4 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
OPERATION OF THE TRANSMISSION ............................................................................................ 24
INPUT SHAFT AND DIRECTIONAL CLUTCHES .......................................................................................... 25
RANGE CLUTCHES ...................................................................................................................................... 26
OUTPUT SECTION ....................................................................................................................................... 27
TRANSMISSION CONTROLS ....................................................................................................................... 28
OPERATION OF THE VALVE ................................................................................................................... 28
ELECTRIC SOLENOID CONTROLS ............................................................................................................. 29
POWER FLOWS, SOLENOIDS AND HYDRAULIC CIRCUITS ...................................................................... 30
NEUTRAL 1ST CLUTCH .......................................................................................................................... 30
NEUTRAL 2ND CLUTCH ......................................................................................................................... 31
NEUTRAL 3RD CLUTCH ......................................................................................................................... 32
NEUTRAL 4TH CLUTCH ......................................................................................................................... 33
FORWARD 1ST SPEED ........................................................................................................................... 34
FORWARD 1ST SPEED (CONTINUED) ................................................................................................... 35
FORWARD 2ND SPEED .......................................................................................................................... 36
FORWARD 2ND SPEED (CONTINUED) ................................................................................................... 37
FORWARD 3RD SPEED .......................................................................................................................... 38
FORWARD 3RD SPEED (CONTINUED) ................................................................................................... 39
FORWARD 4TH SPEED ........................................................................................................................... 40
FORWARD 4TH SPEED (CONTINUED) ................................................................................................... 41
REVERSE 1ST SPEED ............................................................................................................................. 42
REVERSE 1ST SPEED (CONTINUED) ..................................................................................................... 43
REVERSE 2ND SPEED ............................................................................................................................ 44
REVERSE 2ND SPEED (CONTINUED) .................................................................................................... 45
REVERSE 3RD SPEED ............................................................................................................................ 46
REVERSE 3RD SPEED (CONTINUED) ..................................................................................................... 47
REVERSE 4TH SPEED ............................................................................................................................. 48
REVERSE 4TH SPEED (CONTINUED) .................................................................................................
.... 49
TROUBLESHOOTING ....................................................................................................................... 50
TRANSMISSION PROBLEMS ....................................................................................................................... 50
TROUBLESHOOTING PROCEDURES ......................................................................................................... 50
INPUT SHAFT AND DIRECTIONAL CLUTCH PROBLEMS ..................................................................... 50
TRANSMISSION PRESSURE CHECKS .................................................................................................. 50
MECHANICAL AND ELECTRICAL CHECKS ................................................................................................ 50
CHECK POINT .............................................................................................................................................. 51
NUMBERING OF PORTS FOR HYDRAULIC CIRCUIT DIAGRAMS ........................................................ 52
CHECK POINTS CONTROL VALVE ........................................................................................................ 53
TROUBLESHOOTING GUIDE ....................................................................................................................... 54
LOW CLUTCH PRESSURE ..................................................................................................................... 54
LOW CHARGING PUMP OUTPUT .......................................................................................................... 54
OVERHEATING ........................................................................................................................................ 54
LACK OF POWER .................................................................................................................................... 54
SPEED SENSOR STATIC STANDALONE TEST ........................................................................................... 55
ASSEMBLY INSTRUCTIONS ............................................................................................................ 56
ASSEMBLY INSTRUCTIONS ........................................................................................................................ 56
CONTROL VALVE ASSEMBLY INSTRUCTIONS ......................................................................................... 63
CLUTCH PACKS ASSEMBLY INTRUCTIONS ............................................................................................. 64
ASSEMBLY INSTRUCTIONS FOR FORWARD AND REVERSE CLUTCH DISCS PACK ........................ 64
ASSEMBLY INSTRUCTIONS FOR 1
ST
AND 2
ND
CLUTCH DISCS PACK .............................................. 65
ASSEMBLY INSTRUCTIONS FOR 3
RD
AND 4
TH
CLUTCH DISCS PACK .............................................. 66
END-STOP PLIER SETTING ......................................................................................................................... 67
RETAINING SNAP RING FOR BORES .................................................................................................... 67
RETAINING SNAP RING FOR SHAFTS ................................................................................................... 67
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