Remove clutch piston assembly.
Figure 93 Remove spring retainer and spring.
Figure 96 Remove inner piston ring from shaft.
Figure 94 Remove return spring spacer.
Figure 97 Remove upper sealing ring from turbine shaft.
TE 13/17 3 SD
02/02
9-19
DISASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 98 Remove lower sealing ring from turbine shaft.
Figure 99 Use a press bench to remove bearing from shaft.
TE 13/17 3 SD
02/02
9-20
REASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 100 Warm bearing to 120° C [248° F] and install on shaft.
Figure 103 Install piston inner seal on shaft.
Figure 101 Install lower seal ring on shaft.
Figure 104 Refer to Cleaning and Inspection pages. Install clutch piston outer seal and install piston in clutch drum.
Note: Ring must be sized before installing in clutch drum. Sizing is best accomplished by rotating piston while holding a round object against the new sealing ring. Rotate piston until seal is flush with outer diameter of piston.
Figure 102 Install upper seal ring on shaft.
TE 13/17 3 SD
02/02
9-21
REASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 105 Install clutch piston wear plate.
Figure 108 Install one outer half disc with friction material away from piston.
Figure 106 Install piston spring and spring retainer.
Figure 109 Install one steel disc. Alternate friction and steel discs until proper amount of discs are installed. First and last disc are steel.
Figure 107 Compress return spring and install snap ring.
Figure 110 Install one outer half disc with friction material down.
TE 13/17 3 SD
02/02
9-22
REASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 111 Install end plate.
Figure 114 Install inner thrust bearing and spacers.
Figure 112 Install end plate retaining ring.
Figure 115 Install needle bearings and spacer.
Figure 113 Install thrust bearing snap ring.
Figure 116 Install 1st clutch gear in clutch drum. Align splines on clutch gear with internal teeth of steel discs. Do not force this operation. Gear splines must be in full position with internal teeth of all inner discs.
TE 13/17 3 SD
02/02
9-23
REASSEMBLY OF 1ST CLUTCH DRUM AND TURBINE SHAFT
Figure 117 Install outer thrust bearing and spacers.
Figure 118 Install outer thrust bearing retaining snap ring.
Figure 119 Warm bearing to 120°C [248°F] and install bearing on shaft.
TE 13/17 3 SD
02/02
9-24
DISASSEMBLY OF REV CLUTCH DRUM
Figure 120 Remove outer bearing snap ring.
Figure 123 Remove end plate retaining ring.
Figure 121 Use a bearing puller to remove gear and bearing.
Figure 124 Remove end plate spacer ring.
Figure 122 Clutch gear and bearing removed.
Figure 125 Remove end plate and seal as an assembly.
TE 13/17 3 SD
02/02
9-25
DISASSEMBLY OF REV CLUTCH DRUM
Figure 126 Remove inner and outer discs.
Figure 129 Remove inner bearing snap ring.
Figure 127 Use a bearing puller to remove clutch inner bearing.
Figure 130 Compress spring to remove spring retainer snap ring.
Figure 128 Inner bearing removed.
Figure 131 Remove spring and spring retainer.
TE 13/17 3 SD
02/02
9-26
DISASSEMBLY OF REV CLUTCH DRUM
Figure 132 Remove piston wear plate.
Figure 133 Remove clutch piston assembly.
Figure 134 Remove clutch piston inner seal.
TE 13/17 3 SD
02/02
9-27
DISASSEMBLY OF 2ND CLUTCH DRUM
Figure 135 Remove backing plate retaining ring.
Figure 138 Remove inner and outer discs.
Figure 136 Remove backing plate.
Figure 139 Remove one outer half disc.
Figure 137 Remove one outer half disc.
Figure 140 Compress spring and remove spring retainer snap ring.
TE 13/17 3 SD
02/02
9-28
DISASSEMBLY OF 2ND CLUTCH DRUM
Figure 141 Remove spring and spring retainer.
Figure 144 Remove inner piston ring.
Figure 142 Remove piston wear plate.
Figure 145 Remove clutch shaft sealing ring
Figure 143 Remove clucth piston assembly.
TE 13/17 3 SD
02/02
9-29
REASSEMBLY OF 2ND CLUTCH DRUM
Figure 146 Install clutch shaft sealing ring.
Figure 149 Install piston wear plate.
Figure 147 Install inner piston sealing ring.
Figure 150 Install piston spring and spring retainer.
Figure 148 Refer to Cleaning and Inspection pages.
Figure 151 Compress return spring and install snap ring.
Install clutch piston outer seal ring and size as explained in figure 104.
TE 13/17 3 SD
02/02
9-30
REASSEMBLY OF 2ND CLUTCH DRUM
Figure 152 Install one outer half disc with friction material away from piston.
Figure 155 Install backing plate.
Figure 153 Install one steel disc. Alternate friction and steel discs until proper amount of discs are installed. First and last discs are steel.
Figure 156 Install backing plate spacer.
(See assembly Instructions page)
Only fitted on TE13. See assembly instruction page.
Figure 154 Install one outer half disc with friction material down.
Figure 157 Install backing plate retaining ring..
TE 13/17 3 SD
Note:
02/02
9-31
REASSEMBLY OF REV CLUTCH DRUM
Figure 158 Install piston inner seal on shaft.
Figure 161 Install piston spring and spring retainer.
Figure 159 Refer to Cleaning and Inspection pages.
Figure 162 Compress return spring and install snap ring.
Install clutch piston outer seal ring and size as explained in figure 104.
Figure 160 Install piston wear plate.
Figure 163 Install one steel disc. Alternate friction and steel discs until proper amount are installed. First and last discs are steel. (See assembly instructions)
TE 13/17 3 SD
02/02
9-32
REASSEMBLY OF REV CLUTCH DRUM
Figure 164 Install new seal into backing plate and install plate.
Figure 167 Install inner bearing retaining ring.
Figure 165 Install spacer ring.
Figure 168 Install clutch gear inner bearing. Make sure bearing shield is on the outside
Figure 166 Install backing plate retaining ring.
Figure 169 Tap bearing into place.
TE 13/17 3 SD
02/02
9-33
REASSEMBLY OF REV CLUTCH DRUM
Figure 170 Install reverse clutch gear in clutch drum. Align splines on clutch gear with internal teeth of steel discs. Do not force this operation.
Figure 173 Install outer bearing snap ring.
Gear splines must be in full position with internal teeth of all inner discs.
Figure 171 Install clutch gear outer bearing.
Figure 172 Tap bearing into place.
TE 13/17 3 SD
02/02
9-34
DISASSEMBLY OF 3RD CLUTCH DRUM
Figure 174 Remove 3rd shaft front bearing snap ring.
Figure 177 Remove thrust bearing and spacers.
Figure 175 Remove 3rd shaft front bearing.
Figure 178 Remove 3rd clutch gear.
Figure 176 Remove thrust bearing snap ring.
Figure 179 Remove 3rd clutch gear needle bearing.
TE 13/17 3 SD
02/02
9-35
DISASSEMBLY OF 3RD CLUTCH DRUM
Figure 180 Remove inner thrust bearing and spacers.
Figure 183 Remove end plate spacer.
Figure 181 Remove thrust bearing snap ring.
Figure 184 Remove end plate.
Figure 182 Remove end plate retaining ring.
Figure 185 Remove inner and outer discs.
TE 13/17 3 SD
02/02
9-36
DISASSEMBLY OF 3RD CLUTCH DRUM
Figure 186 Compress spring and remove snap ring.
Figure 189 Remove clutch piston assembly.
Figure 187 Remove Belleville washer spring pack.
Figure 190 Remove inner piston ring.
Figure 188 Remove piston wear sleeve.
TE 13/17 3 SD
02/02
9-37
DISASSEMBLY OF FWD CLUTCH DRUM
Figure 191 Remove outer bearing snap ring.
Figure 194 Remove end plate retaining ring.
Figure 192 Use a bearing puller to remove gear and bearing.
Figure 195 Remove end plate and seal as an assembly.
Figure 193 Clutch gear and bearing removed.
Figure 196 Remove inner and outer discs.
TE 13/17 3 SD
02/02
9-38
DISASSEMBLY OF FWD CLUTCH DRUM
Figure 197 Use a bearing puller to remove clutch inner bearing.
Figure 200 Spring and spring retainer removed.
Figure 198 Remove inner bearing snap ring.
Figure 201 Remove piston wear plate.
Figure 199 Compress spring and remove spring retainer snap ring.
Figure 201 Remove clutch piston assembly.
TE 13/17 3 SD
02/02
9-39
DISASSEMBLY OF FWD CLUTCH DRUM
Figure 202 Remove clutch piston inner seal.
TE 13/17 3 SD
02/02
9-40
REASSEMBLY OF FWD CLUTCH DRUM
Figure 203 Install piston inner seal.
Figure 206 Install piston return spring and spring retainer
Figure 204 Refer to Cleaning and Inspection pages.
Figure 207 Compress spring and spring retainer. Install retainer snap ring.
Install clutch piston outer seal ring and size as explained in figure 104.
Figure 205 Install piston wear plate.
TE 13/17 3 SD
Be sure snap ring is in full position in groove.
Figure 208 Install inner bearing snap ring.
02/02
9-41
REASSEMBLY OF FWD CLUTCH DRUM
Figure 209 Install one steel disc. Alternate friction and steel discs until the corect amount of discs are installed. First and last discs are steel.
Figure 212 Install clutch gear inner bearing. Be sure that shield faces out.
(See assembly instructions.)
Figure 210 Install new seal into end plate and install end plate.
Figure 213 Tap bearing into place.
Figure 211 Install end plate retaining ring.
Figure 214 Install clutch gear in clutch drum. Align splines on clutch gear with internal splines of steel discs. Do not force this operation. Gear splines must be in full position with internal teeth of all inner discs.
TE 13/17 3 SD
02/02
9-42
REASSEMBLY OF FWD CLUTCH DRUM
Figure 215 Install outer bearing.
Figure 216 Tap bearing into place.
Figure 217 Install outer bearing retaining ring.
TE 13/17 3 SD
02/02
9-43
REASSEMBLY OF 3RD CLUTCH DRUM
Figure 218 Install new inner piston sealing ring.
Figure 221 Install clutch piston return disc springs. First spring with large diameter of bevel towards wear sleeve. See figure 222
Shaft Piston Wear sleeve
Figure 219 Refer to Cleaning and Inspection pages.
Figure 222
Install clutch piston outer seal. Seal must be sized. See figure 104.
Figure 220 Install piston wear sleeve.
TE 13/17 3 SD
Figure 223 Install disc washer spring retainer ring.
02/02
9-44
REASSEMBLY OF 3RD CLUTCH DRUM
Figure 224 Compress spring and install clutch piston spring retainer snap ring. Be sure ring is in full position in groove
Figure 227 Install one outer half disc with friction material down.
Figure 225 Install one outer half disc with friction material away from piston.
Figure 228 Install end plate.
Figure 226 Install one steel disc. Alternate friction and steel discs until proper amount of discs are installed. First and last disc are steel.
Figure 229 Install end plate spacer.
(See assembly instructions.)
TE 13/17 3 SD
02/02
9-45
REASSEMBLY OF 3RD CLUTCH DRUM
Figure 230 Install end plate retaining ring.
Figure 233 Install needle bearing.
Figure 231 Install thrust bearing snap ring.
Figure 234 Install 3rd clutch gear in clutch drum. Align splines on clutch gear with internal teeth of steel discs. Do not force this operation. Gear splines must be in full position with internal teeth of all inner discs.
Figure 232 Install thrust bearing and spacers.
Figure 235 Install outer thrust bearing and spacers.
TE 13/17 3 SD
02/02
9-46
REASSEMBLY OF 3RD CLUTCH DRUM
Figure 236 Install Install outer thrust bearing retaining snap ring.
Figure 237 Warm bering to 120° C [248° F] and install bearing.
Figure 238 Install bearing retaining ring.
TE 13/17 3 SD
02/02
9-47
DISASSEMBLY OF OUTPUT SHAFT
Figure 239 Use a bearing puller as shown to remove speed sensor gear and bearing.
Be careful not to damage teeth on speed sensor gear.
Figure 240 Gear, bearing and spacer removed.
Figure 241 Use bearing puller
TE 13/17 3 SD
02/02
9-48
REASSEMBLY OF OUTPUT SHAFT
Figure 242 Warm bearing to 120° C [248° F] and install bearing.
Figure 245 Warm bearing to 120° C [248° F] and install bearing.
Figure 243 Turn shaft and Install speed sensor gear.
Figure 244 Install spacer.
TE 13/17 3 SD
02/02
9-49
REASSEMBLY OF TRANSMISSION CASE
Figure 246 Install input shaft rear bearing retaining snap ring.
Figure 249 Fit special tool to prevent gear from dropping when transmission is turned. See special Tools Section page 2.
Figure 247 Install turbine shaft and 1st clutch as an assembly.
Figure 250 Install suction tube using Loctite© 243 on fixing bolts and tighten to specified torque.
Figure 248 Install FWD and 3RD shaft gear.
Figure 251 Install upper oil baffle plate using Loctite© 243 on fixing bolts and tighten to specified torque.
TE 13/17 3 SD
02/02
9-50
REASSEMBLY OF TRANSMISSION CASE
Figure 252 Install oil baffle plate mounting spacers. (Longest one in the middle).
Figure 255 Raise 2ND gear up to allow 3RD/FWD shaft assembly to be installed.
Figure 253 Install oil baffle using Loctite© 243 on fixing bolts and tighten to specified torque.
Figure 256 Install 2ND clutch gear retaining ring.
Figure 254 Install 2ND clutch gear.
Figure 257 Install 2ND clutch pilot shaft pilot bearing.
TE 13/17 3 SD
02/02
9-51
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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3 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 3.
Figure 316 Install torque converter gear.
TE 13/17 3 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 3 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
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