DANA SPICER 6000 EHO User manual

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

INDEX
DISCLAIMER
The official language chosen by the Product manufacturer is English. No liability is assumed as a result of translations in
other languages not in compliance with the original meaning. In case of conflicting language versions of this document, the
English original prevails. Dana shall not be liable for any misinterpretation of the content here into. Photos and illustrations
might not represent the exact product.
© 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.
THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

3TSM-0238 - 6000 Transmission Service Manual Dana Incorporated
INDEX
VERSION TRACKING ................................................................................................................................... 7
MANUAL APPLICABILITY AND SUPPORTED MODELS ............................................................................. 7
INTRODUCTION ................................................................................................................................ 8
FOREWORD ................................................................................................................................................. 8
SAFETY PRECAUTIONS .............................................................................................................................. 8
CLEANING AND INSPECTION ......................................................................................................... 9
CLEANING .................................................................................................................................................... 9
BEARINGS ............................................................................................................................................... 9
HOUSINGS, COVERS, AND CAPS ......................................................................................................... 9
INSPECTION ................................................................................................................................................. 9
BEARINGS ............................................................................................................................................... 9
OIL SEALS, GASKETS AND RETAINING RINGS .................................................................................... 9
GEARS AND SHAFTS .............................................................................................................................. 9
HOUSINGS, COVERS, AND CAPS ......................................................................................................... 9
SPECIFICATIONS .............................................................................................................................. 10
IDENTIFICATION TAG .................................................................................................................................. 10
GENERAL SPECIFICATIONS ....................................................................................................................... 10
TORQUE CHARTS ........................................................................................................................................ 11
HYDRAULIC COOLER LINES SPECIFICATIONS ......................................................................................... 13
PRESSURE AND TEMPERATURE SPECIFICATIONS .................................................................................. 13
ELECTRICAL SPECIFICATIONS ................................................................................................................... 14
MAINTENANCE ................................................................................................................................. 15
OIL SPECIFICATION ..................................................................................................................................... 15
RECCOMENDED LUBRICANTS .............................................................................................................. 15
MAINTENANCE INTERVALS ................................................................................................................... 16
SERVICING MACHINE AFTER COMPONENT OVERHAUL ......................................................................... 16
FILLING INSTRUCTIONS ............................................................................................................................. 17
INSTALLATION DETAIL .................................................................................................................... 18
PLUMBING DIAGRAM .................................................................................................................................. 18
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

4Dana 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 1ST AND 2ND CLUTCH DISCS PACK .............................................. 65
ASSEMBLY INSTRUCTIONS FOR 3RD AND 4TH CLUTCH DISCS PACK .............................................. 66
END-STOP PLIER SETTING ......................................................................................................................... 67
RETAINING SNAP RING FOR BORES .................................................................................................... 67
RETAINING SNAP RING FOR SHAFTS ................................................................................................... 67

5Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
SECTIONAL VIEWS AND PARTS IDENTIFICATION ....................................................................... 68
GROUP-3RD & 4TH CLUTCH ...................................................................................................................... 68
GROUP-FORWARD AND REVERSE CLUTCH ............................................................................................. 70
GROUP-1ST & 2ND CLUTCHES .................................................................................................................. 72
GROUP-FORWARD/REVERSE SHAFT ........................................................................................................ 74
GROUP-1ST/3RD & 2ND/4TH SHAFT ......................................................................................................... 76
GROUP-BASE PARTS .................................................................................................................................. 78
ASSY-CONTROL VALVE .............................................................................................................................. 80
ASSY-CONTROL VALVE - 2 ......................................................................................................................... 82
ASSY-SOLENOID PLATE ............................................................................................................................. 85
ASSY-CONTROL VALVE WITH VARIABLE RESTRICTIONS ........................................................................ 86
FLANGE-CROSS SERRATED 155KV70 ....................................................................................................... 88
FLANGE-CROSS SERRATED 180KV70 ....................................................................................................... 89
GROUP-FORWARD SHAFT ......................................................................................................................... 90
GROUP-OUTPUT SHAFT ............................................................................................................................. 92
GROUP-IDLER SHAFT ................................................................................................................................. 94
DISASSEMBLY & ASSEMBLY .......................................................................................................... 97
DISASSEMBLY ............................................................................................................................................. 97
ASSEMBLY ................................................................................................................................................... 112
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

6Dana Incorporated TSM-0238 - 6000 Transmission Service Manual

VERSION TRACKING
7Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
VERSION TRACKING
MANUAL APPLICABILITY AND SUPPORTED MODELS
FILE NAME REVISION DATE CHANGES DESCRIPTION
TSM-0238E_Rev.00 6000 EHO Rev. 00 05/11/2019 Document issued
TSM-0238E_Rev.01 6000 EHO Rev. 01 21/01/2020
- Updated Disassembly & Assembly p. 97.
- Added AS0010012800 p. 153.
- Added AS0010012900 p. 153.
TSM-0238E_Rev.02 6000 EHO Rev. 02 17/09/2020
- Update Operation of the Valve p. 28
- Electric Solenoid Controls p. 29
- Added Clutch packs assembly intructions p. 64
- Update Assembly p. 112
MODELS
6000 EHO

8Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
INTRODUCTION
FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on
the maintenance and repair of the SPICER OFF-HIGWAY PRODUCTS product.
Extreme care has been exercised in the design, selection of materials, and manufacturing of these units. The slight outlay in
personal attention and cost required to provide regular and proper lubrication, inspection at stated intervals, and such
adjustments as may be indicated, will be reimbursed many times in low cost operation and trouble-free service.
In order to become familiar with the various parts of the product, its principle of operation, troubleshooting and adjustments, it
is urged that the mechanic studies the instructions in this manual carefully and uses it as a reference when performing mainte-
nance and repair operations.
Whenever repair or replacement of component parts is required, only Dana Incorporated approved parts as listed in the appli-
cable parts manual should be used. 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.
SAFETY PRECAUTIONS
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed.
Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine. If
replacement parts are required, the parts must be replaced by spare parts which have the same part number or with equivalent
parts. DO NOT USE A SPARE PART OF LESSER QUALITY.
The service procedures recommended in this manual are effective methods for performing service and repair.
Some of these procedures require the use of tools specifically designed for the purpose.
Accordingly, anyone who intends to use a spare part, service procedure or tool, which is not recommended by Dana Incorpo-
rated, must first determine that neither his safety nor the safe operation of the machine will be jeopardized by the spare part,
service procedure or tool selected.
IMPORTANT:
ALWAYS FURNISH THE DISTRIBUTOR WITH THE SERIAL AND MODEL NUMBER WHEN ORDERING PARTS.
TOWING OR PUSHING
Before towing the vehicle, be sure to lift the driven axle wheels off the ground or disconnect the driveline to avoid damage to
the transmission during towing.
Because of the design of the hydraulic system, the engine cannot be started by pushing or towing.
CAUTION
IMPORTANT:
IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS ‘CAUTIONS AND NOTICES' THAT MUST BE CA-
REFULLY OBSERVED IN ORDER TO REDUCE THE RISK OF PERSON AL INJURY DURING SERVICE OR REPAIR, OR
THE POSSIBILITY THAT IMPROPER SERVICE OR REPAIR MAY DAMAGE THE UNIT OR RENDER IT UNSAFE. IT IS ALSO
IMPORTANT TO UNDERSTAND THAT THESE ‘CAUTIONS AND NOTICES' ARE NOT EXHAUSTIVE, BECAUSE IT IS IM-
POSSIBLE TO WARN ABOUT ALL POSSIBLE HAZARDOUS CONSEQUENCES THAT MIGHT RESULT FROM FAILURE
TO FOLLOW THESE INSTRUCTIONS.
When maintenance works require welding, disconnect both connectors from the transmission controller and from the valve
unit, before any welding is started.
CAUTION
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a situation which, if not avoided, may result in da-
mage to components.
Indicates information which may make product service ea-
sier to perform.
DANGER
WARNING
CAUTION
NOTICE

9Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
CLEANING AND INSPECTION
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 drying 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 solu-
tion 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 absorbent 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 showing indi-
cation 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 load oils seals, “O” rings, metal sealing rings, gaskets and snap rings is more economical when the unit
is disassembled than premature overhaul to replace these parts at a future time.
Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing mem-
bers should be handled carefully, particularly when being installed.
Cutting, scratching or curling under of lips of seals seriously impairs its efficiency.
When assembling new metal type sealing rings, these should be lubricated with a coat of chassis grease to stabilize rings in
their grooves for ease of assembly of mating members. Lubricate all “O” rings and seals with recommended type Automatic
Transmission Fluid before assembly.
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.
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.
Care should be exercised to avoid skin rashes, fire hazards, and inhalation of vapors when using solvent type and alkali clea-
ners.
DANGER

10 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
SPECIFICATIONS
IDENTIFICATION TAG
The nameplate contains both the model and serial number of the unit.
GENERAL SPECIFICATIONS
* Without cooler and hydraulic lines. Consult equipment operator's manual for complete system capacity.
Weight (dry). 891.52 kg / 1965.46 lb
Length (maximum). 800 mm / 314.96" in
Width (maximum). 633.22 mm / 249.29" in
Height (maximum). 1134.54 mm / 446.66" in
Oil Capacity. 32 Liters / 8,5 US Gallons
MODEL
SERIAL
TENBRIELE 3
B-8200
BELGIUM
SPICER OFF-HIGHWAY

TORQUE CHARTS
11Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
TORQUE CHARTS
TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED THREADS
NOM. SIZE
Grade 8.8 Grade 10.9 Grade 12.9
Coarse thread Coarse thread Coarse thread
[Nm] Lbf-ft [Nm] Lbf-ft [Nm] Lbf-ft
M5x0.8 [5-6] 3.7-4.4 [7-8] 5.2-5.9 [8-10] 5.9-7.4
M6x1 [8-10] 5.9 -7.4 [12-15] 8.9-11.1 [13-16] 9.6-11.8
M8x1.25 [20-25] 14.8-18.4 [30-35] 22.1-25.8 [35-40] 25.8-29.5
M10x1.5 [40-50] 29.5 -36.9 [60-65] 44.3-47.9 [65-75] 47.9-55.3
M12x1.75 [68-75] 50.2-55.3 [100-110] 73.8-81.1 [115-130] 85-96
M14x2 [110-125] 81-92 [150-175] 111-129 [180-210] 133-155
M16x2 [170-190] 125-140 [240-275] 177-203 [280-320] 207-236
M20x2.5 [320-360] 236-266 [450-500] 332-369 [525-600] 387-443
M24x3 [570-650] 420-479 [800-900] 590-664 [900-1050] 664-774
M30x3.5 [1150-1300] 848-959 [1600-1800] 1180-1328 [1850-2100] 1364-1549
M36x4 [2000-2250] 1475-1660 [2749-3149] 2028-2323 [3249-3699] 2397-2729
TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED THREADS
NOM. SIZE
GRADE 8.8 Grade 10.9 Grade 12.9
Coarse thread Coarse thread Coarse thread
[Nm] Lbf-ft [Nm] Lbf-ft [Nm] Lbf-ft
M8x1 [23-28] 17-20 [34-39] 25-28 [41-46] 30-34
M10x1 [47-57] 35-42 [71-81] 52-60 [84-94] 62-69
M10X 1.25 [44-54] 32-40 [67-77] 49-57 [79-89] 58-66
M12x1.25 [82-92] 60-68 [120-130] 89-96 [143-158] 105-116
M12x 1.5 [78-88] 58-65 [117-127] 86-94 [138-153] 101-112
M14x1.5 [128-143] 94-105 [193-208] 142-153 [220-250] 162-184
M16x1.5 [215-228] 159-169 [293-308] 216-227 [350-370] 258-273
M18x1.5 [300-320] 221-236 [433-448] 319-330 [500-540] 369-398
M18x2 [280-300] 207-221 [413-428] 304-315 [470-510] 347-376
M20x1.5 [410-450] 302-332 [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

12
TORQUE CHARTS
Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
TORQUE SPECIFICATIONS FOR LUBRICATED OR PLATED THREADS
NOM. SIZE
Grade 5 Grade 8
Fine thread Coarse thread Fine thread Coarse thread
[Nm] Lbf-ft [Nm] Lbf-ft [Nm] Lbf-ft [Nm] Lbf-ft
43556 [12-15] 43778 [11-14] 43746 [15-18] 41579 [12-15] 43778
42491 [22-27] 16-20 [16-22] 42705 [38-43] 28-32 [35-41] 26-30
43680 [35-39] 26-29 [31-34] 23-25 [50-56] 37-41 [45-49] 33-36
42552 [56-61] 41-45 [50-56] 37-41 [79-87] 58-64 [70-77] 52-57
43497 [87-95] 64-70 [77-85] 57-63 [122-134] 90-99 [108-119] 80-88
42614 [123-136] 91-100 [111-122] 82-90 [174-191] 128-141 [156-172] 115-127
43682 [173-191] 128-141 [153-168] 113-124 [224-268] 180-198 [216-237] 159-175
43558 [302-332] 223-245 [271-298] 200-220 [427-470] 315-347 [382-420] 282-310
Torque specifications for plugs
NPFT Nom. Size
O-ring ports
[Nm] lbf-ft
5/16x24 [4-7] 43588
3/8x24 [7-11] 43682
7/16x20 [9-14] 43745
1/2x20 [14-18] 41548
9/16x18 [16-20] 42339
3/4x16 [27-34] 20-25
7/8x14 [41-47] 30-35
1 1/16x12 [61-68] 45-50
1 5/16x12 [88-102] 65-75
1 5/8x12 [102-115] 75-85
1 7/8x12 [102-115] 75-85
Torque specifications for plugs
METRIC Nom. Size
O-ring ports
[Nm] lbf-ft
M10x1 [8-9] 43652
M12x1.5 [14-18] 41518
M14x1.5 [16-20] 42339
M16x1.5 [27-34] 20-25
M18x1.5 [34-41] 25-30
M22x1.5 [48-60] 35-44
M26x1.5 [61-68] 45-50
M27x2 [81-89] 60-66
M33x2 [112-140] 83-103
Torque specifications for plugs
Nom. Size
Pipe Plugs
[Nm] Lbf-ft
1/16x27 [7-9] 43651
1/8x27 [9-14] 43745
1/4x18 [20-27] 15-20
3/8x18 [34-41] 25-30
1/2x14 [41-47] 30-35
3/4x14 or 10 [54-61] 40-45
1x11 1/2 [68-75] 50-55
1 1/4x11 1/2 [81-88] 60-65
Torque specifications for plugs
METRIC Nom. Size
Permanent Plugs
Nm Lbf-ft
M18x1.5 6H [25-30] 34-41
M26x1.5 6H [45-50] 61-68
Torque specification
NFPT Nom. Size
Elastic Stop Nuts
Nm Lbf-ft
1.00x20 [542-610] 150-200
1.25x18 [407-474] 200-250
1.50x18 [271-339] 300-350
1.75x12 [203-271] 400-450

HYDRAULIC COOLER LINES SPECIFICATIONS
13Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
HYDRAULIC COOLER LINES SPECIFICATIONS
PRESSURE AND TEMPERATURE SPECIFICATIONS
* Refer to Connection points p. 19 for check port identification.
† All pressures and flows to be measured with oil temperature 82-93ºC / 180-200ºF.
Lines and Fittings (Minimum). 31,75 mm / 1"1/4 internal diameter
Continuous Operating Temperature. Ambient to 120°C / 248°F
Continuous Pressure. 20 bar / 290 PSI continuous pressure
Conformance. SAE J1019 and SAE J517, 100RI
Normal Operating Temperature.
82-93ºC / 180-200ºF.
Measured at temperature check port converter out
Maximum Temperature. 120ºC / 248ºF
Regulator Pressure.
Vehicle in Neutral & Port 31*
At 600 RPM minimum: 12,4 bar 180 PSI
At no load GOV. speed: 12,4 bar 180 PSI
Pump Flow. See at the torque converter manual.
Lube Pump Flow. See at the torque converter manual.
Clutch Pressure.
1st clutch: Port 41*
2nd clutch: Port 42*
3rd clutch: Port 43*
Forward High clutch: Port 44*
Forward Low clutch: Port 45* Reverse clutch: Port 46*
At 2200 RPM:
12.4 to 15.1 bar (180 to 220 PSI)
Filter Bypass Valve. See Technical Specs of Converters
To cooler Pressure.
Port 37*
2 bar (29 PSI) minimum at 2000rpm
5.5 bar (79.7 PSI)at no load governed speed
Clutch Leakage.
Neutral: N1 - N2 - N3 - N4 between 6 - 12 l/min; 1.58 - 3.17 GPM
Forward: F1 - F2 - F3 - F4 between 13 - 21 l/min; 3.43 - 5.54 GPM
Reverse: R1 - R2 - R3 - R4 between 13 - 21 l/min; 3.43 - 5.54 GPM
Converter leakage. See Technical Specs of Converters
Safety Valve Cracking Pressure. See Technical Specs of Converters
Converter Out Pressure. See Technical Specs of Converters
Lock-up Pressure. See Technical Specs of Converters

14
ELECTRICAL SPECIFICATIONS
Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
ELECTRICAL SPECIFICATIONS
Solenoid Valves.
Fwr - Rev - 1st - 2nd - 3rd - 4th
Coil Resistance: 24V - 92 +7-4 Ωat 20°C / 68°F
Ouput Speed Sensor.
Type: Magneto resistive sensor
Sensing Distance: 0–1.8 mm / 0–0.07"
Sensor Signal: Generates a square current with a fixed amplitude changing between 7 and
14 mA.

15Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
MAINTENANCE
OIL SPECIFICATION
RECCOMENDED LUBRICANTS
1 - The lubricant must be designed for transmission use. Engine oil is not allowed.
2 - Transmission lubricant must be qualified by one of the following specifications in order of preference:
– CATERPILLAR T0-4
– JOHN DEERE J20 C,D
– MIL-PRF-2104G
– DEXRON I ID OR DEXRON I I I*
3 - For the use of Dexron lubricants in combination with graphitic friction plates (used in i 000 series, hr36000, t 40000) a specific
engineering approval is required.
4 - For electronic modulated transmissions (like the TE series) only Dexron III is approved.
5 - gl-5 oils are not approved.
6 - Multi-viscosity lubricants are approved.
7 - Preferred oil viscosity: select a lubricant with a viscosity grade that fully covers the prevailed ambient temperature on the oil
application chart. Example: ambient temperature from -10 °C (14 °F) to 20 °C (68 °F): select 10W30 when multiple viscosity
grades are suitable, select the grade where the ambient temperature is closest to the middle of the viscosity range. Example:
for ambient temperature of 20 °C (68 °F), SAE 30 is preferred over SAE 40 or SAE 50.
8 - Fire resistant fluid - see vehicle manufacturers recommendations.
9 - Sump preheaters- before operating the transmission fluid must be preheated to a minimum temperature according the vi-
scosity grade, to assure sufficient pumping viscosity.
10 - Warm-up- for full load transmission functionality, a minimum sump temperature of 20 °C (68 °F) is required. Before reaching
20 °C (68 °F) sump temperature only neutral gear or unloaded driving is allowed, not exceeding 1500 engine rpm and not
exceeding half throttle.
11 - 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.
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.

16
SERVICING MACHINE AFTER COMPONENT OVERHAUL
Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
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 oil change interval
The first change of oil and filter element must be done at 100 hours.
Drain and refill system every 1000 hours for average environmental and duty cycle conditions. Severe or sustained high opera-
ting 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.
Every 1000 hours:
• Change oil filter element.
• Drain oil at 65-93°C [150–200°F] and refill system as follows:
1 - Before draining oil it is mandatory to loosen the oil filling plug or the breather (if present), and wait until the internal pressure
is completely released. Remove the oil draining plug and drain oil only when the pressure is completely released. Drain tran-
smission.
2 - Remove and discard filter.
3 - Install new filter.
4 - Refill transmission to FULL mark.
5 - Run engine at 500 - 600 RPM to prime converter and lines.
6 - Recheck level with engine running at 500 - 600 RPM and add oil to bring level to LOW mark. When oil temperature is hot
82.2-93.3°C [180-200°F] make final oil level check and adjust if necessary to bring oil level to FULL mark.
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.
SERVICING MACHINE AFTER COMPONENT OVERHAUL
The transmission and its allied hydraulic system are important links in the driveline between the engine and the wheels. The
proper operation of either unit depends greatly on the condition and operation of the other. Therefore, whenever repair or
overhaul of one unit is performed, the balance of the system must be considered before the job can be considered complete.
After the overhauled or repaired transmission has been installed in the machine, the oil cooler, and connecting hydraulic system
must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgement must be exercised as
to the method employed.
The following are considered the minimum steps to be taken:
1 - Drain entire system thoroughly.
2 - Disconnect and clean all hydraulic lines. Where feasible hydraulic lines should be removed from machine for cleaning.
3 - Replace oil filter element.
4 - The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and compressed air until all foreign
material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler
assembly should be removed from machine for cleaning, using oil, compressed air, and steam cleaner for that purpose.
5 - Reassemble all components and use only type oil (See chapter Reccomended lubricants p. 15). 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 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.
IMPORTANT:
NEVER USE FLUSHING COMPOUNDS FOR CLEANING PURPOSES.

FILLING INSTRUCTIONS
17Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
FILLING INSTRUCTIONS
Fill torque converter and transmission through filler opening until fluid comes up to LOW mark on transmission dipstick.
1 - Remove LOWER check plug, fill until oil runs from LOWER oil level hole. Replace filler and level plug.
2 - 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)
3 - Add quantity necessary to bring fluid level to LOW mark on dipstick or runs freely from LOWER oil level check plug hole.
4 - Install oil level plug or dipstick. Recheck with hot oil (82 - 93° C) [180 - 200° F]
5 - Bring oil level to full mark on dipstick or runs freely from UPPER oil level plug.
NOTE:
If the dipstick is not accessible oil level check plugs are provided. (See below)
Oil Level Glasses
Oil Level Check
3/4-14 NPTF
Drain Plug

18 Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
INSTALLATION DETAIL
PLUMBING DIAGRAM
Oil to Cooler
Low pressure
High pressure
Suction and Drain
F
A
D
B
C
E
CHECK POINTS
A. CLUTCH PRESSURE
B. CONVERTER INLET
C. CONVERTER OUTLET
D. LUBE PRESSURE
E. COOLER INLET
F. COOLER OUTLET
OIL COOLER
SUCTION LINE
FROM CHARGING PUMP
CONVERTER IN LINE
SELECT LOWEST CONNECTION FOR
GRAVITY DRAIN TO TRANSMISSION
WHEN RETARDER IS USED
IT MUST BE PLUMBED
IN THIS LINE
CHARGING
PUMP
PRESSURE
REGULATOR
VALVE
COOLER OUT LINE
DRAIN MUST HAVE CONTINEOUS SLOPE
FROM CONVERTER TO TRANSMISSION
OIL FILTER
CONVERTER RETURN LINE
CONVERTER
TRANSMISSION

CONNECTION POINTS
19Dana IncorporatedTSM-0238 - 6000 Transmission Service Manual
CONNECTION POINTS
FRONT VIEW
1 - Port 22 Drain Connection Ø38 Split Flange
2 - 1.3125 O-ring Port
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
5
2
1
7
6
4
3

20
CONNECTION POINTS
Dana Incorporated TSM-0238 - 6000 Transmission Service Manual
SIDE VIEW
1 - Valve connector Deutch HD34-18-14 PE
2 - Port 23 Pressure Regulator OUT Ø38 Split Flange
3 - Port 83 Lube IN Ø38 Split Flange
REAR VIEW
1 - Ø26,12-26,44 6 Mounting Holes
2 - Oil Level Glasses
3 - Oil Level Check
4 - 3/4-14 NPTF Drain Plug
5 - Port 22 Transmission Drain Ø38 Split Flange
1
32
1
2
3
4
5