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