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DANA SPICER 6000 EHO Service Manual

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6000 EHO
TSM-0238E
Allied Form: 80-1381
September 2020
Rev: 06/2022

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Summary of Contents for DANA SPICER 6000 EHO

  • Page 1 6000 EHO TSM-0238E Allied Form: 80-1381 September 2020 Rev: 06/2022...
  • Page 2 © Copyright 2020 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means, electronic or other- wise, without prior written approval.

  • Page 3: Table Of Contents

    CONNECTION POINTS ..........................19 FRONT VIEW ............................19 SIDE VIEW ............................... 20 REAR VIEW .............................. 20 CHECK POINTS CONTROL VALVE ......................21 SPEED SENSOR INSTALLATION ......................... 22 SPEED SENSOR INSTALLATION ......................... 22 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 4 CLUTCH DISCS PACK ..........65 ASSEMBLY INSTRUCTIONS FOR 3 AND 4 CLUTCH DISCS PACK ..........66 END-STOP PLIER SETTING ......................... 67 RETAINING SNAP RING FOR BORES ....................67 RETAINING SNAP RING FOR SHAFTS ....................67 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 5 SPECIAL TOOLS ............................140 AS0010005000 ............................140 AS0010009800 ............................142 TG1500106500 ............................144 TG1500106700 ............................149 AS0010012800 ............................153 AS0010012900 ............................153 AS0010004200-000-001 ......................... 154 AS0010005900-000-001 ......................... 155 AS0010006200-000-001 ......................... 156 AS0010006400-000-001 ......................... 157 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 6 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 7: Version Tracking

    - Electric Solenoid Controls p. 29 TSM-0238E_Rev.02 6000 EHO Rev. 02 17/09/2020 - Added Clutch packs assembly intructions p. 64 - Update Assembly p. 112 MANUAL APPLICABILITY AND SUPPORTED MODELS MODELS 6000 EHO TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 8: Introduction

    Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment. Dana Incorporated does not warrant repair or replacement parts, nor failures resulting from the use of parts which are not supplied or approved by Dana Incorporated.

  • Page 9: Cleaning And Inspection

    Inspect housings, covers, and caps to be certain they are thoroughly cleaned and that mating surfaces, bearing bores, etc. are free from nicks or burrs. Check all parts carefully for evidence of cracks or conditions which can cause oil leaks or failures. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 10: Specifications

    633.22 mm / 249.29" in Height (maximum). 1134.54 mm / 446.66" in Oil Capacity. 32 Liters / 8,5 US Gallons * Without cooler and hydraulic lines. Consult equipment operator's manual for complete system capacity. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 11: Torque Charts

    [595-645] 439-476 [683-758] 503-559 M22x1.5 [560-600] 413-443 [795-845] 586-623 [923-998] 681-736 M24x1.5 [720-800] 531-590 [1040-1140] 767-841 [1195-1345] 882-992 M24x2 [690-770] 509-568 [990-1090] 730-804 [1145-1295] 845-955 M27x1.5 [1070-1150] 789-848 [1530-1630] 1129-1202 [1775-1925] 1309-1420 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 12 42339 Lbf-ft M16x1.5 [27-34] 20-25 1.00x20 [542-610] 150-200 M18x1.5 [34-41] 25-30 1.25x18 [407-474] 200-250 M22x1.5 [48-60] 35-44 1.50x18 [271-339] 300-350 M26x1.5 [61-68] 45-50 1.75x12 [203-271] 400-450 M27x2 [81-89] 60-66 M33x2 [112-140] 83-103 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 13: Hydraulic Cooler Lines Specifications

    Lock-up Pressure. See Technical Specs of Converters * Refer to Connection points p. 19 for check port identification. † All pressures and flows to be measured with oil temperature 82-93ºC / 180-200ºF. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 14: Electrical Specifications

    Coil Resistance: 24V - 92 +7-4 Ω at 20°C / 68°F Type: Magneto resistive sensor Sensing Distance: 0–1.8 mm / 0–0.07" Ouput Speed Sensor. Sensor Signal: Generates a square current with a fixed amplitude changing between 7 and 14 mA. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 15: Maintenance

    Wear metal analysis can provide useful information but a transmission should not be removed from service based solely on this analysis. 12 - Any deviation from this chart must have written approval from the application engineering department of Dana Incorporated. *Dexron is a registered trademark of General Motors Corp.

  • Page 16: Maintenance Intervals

    Recheck with hot oil 82.2 - 93.3°C [180 – 200°F]. – Adjust oil level to FULL mark on dipstick. 6 - Recheck all drain plugs, lines, connections, etc… for leaks and tighten where necessary. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 17: Filling Instructions

    Install oil level plug or dipstick. Recheck with hot oil (82 - 93° C) [180 - 200° F] Bring oil level to full mark on dipstick or runs freely from UPPER oil level plug. Oil Level Glasses 3/4-14 NPTF Oil Level Check Drain Plug TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 18: Installation Detail

    IT MUST BE PLUMBED IN THIS LINE PRESSURE REGULATOR VALVE CHARGING PUMP OIL FILTER CONVERTER SELECT LOWEST CONNECTION FOR GRAVITY DRAIN TO TRANSMISSION TRANSMISSION DRAIN MUST HAVE CONTINEOUS SLOPE FROM CONVERTER TO TRANSMISSION Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 19: Connection Points

    3 - 1 NPTF Threads Optional Dipstick 4 - Port 80 Suction Line Ø50.8 Split Flange 5 - Ø26,12-26,44 6 Mounting Holes 6 - Breather 7 - Port 16 Pressure Regulator In Ø38 Split Flange TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 20: Side View

    REAR VIEW 1 - Ø26,12-26,44 6 Mounting Holes 4 - 3/4-14 NPTF Drain Plug 2 - Oil Level Glasses 5 - Port 22 Transmission Drain Ø38 Split Flange 3 - Oil Level Check Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 21: Check Points Control Valve

    6 - Port 36 Solenoid pressure M14 x 1.5 deutz 0462-209-16141 7 - Port 31 Regulated pressure M14 x 1.5 14 - From charging pump Ø38 split flange 8 - Port 37 Converter in pressure M14 x 1.5 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 22: Speed Sensor Installation

    Function Connection Current Input Hot Wire Current Output Ground Wire CAUTION The sensor wires have a polarity. Be sure to correctly observe sensor polarities as wrong connections will deactivate the sen- sor!. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 23 Position of clamp must be 180° in relation to position sign on speed sensor clamp must be fixed Item Description Support speed sensor Screw O-ring DIA 15x1.8 Assy speed sensor AMP Transmission model. ASSY Part Nr Connector Type X Position 6000 4209752 AMP 2 pins Drum speed 180° TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 24: Operation Of The Transmission

    OPERATION OF THE TRANSMISSION IDLER Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 25: Input Shaft And Directional Clutches

    The engagement of all range and directional clutches is modulated and idraulic 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. IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 26: Range Clutches

    Once a directional clutch is engaged, power is transmitted to the range clutches. Operation and actuation of the directional clutches is similar to the range clutches. The engagement of the directional and range clutches is modulated. IDLER Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 27: Output Section

    OUTPUT SECTION OUTPUT SECTION With a range clutch engaged, power is finally transmitted to the output shaft. Output rotation is the opposite to input rotation when the forward clutch is engaged. IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 28: Transmission Controls

    On the front drive only or the rear drive only, the output shaft is a one piece type and an output fl ange assembled only on the required end. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 29: Electric Solenoid Controls

    Neutral 4 Neutral 3 Neutral 2 Neutral 1 Reverse 4 Rev, 4th Reverse, 4th Reverse 3 Rev, 3rd Reverse, 3rd Reverse 2 Rev, 2nd Reverse, 2nd Reverse 1 Rev, 1st Reverse, 1st TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 30: Power Flows, Solenoids And Hydraulic Circuits

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS NEUTRAL 1ST CLUTCH Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 31: Neutral 2Nd Clutch

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS NEUTRAL 2ND CLUTCH TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 32: Neutral 3Rd Clutch

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS NEUTRAL 3RD CLUTCH Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 33: Neutral 4Th Clutch

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS NEUTRAL 4TH CLUTCH TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 34: Forward 1St Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 1ST SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 35: Forward 1St Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 1ST SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 36: Forward 2Nd Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 2ND SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 37: Forward 2Nd Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 2ND SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 38: Forward 3Rd Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 3RD SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 39: Forward 3Rd Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 3RD SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 40: Forward 4Th Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 4TH SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 41: Forward 4Th Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS FORWARD 4TH SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 42: Reverse 1St Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 1ST SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 43: Reverse 1St Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 1ST SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 44: Reverse 2Nd Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 2ND SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 45: Reverse 2Nd Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 2ND SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 46: Reverse 3Rd Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 3RD SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 47: Reverse 3Rd Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 3RD SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 48: Reverse 4Th Speed

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 4TH SPEED Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 49: Reverse 4Th Speed (Continued)

    POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS REVERSE 4TH SPEED (CONTINUED) IDLER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 50: Troubleshooting

    Air clean the radiator, if neces- sary. • The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no- load governed speed specifications. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 51: Check Point

    To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with the converter at “stall”. DANGER Be careful the vehicle does not move unexpectedly when operating the engine and converter at stall rpm. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 52: Numbering Of Ports For Hydraulic Circuit Diagrams

    60 Pressure Intensifier 1st 61 Pressure Intensifier 2nd 62 Pressure Intensifier 3rd 63 Pressure Intensifier High 64 Pressure Intensifier FWD 65 Pressure Intensifier REV NOTE: For ports drawings see chapter Installation detail p. 18 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 53: Check Points Control Valve

    6 - Port 36 Solenoid pressure M14 x 1.5 deutz 0462-209-16141 7 - Port 31 Regulated pressure M14 x 1.5 14 - From charging pump Ø38 split flange 8 - Port 37 Converter in pressure M14 x 1.5 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 54: Troubleshooting Guide

    Change cooler lines LACK OF POWER Cause. Remedy Low engine RPM at converter stall. Tune engine check governor See the Overheating section above and make same checks. Make corrections as explained in “Overheating” Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 55: Speed Sensor Static Standalone Test

    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). By slowly moving gear teeth or a metal part in front of the sensor (1.8 mm max. distance), toggling between the two levels should be noticed. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 56: Assembly Instructions

    ASSEMBLY INSTRUCTIONS ASSEMBLY INSTRUCTIONS 2.11 2.7 8.13 2.11 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 57 0,0000 (line to line) to a maximum of 0,102 mm (0,004") loose (endplay). After selection of proper snap ring and tan- ged washer, do not intermix parts prior to re-assembly on transmission. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 58 WARNING :HEAVY SPRING LOAD ! Use the correct tools to assemble and disassemble this item Only use the specified lifting locations to lift the transmission or subassemblies CAUTION WARNING :HEAVY SPRING LOAD Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 59 Shim bearings to produce 6-8 lbs-inch (0.68 – 0.90 Nm) preload 10.14 Shim bearings to produce 6-10 lbs-inch (0.68 – 1.13 Nm) preload 12.1 Seals must be pressed in perpendicularly on shaft axis from this side. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 60 ASSEMBLY INSTRUCTIONS 12.1 Torque to 200-250 lbs-ft (271 - 340 Nm) 12.1 Seals must be pressed in perpendicularly on shaft axis from this side. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 61 ASSEMBLY INSTRUCTIONS 2.21 2.21 Torque to 20-25 lbs.ft (27-34Nm) WARNING :HEAVY SPRING LOAD! Use the correct tools to assemble and disassemble this item CAUTION WARNING :HEAVY SPRING LOAD TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 62 ASSEMBLY INSTRUCTIONS Apply Loctite 577,when threads are without coating Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 63: Control Valve Assembly Instructions

    3 - Install thirteen (13) bolts and hand-tighten in the numerical sequence indicated on the drawing 4 - Then torque all thirteen (13) bolts twice to 50–56 N·m in the correct sequence. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 64: Clutch Packs Assembly Intructions

    One to five shims could be required to reach the proper thickness of the clutch pack. Below chart, is indicating the position of the shims within the pack considering the needed quantity. Shim-separator (s) will replace Disc-separator Outer in the pack. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 65: Assembly Instructions For 1

    One to five shims could be required to reach the proper thickness of the clutch pack. Below chart, is indicating the position of the shims within the pack considering the needed quantity. Shim-separator (s) will replace Disc-separator Outer in the pack. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 66: And 4 Clutch Discs Pack

    One to five shims could be required to reach the proper thickness of the clutch pack. Below chart, is indicating the position of the shims within the pack considering the needed quantity. A Shim-separator (s) will replace a Disc-separator Outer in the pack. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 67: End-Stop Plier Setting

    CAUTION This procedure is aligned with DIN standard. In any case, DIN 472 regulation prevails. CAUTION Snap ring replacement is mandatory if they are removed wi- thout pre-setted plier. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 68: Sectional Views And Parts Identification

    SECTIONAL VIEWS AND PARTS IDENTIFICATION GROUP-3RD & 4TH CLUTCH Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 69 PISTON-CLUTCH RING-PISTON OUTER SPRING-PISTON RING EXPANDER OUTER RING-PISTON SPRING-PISTON RING EXPANDER INNER HUB-CLUTCH SNAP RING-INTERNAL WASHER-CLUTCH HUB RING-SNAP ASSY-CLUTCH PACK SHIMMED PLATE-FRICTION SHIM-SEPARATOR OUTER PLATE-END RING-SNAP SPRING-BELLEVILLE DISC ASSY RETAINER-SNAP RING RING-SNAP TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 70: Group-Forward And Reverse Clutch

    GROUP-FORWARD AND REVERSE CLUTCH GROUP-FORWARD AND REVERSE CLUTCH 19 36 11 13 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 71 RING-PISTON OUTER SPRING-PISTON RING EXPANDER OUTER RING-PISTON INNER SPRING-PISTON RING EXPANDER INNER HUB-CLUTCH SNAP RING-INTERNAL WASHER-CLUTCH HUB RING-SNAP ASSY-CLUTCH PACK SHIMMED PLATE-FRICTION SHIM-SEPARATOR OUTER PLATE-END RING-SNAP SPRING-BELLEVILLE DISC ASSY RETAINER-SNAP RING RING-SNAP TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 72: Group-1St & 2Nd Clutches

    GROUP-1ST & 2ND CLUTCHES GROUP-1ST & 2ND CLUTCHES 27 26 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 73 PISTON-CLUTCH RING-PISTON SPRING-PISTON RING EXPANDER OUTER RING-PISTON INNER SPRING-PISTON RING EXPANDER INNER HUB-CLUTCH WASHER-CLUTCH HUB RING-RETAINING RING-RETAINING EXTERNAL TYPE ASSY-CLUTCH PACK SHIMMED PLATE-FRICTION SHIM-SEPARATOR OUTER PLATE-END RING-SNAP SPRING-BELLEVILLE WASHER-SNAP RING RETAINER RING-SNAP TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 74: Group-Forward/Reverse Shaft

    GROUP-FORWARD/REVERSE SHAFT GROUP-FORWARD/REVERSE SHAFT Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 75 ITEM DESCRIPTION SHAFT-INPUT AND REVERSE SPACER INPUT GEAR 50T SPACER BEARING-BALL BALL NUT-NYLON INSERT BEARING-BALL INPUT BRG CAP (OPEN) OIL-SEAL BEARING CAP GASKET CAPSCREW Not used in this model O-RING WASHER-FLANGE NUT-FLANGE TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 76: Group-1St/3Rd & 2Nd/4Th Shaft

    GROUP-1ST/3RD & 2ND/4TH SHAFT GROUP-1ST/3RD & 2ND/4TH SHAFT Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 77 GROUP-1ST/3RD & 2ND/4TH SHAFT ITEM DESCRIPTION SHAFT-1ST/3RD AND 2ND/4TH ASSEMBLY-TAPERED BEARING PIN-BEARING LOCK SNAP RING SPACER GEAR-OUTPUT WASHER CYLINDRICAL ROLLER BEARING NUT-NYLON INSERT GEAR-OUTPUT TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 78: Group-Base Parts

    GROUP-BASE PARTS GROUP-BASE PARTS 18 19 21 21A Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 79 GASKET-OIL SUMP FRAME ASSY-OIL SUMP WASHER GASKET-OIL SUMP MAGNET-SUMP PLUG AIR-BREATHER FITTING-ELBOW 90 DEGREE STREET COVER-SPLIT FLANGE COVER-SPLIT FLANGE O-RING O-RING CAPSCREW LOCKWASHER PLUG PLUG PLUG O-RING PLUG FITTING-PIPE CAP NIPPLE-PIPE DIPSTICK ASSY-DIPSTICK HOUSING TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 80: Assy-Control Valve

    ASSY-CONTROL VALVE ASSY-CONTROL VALVE Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 81 ASSY-CONTROL VALVE ITEM DESCRIPTION ADAPTOR-VALVE CONTROL COVER GASKET O-RING CAPSCREW GASKET CONTROL VALVE ASSY-CONTROL VALVE O-RING CAPSCREW LOCKWASHER CAPSCREW LOCKWASHER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 82: Assy-Control Valve - 2

    ASSY-CONTROL VALVE - 2 ASSY-CONTROL VALVE - 2 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 83 ASSY-CONTROL VALVE WITH VARIABLE RE- STRICTIONS ASSEMBLY-SOLENOID PLATE PLATE-SPACER SCREW M8X100 CAPSCREW CAPSCREW LOCKWASHER GASKET PLATE SPACER TO PLATE SOLENOID GASKET SPOOL BODY TO PLATE SPACER GROUP-WIRING HARNESS LOCKWASHER CAPSCREW COVER-SPLIT FLANGE O-RING COVER-PROTECTION TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 84 SOLENOID FWD CLUTCH WIRE COLOR BLACK SOLENOID 4TH CLUTCH WIRE COLOR ORANGE SOLENOID 3RD CLUTCH WIRE COLOR WHITE APPLY LOCTITE NO. 243 OR 245 APPLY LOCTITE NO. 5205 BETWEEN ADAPTER AND VALVE Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 85: Assy-Solenoid Plate

    ASSY-SOLENOID PLATE ASSY-SOLENOID PLATE ITEM DESCRIPTION PLATE-SOLENOID NON TOTAL NEUTRAL SCREW CLAMP-SOLENOID SOLENOID 24V RING-SNAP SCREW M5 DISC-FILTER PLUG-RESTRICTION DIA. 0,8 STRAP 2,4 X 200 MM SCREW M5 CLAMP WIRING LOCKWASHER TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 86: Assy-Control Valve With Variable Restrictions

    ASSY-CONTROL VALVE WITH VARIABLE RESTRICTIONS ASSY-CONTROL VALVE WITH VARIABLE RESTRICTIONS 18 28 10 33 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 87 GASKET COVER DIRECTION SPOOLS COVER-DIRECTION SPOOLS SEAT-SAFETY VALVE SAFETY VALVE SPACER BALL SPRING-SAFETY VALVE SCREW PLUG-SCREW TYPE O-RING SPRING MIDDLE SOFT ACCUMULATOR SPRING-HELICAL PIN-STOP HARD ACCUMULATOR ASSY-MODULATOR SPOOL ASSY-MODULATOR SPOOL ASSY-MODULATOR SPOOL ASSY-MODULATOR SPOOL PLUG TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 88: Flange-Cross Serrated 155Kv70

    FLANGE-CROSS SERRATED 155KV70 FLANGE-CROSS SERRATED 155KV70 ITEM DESCRIPTION FLANGE-CROSS SERRATED 155KV70 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 89: Flange-Cross Serrated 180Kv70

    FLANGE-CROSS SERRATED 180KV70 FLANGE-CROSS SERRATED 180KV70 ITEM DESCRIPTION FLANGE-CROSS SERRATED 180KV70 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 90: Group-Forward Shaft

    GROUP-FORWARD SHAFT GROUP-FORWARD SHAFT Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 91 GROUP-FORWARD SHAFT ITEM DESCRIPTION SHAFT-INPUT AND REVERSE SPACER INPUT GEAR 50T SPACER BEARING-BALL BALL NUT-NYLON INSERT BEARING-BALL SPACER NUT-FLANGE REV. BRG. CAP BEARING CAP GASKET CAPSCREW Not Used On This Model TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 92: Group-Output Shaft

    GROUP-OUTPUT SHAFT GROUP-OUTPUT SHAFT Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 93 ASSY-BRG.CAP AND OIL SEAL SEAL-OIL - PART OF ITEM 6 O-RING-BEARING CAP SHIM-BEARING CAP .004 SHIM-BEARING CAP .007 SHIM-BEARING CAP .010 SCREW-BEARING CAP Not Used On This Model O-RING FLANGE WASHER-FLANGE NUT-FLANGE TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 94: Group-Idler Shaft

    GROUP-IDLER SHAFT GROUP-IDLER SHAFT Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 95 CONE-REAR BEARING GEAR-IDLER 46T SHIM-RETAINING PLATE .004 SHIM-RETAINING PLATE .007 SHIM-RETAINING PLATE .010 SHIM-RETAINING PLATE .020 PLATE-GEAR RETAINER CAPSCREW-RETAINING PLATE PLATE-IDLER SHAFT LUBE SCREW-IDLER SHAFT LUBE PLATE CAP Not Used On This Model TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 96 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 97: Disassembly & Assembly

    FIGURE 3: Remove valve using 2x eyebolt (M14) and 2x gui- de pins. FIGURE 1: Cover photo. FIGURE 4: Remove gasket. FIGURE 2: Remove 13x cap-screws + washers (size 5/8). FIGURE 5: Remove 6x O-rings. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 98 FIGURE 6: Remove 12x cap-screws (size 8). FIGURE 9: Remove 6x O-rings. FIGURE 7: Remove adaptor plate. FIGURE 10: Remove 26x cap-screws + washers (size 9/16). FIGURE 8: Remove gasket. FIGURE 11: Remove cover. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 99 To avoid injury to eyes, wear eye protection equipment. CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p. 64. FIGURE 15: Remove hub-assembly. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 100 To avoid injury to eyes, wear eye protection equipment. CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p. 64. FIGURE 17: Remove discs + shims. FIGURE 19: Remove spacer. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 101 FIGURE 22: Remove piston, use two guide pins. FIGURE 23: Remove clutch-assembly using special tool TG1500106700 (see drawing TG1500106700 p. 149). FIGURE 21: Remove snapring, spacer, Belleville washers and spacer. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 102 These parts must be reassembled on the same support they were removed from. If taper bearings, clutch support or clutch drum are to be replaced, reassemble with new parts as explained later in the manual. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 103 FIGURE 28: Remove cover. FIGURE 31: Remove baffle. FIGURE 29: Remove gasket. FIGURE 32: Remove gasket. FIGURE 30: Remove 3x cap-screw (size 9/16). FIGURE 33: Remove 20x cap-screws + washers (size 9/16). TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 104 DISASSEMBLY FIGURE 34: Remove cover. FIGURE 37: Remove Reverse cap. FIGURE 35: Remove gasket. FIGURE 38: Remove gasket. FIGURE 36: Remove 4x cap-screws (size ¾). FIGURE 39: Loosen nylon nut. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 105 FIGURE 40: Remove nylon nut, spacer and O-ring. FIGURE 43: Remove input cap. FIGURE 41: Remove flange. FIGURE 44: Remove gasket. FIGURE 42: Remove 4x cap-screws (size ¾). FIGURE 45: Prevent gear from moving and tap on forward shaft. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 106 FIGURE 49: Tap out bearing + ball. FIGURE 47: Remove gear and spacer. FIGURE 50: Remove bearing + ball. NOTE: Forward and reverse shafts are disassembled in a similar manner. FIGURE 48: Remove spacer. FIGURE 51: Loosen nut. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 107 FIGURE 52: Remove nut, spacer and O-ring. FIGURE 55: Remove front output cap. FIGURE 53: Remove output flange. FIGURE 56: Loosen nut. FIGURE 54: Remove 6x cap-screw (size ¾). FIGURE 57: Remove nut, spacer and O-ring. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 108 FIGURE 61: Remove output shaft + bearing assembly. FIGURE 59: Remove 6x cap screws (size ¾). FIGURE 62: Remove small output gear + bearing cone. FIGURE 60: Remove rear output cap + shims. FIGURE 63: Remove big output gear. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 109 DISASSEMBLY FIGURE 66: Remove spacer and shims. FIGURE 64: Remove bearing cup. FIGURE 67: Remove gear. FIGURE 65: Remove 3x cap screws (size 7/8). FIGURE 68: Remove 2x cap screws (side ¾). TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 110 FIGURE 70: Remove idler shaft (prevent shaft from drop- FIGURE 73: Remove 2x spacers and gear. ping!). FIGURE 74: Tap out bearing. FIGURE 71: Remove bearing cone. NOTE: 2/4de shaft is removed in a similar way. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 111 DISASSEMBLY FIGURE 75: Remove bearing cup. FIGURE 76: Remove bearing cup. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 112: Assembly

    ASSEMBLY ASSEMBLY FIGURE 77: Install bearing cup. FIGURE 79: Remove bearing cone idler shaft. FIGURE 78: Install bearing cup. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 113 FIGURE 81: Lower idler shaft into transmission case (eyebolt M12). WARNING Wear protective garments when handling hot objects. Use heat resistant gloves to pick up hot objects. Keep body parts and clothes away from heat source. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 114 FIGURE 85: Install gear (groove on top). Use heat resistant gloves to pick up hot objects. Keep body parts and clothes away from heat source. FIGURE 86: Install shims and spacer. FIGURE 83: Install lube plate. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 115 FIGURE 88: Measure rolling torque when using new bea- rings, rolling torque must be 6 to 10 inch lbs. Add shims for less rolling torque, remove shims for more rol- ling torque. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 116 Insert shaft into shaft bore and through the 1st/3 gear. Align double taper bearing lock pin with notch in bearing bore. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 117 FIGURE 95: Install bearing (heat to 120°C). WARNING Wear protective garments when handling hot objects. Use heat resistant gloves to pick up hot objects. Keep body parts and clothes away from heat source. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 118 WARNING Do not mix parts from different clutches. FIGURE 98: Tighten 8x cap screws to 80-88 ft·lbs (cap screws should be precoated, size ¾). Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 119 FIGURE 100: Tap bearing in position using special tool AS0010004200 (see drawing AS0010004200-000-001 FIGURE 102: Install clutch support assembly, align with 8x p. 154). cap screws and tap clutch support down before driving the cap screws. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 120 Install long spacer underneath small spacer!. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 121 Pull the shaft from the other side into position. FIGURE 108: Install new seal, apply Loctite 641 using special tools AS0010006200 (see drawing AS0010006200-000-001 p. 156) and AS0010005900 (see drawing AS0010005900- 000-001 p. 155). TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 122 FIGURE 110: Install input cap + 4x cap screws, torque to 57- FIGURE 113: Block input shaft and torque nylon nut to 150- 63 ft·lbs (size ¾). 175 ft·lbs FIGURE 111: Install flange. FIGURE 114: Install spacer. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 123 FIGURE 116: Tap bearing in position using special tool AS0010004200 (see drawing AS0010004200-000-001 p. 154). FIGURE 118: Install clutch support assembly, align with 8x cap screws and tap clutch support down before driving the cap screws. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 124 FIGURE 121: Remove bearing. screws should be precoated, size ¾). NOTE: Reverse shaft is assembled in a similar way. FIGURE 120: Position output gears, both hubs to the input side of the case. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 125 Use heat resistant gloves to pick up hot objects. Keep body parts and clothes away from heat source. FIGURE 124: Install bearing cup using speial tool AS0010009800 (see drawing AS0010009800 p. 142). TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 126 ASSEMBLY FIGURE 125: Remove O-ring. FIGURE 127: Install oil-seal. FIGURE 126: Remove oil-seal. FIGURE 128: Install O-ring. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 127 FIGURE 130: Install bearing cone (heat to 120°C). WARNING Wear protective garments when handling hot objects. Use heat resistant gloves to pick up hot objects. Keep body parts and clothes away from heat source. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 128 6 to 8 inch lbs. more torque to turn the gear train with cap screws torque than when bolts were loose. Add or remove shims from bearing cap to adjust preload when needed. FIGURE 134: Install O-ring, washer and nylon nut. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 129 FIGURE 135: Torque nylon nut to 250-300 ft·lbs FIGURE 137: Remove outer piston ring and expander. NOTE: Repeat for other side. FIGURE 138: Remove bearing cone. FIGURE 136: Remove inner piston ring and expander. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 130 ASSEMBLY FIGURE 139: Remove bearing cup. FIGURE 141: Install bearing cup. FIGURE 140: Remove bearing cup. FIGURE 142: Install bearing cup. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 131 ASSEMBLY FIGURE 143: Install inner piston ring and expander. FIGURE 145: Install piston, use two guide pins. FIGURE 144: Install outer piston ring and expander. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 132 ASSEMBLY FIGURE 146: Install spacer, Belleville washers, spacer and FIGURE 147: Using special tool AS0010012900 (see drawing snapring. AS0010012900 p. 153), push Belleville washers down and in- stall snapring in position. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 133 To avoid injury to your eyes, wear protective glasses during this procedure. CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p. 64. FIGURE 149: Install bearing. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 134 Value must be between .000 to a maxi- mum .002 loose (end play). Adjust snap-ring and washer if ne- eded. See chart for snap-ring and washer thickness. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 135 CAUTION MANDATORY PROCEDURE Set the pliers following the correct procedure shown in p. 64. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 136 Clutch being assembled is the 1 clutch. Different amounts of discs are mounted, check parts list for cor- rect amount, for shimming of clutch packs refer to Clutch packs assembly intructions p. 64. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 137 FIGURE 161: Install 3x cap screws, apply Loctite 243, torque to 23-25 ft·lbs (size 9/16). FIGURE 159: Install 20x cap screws + washers, torque to 23- FIGURE 162: Install gasket. 25 ft·lbs (cap screws should be precoated, size 9/16). TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 138 FIGURE 164: Install 18x cap screws + washers, torque to 23- 25 ft·lbs (cap screws should be precoated, size 9/16). 25 ft·lbs (cap screws should be precoated, size 9/16). FIGURE 168: Install 6x O-rings + gasket. FIGURE 165: Install gasket. Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 139 FIGURE 170: Install 12x cap screws, apply Loctite 243, tor- que to 41-46 ft·lbs (size 8). FIGURE 173: Install 13x cap screws + washers, torque to 41- 46 ft·lbs (size 5/8). FIGURE 171: Install 6x O-rings + gasket. TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 140: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS AS0010005000 AS0010005000-000-001 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 141 SPECIAL TOOLS AS0010005000-000-002 TOOL00000516_A TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 142: As0010009800

    SPECIAL TOOLS AS0010009800 AS0010009800-000-001 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 143 SPECIAL TOOLS AS0010009800-000-002 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 144: Tg1500106500

    SPECIAL TOOLS TG1500106500 TG1500106500-000-001 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 145 SPECIAL TOOLS TG1500106500-000-002 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 146 SPECIAL TOOLS TG1500106500-000-003 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 147 SPECIAL TOOLS TG1500106500-000-004 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 148 SPECIAL TOOLS TG1500106500-000-005 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 149: Tg1500106700

    SPECIAL TOOLS TG1500106700 TG1500106700-000-001 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 150 SPECIAL TOOLS TG1500106700-000-002 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...
  • Page 151 SPECIAL TOOLS TG1500106700-000-003 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 152 SPECIAL TOOLS TG1500106700-000-004 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 153: As0010012800

    SPECIAL TOOLS AS0010012800 AS0010012900 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 154: As0010004200-000-001

    SPECIAL TOOLS AS0010004200-000-001 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 155: As0010005900-000-001

    SPECIAL TOOLS AS0010005900-000-001 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...

  • Page 156: As0010006200-000-001

    SPECIAL TOOLS AS0010006200-000-001 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual...

  • Page 157: As0010006400-000-001

    SPECIAL TOOLS AS0010006400-000-001 TSM-0238 - 6000 Transmission Service Manual Dana Incorporated...
  • Page 158 Copyright 2020 Dana Incorporated For product inquiries or support, All content is subject to copyright by Dana and may not visit www.dana.com. be reproduced in whole or in part by any means, For other service publications, visit electronic or otherwise, without prior written approval.

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