TE10 3 Service Manual 6193.291

CONTENTS
Contents ..........................................................I Gear Group ...................................................... 55

Towing or Pushing ........................................... 1 Auxiliary Pump Drive Group ............................. 57
Introduction .....................................................2 Charging Pump Drive Group ............................ 59
Foreword .......................................................... 2 Forward Shaft Group ........................................ 61
Safety Precautions ........................................... 2 Reverse Idler Group ......................................... 63
Specifications .................................................. 3 Reverse & Second Group ................................ 65
Identification Tag .............................................. 3 Low Shaft Group .............................................. 67
General Specifications ..................................... 3 Third Group ...................................................... 69
Hydraulic Cooler Lines Specifications .............. 3 Output Shaft Group .......................................... 71
Pressure and Temperature Specifications ....... 4 Charging Pump & Filter Assembly Group ........ 73
Electrical Specifications ................................... 5 Control Valve Group ......................................... 75
Maintenance ...................................................6 Installation Diagrams .......................................77
Recommended Lubricants ............................... 6 Transmission Assembly Instructions ................ 77
Maintenance Intervals ...................................... 6 Control Valve Assembly Instructions ................ 79
Servicing Machine After Component Overhaul 7 Cleaning and Inspection ..................................80
Automatic Calibration Procedure ..................... 8 Cleaning ........................................................... 80
Drive Plate Installation .................................... 12 Inspection ......................................................... 80
Transmission to Engine Installation ................13 Disassembly & Reassembly ............................82
External Plumbing Installation ......................... 14 Getting Started ................................................. 82
Cooler & Filter Line Specifications ................... 14 Transmission Case Disassembly ..................... 82
Remote Filter (Optional) ................................... 14 Converter Housing Disassembly ...................... 90
Speed Sensor Installation ...............................15 Forward Clutch Disassembly ............................ 93
Speed Sensor Only .......................................... 15 Forward Clutch Reassembly ............................ 95
Speed Sensor & Temperature Sensor Combined 15 First Clutch Disassembly .................................. 97
Transmission Operation ..................................16 First Clutch Reassembly .................................. 99
Converter, Pump Drive Section, & Pressure Reverse Clutch Disassembly ........................... 102
Regulating Valve .............................................. 16
Reverse Clutch Reassembly ............................ 104
Input Shaft & Directional Clutches ................... 17
Second Clutch Disassembly ............................. 107
Range Clutches ............................................... 18
Second Clutch Reassembly ............................. 108
Output Section ................................................. 18
Third Clutch Disassembly ................................. 109
Transmission Controls ..................................... 19
Third Clutch Reassembly ................................. 110
Power Flows, Activated Solenoids, & Hydraulic
Circuits ............................................................. 21 Third Clutch Shaft Front Bearing Disassembly 112
Third Clutch Shaft Front Bearing Reassembly . 113
Gear & Clutch Layout ...................................... 35
Turbine Shaft Disassembly ............................... 114
Troubleshooting .............................................. 36
TE10 Transmission .......................................... 36 Output Shaft Disassembly ................................ 115
Troubleshooting Procedures ............................ 36 Output Shaft Reassembly ................................ 115
Troubleshooting Guide ..................................... 38 Turbine Disassembly ........................................ 116
Check Points .................................................... 39 Turbine Reassembly ........................................ 117
Checkports ....................................................... 42 Converter Case Reassembly ........................... 118
Full Flow Valve Components ........................... 43 Transmission Case Reassembly ...................... 120
Speed Sensor - Static Standalone Test ............ 44 Torque Specifications ......................................131
Lubricated or Plated Screw Threads ................ 131
Exploded Views .............................................. 45
Converter Housing Group ................................ 45 O-ring Port Plug ................................................ 132
Transmission Case Group ............................... 47
Turbine Shaft & Stator Support Group ............. 49
Drive Plate Group ............................................ 51
Torque Converter Assembly Group .................. 53
TSM-0050 - TE10 3-Speed with Full Flow Control Valve Service Manual Dana Holding Corporation I
TOWING OR PUSHING
Before towing the vehicle, be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid dam-
age to the transmission during towing.
NOTE:
1 Dana Holding Corporation TSM-0050 - TE10 3-Speed with Full Flow Control Valve Service Manual
INTRODUCTION
Foreword
This manual has been prepared to provide the customer and maintenance personnel with information and instruc-
tions on the maintenance and repair of Dana Spicer products.
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 inter-
vals, and adjustments as 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 mechanics study the instructions in this manual carefully and use it as a reference
when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only Dana Spicer approved parts, as listed in the
applicable service parts list, should be used. Use of “will fit” or non-approved parts may endanger proper operation
and performance of the equipment. Dana does not warrant repair, replacement parts, or failures resulting from the
use of parts which are not supplied or approved by Dana.
IMPORTANT:
ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.
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 part must be replaced with a Dana specified
replacement part. NEVER use a replacement part of lesser quality.
The service procedures recommended in this manual are effective methods of performing service and repair.
Some of these procedures require the use of unique tools. Accordingly, anyone who intends to use a replacement
part, service procedure, or tool, which is not recommended, must first determine that neither their safety or the safe
operation of the machine will be jeopardized by the replacement part, service procedure, or tool selected.
It is important to note that this manual contains various precautions that must be carefully observed in order to
reduce the risk of personal injury during service or repair. Improper service or repair may also damage the unit or
render it unsafe. It is important to understand that these precautions are not exhaustive. It is impossible to warn of
all possible hazardous consequences that may result from following or failing to follow these instructions.
Indicates an imminently hazardous situation which,

if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor injury.
Indicates a situation which, if not avoided, may result

in damage to components.
ASM-0102 - 21D Axle Service Manual Dana Holding Corporation 2

SPECIFICATIONS
Identification Tag
The nameplate contains both the model and serial number of the unit.
General Specifications
Weight (dry) + 800 lbs / 360 kg

Length (maximum) 31.7” / 805 mm
Width (maximum) 20.7” / 526 mm
Height (maximum) 30.8” / 783 mm
Oil Capacity + 6.7 US gallons / 25.6 liters*

* Without cooler and hydraulic lines. Consult equipment operator’s manual for complete system capacity.
Hydraulic Cooler Lines Specifications
Lines and Fittings (Minimum) 0.75” / 19 mm internal diameter

Continuous Operating Temperature ambient to 248°F / 120°C
435 PSI / 30 bar continuous pressure
Continuous Pressure
and 652 PSI / 45 bar intermittent surges
Conformance SAE J1019 and SAE J517, 100RI
Pressure and Temperature Specifications
Normal Operating 158-248ºF / 70-120ºC
Temperature Measured at temperature check port converter out (port 71-* )
Maximum Temperature 248ºF / 120ºC
Vehicle in Neutral & Port 31*

†
Regulator Pressure At 600 RPM minimum: 250 PSI / 17.2 bar minimum
At 2200 RPM: 290 PSI / 20.0 bar maximum
Pump Flow†
At 1800 RPM
19.6 GPM / 74.5 l/min minimum
1st clutch: Port 41*

2nd clutch: Port 68*
3rd clutch: Port 43*
Forward clutch: Port 45*
Clutch Pressure†
Reverse clutch: Port 46*
At 2000 RPM:
250-290 PSI / 17.2-20.0 bar clutch activated
0-3 PSI / 0-0.2 bar clutch released
Filter Bypass Valve† Set at 30-50 PSI / 2.1-3.4 bar
Port 33/34
Lube Pressure† 7.2-11.6 PSI / 0.5-0.8 bar
at 17 GPM / 64.3 l/min pump flow +1500 RPM
Safety Valve
Cracking Pressure†
120-175 PSI / 8.2-12.1 bar
Port 32
† 25 PSI / 1.7 bar minimum
Converter Out Pressure
2000 RPM and maximum 70 PSI / 4.8 bar
at no load governed speed
* Refer to “Troubleshooting”, see page 36, for check port identification.
† All pressures and flows to be measured with oil temperature 180-200ºF / 82-93ºC.
TSM-0050 - TE10 3-Speed with Full Flow Control Valve Service Manual Dana Holding Corporation 4
Electrical Specifications
FWD/REV - 1st/3rd - 2nd

Proportional Valves
Coil Resistance: 7.25Ω at 68°F / 20°C
FWD/N/REV - 1st/3rd
Selection Valves
Coil Resistance: 28.5Ω at 68°F / 20°C
Type: Magneto resistive sensor
Sensing Distance: 0-0.07" / 0-1.8 mm
Speed Sensor
Sensor Signal: Generates a square current with a fixed
amplitude changing between 7 and 14 mA.
Material: Silicon
Temperature Sensor
Resistance: 77°F / 25°C = 2000Ω + 1%
Supply Voltage: 4.5-5.5V
Maximum Current: 10mA
Pressure Sensor Pressure Range: 14.5-450 PSI / 1-31 bar
+ 1.2% full scale (450 PSI / 31 bar) range 14.5-363 PSI / 1-25 bar
+ 2.5% full scale (450 PSI / 31 bar) range 363-450 PSI / 25-31 bar
Temperature Sensor
Ambient
Resistance
Temperature
Ω
ºC
-50 1040
-30 1250
-10 1500
10 1770
25 2000
30 2090
50 2400
70 2800
90 3180
110 3630
130 4050
150 4490
MAINTENANCE
Recommended Lubricants
Only Dextron® III is approved.
Sump preheaters
Preheat the transmission fluid to the minimum temperature for the oil viscosity used before engine start up.
Normal oil change interval

Drain and refill system every 1000 hours for average environmental and duty cycle conditions. Severe or sustained high
operating temperature or very dusty atmospheric conditions will result in accelerated deterioration 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 metal analysis
can provide useful information but a transmission should not be removed from service based solely on this analysis.
Filters
Service oil filters element every 1000 hours under normal environmental and duty cycle conditions.
Maintenance Intervals
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.
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 deteriora-
tion and contamination.
For extreme conditions judgement must be used to determine the required change intervals.
Every 1000 hours:
• Change oil filter element.
• Drain oil at 150–200°F / 65-93°C and refill system as follows:
1. Drain transmission.
2. Remove and discard filter. Install new filter.
3. Refill transmission to FULL mark.
4. Run engine at 500 - 600 RPM to prime converter 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 180-200°F / 82.2-93.3°C make final oil level check and adjust if necessary to bring oil level to FULL mark.
NOTE:
Every 2000 hours:

Perform Automatic Clutch Calibration
Servicing Machine After Component 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 clean-
ing.
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.
IMPORTANT:
NEVER use flushing compounds for cleaning purposes.
5. Reassemble all components and use only type oil (See chapter 4.1.1 “Recommended lubricants”).
Fill the transmission through filler opening until fluid comes up to FULL mark on transmission dipstick.
• Remove filler plug and fill oil until FULL mark.
• Run engine two minutes at 500 - 600 RPM to prime torque converter and hydraulic lines.
• Recheck level of fluid in transmission with engine running at idle (500 - 600 RPM).
• Add quantity necessary to bring fluid level to LOW mark on dipstick.
• Recheck with hot oil 180 – 200°F [82.2 - 93.3°C].
• Adjust oil level to FULL mark on dipstick.
6. Recheck all drain plugs, lines, connections, etc… for leaks and tighten where necessary.
7. Perform automatic calibration.
Automatic Calibration Procedure
Introduction
The APC200 firmware contains an automatic transmission calibration procedure, which is able to optimize the shift
quality of the transmission.
An automatic calibration has to be done:
• When the vehicle is build at the OEM
• Every 2000 hours of transmission operation
• When an overhaul of the transmission is done
• When the transmission is repaired
• When the APC200 is replaced
ENTERING AUTOMATIC CALIBRATION MODE

The automatic calibration mode is entered by pressing the S-button on the APC200 display for 15 seconds during
power-up.
PERFORMING AUTOMATIC CALIBRATION
Before the automatic calibration can be started, a number of conditions need to be fulfilled:
• The parking brake on the vehicle has to be activated.
• The transmission temperature needs to be above 60°C. See the next paragraph how to use the ‘HEAT’-mode
to do this in a time effective way.
• The engine speed has to be kept at around 800 rpm (± 200 rpm) during the complete calibration. If the APC200
has control over the engine, the engine speed will be adapted automatically.
1. If all the conditions mentioned above are met, the actual automatic calibration can be performed starting from the
following display on the APC200:
2. To trigger the automatic calibration procedure, push the S-button once. The APC200 display readout will show:
3. The APC200 asks for the shift lever to be put in FORWARD.

The automatic transmission calibration procedure starts. This is indicated on the APC200 display:
‘C1’ stands for ‘clutch 1’ being forward, while ‘M1’ stands for ‘mode 1’ of the calibration.
4. When all clutches have been calibrated, the APC200 displays:
5. At this point, the automatic calibration has completed successfully. The normal duration of a complete transmission
calibration is around 15 minutes.
6. To exit the automatic calibration mode, switch off the vehicle ignition key. Make sure that the APC200 has powered
down – wait for 2 seconds. Now restart the vehicle and the new tuning results will be activated automatically.
Troubleshooting
If anything different than described above appears on the APC200 display, there can be two possible reasons:
• The calibration conditions are not fulfilled (temperature is too low, parking brake switched off, the vehicle is
moving, engine rpm is too high or too low).
• A calibration error has occurred during the calibration. This message starts with an ‘E’ (see “CALIBRATION
CONDITION MESSAGES AND CALIBRATION ERRORS”, on page 11).
By selecting REVERSE on the shift lever, while the automatic calibration is performing, the procedure will abort the auto-
matic calibration immediately and restart the APC200. This feature can be used when something goes wrong during the
calibration procedure.
NOTE:
HEATING UP THE TRANSMISSION BY USING THE ‘HEAT’-MODE
The ‘HEAT’-mode allows to select forward / reverse while the parking brake is activated, without forcing neutral and will
disable the inching and declutch function. During the heat mode the highest gear is forced – even when the shift lever is
in a lower gear. This combination allows the driver to heat up the transmission by going into stall.
‘HEAT’-mode can be activated in the same way automatic calibration mode is entered (see “ENTERING AUTOMATIC
CALIBRATION MODE”, on page 8). Once “tran” is displayed on the screen, press the M-button once to go into the
“HEAT”-mode. The APC200 will display:
To trigger the ‘HEAT’-mode, push the S-button. The APC200 will display the sump temperature:
This means the actual sump temperature of the transmission is 20°C.

Perform the following steps in order to heat up the transmission:
1. Make sure the parking brake is active and works properly.
2. Put the transmission in forward by selecting forward with the shift lever and then accelerates the engine to full throt-
tle.
3. Keep the engine at full throttle for about 15 seconds and then put the gearbox in neutral by selecting neutral with
the shift lever. Keep the engine at full throttle!
4. Keep the gearbox in neutral at full engine throttle for about 15 seconds again.
5. Release the throttle pedal and decelerate the engine to idle.
6. Go back to point 2 and repeat until the APC200 display shows a temperature above 60°C. When the temperature is
above 60°C, the temperature indication on the display starts blinking. Now switch to automatic calibration by
pressing the M-button several times – until the APC200 displays “tran”.
During this warm up procedure, it is possible for the converter out temperature of the transmission to exceed the maxi-
mum limit. This is a consequence of heating up the transmission using this quick procedure. When this occurs, the
engine speed will be limited to half throttle when the APC200 has engine control or forcing neutral when the APC200
has no engine control. To solve this, simply leave the transmission in neutral for a minute and throttle the engine to
around 1300 rpm. This will allow the heat in the converter to be evacuated. After one or two minutes, resume the heat-
ing up procedure if the transmission temperature has not reached 60°C yet.
CALIBRATION CONDITION MESSAGES AND CALIBRATION ERRORS
This chapter gives an overview of the most common calibration condition messages. Many calibration condition mes-
sages can be corrected, however, if any calibration error messages appear, contact the OEM of the machine.
Calibration Condition Messages
The APC200 expects the shift lever to

be in NEUTRAL, but finds it in another
Put the shift lever back in NEUTRAL.
position.
(FORWARD or REVERSE)
THE APC200 expects the parking brake

Put the parking brake ON.
to be ON while it is OFF.
Verify that the parking brake is ON and

working properly. If this is already the
case, keep the machine at standstill by
The APC200 has detected output using the brake.
speed. Once the machine has been stopped,
the APC200 will ask the driver to shift to
FORWARD before continuing the
calibration.
Engine RPM is to low according to the

limit that is necessary for calibration.
When during the automatic transmission
calibration the temperature becomes to
low, the APC200 display indicates the
Engine RPM is to high according to the
actual transmission temperature.
limit that is necessary for calibration.
After being to low or to high, the engine

RPM is coming back into the correct
boundaries for calibration.
Use the M-button on the APC200 to go

back to the 'HEAT' mode and the S-but-
When during the automatic transmission ton to trigger this mode. Then warm-up
calibration the temperature becomes to the transmission again until the temper-
low, the APC200 display indicates the ature is above 140°F [60°C]. Then go
actual transmission temperature. back to the automatic tuning mode by
the M-button and trigger this one again
to continue calibration.
Calibration errors
Calibration errors have the form ‘E1.xx’ or ‘E2.xx’ (example: E1.25). Please contact the OEM of the machine if an error of
this form appears on the display.
DRIVE PLATE INSTALLATION
Proper identification is determined by measuring the bolt circle diameter (see dimension “A” in the illustration below)
and then ordering the appropriate drive plate kit from the table.
Each kit includes: Each kit includes:

2 Intermediate Drive Plates 3 Intermediate Drive Plates
1 Drive Plate & Weld Nut Assembly 1 Backing Ring
1 Backing Ring 10 Mounting Capscrews
10 Mounting Capscrews 10 Lockwashers
10 Lockwashers Instruction Sheet
Instruction Sheet
11.380” [288.9 mm] diameter 11.380” [288.9 mm] diameter

1. Position drive plate and weld nut assembly on torque converter assembly with weld nuts toward converter.
2. Align intermediate drive plates and backing ring with holes in torque converter assembly.
3. Two dimples 180o apart in backing ring must be facing outward toward engine flywheel (hollow side facing torque
converter assembly).
4. Install capscrews and lockwashers. Tighten capscrews to 30-37 lbs. ft. (40-50 N•m).
NOTE:
TRANSMISSION TO ENGINE INSTALLATION
1. Remove all burrs from flywheel mounting face and

nose pilot bore. Clean drive plate surface with sol-
vent. Dry thoroughly.
2. Check engine flywheel and housing for conformance
to standards SAE #3 per SAE J-927 and J-1033 tol-
erance specifications for pilot bore size, pilot bore
runout, and mounting face flatness. Measure and
record engine crankshaft end play.
3. Install two 2.50” [63.5 mm] long transmission to fly-
wheel housing guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to
align a drive plate mounting screw hole with the fly-
wheel housing access hole.
4. *
Install a 4.00” [101.6 mm] 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 3.
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 3.
Locate transmission on flywheel housing.
6. Align drive plate to flywheel and transmission to fly-
wheel 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.
*
7. Remove drive plate locating stud.
8. Install drive plate attaching screw and washer. Snug
screw but . Some engine flywheel
housings have a hole located on the flywheel hous-
ing 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 . After all eight (8) screws
are installed, tighten each capscrew to 26-29 lbs. ft.
(35-39 N•m). 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.
9. Measure engine crankshaft end play after transmis-
sion has been completely installed on engine fly-
wheel. This value must be within 0.001” [0.025 mm]
of the end play recorded in Step 2.
* Does not apply to units having 3 intermediate drive plates. See Figure 4.
EXTERNAL PLUMBING INSTALLATION
Cooler & Filter Line 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 (435 psi) continuous pressure and with 45 bar (652 psi) intermittent surges.
• Conform SAE J1019 and SAE J517,100RI.
Remote Filter (Optional)
SPEED SENSOR INSTALLATION
Speed Sensor Only
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 gear teeth (teeth rotation as shown), or 180° rotated.
The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 - 14 mA.
The sensor has an integrated AMP super seal 2 pin connector. The two pins are numbered 1 and 2.
Following table shows the relation between wire color, pin number, and connection.
Pin Function Connection
1 Current Input Hot Wire
2 Current Output Ground Wire
Speed Sensor & Temperature Sensor Combined

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 gear teeth (teeth rotation as shown), or 180° rotated.
The magneto resistive sensor generates a square wave current with a fixed amplitude changing between 7 - 14 mA.
The sensor has an integrated AMP super seal 3-pin connector. The pins are numbered 1, 2, and 3.
Following table shows the relation between wire color, pin number, and connection.
Pin Function Connection
1 Current Input Hot Wire
2 Current Output Ground Wire
3 Temperature Input Hot Wire
The sensor wires have a polarity. Be sure to correctly observe

sensor polarities, as wrong connections will deactivate the sensor!
TRANSMISSION OPERATION
Converter, Pump Drive Section, & 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 con-
verter. 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 con-
verter 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.
Input Shaft & Directional Clutches
The turbine shaft driven from the turbine transmits power to the forward or reverse 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 external splines, and friction discs with internal splines, are alter-
nated 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 oppo-
site direction as long as no pressure is present in that specific clutch.
To engage the clutch, the current on the electronic controlled modulation solenoids should go from 1000 mA to 0 mA in
order to change the pressure to the clutch from 0 to maximum pressure via a modulated way. The oil under pressure will
go through tubes and passages to the selected clutch shafts.
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.
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.
Range Clutches
Once a directional clutch is engaged power is transmitted to the range clutches (1st, 2nd or 3rd).Operation and actua-
tion of the range clutches is similar to the directional clutches.
Output Section
With a range clutch engaged, power is finally transmitted to the output shaft.Output rotation is same as the input rota-
tion when the forward clutch is engaged.
Transmission Controls
The transmission is controlled by the control valve (refer to hydraulic diagrams for additional information). The control
valve assembly is mounted directly on the side of the converter housing. The function of the control valve assembly is to
direct oil under pressure to the desired directional and speed clutches.
Operation of the Valve

Regulated pressure 319-377 PSI [22-26 bar] is directed to the proportional valve and selector valves to activate the
required clutches.
When activated the proportional valve will give an output pressure curve from 0-377 PSI [0-26 bar] proportional to a cur-
rent from 0 mA to 1000 mA. Dampers are used to dampen any hydraulic vibration.
Directional Selection
When a direction (forward or reverse) is selected, the required selector valve is activated for forward or reverse and the
proportional valve will provide a pressure rise from 0 to 26 bar feeding the directional clutch with modulated pressure.
Range Selection
When 1st clutch is selected, the 1st/3rd selector valve is activated and the 1st/3rd proportional valve will provide a pres-
sure rise from 0 to 26 bar feeding the 1st clutch with modulated pressure.
When 2nd clutch is selected, the 1st/3rd proportional valve will decrease pressure from 26 to 0 bar, thus releasing the
1st clutch in a controlled manner. At the same time, the 2nd proportional valve is activated and will provide a pressure
curve from 0 to 26 bar, which will provide clutch overlap. When the shift is finalized, the 1st/3rd selector valve is deacti-
vated.
When 3rd clutch is selected, the 1st/3rd selector valve is not activated. The 2nd proportional valve will decrease pres-
sure from 26 to 0 bar, thus releasing the 2nd clutch in a controlled manner. At the same time the 1st/3rd proportional
valve is activated and will provide a pressure curve from 0 to 26 bar, which will provide clutch overlap.
Restriction Plug
The pressure line is connected to the drain line via a restricted hole. This ensures the drain line remains air free at all
times and guarantees reliable operation of the proportional valves.
Pressure Sensor
The control valve also has a pressure sensor installed to monitor overlap on range clutches.
Electric Solenoid Controls
Transmission Activated Activated Activated

Gear Selector Valve Proportional Valve Clutches
Forward 3 FWD FWD/REV, 1st/3rd Forward, 3rd
Forward 2 FWD, 2nd FWD/REV, 2nd Forward, 2nd
Forward 1 FWD, 1st/3rd FWD/REV, 1st/3rd Forward, 1st
Neutral 3 1st/3rd 3rd
Neutral 2 2nd 2nd 2nd
Neutral 1 1st/3rd 1st/3rd 1st
Reverse 3 REV FWD/REV, 1st/3rd Reverse, 3rd
Reverse 2 REV, 2nd FWD/REV, 2nd Reverse, 2nd
Reverse 1 REV, 1st/3rd FWD/REV, 1st/3rd Reverse, 1st
Power Flows, Activated Solenoids, & Hydraulic Circuits
Neutral Selected
Neutral (Continued)
Forward 1st Speed
Forward 1st Speed (Continued)
Forward 2nd Speed
Forward 2nd Speed (Continued)
Forward 3rd Speed
Forward 3rd Speed (Continued)
Reverse 1st Speed
Reverse 1st Speed (Continued)
Reverse 2nd Speed
Reverse 2nd Speed (Continued)
Reverse 3rd Speed
Reverse 3rd Speed (Continued)
Gear & Clutch Layout
TROUBLESHOOTING
The following information is presented as an aid to isolate and determine the specific problem areas 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 cor-
rect functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the
transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assem-
bly, oil cooler, filter, connecting lines, and controls, including the engine, as a complete system.
By analyzing 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.
TE10 Transmission
TE10 (power shift with torque converter transmission) troubles fall into four general categories:
1. Mechanical problems.
2. Hydraulic problems.
3. Electrical problems.
4. Controller problems
In addition to the mechanical and electrical components, all of which must be in the 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.
Troubleshooting Procedures
Stall Test
A stall test to identifies transmission, converter, or engine problems.
Use following procedure:
1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels.
2. Put the directional control lever in FORWARD (or REVERSE, as applicable).
3. Select the highest speed in manual modeWith the engine running, slowly increase engine speed to approximately
one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range.
Do not operate the converter at stall condition longer than 30 seconds at one
time, shift to neutral for 15 seconds and repeat the procedure until desired
temperature is reached. Excessive temperature 120 °C (250 F) maximum will
cause damage to transmission clutches, fluid, converter, and seals.
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.
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 the proper cooling and operating temperatures for the engine and transmission. Air
clean the radiator, if necessary.
• 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.
Hydraulic Checks
Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure
and rate of oil flow, it is important 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 con-
verter and its fluid circuit lines must be fully charged (filled) at all times.
NOTE:
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” (see “Stall Test”, on page 36).
Be careful the vehicle does not move unexpectedly

when operating the engine and converter at stall rpm.
Troubleshooting Guide
Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.
Low Clutch Pressure

Cause Remedy
Low oil level Fill to proper level
Clutch pressure regulating valve stuck open Clean valve spool and housing
Faulty charging pump Replace pump
Broken or worn clutch shaft or piston sealing rings Replace sealing rings
Clutch piston bleed valve stuck open Clean bleed valves thoroughly
Low Charging Pump Output

Cause Remedy
Suction screen plugged Clean suction pump
Defective charging pump Replace pump
Overheating
Cause Remedy
Worn oil sealing rings Remove, disassemble, & rebuild converter assembly
Worn charging pump Replace charging pump
Dirty oil cooler Clean cooler
Restriction in cooler lines Change cooler lines
Noisy Converter
Cause Remedy
Worn charging pump Replace charging pump
A complete disassembly will be necessary to determine
Worn or damaged bearings
which bearing is faulty
Defective charging pump Replace pump
Lack of Power
Cause Remedy
Low engine RPM at converter stall Tune engine check governor
See “Overheating” section above and make same
Make corrections as explained in “Overheating”
checks
Check Points
Front View
Rear View
Left View
Right View
Top View
Checkports
31A System Pressure
41 1st Clutch Pressure
42 2nd Clutch Pressure
43 3rd Clutch Pressure
45 FWD Clutch Pressure
46 REV Clutch Pressure
66 FWD/REV Regulated Pressure
67 1st / 3rd Regulated Pressure
68 2nd Regulated Pressure
Full Flow Valve Components
Speed Sensor - Static Standalone Test
In order to be able to sense the currents, a series resistor of e.g. 200 W must be used. This resistor is integrated in the
controller, but when the sensor is to be tested, 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-1.6V (for the 7mA ± 1mA current level) or 2.6-3.0V (for the 14mA ± 1mA cur-
rent level)
If the teeth can be moved slowly, distinct toggling between the two levels should be noticed.
EXPLODED VIEWS
Converter Housing Group
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
Housing - Converter Assy
1 1 8 Capscrew 17
includes items 1A, 1B, 1C, 1D
1A Plug 1 9 Lockwasher 17
1B Plug (N.S.S.) 1 10 Pin - Dowel 1
1C Plug 1 11 Clip - Sleeve 2
1D Plug 1 12 Screw - Sleeve Clip 2
2 Sleeve - Converter Housing 2 13 Lockwasher - Sleeve Clip 2
3 Plug (N.I.) 2 14 Sensor - Speed & Screw 1
4 Plug 1 15 O-ring 1
5 O-ring 1 16 Switch - Temperature 2
6 Plug 1 17 Breather - Air 1
Gasket - Converter Housing to

7 1 18 Plug 2
Transmission Case
N.S.S. = Not Sold Separately

N.I. = Not Illustrated
Transmission Case Group
Assy - Transmission Case
1 1 14 Plug - Magnetic 1
Includes Items 2 thru 10
2 Assy - Suction Tube 1 15 Pin - Dowel 2
3 Sleeve - Press & Lube Tube 4 16 Baffle - Oil 1
4 Tube - 3rd Clutch 1 17 Plug - Dipstick Hole 1
5 O-ring 1 18 Not Used on This Model
6 Capscrew 1 19 Not Used on This Model
Gasket - Rear Cover to

7 Plug 1 20 1
Transmission Case
Tube - Low Speed Clutch

8 1 21 Fitting - Plug, O-ring Seal 1
Pressure
Lockwasher - Pump Mount-

9 Plug 1 22 14
ing Screw
10 Lockwasher 1 23 Capscrew 14
Assy - Rear Cover, Plug, &

11 Seal 1 24 O-ring 1
Includes Items 12, 12A, & 13
12 Plug 1 25 O-ring 4
Assy - Speed Sensor

12A O-ring 1 26 26.3 mm 3
Includes Item 27
13 Seal - Oil 1 27 O-ring 1

Turbine Shaft & Stator Support Group
1 Shaft - Turbine 1 9 Screw - Stator Support 6
2 Not Used on This Model 10 Piston Ring 1
3 Bearing - Turbine Shaft 1 11 Spring - Piston Ring Expander 1
Assy - Oil Baffle

4 Snap Ring External - Special 1 12 1
Includes Item 13
5 Washer - Bearing Support 1 13 Seal - Oil Baffle 1
6 Bearing Retaining Ring 1 14 Ring - Oil Baffle Seal 1
7 Piston Ring 1 15 Ring - Oil Baffle Retaining 1
8 Stator Support 1

Drive Plate Group
1 Capscrew 10 3 Ring - Backing 1
Kit - TE10 13.5 Drive Plate

2 Lockwasher 10 4 1
Includes Items 1 thru 3

Torque Converter Assembly Group
1 Gear - Impeller Hub 1 13 Screw - Turbine Hub 12
2 Bearing - Impeller Hub Gear 1 14 Ring - Turbine to Hub Screw 1
3 Spacer - Without Freewheel 1 15 Bearing - Turbine Hub 1
4 O-ring - Impeller Hub 1 16 Ring - Turbine Hub Retaining 1
5 Ring - Backing 1 17 Cover - Impeller 1
6 Screw - Turbine Hub 8 18 Spacer - Turbine Hub 1
7 Impeller 1 19 O-ring - Impeller to Cover 1
Member - Reaction
8 1 20 Screw - Impeller to Cover 24
15 blades
Ring - Reaction Member Lockwasher - Impeller to

9 1 21 24
Retaining Cover Screw
Hub - Turbine
10 1 22 O-ring 1
18 blades
11 Hub - Turbine 1 23 Bore - Plug 1
12 Ring - Turbine Hub Retaining 1 24 Snap Ring 1

Gear Group
1 Gear - Reverse Idler 1 3 Gear - Forward Shaft 1
2 Gear - Reverse Clutch 1 4 Gear - Low Clutch 1

Auxiliary Pump Drive Group
1 Support - Pump Drive Bearing 1 9 Adaptor Pump SAE C to SAE C 1
2 Capscrew 2 10 Gasket - Pump Mounting Cover 1
3 Washer - Bearing Support 2 11 Cover - Pump Mounting 1
Washer - Bearing Support Screw

4 2 12 Stud - Pump Adaptor 4
Sealing
Lockwasher - Pump Adaptor

5 Bearing - Ball 1 13 4
Screw
Ring - Drive Gear Bearing

6 1 14 Nut 4
Retainer
7 Gear - Pump Drive (46T-10P) 1 15 Spacer - Pump Adaptor (8mm) 4
8 O-ring 1

Charging Pump Drive Group
1 Support - Pump Drive Bearing 1 8 Ball - Idler Shaft Lock 1
2 Bearing - Pump Drive Gear 1 9 Bearing - Idler Gear Stub Shaft 1
Ring - Drive Gear Bearing Locat-

3 2 10 Ring - Idler Gear Bearing Locating 2
ing
Ring - Idler Gear Bearing

4 Ring - Drive Gear Bearing Set 1 11 2
Retaining
5 Gear - Charging Pump Drive 1 12 Screw - Bearing Support 2
6 Gear - Pump Drive Idler 1 13 Lockwasher - Bearing Support 2
7 Shaft - Idler 1

Forward Shaft Group
Assy - Forward Shaft, Gear,
1 1 9 Snap Ring - Backing Plate 1
Drum, & Plug
Assy - Clutch Piston Assy - Disc Spring

2 1 10 1
Includes Items 3 & 4 Includes 13 washers
3 Seal - Clutch Piston, Outer 1 11 Snap Ring - Retaining 1
4 Seal - Clutch Piston, Inner 1 12 Bearing - Ball 1
5 Disc - Inner 12 13 Ring - Bearing Retaining 1
6 Disc - Outer 12 14 Piston - Ring 2
7 Spacer - Clutch Piston Spring 1 15 Bearing - Forward Shaft Pilot 1
Assy - End Plate & Seal

8 1 16 Ring - Gear Retaining 1
Includes Item 8A
Forward Shaft Gear

8A Seal Lip 1 17 (see “Gear Group”, on
page 55)

Reverse Idler Group
1 Shaft - Reverse Idler 1 5 Assy - Bearing 1
2 O-ring - Idler Shaft 1 6 Nut - Bearing Retaining Plate 1
Gear - Reverse Idler

3 Ball 1 7
(see “Gear Group”, on page 55)
4 Washer - Tanged 2

Reverse & Second Group
Assy - Rev & 2nd Shaft, Gear, Assy - Disc Spring

1 1 18 1
Drum, & Plug Including 5 Washers
Assy - Clutch Piston Snap Ring - 2nd Clutch Disc

2 1 19 1
Including Items 2 & 3 Hub
3 Seal - Clutch Piston, Outer 1 20 Bearing - Clutch Driven Gear 1
4 Seal - Clutch Piston, Inner 1 21 Bearing - Ball 1
Assy - Clutch Piston Snap Ring - Front Bearing

5 1 22 2
Including Items 6 & 7 Rear
Bearing - Reverse & 2nd

6 Seal - Clutch Piston, Outer 1 23 1
Shaft Front
Snap Ring - Front Bearing

7 Seal - Clutch Piston, Inner 1 24 1
Rear
Snap Ring - Front Bearing

8 Disc - Inner - Rev 12 25 1
Front
9 Disc - Inner - 2nd 6 26 Snap Ring - Front Bearing 1
10 Disc - Outer 18 27 Piston - Ring 3
Spacer - Piston Return Spring Spacer - Clutch Driven Gear

11 1 28 1
- Rev Bearing
Plate - Clutch Disc Backing -

12 1 29 Retaining Ring 1
2nd
Bearing - Reverse & 2nd

13 Snap Ring - Backing Plate 2 30 1
Shaft Rear
Spacer - Clutch Piston Spring

14 1 31 Hub - 2nd Clutch 1
- 2nd
Assy - End Plate & Seal

15 1 32 Retaining Ring 1
Including Item 16
16 Seal Lip 1 33 Retainer - Spring 1
Assy - Disc Spring

17 1 34 Snap Ring - Retainer 1
Including 13 Washers

Low Shaft Group
Spacer - Piston Return
1 Assy - Low Shaft, Hub & Drum 1 12 1
Spring
Assy - Clutch Piston

2 1 13 Bearing - Low Speed Gear 1
Including Items 3 & 4
3 Seal - Clutch Piston, Outer 1 14 Bearing - Low Speed Gear 1
Spacer - Low Speed Gear

4 Seal - Clutch Piston, Inner 1 15 1
Bearing
Ring - Low Speed Gear

5 Plate - Friction 13 16 2
Bearing Locating
6 Disc - Outer 13 17 Ring - Piston 1
Bearing - Low Speed Clutch

7 Plate - Clutch Disc Backing 1 18 1
Shaft Front
Bearing - Low Speed Clutch

8 Ring - Backing Plate Retaining 1 19 1
Shaft Rear
Assy - Disc Spring

9 1 20 Spacer - Front Bearing 1
Including 11 Washers
10 Retainer - Spring 2 21 Snap - Ring External 1
11 Snap Ring - Spring Retainer 2

Third Group
Assy - 3rd Shaft, Gear, Drum, Disc - Inner (Mount closest
1 1 11A 2
& Plug to the clutch piston)
Piston - Ring 3rd Clutch Shaft

2 2 12A Plate - Friction 2
Cast Iron
Bearing - 3rd Clutch Shaft

3 1 12 Plate - Friction 5
Front
Snap Ring - Front Bearing Spacer - Clutch Piston

4 1 13 1
Next to Piston Ring Groove Spring
Snap Ring - 3rd Clutch Shaft

5 1 14 Plate - Clutch Disc Backing 1
Front Bearing
Assy - Clutch Piston

6 1 15 Snap Ring - Backing Plate 1
Including Items 7 & 8
Bearing - 3rd Clutch Shaft

7 Seal - Clutch Piston, Outer 1 16 1
Pilot
8 Seal - Clutch Piston, Inner 1 17 Hub - 3rd Clutch 1
Assy - Disc Spring Snap Ring - 3rd Clutch Disc

9 1 18 1
Including 5 Washers Hub
10 Retaining Ring 1 19 Retainer 1
11 Disc - Inner 4 20 Snap Ring - Retainer 1

Output Shaft Group
1 Shaft - Output 1 5 Ring - Snap 1
2 Bearing - Ball 1 6 O-ring 1
3 Snap Ring External - Special 1 7 Washer - Flange 1
4 Bearing - Output Shaft Rear 1 8 Nut - Flange 1

Charging Pump & Filter Assembly Group
1 Assy - Charging Pump 1 5 Screw - Pump Mounting 4
2 Assy - Oil Filter 1 6 Screw - Pump Mounting 1
Gasket - Pump Assy to Con- Lockwasher - Pump Mount-

3 1 7 5
verter Housing ing Screw
4 O-ring 1

Control Valve Group
Assy - Control Valve & Plugs
1 1 16 O-ring 1
Including items 2 thru 4A
2 Plug - Expansion N.S.S. 19 17 O-ring 1
3 Plug - Expansion N.S.S. 3 18 O-ring 1
4 Plug - Expansion N.S.S. 7 19 Spool 3
4A Plug - Orifice 0.8mm 1 19A Pin - Accumulator Stop 3
5 Solenoid - Valve 3 20 Spring - Accumulator 3
Plug
6 O-ring 3 21 3
Includes item 22
7 O-ring 6 22 O-ring 3
8 Capscrew 8 23 Sensor - Valve Pressure 2
Assembly - Solenoid Plug

9 1 24 2
Including items 10 thru 13 Includes item 25
Plug
11 O-ring 1 26 8
Includes item 27
13 O-ring 1 28 Lockwasher 15
14 Solenoid - Drop-in 1 29 Capscrew 15
Gasket - Valve to Transmis-

15 O-ring 1 30 1
sion Case

INSTALLATION DIAGRAMS
Transmission Assembly Instructions
• All lead in chamfers for oil seals, piston rings, and “O”-rings must be smooth and free from burrs.
Inspect at assembly.
• Lubricate all piston ring grooves and “O”-rings with oil before assembly.
• Apply a thin coating of grease between seal lips on lip type seals prior to assembly.
• Use only pre-coated pipe plugs. On uncoated pipe plugs apply a light coat of Loctite # 592.
• 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.
Tighten oil filter to 20-25 lbs. ft. [27-34 N•m].
Tighten nuts to 30-37 lbs. ft. [40-50 N•m].
The clutch springs: The concave side of the first disc spring must be placed
against the clutch piston wear sleeve. The remaining springs of each clutch to
be stacked alternately reversed. NEVER mix springs.
HEAVY SPRING LOAD! Use the correct tools to

assemble and disassemble this item!
13 outer steel plates / 13 inner plates alternatively assembled, starting with outer
steel plate. Clearance between clutch piston and steel separator plate to be .153-
.232” [3.9 - 5.9 mm].
12 outer steel plates / 12 inner plates alternatively assembled, starting with outer
steel plate. Clearance between clutch piston and steel separator plate to be .142-
.220” [3.6 - 5.6 mm]
Apply Loctite 641 to the O.D. of the seals.
Torque to 12-16 lbs. ft. [12-22 N•m].
2 separator plates with inner splines and thickness 3+0.06mm (mounted

closest to the clutch piston / 5 friction plates (friction on both sides) with outer
splines / 4 separator plates with inner splines and thickness 2+0.06 mm /
2 one-side friction plates with outer splines. Clearance between clutch piston
and steel separator plate to be .072-.152” [1.82 - 3.87 mm].
Apply Loctite 510 around dowel holes or dowel pins.
Tighten to 200 - 250 lbs. ft. [271 - 340 N•m]

Stake nut securely into shaft notch after tightening to proper torque.
6 outer steel plates / 6 inner plates alternately assembled, starting with outer
steel plate. Clearance between clutch piston and steel separator plate to be
.072-.152” [1.82 - 3.87 mm].
Be sure shielded and sealed bearings are mounted as shown.
Control Valve Assembly Instructions
Tighten 2 coil nuts to 250-300 lbs.ft. [6.8-9.5 N•m]
Tighten 1 valve to 39-54 lbs. ft. [53-73 N•m]
Tighten 6 screws to 3.7-4.4 lbs. ft. [5-6 N•m]
Tighten 2 coil nuts to 5-7 lbs. ft. [6.8-9.5 N•m]
Tighten 2 pressure sensors to 5-8 lbs. ft. [7-11 N•m]
Tighten 2 valves to 25-27 lbs. ft. [34-36 N•m]
CLEANING AND INSPECTION
Care should be exercised to avoid skin rashes, fire hazards,

and inhalation of vapors when using solvent type and alkali
cleaners.
Cleaning
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid
and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials.
Thoroughly dry all cleaned parts immediately by using moisture-free compressed air or soft lint-free absorbent wiping
rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound.
BEARINGS
Remove bearings from cleaning fluid and strike larger side of cone 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 bearings to
avoid spinning. DO NOT SPIN BEARINGS WHEN DRYING. Bearings may be rotated slowly by hand to facilitate the dry-
ing process.
HOUSINGS, COVERS, AND CAPS

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.
All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft lint-free absor-
bent wiping rags, free of abrasive materials such as metal filings, contaminated oil, or lapping compound.
Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all parts show-
ing indication of wear or stress will eliminate costly and avoidable failures at a later date.
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 clean light oil and wrap in clean lint-free cloth or paper to protect them until
installed.
OIL SEALS, GASKETS AND RETAINING RINGS

Replacement of spring loaded oil seals, gaskets, and retaining rings are more economical when the unit is disassem-
bled than to risk premature overhaul to replace these parts at a future time. 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, particu-
larly when being installed. Cutting, scratching, or curling under the lip of the seal seriously impairs its efficiency. At reas-
sembly, lubricate rings and seals with Multipurpose Lithium Grease Grade 2 for axles and Automatic Transmission Fluid
for transmissions.
GEARS AND SHAFTS

If Magna-Flux or a dye penetrant process is available, use this process to check parts. Examine teeth and the ground/
polished surfaces of all gears and shafts carefully for wear, pitting, chipping, nicks, cracks, or scoring. If gear teeth are
cracked or show spots where case hardening is worn through, replace with new gear. Small nicks may be removed with
suitable hone stone. Inspect shafts to make certain they are not sprung, bent, or have twisted splines.
ASM-0102 - 21D Axle Service Manual Dana Holding Corporation 80

HOUSINGS, COVERS, AND CAPS
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.
81 Dana Holding Corporation ASM-0102 - 21D Axle Service Manual

DISASSEMBLY & REASSEMBLY
Getting Started
Cleanliness is of extreme importance in the repair and over-

haul of the transmission. Before conducting repairs, the
exterior of the unit must be thoroughly cleaned to prevent
dirt and foreign debris from entering the transmission.
When maintenance work requires welding, disconnect both

connectors from the APC200 and from the control valve unit
before any welding is started.
NOTE:
FIGURE 2: Remove the valve assembly:
The area around the valve must be clean and free of any foreign
material. See “Cleaning and Inspection”, on page 80.
Unscrew 16 bolts (marked with hexagons on the drawing) some

The disc spring packs are to be used as complete turns.
assemblies and care should be taken not to intermix the When all bolts are loose, the valve should move.
individual disc springs with disc springs in another clutch
Replace 2 bolts by aligning studs.
or disc spring pack.
Remove the remaining 14 hex bolts and valve from the
Each disc spring assembly is made up of selected transmission case.
springs to precisely match each part within this assem-
bly. Failure to replace all piston return springs can result
in unequal deflection within the spring pack. The result of
this imbalance may adversely affect overall life of springs.
Transmission Case Disassembly
FIGURE 3: Valve assembly removal.
FIGURE 1: Front view of the TE10 3 speed.
FIGURE 4: Remove oil filter element.It is recommended that a

small pan be used to catch remaining oil in element.
FIGURE 5: Remove pressure regulating valve and charging FIGURE 8: Remove speed sensors (4).
pump screws and washers. Remove pressure regulating valve
and charging pump as an assembly.
FIGURE 9: Remove drive plate nuts and lockwashers. Remove

FIGURE 6: When used remove shipping cover screws and drive plates and backing ring.
washers. Remove shipping cover plate.
FIGURE 10: Remove impeller cover to impeller bolts and

FIGURE 7: Remove auxiliary pump adaptor. lockwashers. Use a small pan to catch the oil left in the converter.
FIGURE 11: Remove turbine hub to turbine shaft snap ring, bore FIGURE 14: Remove turbine hub retaining ring.
plug, and o-ring.
FIGURE 15: Remove reaction member retaining ring.

FIGURE 12: While collapsing snap ring, use a screwdriver to pry
impeller cover loose.
FIGURE 16: Remove reaction member.
FIGURE 13: Remove impeller cover.
FIGURE 17: Remove reaction member spacer. FIGURE 20: Remove impeller assembly.
FIGURE 18: Remove turbine hub screws FIGURE 21: Remove oil baffle retaining ring.
FIGURE 19: Remove backing ring. FIGURE 22: Remove oil baffle, seal, and seal ring.
FIGURE 23: Remove impeller hub gear and bearing as an FIGURE 26: Remove pump drive gear bearing support bolts.
assembly. Remove gear and bearing as an assembly.
FIGURE 24: Remove pump drive idler gear set ring. FIGURE 27: Remove auxiliary pump drive gear bearing support
bolts. Remove gear and bearing as an assembly from behind.
FIGURE 25: Remove idler gear and bearing as an assembly.

FIGURE 28: Support converter housing with a chain hoist.
Remove converter housing to transmission case bolts.
FIGURE 29: Separate converter housing from transmission case. FIGURE 32: Remove 2nd speed clutch disc hub.
NOTE:
FIGURE 33: Remove 3rd speed clutch disc hub snap ring
retainer, outer ring, and ring retainer.
FIGURE 30: Converter housing separated from transmission
case.
FIGURE 34: Remove 3rd clutch disc hub.
FIGURE 31: Remove 1st speed clutch disc hub snap ring
retainer, outer ring, and ring retainer.
FIGURE 35: Loosen the flange nut. FIGURE 38: Remove rear cover screws and lockwashers.
FIGURE 39: Using pry slots provided, pry cover from

FIGURE 36: Remove flange nut, washer, and o-ring.
transmission housing, tapping shafts with soft hammer to assist
removal.
FIGURE 37: Remove output flange.

FIGURE 40: After the rear cover is removed, remove the rear
cover to transmission case gasket.
FIGURE 41: Spread the ears on the 1st speed clutch front FIGURE 44: Remove low clutch shaft rear bearing.
bearing snap ring and tap the clutch input shaft from the case.
FIGURE 45: Remove low clutch shaft assembly and output shaft
FIGURE 42: Spread the ears on the 3rd speed clutch front assembly from case.
bearing snap ring and tap the clutch input shaft from the case.
FIGURE 46: Remove oil baffle.

FIGURE 43: Attach bearing puller to low clutch shaft rear
bearing.
Converter Housing Disassembly
FIGURE 47: Spread the ears on the forward gear shaft bearing
retaining ring.
FIGURE 50: Remove reverse/2nd clutch shaft rear bearing and
3rd clutch shaft pilot bearing.
FIGURE 48: Remove forward gear shaft assembly.
FIGURE 51: Remove forward clutch shaft pilot bearing.
FIGURE 49: Remove suction tube assembly capscrew and

lockwasher. FIGURE 52: Spread ears on 3rd clutch front bearing snap ring.
Pull 3rd clutch assembly from converter case.
FIGURE 53: Spread ears on reverse/2nd clutch front bearing FIGURE 56: Attach bearing puller to reverse idler gear and
snap ring. Pull reverse/2nd clutch assembly from converter case. bearing assembly.
FIGURE 54: Loosen reverse idler shaft nut. FIGURE 57: Remove bearing spacer.
FIGURE 55: Remove reverse idler shaft nut and washer. FIGURE 58: Tap reverse idler shaft from case.
FIGURE 59: Remove inner taper bearing and spacer. FIGURE 62: If stator support is to be removed. Remove stator
support screws and tap stator support from converter case.
FIGURE 60: Remove idler shaft. Use caution not to lose shaft
lock ball. FIGURE 63: Remove oil sealing ring sleeve retainer screw and
washer. Remove sleeve lock.
FIGURE 61: Spread ears on turbine shaft bearing locating snap

ring. Tap turbine shaft and bearing assembly from stator support. FIGURE 64: Attach sleeve puller to sleeve.
FIGURE 65: Remove sleeve. FIGURE 68: Remove inner and outer discs.
Forward Clutch Disassembly
FIGURE 69: Compress piston return disc spring pack and

remove spring retainer snap ring.
FIGURE 66: Remove end plate retaining ring.
Use caution when removing snap ring.

Force of spring is 1350 N•m.
FIGURE 67: Remove end plate.
FIGURE 70: Remove piston return disc spring pack.

NOTE:
FIGURE 71: Remove return spring spacer. FIGURE 74: Remove snap ring.
FIGURE 72: Remove clutch piston. FIGURE 75: Remove forward shaft gear.
FIGURE 73: Turn clutch over and remove clutch shaft piston FIGURE 76: Attach bearing puller to forward shaft bearing and
rings (2). remove.
Forward Clutch Reassembly
FIGURE 80: Install piston return disc springs. First spring with
large diameter towards spacer. Alternate (13) disc springs.
FIGURE 77: Install new clutch piston inner sealing ring. Refer to NOTE:
the “Cleaning and Inspection” pages.
NOTE:
FIGURE 81: Spring and spacer position.
FIGURE 78: Install new clutch piston inner sealing ring.
FIGURE 82: Compress return disc springs and install spring

retaining snap ring. Be sure snap ring is in full position in groove.
FIGURE 79: Install piston return spring spacer. Use caution when installing snap ring.
FIGURE 83: Install one (1) steel disc. Install one (1) friction disc. FIGURE 86: Install bearing.
Alternate steel and friction discs until proper amount are
installed. First disc next to the piston is steel, last disc installed is
friction.
FIGURE 87: Install forward shaft gear.
FIGURE 84: Install new seal in clutch end plate. Install end plate
in clutch drum.
FIGURE 88: Install snap ring.
FIGURE 85: Install end plate retaining ring.
FIGURE 89: Turn clutch over and install clutch shaft piston rings FIGURE 92: Remove spacer.
(2).
First Clutch Disassembly
FIGURE 90: Attach bearing puller to front bearing.
FIGURE 91: Remove front bearing, spacer and low gear.
FIGURE 95: Remove inner and outer discs. FIGURE 98: Remove bearing locating ring snap ring.
FIGURE 96: Remove bearing. FIGURE 99: Compress return spring and remove return spring
retaining snap ring.

FIGURE 97: Remove bearing locating ring.
FIGURE 100: Remove return spring retaining ring retainer.
FIGURE 101: Remove piston return disc springs. FIGURE 104: Turn clutch over and remove clutch shaft piston
NOTE: ring (1).
First Clutch Reassembly
FIGURE 105: Install new clutch piston inner sealing ring. Refer to
the “Cleaning and Inspection” pages. The bleed valve in the
FIGURE 102: Remove piston spacer. clutch piston must be clean and free of any foreign material.
NOTE:
FIGURE 103: Remove clutch piston.
FIGURE 106: Install new clutch piston outer sealing ring and
install clutch piston in clutch drum. Use caution as not to damage
newly installed seal rings. The bleed valve in the piston must be
clean and free of any foreign material.
FIGURE 110: Position piston return disc spring retaining ring

retainer on clutch shaft.
FIGURE 107: Install piston spacer.
FIGURE 111: Compress springs and install retainer snap ring.

Be sure snap ring is in full position in groove.
FIGURE 108: Install piston return springs. First spring with large
diameter towards spacer. Alternate eleven (11) springs.
Use caution when installing snap ring.

FIGURE 112: Install inner bearing locating ring snap ring.
FIGURE 113: Position inner bearing retaining ring retainer. FIGURE 116: Install end plate retaining ring.
FIGURE 117: Warm clutch driven gear and hub assembly to

248°F [120°C].
FIGURE 114: Install one (1) steel disc. Install one (1) friction disc.
Alternate steel and friction discs until proper amount of discs are Align splines on clutch gear with internal teeth of friction discs
installed. First disc next to piston is steel, last disc is friction. and gently put gear into position.
Gear splines must be in full position with internal teeth of all

friction discs.
FIGURE 115: Install clutch end plate.
FIGURE 118: Install front bearing spacer.
FIGURE 119: Warm front bearing to 248°F [120°C] and install on FIGURE 122: Remove front bearing retaining ring.
shaft with groove down (as shown).
FIGURE 123: Remove front bearing.

FIGURE 120: Turn clutch over and install clutch shaft piston ring
(1).
Reverse Clutch Disassembly
FIGURE 124: Remove clutch gear bearing retaining ring.
FIGURE 121: Remove clutch shaft piston rings (3).
FIGURE 125: Using a puller as shown, remove reverse gear. FIGURE 128: Remove end plate retaining ring.
FIGURE 126: Remove bearing spacer. FIGURE 129: Remove end plate.
FIGURE 127: Remove bearing using a bearing puller. FIGURE 130: Remove inner and outer clutch discs.
FIGURE 131: Compress piston return discs spring. Remove FIGURE 134: Remove clutch piston.
return spring retainer ring.
Reverse Clutch Reassembly

FIGURE 135: Install new clutch piston inner sealing ring. See
“Cleaning and Inspection”, on page 80.
NOTE:
FIGURE 132: Remove return disc springs.

NOTE:
newly installed seal rings.
FIGURE 133: Remove piston spacer.
FIGURE 137: Remove clutch piston. FIGURE 140: Compress return disc springs and install disc
spring retainer snap ring. Be sure snap ring is in full position in
groove.

large diameter towards spacer. Alternate thirteen (13) springs.
Alternate steel and friction discs until the proper amount of discs
are installed. First disc next to the piston is steel, last disc
installed is a friction disc.
FIGURE 142: Install new seal in end plate and install end plate in
clutch drum.
FIGURE 143: Install end plate retainer ring. FIGURE 146: Warn clutch shaft front bearing to 248°F [120°C]
and install on clutch shaft with groove up as shown.
FIGURE 144: Warm reverse gear and hub and bearing assy to
248°F [120°C] Install into clutch drum. Align splines on reverse FIGURE 147: Install bearing retaining ring.
gear with internal teeth of friction discs.
Gear splines must be in full contact with internal teeth of all

friction discs.
FIGURE 148: Install clutch shaft piston rings (3).
FIGURE 145: Install bearing retaining snap ring.
Second Clutch Disassembly
FIGURE 152: Compress piston return disc springs and remove

spring retaining snap ring.

FIGURE 153: Remove piston return disc springs.
FIGURE 151: Remove inner and outer discs.
FIGURE 154: Remove piston spacer.
FIGURE 155: Remove clutch piston.
FIGURE 158: Install piston return spring spacer.

Second Clutch Reassembly
FIGURE 156: Install new clutch piston inner sealing rings. Refer large diameter towards spacer. Alternate five (5) springs.
to the “Cleaning and Inspection” pages.
NOTE:
FIGURE 161: Compress return disc springs and install retainer FIGURE 164: Install end plate retaining ring.
snap ring. Be sure snap ring is in full position in groove.
Third Clutch Disassembly

installed. First disc next to piston is steel, last disc installed is
friction.
FIGURE 163: Install end plate.
FIGURE 167: Remove inner and outer discs. FIGURE 170: Remove piston spacer.
FIGURE 168: Compress piston return disc springs and remove FIGURE 171: Remove clutch piston.
spring retaining snap ring.
Third Clutch Reassembly

FIGURE 172: Install new clutch piston inner sealing ring. Refer to
the “Cleaning and Inspection” pages.
NOTE:
FIGURE 169: Remove piston return disc springs.
FIGURE 173: Install new clutch piston outer sealing ring and FIGURE 176: Spring and spacer position.
FIGURE 177: Compress return disc springs and install retainer

snap ring. Be sure snap ring is in full position in groove.
FIGURE 174: Install piston return spring spacer.

large diameter towards spacer. Alternate five (5) springs.
FIGURE 178: Install half disc.
FIGURE 179: Install one (1) steel disc. Install one (1) friction disc. FIGURE 182: Install end plate retaining ring.
installed. First disc next to piston is steel, last disc installed is Third Clutch Shaft Front Bearing
friction.
Disassembly
FIGURE 180: Install half disc. FIGURE 183: Remove piston rings.
FIGURE 181: Install end plate. FIGURE 184: Remove bearing retaining ring.
Third Clutch Shaft Front Bearing
Reassembly
FIGURE 185: Using a bearing puller, remove the bearing.
FIGURE 186: Warm bearing to 248°F [120°C] and install on shaft

as shown.
NOTE:
FIGURE 187: Install bearing retaining ring.
FIGURE 188: Install piston rings (2).
Turbine Shaft Disassembly Turbine Shaft Reassembly
FIGURE 192: Warm bearing to 248°F [120°C] and install on shaft

FIGURE 189: Remove oil seal ring.
as shown.
NOTE:
FIGURE 190: Remove bearing retaining ring and washer.
FIGURE 193: Install washer and bearing retainer.
FIGURE 191: Using a bearing puller, remove the bearing.
FIGURE 194: Install oil sealing ring.
Output Shaft Disassembly
FIGURE 198: Remove bearing on opposite end of shaft.
FIGURE 195: Remove output shaft snap ring, bearing, and oil
seal from the transmission case rear cover.
Output Shaft Reassembly
FIGURE 196: Remove output shaft rear bearing with puller as

shown. FIGURE 199: Warm bearing to 248°F [120°C] an install on shaft
as shown.
FIGURE 197: Remove inner bearing race.

FIGURE 200: Position inner bearing race on shaft.
Turbine Disassembly
FIGURE 204: Remove turbine to turbine hub bolts.
FIGURE 201: Remove impeller from cover.
FIGURE 205: Remove turbine backing plate.
FIGURE 202: Remove turbine retaining ring and tap turbine from
turbine cover with a soft hammer.
FIGURE 206: Remove turbine from turbine hub.
FIGURE 203: Remove turbine hub spacer.
Turbine Reassembly
FIGURE 207: Install turbine on turbine hub. Position backing ring FIGURE 210: Install new o-ring in impeller cover. Place turbine
in turbine. assembly in impeller cover.
FIGURE 208: Install self locking screws. Tighten screws 79-87

N•m [58-64ft.lbs]
NOTE:
FIGURE 209: Install spacer, turbine hub bearing, and retaining

ring.
Converter Case Reassembly
See cleaning and inspection pages.
If stator support was disassembled.
Install new sealing ring and oil sealing ring on support.
Press support bearing into position.
NOTE:
Clean stator support mounting surface and tapped holes

with solvent. Dry thoroughly, being certain tapped holes
are clean and dry.
FIGURE 212: Drop lock ball in position as shown.
Position stator support in converter housing aligning
holes in support with holes in housing. Tap support into
place with a soft hammer.
Stator support screw assembly.
Install 6 special stator support screws. Tighten screws
12-16 lbs. ft. [16.3-21.6 N•m].
NOTE:
FIGURE 213: Install idler shaft spacer.
FIGURE 211: With new o-ring installed, position idler shaft in

converter housing. Align groove in shaft with groove in converter
FIGURE 214: Warm lower taper bearing race to 248°F [120°C]
housing. Tap in place.
and install on shaft.
FIGURE 215: Install spacer. FIGURE 218: Install spacer.
FIGURE 216: Install idler gear. FIGURE 219: Install retainer nut and torque to 200-250 lbs.
ft.[271.2-338.9 N•m]
FIGURE 217: Warm idler gear outer tapered bearing race and
install on shaft with large diameter up. FIGURE 220: Stake nut securely in shaft notch.
Transmission Case Reassembly
FIGURE 221: Spread ears on turbine shaft bearing retainer ring

located in reaction member support. Tap turbine shaft and
FIGURE 224: Install new o-ring and suction tube.
bearing into position, being certain bearing snap ring is in full
position in snap ring groove.
FIGURE 225: Install suction tube bolts and tighten to specified

FIGURE 222: Spread ears on Rev/2nd clutch front bearing
locating ring. Tap Rev/2nd clutch drum into place, being certain torque. See “Torque Specifications”, on page 131.
bearing snap ring is in full position in snap ring groove.
FIGURE 223: Spread ears on 3rd clutch front bearing locating

ring. Tap 3rd clutch drum into place, being certain bearing snap FIGURE 226: Install the gear retaining ring.
ring is in full position in snap ring groove.
FIGURE 227: Position oil sump oil baffle in case. FIGURE 230: Position a new gasket and o-ring onto the rear
transmission case.
NOTE:
FIGURE 228: Install output shaft and 1st clutch assemblies at

the same time. Best is to lower the output shaft with a chain hoist
whilst installing 1st clutch drum.
FIGURE 231: Install output seal in transmission rear cover using
seal driver.
FIGURE 229: Warm 1st clutch rear bearing to 248°F [120°C] and
install bearing with locating ring groove up as shown.
FIGURE 232: Install output shaft bearing in transmission rear
cover using driver.
FIGURE 233: Install output shaft bearing snap ring. FIGURE 236: Install output flange.
FIGURE 234: The use of aligning studs will facilitate rear cover FIGURE 237: Install output flange o-ring, washer, and nut.
installation. Tap cover in place.
FIGURE 238: Tighten flange nut to 200-250 lbs. ft. [271.2-338.9

FIGURE 235: Apply Loctite #262 to rear cover bolts. Install N•m]
washers and bolts and tighten to specified torque. See “Torque
Specifications”, on page 131.
FIGURE 239: Position 2nd speed clutch hub on 1st speed clutch
shaft. FIGURE 242: Install disc hub retaining ring, retaining ring
retainer and retainer retaining snap ring.
FIGURE 240: Install disc hub retaining ring, retaining ring FIGURE 243: Install pilot bearing on low clutch shaft.
retainer and retainer retaining snap ring.
FIGURE 244: Position new gasket and o-rings on transmission

FIGURE 241: Position 3rd speed clutch disc hub on output case.
shaft. NOTE:
FIGURE 245: Install pilot bearing on 2nd and 3rd clutch shaft. FIGURE 248: Position auxiliary pump drive gear and bearing
assembly in converter housing and install capscrews.
FIGURE 246: The use of aligning studs will facilitate aligning the
converter housing to the transmission case. Install converter FIGURE 249: Tighten capscrews to specified torque.
housing assembly to transmission assembly using extreme
caution as to align the clutch pilots into the clutch disc hubs. As
the clutch pilots enter the disc hubs, turn the turbine shaft and
output shaft back and forth. This will help align all of the clutch
inner discs with the disc hubs.
FIGURE 250: Position charging pump drive gear and bearing

assembly. Install capscrews.
FIGURE 247: When all clutches are properly aligned, the

converter case will be tight against the transmission housing.
Install two (2) housing to housing bolts and lockwashers. Remove
aligning studs. Install remaining bolts and lockwashers. Tighten
bolts to specified torque. See torque chart.
FIGURE 251: Tighten capscrews to specified torque. See FIGURE 254: Install o-ring.
“Torque Specifications”, on page 131.
FIGURE 255: Install gear.

FIGURE 252: Install pump idler gear and bearing assembly on
shaft.
FIGURE 256: Install tooling AS0024014700.
FIGURE 253: Install idler gear retaining ring.
FIGURE 257: Install oil baffle. FIGURE 260: Apply a light coat of Permatex #2 to the outer
diameter of the oil baffle oil seal. Install impeller assembly and oil
baffle using caution as not to cut, break or unhook the oil sealing
ring on the support.
FIGURE 258: Install oil baffle snap ring and remove tooling
AS0024014700.
FIGURE 261: Install backing ring.
FIGURE 259: Install oil baffle o-ring.
FIGURE 262: Tighten capscrews to specified torque. See

“Torque Specifications”, on page 131.
FIGURE 263: Position impeller hub bearing spacer on stator FIGURE 266: Install turbine hub locating ring.
support.
FIGURE 267: With a new impeller cover to impeller o-ring in

FIGURE 264: Install reaction member with thick side of blades place, install turbine and impeller cover assembly on turbine
out. shaft.
FIGURE 265: Install reaction member retaining ring. FIGURE 268: Install turbine hub to turbine shaft retaining ring.
FIGURE 269: Install impeller cover to impeller screws and FIGURE 272: Install drive plate capscrews and lockwashers.
lockwashers. Tighten screws to specified torque.
FIGURE 273: Install the auxiliary pump adaptor o-ring.
FIGURE 270: Install o-ring and bore plug.
FIGURE 274: Install auxiliary pump adaptor, gasket, and cover.
FIGURE 271: Install bore plug snap ring.
FIGURE 275: Install cover screws and lockwashers and tighten FIGURE 278: Install filter adaptor, washers and capscrews and
to specified torque. See “Torque Specifications”, on page 131. tighten to specified torque.See “Torque Specifications”, on
page 131.
FIGURE 276: Install new charging pump drive gasket.

FIGURE 279: Install new oil filter cartridge.Note: it is
recommended that the filter cartridge be changed after 50 and
100 hours of operation on a new and rebuild or repaired unit.
FIGURE 277: Position charging pump assembly on converter

housing. Install new o-ring in charging pump. Install washers and
capscrews and tighten to specified torque. See “Torque
Specifications”, on page 131. FIGURE 280: Use aligning studs for the reassembly of the
control valve to the transmission case. Install new gasket.
FIGURE 281: Mount control valve. FIGURE 284: Install speed sensors (4) and tighten to specified
torque. See “Torque Specifications”, on page 131.
FIGURE 282: Replace the aligning studs with bolts. Install 14

bolts and hand-tighten in the sequence shown in Figure 283.
Torque all bolts twice to 15-18 lbs. ft. [20-25 N•m] in the
sequence shown in Figure 283.
Re-calibrate the transmission.
FIGURE 283: Control valve bolt tightening sequence.
TORQUE SPECIFICATIONS
Lubricated or Plated Screw Threads
Grade 5
Fine Thread Coarse Thread
Size lbs. ft. N•m lbs. ft. N•m

1/4” (.2500) 9 - 11 12.2 - 14.9 8 - 10 10.8 - 13.6
5/16” (.3125) 16 - 20 21.7 - 27.1 12 - 16 16.3 - 21.7
3/8” (.3750) 26 - 29 35.2 - 39.3 23 - 25 31.2 - 33.9
7/16” (.4375) 41 - 45 55.6 - 61.0 37 - 41 50.2 - 55.6
1/2” (.5000) 64 - 70 86.8 - 94.9 57 - 63 77.3 - 85.4
9/16” (.5625) 91 - 100 123.4 - 135.6 82 - 90 111.2 - 122.0
5/8” (.6250) 128 - 141 173.5 - 191.1 113 - 124 153.2 - 168.1
3/4” (.7500) 223 - 245 302.3 - 332.1 200 - 220 271.1 - 298.2
Grade 8
Fine Thread Coarse Thread
Size lbs. ft. N•m lbs. ft. N•m

1/4” (.2500) 11 - 13 14.9 - 17.6 9 - 11 12.2 - 14.9
5/16” (.3125) 28 - 32 38.0 - 43.4 26 - 30 35.2 - 40.7
3/8” (.3750) 37 - 41 50.2 - 55.6 33 - 36 44.7 - 48.8
7/16” (.4375) 58 - 64 78.6 - 86.8 52 - 57 70.5 - 77.3
1/2” (.5000) 90 - 99 122.0 - 134.2 80 - 88 108.4 - 119.3
9/16” (.5625) 128 - 141 173.5 - 191.1 115 - 127 155.9 - 172.2
5/8” (.6250) 180 - 198 224.0 - 268.4 159 - 175 215.5 - 237.2
3/4” (.7500) 315 - 347 427.0 - 470.4 282 - 310 382.3 - 420.2
METRIC FASTENERS
Lubricated and Plated Bolts, Capscrews, and Studs
Class 8.8 Class 10.9 Class 12.9
8.8 on Bolt Head 10.9 on Bolt Head 12.9 on Bolt Head
Size lbs. ft. N•m lbs. ft. N•m lbs. ft. N•m
M5 3.7 - 4.4 5-6 5.2 - 5.9 7-8 5.9 - 7.4 8 - 10
M6 5.9 - 7.4 8 - 10 8.9 - 11.1 12 - 15 9.6 - 11.8 13 - 16
M8 14.8 - 18.4 20 - 25 22.1 - 25.8 30 - 35 25.8 - 29.5 35 - 40
M10 29.5 - 36.9 40 - 50 44.3 - 47.9 60 - 65 47.9 - 55.3 65 - 75
M12 50.2 - 55.3 68 - 75 73.8 - 81.1 100 - 110 84.8 - 95.9 115 - 130
M14 81.1 - 92.2 110 - 125 110.6 - 129.1 150 - 175 132.8 -154.9 180 - 210
M16 125.4 - 140.1 170 - 190 177.0 - 202.8 240 - 275 206.5 - 236.0 280 - 320
M20 236.0 - 265.5 320 - 360 331.9 - 368.8 450 - 500 387.2 - 442.5 525 - 600
M24 420.4 - 479.4 570 - 650 590.1 - 663.8 800 - 900 663.8 - 774.4 900 - 1050
M30 848.2 - 958.8 1150 - 1300 1180.1 -1327.6 1600 - 1800 1364.5 - 1548.9 1850 - 2100
M36 1475.1 - 1659.5 2000 - 2250 2028.3 - 2323.3 2749 - 3149 2397.1 - 2729.0 3249 - 3699
O-ring Port Plug
Size (NPTF) lbs. ft. N•m Size lbs. ft. N•m
1/16 x 27 5-7 7-9 M10 X 1 6-7 8 - 10
1/8 x 27 7 - 10 9 - 14 M14 X 1.5 7-9 10 - 12
1/4 x 18 15 - 20 20 - 27 M18 X 1.5 25 - 30 34 - 41
3/8 x 18 25 - 30 34 - 41 M22 X 1.5 35 - 44 48 - 60
1/2 x 14 30 - 35 41 - 47 M33 X 2 83 - 103 112 - 140
3/4 x 10 40 - 45 54 - 61
3/4 x 14 40 - 45 54 - 61
1 x 11.5 50 - 55 68 - 75
1-1/4 x 11.5 60-65 81 - 88
Pipe Plugs
Size (NPTF) lbs. ft. N•m
M18 x 1.5
34 - 41 25 - 30
6H
M26 x 1.5
61 - 68 45 - 50
6H

TE10 3 Service Manual 6193.291

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CONTENTS

Contents ..........................................................I Gear Group ...................................................... 55

Indicates an imminently hazardous situation which,

Indicates a potentially hazardous situation which,

Indicates a potentially hazardous situation which,

Indicates a situation which, if not avoided, may result

ASM-0102 - 21D Axle Service Manual Dana Holding Corporation 2

Weight (dry) + 800 lbs / 360 kg

Oil Capacity + 6.7 US gallons / 25.6 liters*

Hydraulic Cooler Lines Specifications

Lines and Fittings (Minimum) 0.75” / 19 mm internal diameter

Vehicle in Neutral & Port 31*

1st clutch: Port 41*

FWD/REV - 1st/3rd - 2nd

Normal oil change interval

Extended oil change interval

Normal drain period

Every 2000 hours:

ENTERING AUTOMATIC CALIBRATION MODE

3. The APC200 asks for the shift lever to be put in FORWARD.

This means the actual sump temperature of the transmission is 20°C.

The APC200 expects the shift lever to

THE APC200 expects the parking brake

Verify that the parking brake is ON and

Engine RPM is to low according to the

After being to low or to high, the engine

Use the M-button on the APC200 to go

Each kit includes: Each kit includes:

11.380” [288.9 mm] diameter 11.380” [288.9 mm] diameter

13.120” [332.2 mm] diameter 13.120” [332.2 mm] diameter

13.500” [342.9 mm] diameter 13.500” [342.9 mm] diameter

1. Remove all burrs from flywheel mounting face and

Remote Filter (Optional)

Speed Sensor & Temperature Sensor Combined

The sensor wires have a polarity. Be sure to correctly observe

Converter, Pump Drive Section, & Pressure Regulating Valve

Operation of the Valve

Transmission Activated Activated Activated

Transmission Pressure Checks

Be careful the vehicle does not move unexpectedly

Low Clutch Pressure

Low Charging Pump Output

1B Plug (N.S.S.) 1 10 Pin - Dowel 1

1C Plug 1 11 Clip - Sleeve 2

1D Plug 1 12 Screw - Sleeve Clip 2

2 Sleeve - Converter Housing 2 13 Lockwasher - Sleeve Clip 2

3 Plug (N.I.) 2 14 Sensor - Speed & Screw 1

5 O-ring 1 16 Switch - Temperature 2

6 Plug 1 17 Breather - Air 1

Gasket - Converter Housing to

N.S.S. = Not Sold Separately

2 Assy - Suction Tube 1 15 Pin - Dowel 2

3 Sleeve - Press & Lube Tube 4 16 Baffle - Oil 1

4 Tube - 3rd Clutch 1 17 Plug - Dipstick Hole 1

5 O-ring 1 18 Not Used on This Model

6 Capscrew 1 19 Not Used on This Model

Gasket - Rear Cover to

Tube - Low Speed Clutch