Eaton Endurant Service Manual Download Page 209

Page: 209 / 248

206

2019.04.4

Clutch Installation

Installation

TRSM0950

Procedure – Engine Flywheel Housing and Fly-
wheel Inspection

Remove the pilot bearing.

Verify flywheel face runout.

Secure the dial indicator base to the flywheel housing
face with the dial indicator finger in contact with the
flywheel face near the outer diameter.

Note:

Clean all dial indicator contact surfaces.

Rotate flywheel one revolution and record flywheel face
runout: maximum runout is 0.008" (0.20 mm).

NOTICE:

If any reading exceeds maximum runout, pre-

mature clutch wear will occur. Refer to OEM engine
manufacture guidelines for repair or replacement.

Verify pilot bearing bore runout.

Secure the dial indicator base to the flywheel housing
face with the dial indicator finger in contact with the
pilot bearing bore.

Note:

Clean all dial indicator contact surfaces.

Rotate flywheel one revolution and record pilot bearing
bore runout: maximum runout is 0.005" (0.13 mm).

NOTICE:

If any reading exceeds maximum runout, pre-

mature clutch wear will occur. Refer to OEM engine
manufacture guidelines for repair or replacement.

Verify flywheel housing inner diameter (ID) runout.

Secure the dial indicator base to the crankshaft with
the dial indicator finger in contact with the flywheel
housing ID.

Note:

Clean all dial indicator contact surfaces.

10.

Rotate crankshaft one revolution and record flywheel
housing (ID) runout: maximum runout is 0.008" (0.20
mm).

NOTICE:

If any reading exceeds maximum, runout pre-

mature clutch wear will occur, Refer to OEM engine
manufacture guidelines for repair or replacement.

11.

Verify flywheel housing face runout.

12.

Secure the dial indicator base to the flywheel face near
the outer diameter with the dial indicator finger in con-
tact with the face of the flywheel housing.

Note:

Clean all dial indicator contact surfaces.

13.

Rotate flywheel one revolution and record flywheel
housing face runout: maximum runout is 0.008" (0.20
mm).

NOTICE:

If any reading exceeds maximum, runout pre-

mature clutch wear will occur. Refer to OEM engine
manufacture guidelines for repair or replacement.

Summary of Contents for Endurant

Page 1: ...Service Manual Endurant 12 Speed Automated Transmission TRSM0950 EN US March 2019 ...

Page 2: ......

Page 3: ...Shaft Disassembly Assembly 101 Main Housing Disassembly Assembly 107 Rear Housing Assembly Disassembly Assembly 117 Clutch Housing Disassembly Assembly 129 Installation Rear Bearing Cover Installation 137 Output Yoke Installation 141 Lower Countershaft Cover and Inertia Brake Installation 143 Input Shaft Cover Installation 147 Upper Countershaft Cover Installation 149 Mechatronic Transmission Modu...

Page 4: ...l aid in the repair of a component While working on a vehicle WARNING Do not modify transmission components or systems Modification altering substituting relocating of transmission components may result in major vehicle com ponent damage severe injury or death WARNING Do not modify transmission service tools Mod ification altering substituting relocating of transmission service tools may result in...

Page 5: ... severe injury or death 5 Turn ignition key Off and allow the engine to shut to down Before working on a vehicle or leaving the cab with engine running 1 Safely come to a complete stop 2 Continue to depress and hold service brake 3 Select Neutral on the driver interface device 4 Apply vehicle parking brake WARNING Apply vehicle parking brake and follow vehicle manufacture parking instructions Fail...

Page 6: ...e Service Procedures are divided in three sections Removal Disassembly Assembly and Installation Removal instructs how to remove the part or assembly from the transmission Disassembly instructs how to take an assem bly apart Assembly instructs how to put together an assembly Installation instructs how to install the part or assembly in the transmission Not all parts have a disas sembly assembly se...

Page 8: ...ng for service assistance or parts have the model and serial numbers handy NOTICE Do not remove or destroy the transmission identification tag Model Number The model number gives basic information about the transmission and is explained below Use this number when calling for ser vice assistance or replacement parts Serial Number The serial number is the sequential identification number of the tran...

Page 10: ... Cummins Automated Transmission Technologies All rights reserved 7 TRSM0950 Removal Oil Drain Procedure Oil Drain Procedure Special Instructions None Special Tools None Component Identification 1 Oil Drain Plug 6 mm Hex 1 ...

Page 11: ...rain Plug Note If reusing oil use a clean container free of con tamination and debris 3 Remove the Oil Drain Plug with a 6 mm hex key and drain the oil 4 If PTO equipped remove PTO and drain the oil 5 Inspect Oil Drain Plug and O ring for damage If dam aged replace the Oil Drain Plug O ring is serviced with plug 6 Install the Oil Drain Plug and torque to 24 5 29 5 Nm 18 22 lb ft NOTICE Do not over...

Page 12: ...RSM0950 Removal Linear Clutch Actuator LCA Removal Linear Clutch Actuator LCA Removal Special Instructions Drain the vehicle air system Special Tools None Component Identification 1 Mechatronic Transmission Module MTM Housing 2 Linear Clutch Actuator LCA 3 LCA Cap Screws x4 T45 Torx 2 3 1 ...

Page 13: ...the lock tab and lifting up on the lever 3 Loosen the 4 LCA cap screws 1 2 turns each with a T45 Torx Note Residual air pressure in the LCA cylinder exhausts between the LCA and MTM housing when the cap screws are loosened 4 Remove the 4 LCA cap screws 5 Remove the LCA from the Mechatronic Transmission Module MTM NOTICE Ensure the key is off and 20 Way TCM Vehicle Harness is disconnected prior to ...

Page 14: ...ved 11 TRSM0950 Removal Linear Clutch Actuator LCA Removal 6 Inspect the plastic socket insert in the release yoke through the LCA opening using a flashlight to verify none of the fingers are missing or damaged Note If the plastic insert is damaged replace the release yoke assembly ...

Page 16: ...l Module TCM Removal Transmission Control Module TCM Removal Special Instructions None Special Tools ServiceRanger Component Identification 1 Transmission Control Module TCM Cover 10 or 13 mm Nuts 2 Transmission Control Module TCM 3 Mechatronic Transmission Module MTM 4 Transmission Control Module TCM Jackscrew 7 mm 3 2 4 1 ...

Page 17: ...the TCM or Mechatronic Transmission Module MTM Note Transmission Control Module TCM is removable with transmission in chassis 1 Connect ServiceRanger and create a Service Activity Report 2 Key off 3 Disconnect the negative battery cable NOTICE Leaving battery cable connected may damage TCM 4 Disconnect the 20 Way TCM Vehicle and Body Harness Connectors from the TCM by depressing the lock tab and l...

Page 18: ...Control Module TCM Removal 5 Unscrew the 4 nuts on the TCM Cover and remove TCM Cover Note TCM Cover nuts are 10 or 13 mm 6 Unscrew the 7 mm jackscrew lift and remove the TCM from the MTM 7 Inspect the TCM Seal for damage NOTICE Replace the TCM Seal if damaged 8 If replacing the TCM transfer the TCM Seal to the new TCM ...

Page 20: ...emoval Special Instructions Manually Vent Linear Clutch Actuator LCA Special Tools Transmission Jack Adapter Plate RR1067TR 2 cap screws and washers M10 x 1 5 x 30 mm minimum class 8 8 Component Identification Procedure Removal 1 Perform Manually Vent Linear Clutch Actuator LCA on page 219 2 Refer to OEM guidelines for transmission removal ...

Page 22: ... to clutch jack manufacturer guidelines for proper installation instructions WARNING Clutch weighs approximately 125 lbs Failure to properly secure the Clutch Alignment Shaft to the clutch jack may result in clutch damage severe injury or death Special Tools Clutch Installation Tool Kit RR2000CL Component Identification 1 Clutch Cover Cap Screws x12 15 mm 2 Clutch Cover 3 Driven Disc Assembly 4 En...

Page 23: ...nstall and hand tighten the 4 stand off bolts RR1063TR 4 in place of the removed Clutch Cover cap screws 3 Insert the clutch jack mounted Clutch Alignment Shaft RR1087TR into the clutch diaphragm spring and pilot bearing WARNING Clutch weighs approximately 125 lbs Dropping clutch may result in damage to clutch seri ous injury or death 4 Remove the 8 remaining 15 mm Clutch Cover cap screws NOTICE D...

Page 24: ...ted Transmission Technologies All rights reserved 21 TRSM0950 Removal Fluid Pressure Sensor FPS Removal Fluid Pressure Sensor FPS Removal Special Instructions None Special Tools None Component Identification 1 Fluid Pressure Sensor x1 1 ...

Page 25: ...es All rights reserved 2019 04 4 Fluid Pressure Sensor FPS Removal Removal TRSM0950 Procedure Removal 1 Unlatch and disconnect the OEM 3 Way Transmission Fluid Pressure Sensor FPS Connector 2 Remove the Transmission FPS 24 mm threaded into the main housing ...

Page 26: ...ll rights reserved 23 TRSM0950 Removal Output Speed Sensor Removal Output Speed Sensor Removal Special Instructions None Special Tools None Component Identification 1 Output Speed Sensor Harness 2 Harness Retainers x2 3 Cap Screw 10 mm 4 Output Speed Sensor Connector ...

Page 27: ...nsor Removal Removal TRSM0950 Procedure Removal 1 Lift the latch on the Output Speed Sensor Harness at the Connector on the Mechatronic Transmission Mod ule MTM 2 Remove the Output Speed Sensor Harness from the Connector on the MTM 3 Remove the Output Speed Sensor Harness tie strap at the Harness Bracket ...

Page 28: ...0 Removal Output Speed Sensor Removal 4 Remove the 2 harness press in retainers from the Main Housing and bracket on Rear Housing 5 Remove the Output Speed Sensor 10 mm cap screw 6 Remove the Output Speed Sensor from the Rear Housing Note The sensor may need to be twisted and pulled from the bore ...

Page 30: ...ic Transmission Module MTM Removal Mechatronic Transmission Module MTM Removal Special Instructions None Special Tools None Component Identification 1 MTM Cap Screws Long x4 13 mm 2 MTM Cap Screws Special x2 15 mm 3 MTM Cap Screws x14 13 mm 4 Mechatronic Transmission Module MTM 5 Main Housing 6 Output Speed Sensor ...

Page 31: ... Perform Transmission Removal on page 17 3 Perform Release Bearing and Clutch Release Yoke Removal on page 31 4 Perform Transmission Control Module TCM Removal on page 13 5 Lift the latch on the Output Speed Sensor Harness at the Connector on the Mechatronic Transmission Mod ule MTM 6 Remove the Output Speed Sensor Harness from the Connector on the MTM 7 Remove the 20 MTM cap screws Note 13 mm x18...

Page 32: ...ic Transmission Module MTM Removal 8 Separate the MTM from the Main Housing at the 2 pry points 9 Remove the MTM from the transmission housing CAUTION MTM weighs approximately 40 lbs Keep fingers clear of pinch point between MTM and other surfaces Dropping MTM could result in component damage and or personal injury ...

Page 34: ...chnologies All rights reserved 31 TRSM0950 Removal Release Bearing and Clutch Release Yoke Removal Release Bearing and Clutch Release Yoke Removal Special Instructions None Special Tools None Component Identification 1 Release Bearing 2 Clutch Release Yoke ...

Page 35: ...emoval TRSM0950 Procedure Removal 1 Perform Transmission Removal on page 17 2 Remove the Release Bearing by sliding the bearing off the input shaft 3 Pull to free the lower Clutch Release Yoke socket from the lower pivot on the clutch housing 4 Pull to free the upper Clutch Release Yoke socket from the Linear Clutch Actuator LCA rod end ...

Page 36: ...s reserved 33 TRSM0950 Removal Release Bearing and Clutch Release Yoke Removal 5 Inspect the plastic socket inserts in the Clutch Release Yoke to verify none of the fingers are missing or dam aged Note If the plastic insert is damaged replace the Clutch Release Yoke assembly ...

Page 38: ... reserved 35 TRSM0950 Removal Upper Countershaft Cover Removal Upper Countershaft Cover Removal Special Instructions None Special Tools None Component Identification 1 Upper Countershaft Cover Cap Screws x6 13 mm 2 Upper Countershaft Cover 3 O ring 4 Upper Countershaft 1 2 3 4 ...

Page 39: ...edure Removal 1 Perform Transmission Removal on page 17 2 Perform Release Bearing and Clutch Release Yoke Removal on page 31 3 Remove the 6 Upper Countershaft Cover 13 mm cap screws and remove cover 4 Remove the Upper Countershaft Cover O ring NOTICE A new Upper Countershaft Cover O ring is required when reinstalling or an oil leak may occur ...

Page 40: ...es All rights reserved 37 TRSM0950 Removal Input Shaft Cover Removal Input Shaft Cover Removal Special Instructions None Special Tools None Component Identification 1 Input Shaft Cover Cap Screws x7 13 mm 2 Input Shaft Cover 3 Seal 4 O ring 5 Input Shaft 1 2 5 4 3 ...

Page 41: ...reserved 2019 04 4 Input Shaft Cover Removal Removal TRSM0950 Procedure Removal 1 Perform Transmission Removal on page 17 2 Perform Release Bearing and Clutch Release Yoke Removal on page 20 3 Remove the 7 Input Shaft Cover 13 mm cap screws 4 Remove the Input Shaft Cover ...

Page 42: ... Inertia Brake Removal Lower Countershaft Cover and Inertia Brake Removal Special Instructions None Special Tools None Component Identification 1 Inertia Brake Cover Cap Screws x6 13 mm 2 Inertia Brake Cover 3 Inertia Brake Cover O ring 4 Inertia Brake Housing 5 Inertia Brake Housing O ring 6 Piston Pin 7 Return Spring 1 2 4 5 6 7 3 ...

Page 43: ...oval 1 Perform Oil Drain Procedure on page 7 2 Perform Transmission Removal on page 17 3 Perform Release Bearing and Clutch Release Yoke Removal on page 20 4 Depress and hold collar on air line fitting and discon nect the air line from the Inertia Brake Cover 5 Remove the 6 Inertia Brake Cover 13 mm cap screws 6 Remove the Inertia Brake Cover and Housing as an assembly ...

Page 44: ...sion Technologies All rights reserved 41 TRSM0950 Removal Lower Countershaft Cover and Inertia Brake Removal 7 Remove Piston Pin from the end of the lower counter shaft 8 Remove the Return Spring from the end of the lower countershaft using a magnet ...

Page 46: ...ransmission Technologies All rights reserved 43 TRSM0950 Removal Output Yoke Removal Output Yoke Removal Special Instructions None Special Tools None Component Identification 1 Retainer Bolt 27 mm 2 Retainer Plate 3 Output Yoke 4 Output Shaft ...

Page 47: ...veline removal 2 Remove the 27 mm Retainer Bolt and Retainer Plate WARNING A new Retainer Bolt is required during Out put Yoke installation Failure to replace the Retainer Bolt may cause a re used Retainer Bolt to loosen during operation and may result in major vehicle com ponent damage severe injury or death 3 Remove the Output Yoke Note There is an interference fit between the Output Yoke and ou...

Page 48: ...rights reserved 45 TRSM0950 Removal Rear Bearing Cover Removal Rear Bearing Cover Removal Special Instructions None Special Tools None Component Identification 1 Output Shaft 2 Thrust Washer 3 O Ring 4 Rear Bearing Cover 5 Wear Sleeve and Dust Cover 6 Cap Screws x8 13 mm ...

Page 49: ...m Output Yoke Removal on page 43 3 Remove the 8 Rear Bearing Cover 13 mm Cap Screws 4 Using a pry bar separate the Rear Bearing Cover from the rear housing Note Two pry points located at 12 and 6 o clock 5 Remove the Rear Bearing Cover Wear Sleeve and Dust Cover NOTICE If replacing the Output Seal a new Rear Bear ing Cover is required when reinstalling or an oil leak may occur 6 Remove the O ring ...

Page 52: ...ransmission Technologies All rights reserved 49 TRSM0950 Removal Harness Bracket Removal Harness Bracket Removal Special Instructions None Special Tools None Component Identification 1 Harness Bracket 2 Harness Bracket Cap Screws x3 10 mm 1 2 ...

Page 53: ... Technologies All rights reserved 2019 04 4 Harness Bracket Removal Removal TRSM0950 Procedure Removal 1 Remove the Output Speed Sensor Harness tie strap at the Harness Bracket 2 Remove 3 Harness Bracket 10 mm cap screws 3 Remove Harness Bracket ...

Page 54: ...Assembly weighs approximately 170 lbs Failure to properly secure and lift the Rear Housing Assembly may result in major vehicle component damage severe injury or death Special Tools Rear Housing Alignment Pins RR1090TR Component Identification 1 Rear Housing Cap Screws x21 16 mm 2 Rear Housing Threaded Cap Screws x3 16 mm 3 90 Degree Lifting Eyes x2 4 Rear Housing 5 Rear Housing Alignment Pins x2 ...

Page 55: ...moval on page 27 5 Perform Output Speed Sensor Removal on page 23 6 Perform Harness Bracket Removal on page 49 7 Perform Output Yoke Removal on page 43 8 Lift transmission vertically onto a bench with an open ing to allow the input shaft to pass through and clutch housing to sit flat on bench WARNING Transmission weighs approximately 550 lbs Keep fingers clear of pinch point between Clutch Housing...

Page 56: ...d cap screws apply paint marks on the Rear Housing to identify location 10 Remove 21 Rear Housing and 3 threaded 16 mm cap screws 11 Install and hand tighten 2 Rear Housing Alignment Pins RR1090TR 180 degrees apart NOTICE Failure to install alignment pins results in transmission component damage 12 Separate the Rear Housing from the Main Housing at the 2 pry points ...

Page 57: ...riate lifting device to safely lift component Note Dual PTO Transmissions are equipped with a rear PTO lube tube port on the pump and rear PTO drive splines on the Upper Countershaft 14 Place Rear Housing Assembly on bench WARNING Rear Housing Assembly weighs approxi mately 170 lbs Keep fingers clear of pinch point between Rear Housing Assembly and other surfaces Dropping Rear Housing may result i...

Page 58: ...Transmission Technologies All rights reserved 55 TRSM0950 Removal 4 Bolt PTO Cover Removal 4 Bolt PTO Cover Removal Special Instructions None Special Tools None Component Identification 1 O ring 2 4 Bolt PTO Cover 3 Cap Screws x4 18 mm 2 1 3 ...

Page 59: ... 2019 04 4 4 Bolt PTO Cover Removal Removal TRSM0950 Procedure Removal 1 Remove 4 Rear PTO Cover 18 mm cap screws 2 Using a soft faced hammer at the 3 o clock position lightly tap to separate the PTO cover from the Rear Housing CAUTION Keep fingers clear to avoid personal injury ...

Page 60: ...chnologies All rights reserved 57 TRSM0950 Removal Oil Pump Removal Oil Pump Removal Special Instructions None Special Tools None Component Identification 1 Oil Pump Assembly Cap Screws x18 13 mm 2 Oil Pump Assembly 3 O ring 4 Oil Pump Range Spacer 1 3 4 2 ...

Page 61: ...13 3 Perform Release Bearing and Clutch Release Yoke Removal on page 31 4 Perform Mechatronic Transmission Module MTM Removal on page 27 5 Perform Output Speed Sensor Removal on page 23 6 Perform Harness Bracket Removal on page 49 7 Perform Output Yoke Removal on page 43 8 Perform Rear Housing Assembly Removal on page 51 9 Remove 18 Oil Pump Assembly 13 mm cap screws 10 Remove Oil Pump Assembly 11...

Page 62: ...moval Main Housing Removal Main Housing Removal Special Instructions None Special Tools Rear Housing Alignment Pins RR1090TR Component Identification 1 Main Housing External Cap Screws x19 16 mm 2 Main Housing 3 Main Housing Internal Cap Screws x6 16 mm 4 Rear Housing Alignment Pins RR1090TR 1 2 4 3 ...

Page 63: ...m Harness Bracket Removal on page 49 7 Perform Output Yoke Removal on page 43 8 Lift transmission vertically onto a bench with on open ing to allow the input shaft to pass through and clutch housing to sit flat on bench WARNING Transmission weighs approximately 550 lbs Keep fingers clear of pinch point between trans mission and other surfaces Dropping transmission may result in major vehicle compo...

Page 64: ...internal Main Housing 16 mm cap screws NOTICE To avoid internal transmission contamination keep internal and external Main Housing cap screws separated 13 Install and hand tighten 2 Rear Housing Alignment Pins RR1090TR in the internal Main Housing cap screw outer threaded holes 14 Remove 2 Rear Housing 90 degree Lifting Eye 15 mm cap screws from Rear Housing ...

Page 65: ...oval Removal TRSM0950 15 Install and hand tighten 2 Rear Housing 90 degree Lift ing Eyes and 15 mm cap screws to Main Housing NOTICE Do not over tighten cap screws Note Install 90 degree Lifting Eyes 180 degrees apart to ensure even lifting 16 Separate Main Housing from Clutch Housing at the 2 pry points ...

Page 66: ...ain Housing from Clutch Housing CAUTION Main Housing weighs approximately 50 lbs Keep fingers clear of pinch point between Main Hous ing and other surfaces Dropping Main Housing could result in component damage and or personal injury NOTICE Use an appropriate lifting device to safely lift component 18 Remove 2 Rear Housing Alignment Pins RR1090TR ...

Page 68: ...Transmission Technologies All rights reserved 65 TRSM0950 Removal 8 Bolt PTO Cover Removal 8 Bolt PTO Cover Removal Special Instructions None Special Tools None Component Identification 1 8 Bolt PTO Cover 2 PTO Cover Cap Screws x8 18 mm 2 1 ...

Page 69: ...Technologies All rights reserved 2019 04 4 8 Bolt PTO Cover Removal Removal TRSM0950 Procedure Removal 1 Perform Oil Drain Procedure on page 7 2 Remove 8 PTO Cover 18 mm cap screws 3 Separate 8 Bolt PTO Cover from Main Housing at the 2 pry points ...

Page 70: ...pring Front 8 Synchronizer Ring 9 Synchronizer Sliding Sleeve 10 Synchronizer Rollers x3 11 Synchronizer Springs and Plungers x3 12 Lower Lube Tube Cap Screw 8 mm 13 Lower Lube Tube 14 Upper Countershaft 15 Main Shaft Assembly 16 Wave Spring Rear 17 Thrust Washer Rear 18 Thrust Bearing Rear 19 Needle Bearing Rear 20 Bearing Race Rear 21 Upper Lube Tube Cap Screw 8 mm 22 Upper Lube Tube 23 Lower Co...

Page 71: ...31 5 Perform Mechatronic Transmission Module MTM Removal on page 27 6 Perform Output Speed Sensor Removal on page 23 7 Perform Harness Bracket Removal on page 49 8 Perform Output Yoke Removal on page 43 9 Perform Upper Countershaft Cover Removal on page 35 10 Remove Upper Countershaft Snap Ring and Flat Washer NOTICE A new snap ring is required when reinstalling 11 Perform Input Shaft Cover Remova...

Page 72: ...move Lower Countershaft Snap Ring and Flat Washer NOTICE A new snap ring is required when reinstalling 15 Perform Rear Housing Assembly Removal on page 51 16 Perform Main Housing Removal on page 59 17 Remove the Upper Lube Tube 8 mm cap screw 18 Remove the Upper Lube Tube 19 Remove the Lower Lube Tube 8 mm cap screw 20 Remove the Lower Lube Tube ...

Page 73: ...22 Hold Rail C Sliding Clutch against Secondary Driven Gear and lift Main Shaft from Primary Drive Gear CAUTION Main Shaft weighs approximately 35 lbs Keep fingers clear of pinch point between Main Shaft and other surfaces Dropping Main Shaft could result in component damage and or personal injury Note Spring and Washer may remain attached to the Main Shaft during removal 23 Remove Wave Spring Rea...

Page 74: ... Countershaft CAUTION Countershaft weighs approximately 35 lbs Keep fingers clear of pinch point between Countershaft and other surfaces Dropping Countershaft could result in component damage and or personal injury 30 Remove Upper Countershaft CAUTION Countershaft weighs approximately 35 lbs Keep fingers clear of pinch point between Countershaft and other surfaces Dropping Countershaft could resul...

Page 75: ...Technologies All rights reserved 2019 04 4 Main Shaft and Countershaft Removal Removal TRSM0950 31 Remove Spherical Washer Front 32 Remove Bearing Race Front 33 Remove Needle Bearing Front 34 Remove Thrust Bearing Front 35 Remove Synchronizer Ring ...

Page 76: ... Sleeve up until Syn chronizer Rollers are free from synchronizer assembly NOTICE Rollers are under spring pressure ensure to slowly lift sleeve so rollers do not eject from the syn chronizer assembly during disassembly 37 Remove 3 Synchronizer Rollers 38 Remove 3 Synchronizer Plungers and Springs from Synchronizer hub 39 Remove Thrust Washer Front 40 Remove Wave Spring Front ...

Page 78: ...embly Output Seal Assembly Special Instructions None Special Tools Output Seal Driver RR1001TR 8 Output Seal Driver Handle RR1001TR 2 Note RR1001TR 2 is part of Output Seal Driver Kit RR1001TR and may have already been purchased to support prior transmission models Component Identification 1 Rear Bearing Cover 2 Output Shaft Seal 1 2 ...

Page 79: ...w Rear Bearing Cover is required when replacing the Output Seal to ensure no leaks occur between the cover and new seal 2 Place the Output Seal Driver RR1001TR 8 onto the Output Seal Driver Handle RR1001TR 2 3 Place the Output Seal onto the Output Seal Driver RR1001TR 8 4 Install the Output Seal and driver assembly into the Rear Bearing Cover and drive until the seal is seated against the cover NO...

Page 80: ...embly Inertia Brake Disassembly Assembly Inertia Brake Disassembly Assembly Special Instructions None Special Tools None Component Identification 1 Inertia Brake Cover 2 Inertia Brake Piston 3 Steel Discs x6 4 Friction Discs x3 5 O ring Front 6 Wear Guides x2 7 Inertia Brake Housing 8 O ring Rear 7 3 4 6 1 2 8 5 ...

Page 81: ...sassembly Assembly Disassembly Assembly TRSM0950 Procedure Disassembly 1 Remove the clutch pack from the Inertia Brake Hous ing 2 Remove the 2 wear guides from the Inertia Brake Housing 3 Remove O ring from the front of the Inertia Brake Housing 4 Remove O ring from the rear of the Inertia Brake Hous ing ...

Page 82: ...ssembly Inertia Brake Disassembly Assembly Procedure Assembly 1 Insert the O ring into the groove on the rear of the Iner tia Brake Housing until fully seated 2 Insert the O ring into the groove on the front of the Inertia Brake Housing until fully seated 3 Install the 2 Wear Guides in the Inertia Brake Housing ...

Page 83: ...y TRSM0950 4 Install the inertia brake clutch pack in the order shown below 1 Steel Disc 1 Friction Disc 2 Steel Discs 1 Friction Disc 2 Steel Discs 1 Friction Disc and 1 Steel Disc Note Steel Discs align with Wear Guides Friction Discs spline to the lower countershaft 5 Place Inertia Brake Cover and Piston on the Housing Align the bolt holes ...

Page 84: ... Assembly Input Shaft Pilot Bearing Wear Sleeve Disassembly Assembly Special Instructions None Special Tools Input Shaft Pilot Bearing Wear Sleeve Puller RR1062TR Wear Sleeve Installer RR1061TR Snap Ring Installer RR1061TR 1 Wear Sleeve Driver RR1061TR 2 Component Identification 1 Spiral Snap Ring 2 Pilot Bearing Wear Sleeve 3 Wear Sleeve Alignment Pin 4 Input Shaft ...

Page 85: ...ring Wear Sleeve Disassembly Assembly Disassembly Assembly TRSM0950 Procedure Disassembly 1 Perform Transmission Removal on page 17 2 Remove the Spiral Snap Ring from the input shaft with a pick 3 Install the Input Shaft Pilot Bearing Wear Sleeve Puller RR1062TR over the flats on the Pilot Bearing Wear Sleeve ...

Page 86: ...s All rights reserved 83 TRSM0950 Disassembly Assembly Input Shaft Pilot Bearing Wear Sleeve Disassembly Assembly 4 Tighten the 13 mm jackscrew on the Input Shaft Pilot Bearing Wear Sleeve Puller RR1062TR to remove Wear Sleeve 5 Remove the Wear Sleeve Alignment Pin ...

Page 87: ...embly 1 Clean the Pilot Bearing Wear Sleeve surfaces on the input shaft 2 Apply grease to alignment pin groove on the input shaft to hold the Wear Sleeve Alignment Pin in place 3 Slide the Wear Sleeve Alignment Pin into the groove on the input shaft NOTICE Chamfered end of alignment pin must face forward 4 Align the groove in the Pilot Bearing Wear Sleeve with the Wear Sleeve Alignment Pin ...

Page 88: ...gers clear to avoid personal injury 6 Use the Wear Sleeve Driver RR1061TR 2 to fully seat the Pilot Bearing Wear Sleeve onto the input shaft 7 Inspect the Pilot Bearing Wear Sleeve to ensure it is fully seated on the input shaft NOTICE If there is a gap between the Pilot Bearing Wear Sleeve and the input shaft the Wear Sleeve Alignment Pin may have moved out of the groove remove the Pilot Bearing ...

Page 89: ...eeve Disassembly Assembly Disassembly Assembly TRSM0950 9 Slide the Wear Sleeve Driver RR1061TR 2 over the Snap Ring Installer RR1061TR 1 10 While holding the Snap Ring Installer RR1061TR 1 against the input shaft slide the Wear Sleeve Driver RR1061TR 2 forward and fully seat the Spiral Snap Ring into the snap ring groove ...

Page 90: ...y Assembly Input Shaft Cover Disassembly Assembly Input Shaft Cover Disassembly Assembly Special Instructions None Special Tools Output Shaft Installer Input Shaft Seal Driver RR1070TR Component Identification 1 Input Shaft Cover Cap Screws x7 13 mm 2 Input Shaft Cover 3 Seal 4 O ring 5 Input Shaft 1 2 5 4 3 ...

Page 91: ...e the Input Shaft Cover O ring 2 Place the Input Shaft Cover into a vice equipped with soft faced jaw pads with the drain back port at the 8 o clock position Note Do not over tighten the vice jaws 3 Place a lint free cloth over the Input Shaft Cover 4 Using two pry bars lift under the Input Shaft Seal at the 12 o clock position and remove the Input Shaft Seal from the Input Shaft Cover ...

Page 92: ...s Automated Transmission Technologies All rights reserved 89 TRSM0950 Disassembly Assembly Input Shaft Cover Disassembly Assembly 5 Clean and inspect the Input Shaft Seal bore If seal bore is damaged replace the Input Shaft Cover ...

Page 93: ...ssembly TRSM0950 Procedure Assembly 1 Place the Input Shaft Cover on a bench and place the Input Shaft Seal over the seal bore 2 Place Output Shaft Installer Input Shaft Seal Driver RR1070TR onto the Input Shaft Seal and drive until seal is seated into the cover Note Fully seat Seal into Input Shaft Cover 3 Install Input Shaft Cover O ring ...

Page 94: ...sassembly Assembly Main Shaft Disassembly Assembly Special Instructions None Special Tools 5 32 OD Air Line Component Identification 1 Selective Main Shaft Washer 2 Reverse Gear 3 Main Shaft Washer x4 4 Rail D Sliding Clutch 5 Primary Driven Gear 6 Secondary Driven Gear 7 Main Shaft Assembly 8 Rail C Sliding Clutch 1 2 3 4 5 6 7 8 ...

Page 95: ...d or personal injury 2 Remove Rail C Sliding Clutch 3 Place Main Shaft assembly vertically on a clean flat surface CAUTION Secure Main Shaft Assembly while on flat surface to avoid unexpected movement Failure to properly secure Main Shaft Assembly could result in component damage and or personal injury 4 Remove Main Shaft Key 5 Rotate and remove the Selective Main Shaft Washer above Reverse Gear N...

Page 96: ...RSM0950 Disassembly Assembly Main Shaft Disassembly Assembly 6 Remove Reverse Gear 7 Rotate and remove standard Main Shaft Washer above Rail D Sliding Clutch 8 Remove Rail D Sliding Clutch 9 Rotate and remove standard Main Shaft Washer above Primary Driven Gear 10 Remove Primary Driven Gear ...

Page 97: ...ies All rights reserved 2019 04 4 Main Shaft Disassembly Assembly Disassembly Assembly TRSM0950 11 Rotate and remove standard Main Shaft Washer above Secondary Driven Gear 12 Remove Secondary Driven Gear 13 Rotate and remove last standard Main Shaft Washer ...

Page 98: ...tically on a clean flat surface CAUTION Secure Main Shaft Assembly while on flat surface to avoid unexpected movement Failure to properly secure Main Shaft Assembly could result in component damage and or personal injury 2 Install and rotate the first standard Main Shaft Washer 6 525 mm onto Main Shaft 3 Install a 5 32 OD air line into the main shaft spline to align and hold washer in place ...

Page 99: ...bly Assembly TRSM0950 4 Install Secondary Driven Gear on Main Shaft with clutching teeth facing down 5 Install and rotate a standard Main Shaft Washer 6 525 mm above Secondary Driven Gear 6 Slide the 5 32 OD air line up to align and hold washer in place 7 Install Primary Driven Gear on Main Shaft with clutch ing teeth facing up ...

Page 100: ...mbly Assembly 8 Install and rotate a standard Main Shaft Washer 6 525 mm above Primary Driven Gear 9 Slide the 5 32 OD air line up to align and hold washer in place 10 Install Rail D Sliding Clutch and align the double slot with the 5 32 OD air line 11 Install and rotate a standard Main Shaft Washer 6 525 mm above Rail D Sliding Clutch ...

Page 101: ...e up to align and hold washer in place 13 Install Reverse Gear with clutching teeth facing down 14 Install and rotate the Selective Main Shaft Washer 6 525 6 712 or 6 900 mm above Reverse Gear 15 Slide the 5 32 OD air line up to align and hold washer in place 16 Install Main Shaft Key at the same spline as the 5 32 OD air line Note Insert Main Shaft Key while removing air line ...

Page 102: ...lation into transmission Note Remove magnet from Main Shaft Key after installation of Main Shaft Assembly onto transmission 18 Place Main Shaft Assembly horizontally on a clean flat surface CAUTION Secure Main Shaft Assembly while on flat surface to avoid unexpected movement Failure to properly secure Main Shaft Assembly could result in component damage and or personal injury 19 Install Rail C Sli...

Page 104: ...58 mm 22 inches wide If the Clutch Housing is too large for the available press go to Input Shaft Disassembly Assembly using Input Shaft Press RR1085TR on page 221 Special Tools Input Shaft Cup RR1087TR 6 Input Shaft Stand RR1073TR Input Shaft Bearing Removal and Installation Tool RR1075TR Universal Driver Handle OE8044 T0 Note Universal Driver Handle OE8044 T0 is part of Overhaul Tool Kit RR2012T...

Page 105: ...ress is required for the removal and instal lation of the Input Shaft Failure to use a press results in Input Shaft and or Clutch Housing damage NOTICE Support the Clutch Housing to avoid damag ing the housing and sealing surface Note Clutch Housing is approximately 558 mm 22 inches wide If the Clutch Housing is too large for the available press go to Input Shaft Disassem bly Assembly using Input ...

Page 106: ...ies All rights reserved 103 TRSM0950 Disassembly Assembly Input Shaft Disassembly Assembly 6 Place Input Shaft Bearing Removal and Installation Tool RR1075TR and Universal Driver Handle OE8044 T0 onto Input Bearing 7 Press Input Shaft Bearing from Clutch Housing ...

Page 107: ...earing Removal and Installation Tool RR1075TR and Universal Driver Handle OE8044 T0 onto Input Bearing 4 Press Input Shaft Bearing into Clutch Housing NOTICE Do not over press bearing into Clutch Hous ing Over pressing could result in component damage 5 Verify Input Shaft Bearing is fully seated in Clutch Housing 6 Place Clutch Housing in press with Flywheel Housing side of the Clutch Housing down...

Page 108: ...ut Shaft 9 Press Input Shaft into Input Bearing until full seated NOTICE Do not over press Input Shaft into Clutch Housing Over pressing could result in component damage 10 Install Input Shaft Snap Ring NOTICE A new snap ring is required when reinstalling A used snap ring may detach from Input Shaft and result in transmission component damage Note The snap ring will not install if Input Shaft is n...

Page 110: ...er RR1077TR Input Shaft Bearing Removal and Installation Tool RR1075TR Universal Driver Handle OE8044 T0 Note Universal Driver Handle OE8044 T0 is part of Overhaul Tool Kit RR2012TR and may have already been purchased to support prior transmission models Component Identification 1 Main Shaft Bearing 2 Reverse Idler Gear Shaft x2 3 Rear Countershaft Bearings x2 4 Main Housing 5 Reverse Idler Gear T...

Page 111: ... the Main and Clutch Housing mating surface down CAUTION Main Housing weighs approximately 50 lbs Keep fingers clear of pinch point between Main Hous ing and other surfaces Dropping Main Housing could result in component damage and or personal injury 3 Remove Lower Reverse Idler Gear Shaft from Main Housing by pushing shaft up 4 Remove Lower Reverse Idler Gear washers and bear ing from Main Housin...

Page 112: ...Pump Assembly surface CAUTION Main Housing weighs approximately 50 lbs Keep fingers clear of pinch point between Main Hous ing and other surfaces Dropping Main Housing could result in component damage and or personal injury NOTICE Support the Main Housing to avoid damaging the housing and sealing surface 8 Place Countershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Rea...

Page 113: ...iver Handle OE8044 T0 onto Main Shaft Bearing 12 Press Main Shaft Bearing out of Main Housing NOTICE Support the Main Housing to avoid damaging the housing and sealing surface 13 Place Main Housing vertically in press and support housing on Oil Pump Assembly surface 14 Place Countershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Rear Lower Countershaft Bearing 15 Press ...

Page 114: ... Installer RR1077TR and Universal Driver Handle OE8044 T0 onto Main Shaft Bearing 4 Press Main Shaft Bearing into Main Housing NOTICE Support the Main Housing to avoid damaging the housing and sealing surface NOTICE Do not over press bearing into Main Housing Over pressing could result in component damage 5 Verify Main Shaft Bearing is fully seated into housing 6 Inspect Rear Lower Countershaft Be...

Page 115: ...jury 10 Verify Rear Lower Countershaft Bearing is fully seated into housing 11 Inspect Rear Upper Countershaft Bearing and verify snap ring is fully seated in groove 12 Place Rear Upper Countershaft Bearing into Main Housing 13 Place Countershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Rear Upper Countershaft Bearing 14 Press Rear Upper Countershaft Bearing into Main ...

Page 116: ...shaft Bearing is fully seated into housing 16 Install bearing into Upper Reverse Idler Gear 17 Install and hold Upper Reverse Idler Gear upper washer into Main Housing 18 While holding the upper washer install Upper Reverse Idler Gear bearing and lower washer into Main Hous ing 19 Install Upper Reverse Idler Gear Shaft by pushing shaft into housing through washers bearing and gear ...

Page 117: ...h passage in housing until pin is fully seated into passage Note If necessary use a soft faced hammer to lightly tap shaft into housing 21 Install bearing into Lower Reverse Idler Gear 22 Install and hold Lower Reverse Idler Gear upper washer into Main Housing 23 While holding the upper washer install Lower Reverse Idler Gear bearing and lower washer into Main Hous ing ...

Page 118: ...assembly Assembly 24 Install Lower Reverse Idler Gear Shaft by pushing shaft into housing through washers bearing and gear 25 Align pin with passage in housing until pin is fully seated into passage Note If necessary use a soft faced hammer to lightly tap shaft into housing 26 Perform Fluid Pressure Sensor FPS Installation on page 159 ...

Page 120: ...damage severe injury or death Special Tools Reaction Plate Alignment Pins RR1091TR Range Assembly Removal Installation Tool RR1065TR Rear Housing Stand RR1069TR Input Shaft Bearing Removal and Installation Tool RR1075TR Output Bearing Removal and Installation Tool RR1089TR Universal Driver Handle OE8044 T0 Component Identification 1 Cap Screws and Washers x4 13 mm 2 Range Synchronizer Assembly 3 P...

Page 121: ...l on page 45 2 Place Rear Housing on Rear Housing Stand RR1069TR WARNING Rear Housing weighs approximately 170 lbs Keep fingers clear of pinch point between Rear Housing and other surfaces Dropping Rear Housing may result in major vehicle component damage severe injury or death 3 Remove Rail E Detent Plug with a 6 mm hex key Note Detent Plug is under spring pressure 4 Remove the Rail E Spring and ...

Page 122: ... 6 Install 2 Reaction Plate Alignment Pins RR1091TR onto Reaction Plate dowels NOTICE Failure to use Reaction Plate Alignment Pins RR1091TR results in component damage 7 Install Range Assembly Removal Installation Tool RR1065TR into Sun Gear groove CAUTION Failure to properly secure tool could result in damage to component s or personal injury NOTICE Fully seat tool into groove and hand tighten un...

Page 123: ...Synchronizer Assembly weighs approximately 70 lbs Failure to properly secure and lift the assembly may result in component damage seri ous injury or death NOTICE Use an appropriate lifting device to safely lift component Note Rotate Sun Gear to ease removal 9 Hold Shift Rail E to the Range Synchronizer while removing Range Synchronizer Assembly from Rear Housing 10 After Range Synchronizer Assembl...

Page 124: ...sing and other surfaces Dropping Rear Housing could result in component damage and or personal injury NOTICE Place soft material under Planetary Output Shaft Assembly to cushion removal from Rear Hous ing NOTICE Support the Rear Housing to avoid damaging the housing and sealing surface 14 Press Planetary Output Shaft Assembly out of Rear Housing 15 Remove Rear Housing and Planetary Output Shaft As...

Page 125: ...ION Rear Housing weighs approximately 15 lbs Keep fingers clear of pinch point between Rear Hous ing and other surfaces Dropping the Rear Housing may result in major vehicle component damage severe injury or death NOTICE Support the Rear Housing to avoid damaging the housing and sealing surface 17 Place Output Bearing Removal and Installation Tool RR1089TR and Universal Driver Handle OE8044 T0 ont...

Page 126: ...y 1 Place Rear Housing into press 2 Place Output Bearing onto Rear Housing 3 Place Output Bearing Removal and Installation tool RR1089TR onto Output Bearing NOTICE Do not over press bearing into Rear Housing Over pressing could result in component damage 4 Press Output Bearing into Rear Housing 5 Verify Output Bearing is fully seated 6 Place Rear Housing Stand RR1069TR on Press ...

Page 127: ...rs clear of pinch point between Planetary Output Shaft Assembly and other surfaces Dropping Planetary Output Shaft Assembly could result in component damage and or personal injury 9 Place Input Shaft Bearing Removal and Installation Tool RR1075TR onto Planetary Output Shaft Assem bly 10 Press Planetary Output Shaft Assembly through output bearing until fully seated 11 Remove Rear Housing from pres...

Page 128: ...using Stand RR1069TR 14 For Dual PTO Transmissions install Rear PTO Lube Tube and 8 mm cap screw into Rear Housing and torque to 8 8 10 4 Nm 6 8 lb ft 15 Install Reaction Plate Alignment Pins RR1091TR in Rear Housing NOTICE Failure to use Reaction Plate Alignment Pins RR1091TR results in component damage 16 Inspect plastic Oil Slinger to ensure it is locked into place by three locking tab pins ...

Page 129: ...llation tool RR1065TR CAUTION Range Synchronizer Assembly weighs approximately 70 lbs Failure to properly secure and lift the assembly may result in component damage seri ous injury or death NOTICE Use an appropriate lifting device to safely lift component 19 Install and hold Shift Rail E to Range Synchronizer Assembly Note Ensure the notched end of Shift Rail E is facing up 20 Lower the Range Syn...

Page 130: ...ng Assembly Disassembly Assembly 22 Remove Reaction Plate Alignment Pins RR1091TR 23 Install 4 Reaction Plate cap screws and washers and torque to 21 25 Nm 16 19 lb ft 24 Install Rail E Detent Spring and Plug 25 Torque detent plug to 24 5 29 5 Nm 16 19 lb ft NOTICE Do not over torque detent plug or transmis sion damage may occur ...

Page 132: ...Input Shaft Disassembly Assembly using Input Shaft Press RR1085TR on page 221 Special Tools Countershaft Bearing Installer RR1076TR Input Shaft Cup RR1087TR 6 Front Bearing Capture Plate RR1085TR 7 Input Shaft Bearing Removal and Installation Tool RR1075TR Universal Driver Handle OE8044 T0 Note Universal Driver Handle OE8044 T0 is part of Overhaul Tool Kit RR2012TR and may have already been purcha...

Page 133: ...ge and or personal injury NOTICE A press is required for the removal and instal lation of the Input Shaft Failure to use a press results in Input Shaft and or Clutch Housing damage NOTICE Support the Clutch Housing to avoid damag ing the housing and sealing surface Note Clutch Housing is approximately 558 mm 22 inches wide If the Clutch Housing is too large for the available press go to Input Shaf...

Page 134: ...n press with flywheel housing side of the Clutch Housing down NOTICE Support the Clutch Housing to avoid damag ing the housing 9 Place Input Shaft Bearing Removal and Installation Tool RR1075TR and Universal Driver Handle OE8044 T0 onto Input Bearing 10 Press Input Shaft Bearing from Clutch Housing 11 Place Countershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Lower Co...

Page 135: ... 13 Place Countershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Upper Countershaft Bearing 14 Press Upper Countershaft Bearing from Clutch Hous ing 15 Place Input Shaft Bearing Removal and Installation Tool RR1075TR and Universal Driver Handle OE8044 T0 onto Input Shaft Bearing 16 Press Input Shaft Bearing from Clutch Housing ...

Page 136: ...ntershaft Bearing Installer RR1076TR and Universal Driver Handle OE8044 T0 onto Upper Countershaft Bearing 4 Press Upper Countershaft Bearing into Clutch Housing NOTICE Do not over press bearing into Clutch Hous ing Over pressing could result in component damage 5 Verify Upper Countershaft Bearing is fully seated in Clutch Housing 6 Place Lower Countershaft Bearing into Clutch Housing 7 Place Coun...

Page 137: ...TICE Do not over press bearing into Clutch Hous ing Over pressing could result in component damage 13 Verify Input Shaft Bearing is fully seated in Clutch Housing 14 Install Front Bearing Capture Plate RR1085TR 7 to the Clutch Housing using the Input Shaft Cover threaded mounting holes and hand tighten 4 plate cap screws with a 6 mm hex key 15 Torque cap screws to 21 25 Nm 16 19 lb ft in a criss c...

Page 138: ...ring until full seated NOTICE Do not over press Input Shaft into Clutch Housing Over pressing could result in component damage 20 Remove Front Bearing Capture Plate RR1085TR 7 21 Install Input Shaft Snap Ring NOTICE A new snap ring is required when reinstalling A used snap ring may detach from Input Shaft and result in transmission component damage Note The snap ring will not install if Input Shaf...

Page 139: ...eserved 2019 04 4 Clutch Housing Disassembly Assembly Disassembly Assembly TRSM0950 22 Install and hand tighten Inertia Brake 90 degree airline elbow 15 mm aligning airline inlet with paint mark 23 Install Release Yoke Pivot Pin 30 mm and torque to 130 140 Nm 95 101 lb ft ...

Page 140: ...0 5 9 0 M S R T Rear Bearing Cover Installation Rear Bearing Cover Installation Special Instructions None Special Tools Gasket Sealant Loctite 5188 Gasket Remover Loctite SF 7631 Component Identification 1 Output Shaft 2 Thrust Washer 3 O Ring 4 Rear Bearing Cover 5 Wear Sleeve and Dust Cover 6 Cap Screws x8 13 mm ...

Page 141: ...asive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak 2 Inspect threaded bolt holes for debris and clean if nec essary NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 3 Slide the Output Shaft Thrust Washer over the output shaft and seat it against the Output Bearing 4 Slide th...

Page 142: ...here is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 6 Slide the Rear Bearing Cover over the output shaft Note Align the two pry points at 12 and 6 o clock posi tions 7 Install 8 Rear Bearing Cover 13 mm Cap Screws and torque to 21 25 Nm 16 19 lb ft in a criss cross pat tern 8 Slide the Wear Sleeve and Dust Cover over the output shaft 9 Perfor...

Page 144: ...ion Technologies All rights reserved 141 TRSM0950 Installation Output Yoke Installation Output Yoke Installation Special Instructions None Special Tools None Component Identification 1 Retainer Bolt 27 mm 2 Retainer Plate 3 Output Yoke 4 Output Shaft ...

Page 145: ...tput Yoke 2 Slide the Output Yoke over the output shaft Note The Output Yoke may require to be driven on due to an interference fit 3 Install the Retainer Plate and a new 27 mm Retainer Bolt and torque to 617 690 Nm 455 508 lb ft WARNING A new Retainer Bolt is required during Out put Yoke installation A used Retainer Bolt could loosen during operation and may result in major vehicle com ponent dam...

Page 146: ...nertia Brake Installation Lower Countershaft Cover and Inertia Brake Installation Special Instructions None Special Tools None Component Identification 1 Inertia Brake Cover Cap Screws x6 13 mm 2 Inertia Brake Cover 3 Inertia Brake Cover O ring 4 Inertia Brake Housing 5 Inertia Brake Housing O ring 6 Piston Pin 7 Return Spring 1 2 4 5 6 7 3 ...

Page 147: ...sembly over the Lower Countershaft rotate the assembly to align the Friction Discs to the Lower Countershaft splines and seat the assembly to the clutch housing 3 While holding the Inertia Brake Housing to the clutch housing remove the Inertia Brake Cover NOTICE Ensure the Friction Discs are splined to the lower countershaft and Wear Guides are fully seated 4 Install the Return Spring into the Low...

Page 148: ...7 Install the 6 13 mm cap screws and torque to 21 25 Nm 16 19 lb ft in a criss cross pattern 8 Insert air line in push to connect fitting on the Inertia Brake Cover 9 Perform Release Bearing and Clutch Release Yoke Installation on page 167 10 Perform Transmission Installation on page 211 Note Complete all Service Routines or transmission performance will be degraded ...

Page 150: ...ights reserved 147 TRSM0950 Installation Input Shaft Cover Installation Input Shaft Cover Installation Special Instructions None Special Tools None Component Identification 1 Input Shaft Cover Cap Screws x7 13 mm 2 Input Shaft Cover 3 Seal 4 O ring 5 Input Shaft 1 2 5 4 3 ...

Page 151: ...sealing surfaces on the clutch housing and Input Shaft Cover 2 Slide the Input Shaft Cover over the Input Shaft Note Align TOP at 12 o clock 3 Install the 7 Input Shaft Cover 13 mm cap screws and torque to 21 25 Nm 16 19 lb ft in a criss cross pat tern 4 Perform Release Bearing and Clutch Release Yoke Installation on page 167 5 Perform Transmission Installation on page 211 ...

Page 152: ...ghts reserved 149 TRSM0950 Installation Upper Countershaft Cover Installation Upper Countershaft Cover Installation Special Instructions None Special Tools None Component Identification 1 Cap Screws x6 13 mm 2 Upper Countershaft Cover 3 O ring 4 Upper Countershaft 1 2 3 4 ...

Page 153: ...aft Cover 2 Insert the Upper Countershaft Cover O ring into the groove until fully seated 3 Install the Upper Countershaft Cover to the Clutch Housing 4 Install the six 13 mm cap screws and torque to 21 25 Nm 16 19 lb ft in a criss cross pattern 5 Perform Release Bearing and Clutch Release Yoke Installation on page 167 6 Perform Transmission Installation on page 211 Note Complete all Service Routi...

Page 154: ...ronic Transmission Module MTM Installation Special Instructions None Special Tools Gasket Sealant Loctite 5188 Gasket Remover Loctite SF 7631 Mechanical Diagnostic Kit RR2011TR Component Identification 1 MTM Cap Screws Long x4 13 mm 2 MTM Cap Screws Special x2 15 mm 3 MTM Cap Screws x14 13 mm 4 Mechatronic Transmission Module MTM 5 Main Housing 6 Output Speed Sensor ...

Page 155: ...TICE Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak 3 Inspect threaded bolt holes for debris and clean if nec essary NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 4 Install the Rail B Engagement Tool RR1088TR to the Main Housing and hand tighten with 2 M...

Page 156: ...s All rights reserved 153 TRSM0950 Installation Mechatronic Transmission Module MTM Installation 8 Install the Confirm Neutral Gauge RR1086TR 2 into the slots of the synchronizer and sliding clutches 9 Install the MTM Alignment Tool RR1086TR 1 onto the main housing ...

Page 157: ...le MTM Installation Installation TRSM0950 10 Verify synchronizer and sliding clutches are in neutral by sliding Confirm Neutral Gauge into the slots of MTM Alignment Tool Note If the gauge does not slide into the alignment tool slots neutral is not achieved Go to Step 4 11 Using the Rail E Lever move Rail E to neutral ...

Page 158: ...nfirm Neutral Gauge RR1088TR 2 at Shift Rail E Rail E is in neutral when end of gauge rests against housing with rail against notch end of gauge 13 Move Shift Rail B in the MTM to neutral Rail B is in neutral when the ball detent is in the notch of the Rail B yoke assembly 14 Move Shift Rails C and D in the MTM to neutral Rails C and D are in neutral when the shift inter lock is aligned with the n...

Page 159: ...Verify notch on Rail E is facing up Note If the MTM is installed on the transmission with the notch on Rail E facing down Fault Code 320 SPN 5942 sets Active and the transmission will not shift out of neutral 17 Verify Rail E is in neutral using the Fork Side Actuator end of the Confirm Neutral Gauge RR1088TR 2 at Shift Rail E Rail E is in neutral when end of gauge rests against cover with rail ag...

Page 160: ...e MTM with the Rail E Shift Rail in the Main Housing CAUTION MTM weighs approximately 40 lbs Keep fingers clear of pinch point between MTM and other surfaces Dropping MTM could result in component damage and or personal injury NOTICE If the MTM is installed on the transmission and Rail E in the MTM is not aligned with Rail E in the Main Housing Fault Code 320 SPN 5942 sets Active and the transmiss...

Page 161: ...dule MTM Installation Installation TRSM0950 23 Perform Transmission Control Module TCM Installa tion on page 169 24 Perform Release Bearing and Clutch Release Yoke Installation on page 167 25 Perform Transmission Installation on page 211 Note Complete all Service Routines or transmission performance will be degraded ...

Page 162: ...nsmission Technologies All rights reserved 159 TRSM0950 Installation Fluid Pressure Sensor FPS Installation Fluid Pressure Sensor FPS Installation Special Instructions None Special Tools None Component Identification 1 Fluid Pressure Sensor x1 ...

Page 163: ...llation Installation TRSM0950 Procedure Installation 1 Inspect the Fluid Pressure Sensor FPS and O ring for damage If damaged replace the FPS O ring is ser viced with sensor 2 Install the Transmission FPS into the Main Housing and torque to 19 23 Nm 14 17 lb ft 3 Connect and latch the OEM 3 Way Transmission FPS Connector ...

Page 164: ...s reserved 161 TRSM0950 Installation Output Speed Sensor Installation Output Speed Sensor Installation Special Instructions None Special Tools None Component Identification 1 Output Speed Sensor Harness 2 Harness Retainers x2 3 Cap Screw 10 mm 4 Output Speed Sensor Connector ...

Page 165: ...ealing surface 2 Apply a light coat of transmission oil to the sensor O ring 3 Install the Output Speed Sensor into the bore Note The Sensor may need to be twisted and pushed into the bore 4 Install the Output Speed Sensor 10 mm cap screw and torque to 8 8 10 4 Nm 6 8 lb ft 5 Press the 2 harness press in retainers into the Main Housing and the bracket on the rear housing 6 Secure the Output Speed ...

Page 166: ...omated Transmission Technologies All rights reserved 163 TRSM0950 Installation Output Speed Sensor Installation 7 Connect the Output Speed Sensor Harness to the Con nector on the Mechatronic Transmission Module MTM and close the latch ...

Page 168: ...TRSM0950 Installation Linear Clutch Actuator LCA Installation Linear Clutch Actuator LCA Installation Special Instructions None Special Tools ServiceRanger Component Identification 1 Mechatronic Transmission Module MTM Housing 2 Linear Clutch Actuator LCA 3 LCA Cap Screws x4 T45 Torx 2 3 1 ...

Page 169: ...be damaged and leak 2 Place the LCA on a clean flat surface and push the LCA rod down until it locks to reset the LCA Note A new LCA is already locked in the reset position 3 Insert the LCA into the MTM 4 Install 4 LCA T45 cap screws and torque to 23 28 Nm 17 21 lb ft in a criss cross pattern Note If transmission was removed from the vehicle Perform Release Bearing and Clutch Release Yoke Installa...

Page 170: ...ogies All rights reserved 167 TRSM0950 Installation Release Bearing and Clutch Release Yoke Installation Release Bearing and Clutch Release Yoke Installation Special Instructions None Special Tools None Component Identification 1 Release Bearing 2 Release Yoke ...

Page 171: ...f the Linear Clutch Actuator LCA and press until attached 2 Install the lower Release Yoke socket over the lower pivot on the clutch housing and press until attached 3 Slide the Release Bearing over the input shaft and into the Release Yoke 4 Push the upper end of the Release Yoke back until it locks to reset the LCA 5 Perform Transmission Installation on page 211 Note Complete all Service Routine...

Page 172: ...rol Module TCM Installation Transmission Control Module TCM Installation Special Instructions None Special Tools ServiceRanger Component Identification 1 Transmission Control Module TCM Cover 10 or 13 mm Nuts 2 Transmission Control Module TCM 3 Mechatronic Transmission Module MTM 4 Transmission Control Module TCM Jackscrew 7 mm ...

Page 173: ... Mechatronic Transmission Module MTM Note Transmission Control Module TCM can be installed with transmission in chassis 1 Install the TCM Seal on the 74 Way Harness Connec tor 2 Align the TCM to the 74 Way Harness Connector and TCM studs 3 Torque the TCM Jackscrew to 2 2 5 Nm 17 76 22 08 lb in 4 Install the TCM cover and 4 nuts over the TCM studs and torque to 8 8 10 4 Nm 78 92 lb in in a criss cr...

Page 174: ...ated Serial Number if Unspecified is indicated locate and enter indicated Original Trans Serial Number 13 In the Current MTM Serial Number parameter New Value field enter the MTM serial number Note Refer to SAR locate and enter indicated Current MTM Serial Number if Unspecified is indicated locate and enter indicated Original MTM Serial Num ber 14 Refer to the SAR and change other configuration pa...

Page 176: ...Front 4 Needle Bearing Front 5 Thrust Bearing Front 6 Thrust Washer Front 7 Wave Spring Front 8 Synchronizer Ring 9 Synchronizer Sliding Sleeve 10 Synchronizer Rollers x3 11 Synchronizer Springs and Plungers x3 12 Lower Lube Tube Cap Screw 8 mm 13 Lower Lube Tube 14 Upper Countershaft 15 Main Shaft Assembly 16 Wave Spring Rear 17 Thrust Washer Rear 18 Thrust Bearing Rear 19 Needle Bearing Rear 20 ...

Page 177: ...ss from each other if not already marked Note Paint marks are required for timing the Second ary Drive Gear to the Countershafts 2 Install 3 springs and plungers into Synchronizer hub 3 Install Rail B Synchronizer Sliding Sleeve with bevel facing up NOTICE The tapered side of the sleeve is installed with the bevel facing up 4 Lift and hold the Rail B Synchronizer Sliding Sleeve install 3 rollers o...

Page 178: ...ynchronizer Sliding Sleeve to the neutral position and seat the 3 rollers evenly on the springs and plungers 6 Install Rail B Synchronizer Ring Note Align the 3 tabs on ring to the 3 openings on the hub at each spring and plunger 7 Install Wave Spring Front NOTICE Wave Spring Front is taller than the Wave Spring Rear 8 Install Thrust Washer Front 9 Install Needle Bearing Front ...

Page 179: ...n Installation TRSM0950 10 Install Thrust Bearing Front 11 Install Bearing Race Front 12 Install Spherical Washer Front with conical side down 13 Install Lower Countershaft Pilot Tool RR1071TR to front section of Lower Countershaft Note Lower Countershaft has Inertia Brake Splines on the front and Oil Pump drive slot on the rear ...

Page 180: ...ring will not be properly timed and the Main Hous ing cannot be installed due to countershaft misalign ment Note Paint marks are required for timing the Second ary Drive Gear to the Countershafts 15 Install Lower Countershaft with Countershaft Pilot Tool RR1071TR Ensure timing marks align with Second ary Drive Gear and Lower Countershaft front drive gear CAUTION Countershaft weighs approximately 3...

Page 181: ... not paint marked correctly the gearing will not be properly timed and the Main Hous ing cannot be installed due to countershaft misalign ment Note Paint marks are required for timing the Second ary Drive Gear to the Countershafts 18 Install Upper Countershaft with Upper Countershaft Pilot Tool RR1072TR into bearing Ensure timing marks align with Secondary Drive Gear and Upper Countershaft front d...

Page 182: ...s All rights reserved 179 TRSM0950 Installation Main Shaft and Countershaft Installation 19 Install Primary Drive Gear with clutching teeth facing up onto Rail B Synchronizer 20 Install Bearing Race Rear 21 Install Needle Bearing Rear 22 Install Thrust Bearing Rear ...

Page 183: ...e Spring Rear and install to Main Shaft NOTICE Wave Spring Rear is shorter than the Wave Spring Front Note Transmission assembly lube holds Wave Spring Rear in place during Main Shaft Assembly installa tion 24 Apply transmission assembly lube to Thrust Washer Rear and install to Main Shaft Note Transmission assembly lube holds Thrust Washer Rear in place during Main Shaft Assembly installation ...

Page 184: ...ly installation 26 Slide and hold Rail C Sliding Clutch into Secondary Driven Gear 27 Install Main Shaft Assembly onto Primary Drive Gear and align gearing CAUTION Main Shaft weighs approximately 35 lbs Keep fingers clear of pinch point between Main Shaft and other surfaces Dropping Main Shaft could result in component damage and or personal injury 28 Remove magnet from Main Shaft Key NOTICE Ensur...

Page 185: ...o Clutch Housing and 8 mm cap screw torque to 8 10 Nm 6 13 lb ft 31 Perform Main Housing Installation on page 185 32 Perform Rear Housing Installation on page 197 33 Lift transmission horizontally onto a bench WARNING Transmission weighs approximately 550 lbs Keep fingers clear of pinch point between trans mission and other surfaces Dropping transmission may result in major vehicle component damag...

Page 186: ...ng is required when reinstalling A used snap ring may detach from countershaft and result in transmission component damage 35 Perform Lower Countershaft Cover and Inertia Brake Installation on page 143 36 Install Input Shaft Snap Ring NOTICE A new snap ring is required when reinstalling A used snap ring may detach from Input Shaft and result in transmission component damage 37 Perform Input Shaft ...

Page 187: ...rform Upper Countershaft Cover Installation on page 149 40 Perform Output Yoke Installation on page 141 41 Perform Harness Bracket Installation on page 203 42 Perform Output Speed Sensor Installation on page 161 43 Perform Mechatronic Transmission Module MTM Installation on page 151 44 Perform Transmission Control Module TCM Installa tion on page 169 45 Perform Release Bearing and Clutch Release Y...

Page 188: ...ructions None Special Tools Upper Countershaft Pilot Tool RR1071TR Lower Countershaft Pilot Tool RR1072TR Rear Housing Alignment Pins RR1090TR Gasket Sealant Loctite 5188 Gasket Remover Loctite SF 7631 Component Identification 1 Main Housing External Cap Screws x19 16 mm 2 Main Housing 3 Main Housing Internal Cap Screws x6 16 mm 4 Rear Housing Alignment Pins RR1090TR 1 2 4 3 ...

Page 189: ...pect threaded bolt holes for debris and clean if nec essary NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 3 Slide O ring over the Clutch Housing Inertia Brake air passage alignment pin until fully seated in groove 4 Apply Gasket Sealant to clutch housing as shown in pattern below NOTICE Ensure there is nothing in the thre...

Page 190: ...Eyes 180 degrees apart to ensure even lifting 8 Install and hand tighten 2 Rear Housing Alignment Pins RR1090TR into the Clutch Housing as shown below 9 Lift align and install Main Housing to Clutch Housing CAUTION Main Housing weighs approximately 50 lbs Keep fingers clear of pinch point between Main Hous ing and other surfaces Dropping Main Housing could result in component damage and or serious...

Page 191: ...in Housing Installation Installation TRSM0950 10 Remove 2 Rear Housing Alignment Pins RR1090TR 11 Remove 2 Rear Housing 90 degree Lifting Eyes and 15 mm cap screws from Main Housing 12 Re install 2 Rear Housing 90 degree Lifting Eyes to the Rear Housing and torque to 49 6 55 5 Nm 36 40 lb ft ...

Page 192: ...fingers clear of pinch point between trans mission and other surfaces Dropping transmission may result in major vehicle component damage severe injury or death NOTICE Use an appropriate lifting device to safely lift component 16 Perform Output Yoke Installation on page 141 17 Perform Harness Bracket Installation on page 203 18 Perform Output Speed Sensor Installation on page 161 19 Perform Mechatr...

Page 194: ...s reserved 191 TRSM0950 Installation 8 Bolt PTO Cover Installation 8 Bolt PTO Cover Installation Special Instructions None Special Tools Gasket Sealant Loctite 5188 Gasket Remover Loctite SF 7631 Component Identification 1 8 Bolt PTO Cover 2 PTO Cover Cap Screws x8 18 mm 2 1 ...

Page 195: ...aged and leak 2 Inspect threaded bolt holes for debris and clean if nec essary NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 3 Apply Gasket Sealant to Main Housing as shown in pat tern below NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 4 Install...

Page 196: ...es All rights reserved 193 TRSM0950 Installation Oil Pump Installation Oil Pump Installation Special Instructions None Special Tools None Component Identification 1 Oil Pump Assembly Cap Screws x18 13 mm 2 Oil Pump Assembly 3 O ring 4 Oil Pump Range Spacer 1 3 4 2 ...

Page 197: ...ly NOTICE Ensure spacer tab is aligned to groove and sits flush with housing or component damage may occur during installation 3 While holding the Oil Pump Range Spacer in place align oil pump drive key with slot on Lower Counter shaft and install Oil Pump Assembly to Main Housing NOTICE Ensure drive key is aligned with slot or com ponent damage may occur during Oil Pump Assembly installation to M...

Page 198: ...ces Dropping transmission may result in major vehicle component damage severe injury or death NOTICE Use an appropriate lifting device to safely lift component 8 Perform Output Yoke Installation on page 141 9 Perform Harness Bracket Installation on page 203 10 Perform Output Speed Sensor Installation on page 161 11 Perform Mechatronic Transmission Module MTM Installation on page 151 12 Perform Tra...

Page 200: ...ely 170 lbs Failure to properly secure and lift the Rear Housing may result in major vehicle component damage severe injury or death Special Tools Gasket Sealant Loctite 5188 Gasket Remover Loctite SF 7631 Rear Housing Alignment Pins RR1090TR Component Identification 1 Rear Housing Cap Screws x21 16 mm 2 Rear Housing Threaded Cap Screws x3 16 mm 3 90 Degree Lifting Eyes x2 4 Rear Housing 5 Rear Ho...

Page 201: ...hand tighten 2 Rear Housing Alignment Pins RR1090TR 180 degrees apart NOTICE Failure to install alignment pins results in transmission component damage 5 Lift and install the Rear Housing Assembly on to the Main Housing WARNING Rear Housing Assembly weighs approxi mately 170 lbs Failure to properly secure and lift the Rear Housing may result in major vehicle component damage severe injury or death...

Page 202: ...Use an appropriate lifting device to safely lift component 10 Perform Output Yoke Installation on page 141 11 Perform Harness Bracket Installation on page 203 12 Perform Output Speed Sensor Installation on page 161 13 Perform Mechatronic Transmission Module MTM Installation on page 151 14 Perform Release Bearing and Clutch Release Yoke Installation on page 167 15 Perform Transmission Control Modul...

Page 204: ...sion Technologies All rights reserved 201 TRSM0950 Installation 4 Bolt PTO Cover Installation 4 Bolt PTO Cover Installation Special Instructions None Special Tools None Component Identification 1 O ring 2 4 Bolt PTO Cover 3 Cap Screws x4 18 mm 2 1 3 ...

Page 205: ...wered tools to clean sealing surfaces or sealing surfaces may be damaged and leak 2 Inspect threaded bolt holes for debris and clean if nec essary NOTICE Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened 3 Insert a new 4 Bolt PTO Cover O ring into groove until fully seated 4 Install the 4 Bolt PTO Cover onto Rear Housing with 4 18 m...

Page 206: ...ion Technologies All rights reserved 203 TRSM0950 Installation Harness Bracket Installation Harness Bracket Installation Special Instructions None Special Tools None Component Identification 1 Harness Bracket 2 Harness Bracket Cap Screws x3 10 mm 1 2 ...

Page 207: ...ved 2019 04 4 Harness Bracket Installation Installation TRSM0950 Procedure Installation 1 Install Harness Bracket 2 Install 3 Harness Bracket 10 mm cap screws and torque to 8 8 10 4 Nm 6 8 lb ft 3 Secure the Output Speed Sensor Harness to the Har ness Bracket with a tie strap ...

Page 208: ...Clutch weighs approximately 125 lbs Failure to properly secure the Clutch Alignment Shaft to the clutch jack may result in clutch damage severe injury or death Special Tools Clutch Installation Tool Kit RR2000CL 6 ounce 170 gram hammer 3 8 inch 9 525 mm brass pin punch Starrett B248E Pin Punch Brass Drive 3 8 or equivalent Component Identification 1 Clutch Cover Cap Screws x12 M10 x 1 5 x 80mm min...

Page 209: ...ore runout maximum runout is 0 005 0 13 mm NOTICE If any reading exceeds maximum runout pre mature clutch wear will occur Refer to OEM engine manufacture guidelines for repair or replacement 8 Verify flywheel housing inner diameter ID runout 9 Secure the dial indicator base to the crankshaft with the dial indicator finger in contact with the flywheel housing ID Note Clean all dial indicator contac...

Page 210: ...Pins RR1063TR 3 into the fly wheel directly across from each other at approximately 3 and 9 o clock Note Do not install the Alignment Pins into the center threaded hole of the 3 threaded hole groups 3 Install the Clutch Cover and Driven Disc onto the clutch jack mounted Clutch Alignment Shaft RR1087TR WARNING Clutch weighs approximately 125 lbs Fail ure to properly secure the Clutch Alignment Shaf...

Page 211: ... x 1 5 x 80mm minimum class 10 9 flange type fasteners for the Clutch Cover cap screws 6 Remove the 2 Alignment Pins RR1063TR 3 4 stand off bolts RR1063TR 4 and straps if equipped from the Clutch Cover 7 Install 6 remaining Clutch Cover cap screws finger tight 8 Torque Clutch Cover cap screws 1 through 4 to 30 Nm 23 lb ft as shown in the torque sequence below CAUTION Reference cap screw call out i...

Page 212: ...12 Remove the Clutch Alignment Shaft RR1087TR 13 Locate the 4 Control Fingers in the Clutch Cover 14 Use a 6 ounce 170 gram hammer and a 3 8 inch 9 525 mm brass pin punch and lightly tap the 4 con trol fingers until they contact the flywheel CAUTION Keep fingers clear to avoid personal injury CAUTION Only use tools specified and do not use excessive force to seat the control fingers to the fly whe...

Page 213: ...ted Transmission Technologies All rights reserved 2019 04 4 Clutch Installation Installation TRSM0950 16 Perform Transmission Installation on page 211 Note Complete all Service Routines or transmission performance will be degraded ...

Page 214: ...ghts reserved 211 TRSM0950 Installation Transmission Installation Transmission Installation Special Instructions None Special Tools Transmission Jack Adapter Plate RR1067TR 2 cap screws and washers M10 x 1 5 x 30 mm minimum class 8 8 ServiceRanger Component Identification ...

Page 215: ...tch Actuator LCA 2 Refer to OEM guidelines for transmission installation 3 Perform Oil Fill Procedure on page 213 4 Key on with engine running 5 Allow air pressure to build to governor cut off 6 Connect ServiceRanger 7 Go To Service Routines Note Complete all Service Routines or transmission performance will be degraded 8 Select Start Clutch Calibration and follow on screen prompts 9 Select Start ...

Page 216: ...n Technologies All rights reserved 213 TRSM0950 Installation Oil Fill Procedure Oil Fill Procedure Special Instructions None Special Tools None Component Identification 1 Oil Check Plug 6 mm Hex 2 Oil Drain Plug 6 mm Hex 3 Oil Fill Plug 6 mm Hex 2 3 1 ...

Page 217: ...ith a 6 mm hex key 3 Fill the transmission with PS 386 lube until a small amount of oil runs out of the Oil Check Plug hole Note Fill capacity is approximately 7 5 8 5 liters 16 18 pints depending on the transmission angle 4 Inspect Oil Check Plug and O ring for damage If dam aged replace the Oil Check Plug O ring is serviced with plug 5 Install the Oil Check Plug and torque to 24 5 29 5 Nm 18 22 ...

Page 218: ...ring for damage If dam aged replace the Oil Fill Plug O ring is serviced with plug 7 Install the Oil Fill Plug and torque to 24 5 29 5 Nm 18 22 lb ft NOTICE Do not over torque the Oil Fill Plug or trans mission damage may occur NOTICE If PTO equipped start the engine and run for 1 to 2 minutes to fill the PTO with oil key off and repeat the Oil Fill Procedure ...

Page 220: ...gies All rights reserved 217 TRSM0950 Appendix Oil Level Inspection Procedure Oil Level Inspection Procedure Special Instructions None Special Tools None Component Identification 1 Oil Check Plug 6 mm Hex 2 Oil Drain Plug 6 mm Hex 3 Oil Fill Plug 6 mm Hex 2 3 1 ...

Page 221: ...ge severe injury or death 4 Locate the transmission Oil Check Plug on the left side of the rear housing 5 Place a suitable container under the Oil Check Plug and remove the Oil Check Plug with a 6 mm hex key 6 Oil level is correct when a small amount of oil runs out of the Oil Check Plug hole Note If oil level is low check for leaks repair if neces sary and reference the Oil Fill Procedure on page...

Page 222: ...e manufacture parking instructions Failure to follow these instructions could cause unintended vehicle move ment and may result in major vehicle component damage severe injury of death 3 Loosen the 4 Linear Clutch Actuator LCA cap screws 1 2 turns each with a T45 Torx Note Residual air pressure in the LCA cylinder exhausts between the LCA and Mechatronic Transmis sion Module MTM housing when the c...

Page 224: ... clutch housing Input Shaft Press RR1085TR can be pur chased if the clutch housing does not properly fit the avail able press Special Tools Input Shaft Press RR1085TR Input Shaft Cup RR1087TR 6 Front Bearing Capture Plate RR1085TR 7 Input Shaft Bearing Removal and Installation Tool RR1075TR Input Bearing Driver RR1049TR 4 2 inch 7 16 inch Grade 8 or 50 8 mm M12 Grade 10 9 cap screws washers and nu...

Page 225: ... out of Clutch Housing 3 Place Input Shaft Cup RR1087TR 6 on the end of the Input Shaft 4 Place Input Shaft Press RR1085TR on the flywheel housing side of the Clutch Housing CAUTION Input Shaft Press weighs approximately 30 lbs Keep fingers clear of pinch point between Input Shaft Press and other surfaces Dropping Input Shaft Press could result in component damage and or per sonal injury 5 Install...

Page 226: ... Shaft Press could result in component damage and or per sonal injury 9 Place and support Clutch Housing on a bench 10 Install Input Shaft Press RR1085TR on the Main Housing side of the Clutch Housing aligning the 3 notches on the side of Linear Clutch Actuator opening CAUTION Input Shaft Press weighs approximately 30 lbs Keep fingers clear of pinch points between Input Shaft Press and other surfa...

Page 227: ...R1075TR and Input Shaft Cup RR1087TR 6 onto Input Bearing 13 Rotate jack screw to press Input Shaft Bearing out of Clutch Housing 14 Remove 4 cap screws washers nuts and Input Shaft Press RR1085TR from Clutch Housing CAUTION Input Shaft Press weighs approximately 30 lbs Keep fingers clear of pinch points between Input Shaft Press and other surfaces Dropping Input Shaft Press could result in compon...

Page 228: ...hers and nuts to attach press to housing 3 Place Input Shaft Bearing Removal and Installation Tool RR1075TR Input Bearing Driver RR1049TR and Input Shaft Cup RR1087TR 6 onto Input Bearing 4 Rotate jack screw to press Input Shaft Bearing into Clutch Housing NOTICE Do not over press bearing into Clutch Hous ing Over pressing could result in component damage 5 Remove Input Shaft Bearing Removal and I...

Page 229: ...l Input Shaft Press RR1085TR on the Main Housing side of the Clutch Housing aligning the 3 notches on the side of Linear Clutch Actuator opening CAUTION Input Shaft Press weighs approximately 30 lbs Keep fingers clear of pinch points between Input Shaft Press and other surfaces Dropping Input Shaft Press could result in component damage and or per sonal injury NOTICE Protect Clutch Housing to Main...

Page 230: ...put Shaft Press RR1085TR from Clutch Housing CAUTION Input Shaft Press weighs approximately 30 lbs Keep fingers clear of pinch points between Input Shaft Press and other surfaces Dropping Input Shaft Press could result in component damage and or per sonal injury 16 Remove Front Bearing Capture Plate RR1085TR 7 from Clutch Housing 17 Install Input Shaft Snap Ring NOTICE A new snap ring is required ...

Page 232: ...smission performance and the warranty coverage NOTICE Additives and or friction modifiers are not approved Additives of any kind will affect the transmission performance and the warranty coverage For a list of Eaton approved lubricant suppliers see TCMT0020 Eaton Approved Lubricant Suppliers Lubrication Guide Maintenance and Lubricant Change Intervals Transmission inspections and lubricant change ...

Page 234: ... contamination into the area of concern and temporarily disrupt the leak path i Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level OR ii Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level Operate vehicle to normal transmission operating temperature and inspect the area...

Page 236: ...y in the bore the case should be replaced Bearing Covers Check covers for wear from thrust of adjacent bear ing Replace covers damaged from thrust of bear ing outer race Check cover bores for wear Replace those worn or oversized Gears Check gear teeth for frosting and pitting Frosting of gear teeth faces presents no threat of transmis sion failure Often in continued operation of the unit frosted g...

Page 237: ...nchronizer Assembly Check synchronizer for burrs uneven and exces sive wear at contact surface and metal particles Check blocker pins for excessive wear or loose ness Check synchronizer contact surfaces on the syn chronizer cups for wear Washers Check surfaces of all washers Washers scored or reduced in thickness should be replaced ...

Page 238: ...ain Housing to Clutch Housing cap screws 16 mm x25 44 5 51 5 Nm 33 38 lb ft Output Speed Sensor to Rear Hous ing cap screws 10 mm x1 8 8 10 4 Nm 6 8 lb ft Fluid Pressure Sensor FPS 24 mm Hex x1 26 30 Nm 19 22 lb ft Clutch to flywheel cap screws 15 mm x12 53 5 67 7 Nm 40 50 lb ft 8 Bolt PTO Cover to Main Housing Cap Screws 18 mm x8 69 81 Nm 51 60 lb ft Rear Housing to Main Case Stubbed Cap Screws 1...

Page 240: ... and Cleaning Inspect all transmission components with care If any dam age is found during a component inspection replace the component and do not reuse NOTICE Debris foreign material or moisture allowed to enter into the vehicle air system or MTM air inlet port can cause solenoids and air actuated components to malfunc tion If any component is exposed to dirt or foreign material clean properly wi...

Page 242: ...u minum steel or iron components that are not reused or returned for warranty Used transmission components should be collected and recycled at an authorized facility Recycling Oil Properly dispose of transmission oil Used transmission oil should be collected and recycled at an authorized facility Note Never dispose of oil by putting it in the trash or pour ing it on the ground into sewers or into ...

Page 244: ... input shaft is required to be pressed in and out of the clutch housing Input Shaft Press RR1085TR can be purchased if the clutch housing does not properly fit the available press Overhaul Tool Kit RR2012TR Input Shaft Bearing Removal and Installation Tool RR1075TR Countershaft Bearing Installer RR1076TR Main Shaft Bearing Installer RR1077TR Output Shaft Installer Input Shaft Seal Driver RR1070TR ...

Page 246: ...ver Removal and Installation sections Added Harness Bracket Removal and Installation sections Added Oil Pump Removal and Installation sections Added Main Shaft Disassembly Assembly section Added Input Shaft Disassembly Assembly section Added Main Housing Disassembly Assembly section Added Clutch Housing files Disassembly Assembly section Added Input Shaft Disassembly Assembly using Input Shaft Pre...

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Page 248: ...lities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 80...

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