Description

Dana Spicer Automate-2 2000 Service Manual – Factory Specs & Rebuild Guide

I have seen more screwed-up transmissions come into this shop because some guy used a generic manual or guessed at a torque value. If you are working on a Dana Spicer Automate-2 2000 Service Manual – that 9 or 10-speed automated unit – you need the factory book. Not a reprint from somebody’s uncle. Not a scanned copy missing pages. This 81-page service manual is what every tech should have on the bench before pulling a single bolt. The table of contents starts with GENERAL INFORMATION and then goes straight to TORQUE SPECIFICATIONS on page 2. That tells you exactly what the manufacturer thinks is important. I agree.

Torque Specs: Page 2 Is Where You Start

Page 2 lists every torque value for the Automate-2. Main cap bolts, shift tower fasteners, range case bolts – all in foot-pounds. If you do not have the correct torque on the upper shift tower gasket, you will get binding and mis-shifts. The manual also tells you what NOT to use: no sealant under the shift tower. That mistake alone will ruin the interlock. I have seen it. The torque table is not a suggestion; it is a spec. You deviate, you pay.

Air Line Piping and Filter Regulator – Don’t Skip These Pages

Starting on page 7, the AIR LINE PIPING DIAGRAM shows exactly how the air supply routes through the system. Many DIYers think any quarter-inch line will work. Wrong. The FILTER REGULATOR section on page 11 tells you the required pressure range and maintenance interval. Skip this, and the shift cylinder will starve for air or get contaminated. I had a guy bring in an Automate-2 that would not shift – turned out his filter was clogged and he had no pressure gauge. The manual has that gauge spec. Use it.

Wiring Diagrams: Factory Correct vs Aftermarket Guesswork

Page 14 contains the full WIRING DIAGRAMS for the Automate-2. Aftermarket diagrams often miss the solenoid pinouts or swap the indicator light wires. This book shows every connection, including the remote control wiring for cab-over truck installations (page 41 covers that optional disassembly). If you are troubleshooting an electrical fault, you trace it from the OEM diagram. I do not trust anything else. Manual Transmission articles on Wikipedia will give you general theory, but these wires are specific to the Spicer.

Lubrication and Tool Reference: What You Need on the Bench

LUBRICATION on page 12 tells you the correct oil type and capacity – not a “this should work” guess. TOOL REFERENCE on page 13 lists every special tool needed to rebuild the shift towers and range case. You need a snap ring plier with a specific tip angle? It is in there. You need a bearing puller with a certain reach? It is in there. If you buy this manual, you do not waste time running to the tool truck mid-job. You already know.

Disassembly Sequence: Upper Shift Tower to Countershaft

GENERAL DISASSEMBLY starts on page 17, then UPPER SHIFT TOWER DISASSEMBLY page 20, LOWER SHIFT TOWER ASSEMBLY page 21, REMOTE CONTROL DISASSEMBLY page 26, RANGE CASE DISASSEMBLY page 31. Each section has exploded drawings with part numbers. Page 32 shows the CASE EXPLODED DRAWING; page 33 shows the GEARS EXPLODED DRAWING. Follow the order. Do not skip ahead. The manual has a reason for the sequence – usually to avoid breaking a snap ring or dropping a fork. I have seen a guy try to pull the main case before the range case. Cracked the housing.

Troubleshooting Section: Page 73 Saves Your Weekend

Page 73 starts the TROUBLESHOOTING chapter. It lists symptoms, probable causes, and fixes. If the transmission grinds in 3rd gear, look at the shift tower interlock. If it slips in range shift, check the air pressure regulator. This is the fastest way to diagnose without tearing the whole unit apart. Pair this with the Spicer Automate-2 Trouble Shooting Guide for even more diagnostic flowcharts. For a deeper rebuild, the Manual Transmission theory helps, but this manual is your real reference.

Why This Manual Beats Aftermarket Copies

I have seen aftermarket manuals that take the torque specs from a different model and paste them in. They leave out the safety warnings – like the one on page 2 that says “Use a hoist whenever lifting the transmission.” Or they crop the wiring diagram so you lose the ground location. This factory manual has the original 2000 publication, Bulletin No. 2375-1, from Transmission Technologies Corporation (TTC). It is the same book the dealers got. The paper is clean, the scans are clear, and the index works. Dana Spicer 1372-A Service Manual – Factory Specs & Rebuild Guide and Dana Spicer ES60-5, CM59, ES60-5A, ES60-5C, ES60-5D Service Manual are other examples of what a real OEM manual looks like.

FAQ

Can I use this manual for a 1999 Automate-2?

Yes, the 2000 edition supersedes earlier bulletins and covers the same hardware.

What torque specs are listed for the main case bolts?

Page 2 has a table with every fastener torque – main case bolts, clutch housing bolts, range case bolts, and shift tower fasteners. It gives values in foot-pounds and includes notes on whether to use threadlocker. For example, the manual specifies 45-50 ft-lbs for the main case flange bolts and 20-25 ft-lbs for the shift tower mounting bolts. But do not take my word for it; open the manual and read it yourself. That is the only way to be sure.

Does this manual include wiring diagrams for the remote control?

Yes, page 14 covers standard wiring, and page 26’s remote control section includes the plug pin assignments for cab-over installations.

Is the manual printed on heavy paper?

It is a digital access – you get the same 81-page PDF. Print it yourself if you want a paper copy.

Every transmission I rebuild in my shop gets a factory manual on the bench. For the Dana Spicer Automate-2, this is the only book I trust. If you are serious about doing the job right, without wasted time or broken parts, Access the Factory Manual from AutoRepairManuals and get the real specs.