Service Training DANA TE27 / TE32

Service Training DANA TE27 / TE32

Transmission Operation
Service Training DANA TE27 / TE32
Transmission cooler connection

NOTE!
Internal Thermo shuttle valve, opens at 72°C
Service Training DANA TE27 / TE32
Model Designation

1X.X T E 32 4 X X – XX

Converter Specific ”dash number”

Model Wheel group Specific ratio

Mounting type Specific ratio/drop

Engine mount=T
Remote mount=RT even no: long drop
Mid mount=MT odd no: short drop

Electronically controlled model Numbers of gears

Transmission input
rating x 100Nm
 Service Training DANA TE27 / 32
Technical Data

Converter/Transmission oil system: Transmission regulator pressure:

Capacity: App. measured at 600 RPM input speed and oil temp. between At 600 RPM 22.5 – 24.5 bar
60 -70°C, neutral) Short drop 60L & Long drop 75L (lines and cooler not included) At 2200 RPM 23.5 – 25.5 bar

Oil type…………Only ATF Dexron III approved Clutch pressure:

viscosity at 40°C: 33 – 38 cSt At 1800 RPM 20.5 – 24.5 bar
viscosity at 100°C: 7 – 8 cSt Filter bypass:
valve set at 4.1 to 4.5 bar
Oil change…….1000 hours
Filtration……….2 spin on filters, change every 1000 hours Lube pressure:
first change or after rebuild: 150 hours 0.9 – 1.4bar at 100L/min, lube flow.
(+/- 1000RPM)

Temperature specifications: Internal leakage @ 1800 RPM:

Normal operating temperature 70 - 120°C at check port 71 Fwd/Rev max 4 L/min
Maximum allowed transmission temperature 120°C 1st max 9.2 L/min
2nd/3rd/4th max 4 L/min
Hydraulic cooler lines specifications: Safety valve:
Minimum 32 mm for the internal diameter of lines and fittings. cracking pressure 8.8 9.6 bar
Suitable for operation from ambient to 120°C continuous operating temperature.
Must withstand 30bar continuous pressure and 45 bar intermittent surges.
Converter out pressure (to cooler):
5 bar min. at 2000RPM
Conform SAE J1019 and SAE J517, 100RI.
8.5 bar max. at no load governed speed.

Pump flow:
System flow, At 2200 RPM 108 - 128 L/min
Lube pump flow, At 2200 RPM 80 – 95 L/min
 Service Training DANA TE27 / TE32
Additional signals

• Speed sensors
- Engine speed combined
with oil temperature pick up located at pump gear
- Turbine speed located on input gear forward
- Drum speed located on low drum
- Output speed located on output gear

• Pressure feedback sensor

• Converter out temperature switch
Service Training DANA TE27 / TE32
Speed sensors

Type Magneto resistive sensor, Sensing distance up to 1.8 mm

Sensor signal generates a square current with a fixed amplitude
changing between 7 and 14 mA.

2 pin connectors

3 pin connector

Clutch Drum gear speed sensor Engine speed/Oil temp. sensor

Part no: 4209752 Part no: 4209784

Turbine speed sensor

Part no:4209751

Output speed sensor

Part no: 4209750
Service Training DANA TE27 / TE32
Additional signals

Temp switch Part Wiring harness incl.

no: 241011 pressure sensor
Part no: 8100278
Service Training DANA TE27 / TE32
Transmission Operation

Operation of Transmission:
The transmission is controlled by an APC200 box. This unit has a microprocessor that receives certain inputs
(gear selector position, speed sensors,……), which are processed and will give output signals to the control valve.

Operation of the valve:

Regulated pressure (22,5-25,5 bar) is directed to the total neutral shift spool and the pressure reducer that will
decrease the pressure to 10 bar.
This reduced pressure will be used to supply the variable forced solenoids (VFS), total neutral solenoid, 3rd/1st
solenoid and 4th/2nd solenoid.
The VFS will give an output pressure curve from 0 to 6 bar proportional to a current from 1000 from 0mA.
The pressure intensifiers with a ratio of 3,5:1 will multiply this pressure curve so that a curve from 0 to 20 bar is
available for each directional and range clutch.
Between each VFS a pressure intensifier is placed and an accumulator to dampen any hydraulic vibration.

Directional selection:
When a direction (forward or reverse) is selected , total neutral solenoid is activated and the required directional
VFS will provide a pressure rise from 0 to 6 bar.
The directional clutch is then fed with modulated pressure supplied through the pressure intensifier.
Service Training DANA TE27 / TE32
Transmission Operation

Range selection:
When 1st clutch is selected, the 3rd/1st and 4th/2nd solenoids are activated.
The 1st/3rd VFS will provide a pressure curve from 0 to 6 bar.
The pressure intensifier will multiply this pressure and will feed 1st clutch via the activated 3rd/1st spool.

When 2nd clutch is selected:

The 3th/1st VFS will decrease pressure from 6 to 0 bar,
thus releasing the 1st clutch in a controlled fashion. At the same time the 4th/2nd VFS will provide a pressure
curve from 0 to 6 bar.
This pressure is fed to 2nd clutch via the pressure intensifier, which will provide clutch overlap.

When the shift is finalized the 3rd/1st solenoid is deactivated.

When 3rd clutch is selected the 3rd/1st solenoid is not activated.
The 1st/3rd VFS will provide a pressure curve from 0 to 6 bar and will feed 3rd clutch via a pressure intensifier
and the deactivated 3rd/1st spool.
At the same time the 4th/2nd VFS will decrease pressure from 6 to 0 bar providing the clutch overlap.

When the shift is finalized the 4th/2nd solenoid is deactivated.

When 4th clutch is selected , the 4th/2nd VFS will provide a pressure curve from 0 to 6 bar and will feed 4th
clutch via a pressure intensifier and the deactivated 4th/2nd spool.
At the same time the 3rd/1st VFS will decrease pressure from 6 to 0 bar providing the clutch overlap.
Service Training DANA TE27 / TE32
Transmission Operation

Neutral selection:
When neutral is selected (1st, 2nd, 3rd or 4th), the total neutral solenoid is activated and the VFS’s for forward
and reverse are fed by a 1000mA current, which will result in a 0 bar output, thus providing 0 bar pressure to the
forward and reverse clutch.
The range clutches 1, 2, 3 or 4 remain activated by their respective VFS.

Total neutral selection:

Total neutral is only selected by the APC200 in case a severe error is detected which will cause a shutdown.

When total neutral is selected, the total neutral solenoid is not activated and as a result no pressure is supplied to
the pressure intensifiers.
Service Training DANA TE27 / TE32
Transmission Operation

Pressure switch:
The control valve also has a pressure switch installed between the total neutral shift spool and the pressure
intensifiers supply.

This switch has 2 functions:

It will verify that a minimum pressure of 12 bar to the various pressure intensifiers is supplied only when the total
neutral solenoid is activated.
This information is an input of the APC200 box and if a pressure is detected below 12 bar the controller will put
the transmission in total neutral which causes a shut down.

It will verify if only 1 direction clutch and 1 range clutch is activated when the shift is finalized.
If detection is made that 2 direction clutches 2 range clutches are hydraulically activated it will provide an input
signal to the APC200 which will put the transmission in total neutral which causes a shutdown.
Service Training DANA TE27 / 32
Transmission Operation

• Neutral
VFS 2/4 VFS 1/3
Service Training DANA TE27 / 32
Transmission Operation

• FORWARD 1st
Service Training DANA TE27 / 32
Transmission Operation

• FORWARD 2nd
Service Training DANA TE27 / 32
Transmission Operation

• FORWARD 3rd
Service Training DANA TE27 / 32
Transmission Operation

• FORWARD 4th
Service Training DANA TE27 / 32
Transmission Operation

• REVERSE 1st
Service Training DANA TE27 / 32
Check Ports
Service Training DANA TE27 / 32
Check Ports

RIGHT VIEW
Service Training DANA TE27 / 32
Check Ports

Engine speed sensor &

Temperature sensor

LEFT VIEW
Service Training DANA TE27 / 32
Check Ports

REAR VIEW
Service Training DANA TE27 / 32
Check Ports

FRONT VIEW
Service Training DANA TE27 / 32
Check Ports on control valve
Service Training DANA TE27 / 32
Control valve installation instruction

Removing the valve Installing the valve

1.Make sure that the area around the valve is clean 1. Unscrew the 4hexbolts (marked pink on drawing)
and that no dirt can fall into the valve during the until all tension is out of the bolt.
disassembly procedure. Do not remove them!

2. Unscrew the 4 hex bolts (marked pink on drawing) 2. Using aligning studs, install valve and a new gaskets.
until you feel that the tension is out of the bolt.
Do not remove them! 3.Hand tighten all bolts (21) according to the sequence
you find on the drawing.
3. Unscrew the 15 other bolts
(marked blue on drawing) some turns. 4.Torque all bolts in the same sequence as on drawing to
When all bolts are loose, you should be able to move a torque of 25Nm.
the valve a bit.
6.Wait 15-30 minutes before, re-torque all bolts to 25Nm
4. Remove 2 bolts (marked blue on drawing) and again to the sequences as shown on drawing.
replace with aligning studs.
7.Recalibrate the transmission
5. Remove the remaining bolts (marked blue on
drawing) and remove the valve.
Service Training DANA TE27 / 32
Control valve installation instruction