Manual de Servicio Transmisiones Rockwell 9-10 y 13 Marchas.

Nine–SpeedTen–SpeedThirteen–SpeedTransmissions

Maintenance Manual No. 26ARevised 2-96

Automotive

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Silicone Gasket Materials

WARNINGWhen you apply some silicone gasket materials, small amounts of acid vapor are present. To preventpossible serious personal injury, make sure the work area is well-ventilated. If the silicone gasketmaterial gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by adoctor as soon as possible.

Loctite ®

WARNINGTake care when using Loctite to avoid serious personal injury. Follow the manufacturer's instructionsto prevent irritation to the eyes and skin. If Loctite gets into your eyes, flush them with water for 15minutes. Have your eyes checked by a doctor as soon as possible.

Cleaning Solvents

WARNINGIf you use solvents, hot solution tanks or alkaline solutions incorrectly, serious personal injury canoccur. To prevent serious personal injury, follow the instructions supplied by the manufacturer ofthese products. Do NOT use gasoline to clean parts. Gasoline can explode and cause seriouspersonal injury.

CAUTION

• Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or waterand alkaline solutions will damage these parts. You can use isopropyl alcohol, kerosene or dieselfuel for this purpose.

• If required, use a sharp knife to remove gasket material from parts. Take care not to damageground or polished surfaces.

Service NotesThis Maintenance Manual describes the correct service and repair procedures for the nine-speed, ten-speed andthirteen-speed Design Level One and Design Level Two manual transmissions.

You must follow your company safety procedures when you service or repair equipment. Be sure you understand all theprocedures and instructions before you begin work on the unit. Rockwell uses the following types of notes to givewarning of possible safety problems and to give information that will prevent damage to equipment:

WARNINGA warning indicates procedures that must be followed exactly. Personal injury can occur if theprocedure is not followed.

CAUTIONA caution indicates procedures that must be followed exactly. If the procedure is not followed,damage to equipment or components can occur. Personal injury can also occur in addition to damageor malfunctioning of equipment or components .

TORQUEThis symbol is used to indicate fasteners that must be tightened to a specific tourque value.

NOTEA note indicates an operation, procedure or instruction that is important for correct service. A notecan also give information that will make service easier and quicker.

Some procedures require the use of special tools for safe and correct service. Failure to use these special tools whenrequired, can cause injury to service personnel or damage to vehicle components.

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Table of ContentsSUBJECT PAGE

Section 1 - General Information ................................................................................... 5Description .................................................................................................................... 5Identification .................................................................................................................. 6Nine-Speed Manual Transmissions .............................................................................. 6Ten-Speed Manual Transmissions ............................................................................... 6Thirteen-Speed Manual Transmissions ........................................................................ 6Design Level 1 Manual Transmissions ......................................................................... 6Design Level 2 Manual Transmissions ......................................................................... 8Gear Timing .................................................................................................................. 9Gasket Sealant ........................................................................................................... 12Removing Gasket Sealant .......................................................................................... 12Installing Gasket Sealant ............................................................................................ 12Inspecting Used Parts ................................................................................................. 15Repairing or Replacing Parts ...................................................................................... 19Cleaning Ground or Polished Parts............................................................................. 19Cleaning Rough Parts ................................................................................................. 19Drying the Cleaned Parts ............................................................................................ 19Preventing Corrosion or Rust on Cleaned Parts ......................................................... 19

Section 2 - Lubrication and Maintenance .................................................................. 20Transmission Oil Specifications .................................................................................. 20Transmissions Oil Coolers .......................................................................................... 20Scheduled Maintenance ............................................................................................. 21Checking and Adjusting the Oil Level ......................................................................... 21Checking the Condition of the Breather Vent .............................................................. 22Checking Fastener Torque ......................................................................................... 22Inspecting the Transmission for Leaks and Damage .................................................. 22Draining and Replacing the Transmission Oil ............................................................. 23Adjusting Remote Shift Housing Linkage .................................................................... 24Lubricating the Remote Shift Housing......................................................................... 24

Section 3 - In Vehicle Service ..................................................................................... 25Removing the Shift Lever and Tower Assembly ......................................................... 25Installing the Shift Lever and Tower Assembly ........................................................... 25Removing the Slave Valve .......................................................................................... 27Installing the Slave Valve ............................................................................................ 27Removing the Air Filter and Regulator Assembly ....................................................... 28Installing the Air Filter and Regulator Assembly ......................................................... 29Removing the Output Yoke and Oil Seal .................................................................... 29Installing the Oil Seal and Output Yoke ...................................................................... 30Removing and Installing the Remote Control Assembly ............................................. 33

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Section 4 - Removing and Installing the Transmission ........................................... 34Removing the Transmission ....................................................................................... 34Installing the Transmission ......................................................................................... 36

Section 5 - Overhauling the Shift Lever and Tower Assembly ................................ 41Disassembling the Aluminum Tower Assembly .......................................................... 41Assembling the Aluminum Tower Assembly ............................................................... 43Disassembling the Cast Iron Tower Assembly............................................................ 46Assembling the Cast Iron Tower Assembly ................................................................ 47

Section 6 - Remote Control Assembly ....................................................................... 48Disassembling the Remote Control Assembly ............................................................ 48Assembling the Remote Control Assembly ................................................................. 49

Section 7 - Removing and Installing the Top Cover Assembly ............................... 50Removing the Top Cover Assembly............................................................................ 50Installing the Top Cover Assembly.............................................................................. 52

Section 8 - Overhauling the Top Cover Assembly.................................................... 54Disassembling the Standard and Forward Position Top Cover Assembly .................. 54Assembling the Standard and Forward Position Top Cover Assembly ....................... 60Disassembling the Standard and Forward Position “X” Bar

Top Cover Assembly ................................................................................................ 66Assembling the Standard and Forward Position “X” Bar Top Cover Assembly .......... 72

Section 9 - Removing and Installing the Input Shaft ................................................ 79Removing the Input Shaft ........................................................................................... 79Installing the Input Shaft ............................................................................................. 81

Section 10 - Removing and Installing the Clutch Housing ...................................... 83Removing the Clutch Housing .................................................................................... 83Installing the Clutch Housing ...................................................................................... 83

Section 11 - Removing and Installing the Auxiliary Case ........................................ 85Removing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ................ 85Installing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions .................. 90Removing the Auxiliary Case-Thirteen-Speed Transmissions .................................... 94Installing the Auxiliary Case-Thirteen-Speed Transmissions ...................................... 98Removing the Auxiliary Drive Gear ........................................................................... 102Installing the Auxiliary Drive Gear ............................................................................. 103

Section 12 - Overhauling the Main Case ................................................................. 104Removing the Mainshaft ........................................................................................... 104Removing the Input Shaft ......................................................................................... 110Removing the Main Countershafts ............................................................................ 113

Table of Contents (Continued)SUBJECT PAGE

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Section 12 - Overhauling the Main Case(Continued)............................................. 104Removing the Reverse Idler Gear Assembly ............................................................ 114Removing the Oil Pump ............................................................................................ 115Removing the Magnets ............................................................................................. 116Removing the PTO Covers ....................................................................................... 116Installing the PTO Covers ......................................................................................... 117Installing the Magnets ............................................................................................... 117Installing the Oil Pump .............................................................................................. 118Installing the Reverse Idler Gear Assemblies ........................................................... 118Installing the Input Shaft ........................................................................................... 119Installing the Main Countershafts .............................................................................. 123Installing the Mainshaft ............................................................................................. 125

Section 13 - Overhauling the Auxiliary Drive Gear ................................................. 134Disassembling the Auxiliary Drive Gear Assembly ................................................... 134Assembling the Auxiliary Drive Gear Assembly ........................................................ 136

Section 14 - Overhauling the Mainshaft .................................................................. 137Disassembling the Mainshaft .................................................................................... 137Assembling the Mainshaft ......................................................................................... 139

Section 15 - Overhauling the Main Countershafts .................................................. 150Disassembling the Main Countershaft ...................................................................... 150Assembling the Main Countershaft ........................................................................... 152

Section 16 - Overhauling the Auxiliary Case .......................................................... 155Disassembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions .......155Assembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions............163Disassembling the Auxiliary Case-Thirteen-Speed Transmissions ........................... 174Assembling the Auxiliary Case-Thirteen-Speed Transmissions................................ 182

Section 17 - Main Countershaft End Play Adjustment ........................................... 193Checking and Adjusting the End Play of the Main Countershafts ............................. 193

Section 18 - Auxiliary Countershaft End Play Adjustment .................................... 200Checking and Adjusting the End Play of the Auxiliary Countershafts ....................... 200

Section 19 - Troubleshooting ................................................................................... 207General Information .................................................................................................. 207Troubleshooting Other Systems ............................................................................... 208Troubleshooting Leaks.............................................................................................. 209Troubleshooting Vibrations ....................................................................................... 209Troubleshooting Noises ............................................................................................ 210Troubleshooting Operating Conditions...................................................................... 211


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Section 20 - Specifications ....................................................................................... 214Transmissions Oil Capacities .................................................................................... 214Transmission Oil Specifications ................................................................................ 214Fastener Torque Locations-Nine-Speed and Ten-Speed Transmissions ................. 215Fastener Torque Chart-Nine-Speed and Ten-Speed Transmissions ........................ 218Fastener Torque Locations-Thirteen-Speed Transmissions ..................................... 220Fastener Torque Chart-Thirteen-Speed Transmissions............................................ 223Air Line Locations-Nine-Speed and Ten-Speed Transmissions................................ 225Air Line Identification Chart-Nine-Speed and Ten-Speed Transmissions ................. 226Air Line Locations-Thirteen-Speed Transmissions ................................................... 227Air Line Identification Chart-Thirteen-Speed Transmissions ..................................... 228Holding Cover Template ........................................................................................... 229Special Tools ............................................................................................................ 230

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Section 1General Information

DescriptionSee Figure 1–1.

This publication describes the serviceprocedures for the following Rockwelltransmissions:

● Nine–Speed Transmissions.● Ten–Speed Transmissions.● Thirteen–Speed Transmissions.

Two design levels are described in thispublication:

● Design Level One . This applies totransmissions with serial numbersLB93001999 and below. Snap ringsare used to keep the tapered rollerbearings in the case.

● Design Level Two . This applies totransmissions with serial numbersLB93002000 and above. Retainerplates are used to keep the taperedroller bearings in the case.

Figure 1–1

The main case, which includes the main-shaft, the main countershafts, the inputshaft, the reverse idler gear and the (op-tional) oil pump, are the same for all trans-missions.

The auxiliary case is the same design fornine-speed and ten-speed transmissionswhile the auxiliary case for the thirteen-speed transmission is different. Thethirteen-speed transmission uses a differ-ent case, piston housing and output shaftassembly. The thirteen–speed transmis-sion also uses a splitter gear set in additionto a HI and LO range gear set.

The input torque from the engine is distrib-uted by two countershafts and one main-shaft. An auxiliary case provides the LOand HI ranges of operation.

Tapered roller bearings are used to sup-port the countershafts in the main trans-mission case and the auxiliary section.

NINE-SPEED TRANSMISSIONTEN-SPEED TRANSMISSION

THIRTEEN-SPEED TRANSMISSIONS

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An air shift system is used to select the LOor HI range of operation on all transmis-sions and the DIR and OD “splitter” rangeof operation on thirteen-speed transmis-sions. For more information, see Mainte-nance Manual Number 26B, Nine SpeedManual Transmissions Air Shift Systems orMaintenance Manual 26D, Thirteen-Speed Transmissions Air Shift Systems.

Identification

An identification plate is installed on theside of the transmission. Use the informa-tion on the identification plate when order-ing parts. Figure 1–2.

See Figure 1–2 for an explanation of themodel identification number and the identi-fication plate.

Nine–Speed ManualTransmissions

The transmission is identified by the num-ber “9” in the Speed portion of the modelnumber. Figure 1–2 .

The transmission uses nine forward gears(five gears in the LO range and four gearsin the HI range) and two reverse gears.

The transmission may be either a “DesignLevel 1” or a ”Design Level 2”. See theexplanation in this section.

Ten–Speed ManualTransmissions


The transmission uses ten forward gears(five gears in the LO range and five gearsin the HI range) and two reverse gears.

The transmission is a ”Design Level 2”.See the explanation in this section.

Thirteen–Speed ManualTransmissions


The transmission uses thirteen forwardgears (five gears in the LO range andeight gears in the HI range that are dividedbetween four DIR gears and four O/Dgears) and two reverse gears.

The transmission may be either a “DesignLevel 1” or a ”Design Level 2”.

The auxiliary case is different from the nine-speed and the ten-speed transmissions.

Design Level 1 ManualTransmissions

Design Level 1 Manual Transmissionsapply to transmissions with serial numbersbelow LB93002000.

The transmission is identified by the num-ber “1” in the Design Level portion of themodel number. Figure 1–2 .

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RMX10-145A2S002Rockwell TransmissionModel Number

R M X 2 S 00210-145 A

ROCKWELL

SPECIFICATION

RATIO

TYPEA=AutomatedE=Electric/AirM=ManualS=Engine

SynchroShift

W=Shift byWire

SPEEDProgressiveForwardSpeeds

x 10 =NominalInputTorque

SHIFT PATTERNNo letter=direct drive

standard H patternX=overdrive

standard H patternO=overdrive 9-speed

non-standard patternOR

overdrive 13-speedstandard H pattern

DESIGN LEVEL1=Serial Numbers

LB93001999 andBelow

2=Serial NumbersLB93002000 andAbove

SHIFT BARHOUSINGPOSITIONF=FowardS=Standard

TransmissionSerial Number

O.E.M. TransmissionPart Number

CUST#

MODEL

SERIAL NO. & ASS'Y PLANT

RATIO DATE

Rockwell International

Manufacturing Date

These PlugsIndicate

Oil Pump

Figure 1–2

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Snap rings are used to retain the bearingcups for the main countershaft in the maincase and for the auxiliary countershafts inthe auxiliary case and the main case.

Selective snap rings are used to adjust theend play in the main case and the auxiliarycase.

Design Level 2 ManualTransmissions

Design Level 2 Nine-Speed, Ten-speedand Thirteen-Speed Manual Transmissionsapply to all transmissions with serial num-bers LB93002000 and above.

The transmission is identified by thenumber “2” in the Design Level portion ofthe model number. Figure 1–2.

Retainer plates are used to retain thebearing cups for the main countershaft inthe main case. The bearing cover and theselective washer are used to retain thecups for the auxiliary countershaft in theauxiliary case.

Selective shims are used to adjust the endplay in the main case. Selective washersare used to adjust the end play in theauxiliary case.

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Gear Timing

If the timing marks on the gears are notaligned in the main case or in the auxiliarycase, the transmission will not operate.

The timing marks must be correctlyaligned when the transmission is serviced.

The timing marks will not go out of align-ment during normal vehicle operationunless the gear teeth are damaged.

Timing Marks in Auxiliary Case

NOTE:To make sure the timing marks are inthe correct locations, count the numberof gear teeth, divide the total teethnumber by “2” and put the mark in thecorrect location.

1. Put timing marks on the auxiliary lowgear. Mark one tooth with paint. Marka second tooth opposite (180o) the firsttiming mark. Figure 1–3.

2. Use paint to put timing marks on two

teeth next to each other on each coun-tershaft low gear of the auxiliary coun-tershafts. Make sure the marks arealigned with the “O” stamping on thecountershaft. Figure 1–3.

3. During assembly, each of the twotiming marks on the auxiliary low gearmust be between the two markedteeth on each countershaft low gear.Figure 1–4.

All the timing marks must be aligned ifthe transmission is to operate cor-rectly.

If the timing marks are not painted inthe correct position on the gears, onlyone set of marks will be aligned.

4. To check the alignment of the timingmarks, rotate the output shaft seven(7) complete revolutions. All the gearsmust rotate.

5. For complete service procedures, see‘Assembling the Auxiliary Case’ inSection 16, “Overhauling the AuxiliaryCase”.

Figure 1–3

TIMINGMARKs

"O"STAMPING

TIMING MARKS

AUXILIARY LOW GEAR-MARK ONE TOOTH ONEACH SIDE 180° APART

COUNTERSHAFT LOW GEAR-MARKTWO TEETH OVER "O" STAMPING

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Timing Marks in TransmissionCase

NOTE:To make sure the timing marks are inthe correct locations, count the numberof gear teeth, divide the total teethnumber by “2” and put the mark in thecorrect location.

1. Put timing marks on the main drivegear on the input shaft. Mark onetooth with paint. Mark a second toothopposite (180o) the first timing mark.Figure 1–5.

2. Use paint to put timing marks on twoteeth next to each other on each drivengear of the main countershafts. Makesure the marks are aligned with theslot for the key or the “O” stamping onthe countershaft. Figure 1–5.

3. During assembly, each of the twotiming marks on the main drive gear

must be between the two markedteeth on each countershaft drive gear.Figure 1–6All the timing marks must be aligned ifthe transmission is to operate cor-rectly.If the timing marks are not painted inthe correct position on the gears, onlyone set of marks will be aligned.

NOTE:The main shaft and the auxiliary drivegear must be installed when the align-ment marks in the transmission caseare checked.4. To check the alignment of the timing

marks, rotate the input shaft. All thegears must rotate.

5. For complete service procedures, see‘Assembling the Transmission Case’ inSection 12, “Overhauling the MainCase”.

Figure 1–4

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COUNTERSHAFT DRIVEN GEAR—MARK TWO TEETH OVER

THE SLOT FOR THE KEYOR THE "O" STAMPING

Figure 1–5

Figure 1–6

MAINDRIVE GEAR—MARK ONE TOOTH

ON EACH SIDE180° APART

TIMINGMARK

TIMINGMARKS

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CAUTIONApply the sealant in a 1/8 inch (2 mm)bead. If too much sealant is used, thesealant that extends over the edges canbreak off and plug the oil passages.

2. Apply Loctite® RTV Sealant™ #5699(Rockwell Part Number 2297-A-7021)with a sealant dispenser to one sur-face. Apply the sealant in a continu-ous pattern with a 1/8 inch (2 mm)bead. Make sure the bead encirclesany fastener holes.

3. Install the component as described inthe correct section of this manual.

Figure 1–8

Gasket SealantThe transmission uses Loctite® RTVSealant™ #5699 (Rockwell Part Number2297-A-7021) between the followingcomponents.

NOTE:See Figures 1–9 to 1–11 for sealantpatterns.

● Clutch housing and main case.● PTO covers and main case.● Top cover and main case.● Auxiliary case and main case.● Auxiliary countershaft covers and

auxiliary case.● Output bearing retainer on the auxiliary

case.● Input bearing retainer on the main

case.● Range piston housing to the auxiliary

case.

CAUTIONUse Loctite ® RTV Sealant™ #5699(Rockwell Part Number 2297-A-7021) asa gasket. The use of any other gasketmaterial (such as a corrosive sealant)can cause leaks and damage the trans-mission.

Removing the SealantSee Figure 1–7.

1. Remove the component as describedin the correct section of this manual.

2. Use a scraper to remove all sealantmaterial from the surface.

Installing the SealantSee Figure 1–8.

1. Clean the mounting surfaces with achlorinated solvent such as Loctite®Safety Solvent or equivalent.

SEALANTDISPENSER

Figure 1–7

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Figure 1–9

NOTE:APPLY SEALANTIN A 1/8 INCH(2MM) BEAD

BOLT HOLETRANSMISSION CASE

• PUT THE PATTERN ON THE TRANSMISSION CASE • PUT THE PATTERN ON THE TRANSMISSION CASE


TRANSMISSIONCASE

BOLTHOLE

BOTTOM COVER SIDE COVER

PUT BEADAROUND HOLE

FOUR HOLESSURROUNDEDBY SEALANT

BOLT HOLE

• PUT THE PATTERN ON THE TRANSMISSION CASE

BEAD

BOLT HOLE

NOTE:APPLY SEALANTIN A 1/8 INCH(2MM) BEAD.

REAR COVERTRANSMISSION CASE GASKET PATTERN AUXILIARY COVER GASKET PATTERN

CLUTCH HOUSING-TO-TRANSMISSIONCASE GASKET PATTERN

PTO COVERS-TO-TRANSMISSION CASEGASKET PATTERN

• PUT THE PATTERN ON THE OUTPUT BEARING RETAINER

BOLT HOLE


OIL SLOT

BEAD TO BEKEPT OUTSIDEOF OIL SLOTS

OIL SLOT RETAINER

SHIFT BAR HOUSING-TO-TRANSMISSIONCASE GASKET PATTERN

OUTPUT BEARING RETAINER-TO-AUXILIARYCOVER GASKET PATTERN

INPUT BEARING RETAINER-TO-TRANSMISSION CASE GASKET PATTERN• PUT THE PATTERN ON THE INPUT BEARING RETAINER

RETAINER


OIL SLOT


BOLT HOLE

TRANSMISSION CASE

AUXILIARY COVER-TO-TRANSMISSION CASE GASKET PATTERN• PUT THE PATTERN ON THE AUXILIARY COVER

NOTE: DO NOT BLOCK OIL FEED HOLE


MAKE SURE THEPATTERN IS ON THETRANSMISSIONCASE AND NOTON THE RETAINER

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Figure 1–10

Figure 1–11

PISTONHOUSING

AUXILIARYCOUNTERSHAFTCOVER

NOTE:APPLY SEALANT IN A1/8 INCH (2MM) BEAD.

AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS-TO-AUXILIARY COVER GASKET PATTERN

(NINE-SPEED AND TEN-SPEED TRANSMISSION)

AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS-TO-AUXILIARY COVER GASKET PATTERN

(THIRTEEN-SPEED TRANSMISSION)

PISTONHOUSING

AUXILIARYCOUNTERSHAFTCOVER

NOTE:APPLY SEALANT IN A1/8 INCH (2MM) BEAD.

• PUT THE PATTERN ON THE AUXILIARY COVER

SURROUND ALLHOLES WITH SEALANT

• PUT THE PATTERN ON THE AUXILIARY COVER

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Inspecting the Parts

It is important to inspect all parts beforethe transmission is assembled. Check allparts for wear and replace damaged parts.Replacement of damaged parts now, willprevent failure of the assembly later.

Tapered Roller Bearing Cone

NOTE:The bearing cup and the bearing conemust be replaced as an assembly ex-cept when the cup is loose in the bore.If the cup is loose in the bore, install anoversize cup. In all other situations, do

not replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manufac-turer. For replacement part numbers,see the chart in Figure 1–12.

Inspect the cup, the cone , the rollers andthe cage of all tapered roller bearings. Ifany of the following conditions exist, thecup and the cone must be replaced.

1. The outer surface of the large diameterend of the rollers is worn level with orbelow the center. Figure 1–13.

2. The radius at the large diameter end ofthe rollers is worn to a sharp edge.Figure 1–13.

Tapered Roller Bearing Cup and Cone Replacement Chart

NOTES:➀ Use Part Number XCD2139DT.

➁ Use Part Number XC11807DN.

➂ Use Part Number XC1837DF.

BearingCup

and Cone DesignComponent Location Transmission Level Part Number

Main Countershaft Front All 1 A-1228-W-13492 A-1228-T-1346 ➀

Rear All 1 A-1228-V-13482 A-1228-S-1345 ➁

Auxiliary Countershaft Front 9- and 10-Speed 1 A-1228-X-1350 ➁2 A-1228-S-1345 ➁

13-Speed 1 A-1228-U-13732 A-1228-S-1345 ➁

Rear 9- and 10-Speed 1 A-1228-Y-13732 A-1228-U-1347 ➂

13-Speed 1 A-1228-Y-13512 A-1228-U-1347 ➂

Figure 1–12

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Figure 1–13

Figure 1–14

3. A visible roller groove is worn in theinner race surfaces of the cup or thecone. The groove can be seen at thesmall or large diameter end of bothparts. Figure 1–14.

Figure 1–15

4. Deep cracks or breaks in the surfaceof the cup, cone inner race or roller.Figure 1–15.

5. Bright wear marks on the outer surfaceof the roller cage. Figure 1–16.

6. Etching or pitting on rollers and on thesurfaces of the cup and cone innerrace that touch the rollers. Figure 1–16.

Figure 1–16

7. Spalling or flaking on the cup and coneinner race surfaces that touch therollers. Figure 1–17.

RECESSCENTER

SHARPEDGE

WORNLEVEL

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Figure 1–17

Tapered Roller Bearing Cups

NOTE:The bearing cup and the bearing conemust be replaced as an assembly ex-cept when the cup is loose in the bore.If the cup is loose in the bore, install anoversize cup. In all other situations, donot replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manufac-turer. For replacement part numbers,see the chart in Figure 1–12.

1. Normal cup wear is shown as aneven wear across the surface of thecup. Small indentations are accept-able. Figure 1–18.

Figure 1–18

2. Replace cups with small spalling orflaking marks or light bruising. Figure1–19.

Figure 1–19

3. Replace cups with large spalls anddeep indentations. Figure 1–20.

BRUISES

SMALLSPALL

NO SPALLS

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Figure 1–20

Ball BearingsInspect ball bearings for wear and dam-age. Make sure the bearings rotate in therace. Make sure the outer race is not wornor damaged. On bearings with grooves,make sure the grooves are not worn ordamaged. Replace any worn or damagedbearings.

GearsInspect the teeth of the gears for wear anddamage. Inspect the splines inside thegears for wear and damage. Inspect thegears for cracks or pits. Replace gearsthat are worn, damaged or cracked.

ShaftsInspect the splines and the grooves forwear and damage. Make sure the shaftsare not twisted. Make sure threads on theend of the shafts are not worn or dam-aged. Replace any worn or damagedshafts.

O-Rings and Oil Seals

Inspect the O-rings and the oil seals forcuts and cracks. Make sure the parts arenot brittle or hard. Replace any worn,damaged or hard O-rings and oil seals.

Clutch CollarsInspect the teeth of the outside of theclutch collar for wear and damage. In-spect the splines inside the clutch collar forwear and damage. Replace any worn ordamaged clutch collars.

Case HousingsInspect the case housings for cracks.Replace cracked housings.

Top CoverInspect the tips of the forks for wear anddamage. Make sure the forks are notbent. Make sure the shift rails are notworn or damaged. Inspect the balls andsprings for wear or damage. Replace anyworn or damaged parts.

Output YokesInspect the seal surface, the splines andthe end of the output yoke for wear anddamage. Do not sand or grind the sealsurface. Replace any worn or damagedparts.

LARGE SPALL

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injury, follow the instructions suppliedby the manufacturer. Do NOT use gaso-line to clean parts. Gasoline can ex-plode.

Use a cleaning solvent to clean ground orpolished parts and surfaces. Kerosene ordiesel fuel can be used for this purpose.DO NOT USE GASOLINE.

Do NOT clean ground or polished parts ina hot solution tank or with water, steam oralkaline solutions. These solutions willcause corrosion of the parts.

Cleaning the Rough Parts

Rough parts can be cleaned with theground or polished parts. Rough partsalso can be cleaned in hot solution tankswith a weak alkaline solution. Parts mustremain in the hot solution tanks until theyare completely cleaned and heated.

Drying the Cleaned Parts

must be dried immediately after cleaning.Dry parts with clean paper, rags, or com-pressed air.

Preventing Corrosion andRust on Cleaned Parts

Apply lubricant to cleaned and dried partsthat are not damaged and are to be imme-diately assembled.

If parts are to be stored, apply a specialmaterial that prevents corrosion and rust toall surfaces. Store the parts inside specialpaper or other material that preventscorrosion and rust.

Repairing or Replacing thePartsReplace worn or damaged parts. Thefollowing are some examples to check.

1. Replace any fastener if the corners ofthe head are worn.

2. Replace the washers if damaged.

3. Replace gaskets and oil seals at thetime of transmission repair.

4. Clean the parts and apply new gasketmaterial where required when thetransmission is assembled. See“Gasket Sealant” in this section.

5. Remove nicks, mars and burrs fromparts having machined or groundsurfaces. Use a fine file, india stone orcrocus cloth for this purpose (exceptfor yokes).

6. Clean and repair the threads of fasten-ers and holes. Use a die or tap of thecorrect size or a fine file for this pur-pose.

CAUTIONThreads must be clean and undamagedso that accurate adjustments and cor-rect torque values can be applied tofasteners and parts.

7. Use the correct type of Loctite ® orequivalent and tighten all fasteners tothe correct torque values. See theTorque Chart in Section 20, “Specifica-tions”.

Cleaning the Ground orPolished Parts

WARNINGIf you use cleaning solvents, hot solu-tion tanks or alkaline solutions incor-rectly, injury can occur. To prevent

Page 20

Section 2Lubrication and Maintenance

Transmission Oil CoolersUse a transmission oil cooler for any of thefollowing.

● The transmission operating tempera-ture is always more than 225oF(107oC) at continuous operation or275oF (135oC) at intermittent opera-tion.

● The engine has a horsepower rating of399 HP or more. Some aerodynamicvehicles with less than 399 HP mayrequire a cooler due to the lack of airwhich flows over the transmission todissipate heat.

Transmission OilSpecifications

CAUTIONUse only the specified type of singleweight oils. Do not use multi-viscos-ity oils or EP (Extreme Pressure) gearoils. Multi-viscosity oils and EP gearoils may damage components. The useof multi-viscosity or EP gear oils voidsthe warranty.

Use the specified type of single weight oilwhen adding or replacing oil. Use thecorrect type of oil for the outside tempera-ture. Engine oil, mineral oil and full-syn-thetic lubricants are recommended. DONOT MIX OILS.

See the chart in Figure 2–1 for oil specifi-cations.

Figure 2–1

LUBRICANT TYPE GRADE(SAE) OUTSIDE TEMPERATURE

Full-Synthetic Oil, 50 AllRockwell Specification 0-81

Heavy-Duty Engine Oil 50 Above 10 o F (-12o C)A.P.I.-CD, -CE, -SF or -SG 40 Above 10 o F (-12o C)(Current API Designations 30 Above -15 o F (-26o C)Acceptable)*MIL-L-2104B, C, D or E

Mineral Oil with Rust and 90 Above 10 o F (-12o C)Oxidation Inhibitor A.P.I.-GL-1 80 Above -15 o F (-26o C)

CAUTIONUse only the specified type of single weight oils. Do not use multi-viscosity oilsor EP (Extreme Pressure) gear oils. Multi-viscosity oils and EP gear oils maydamage components. The use of multi-viscosity or EP gear oils voids the war-ranty.

Page 21



3. Check the oil level. The oil level mustbe even with the bottom of the hole ofthe fill plug.

If foam appears when the plug isremoved, air has not been removedfrom the oil. Install the plug and waitfor the air to dissipate.

If oil flows from the hole when the plugis loosened, the oil level is high. Letthe oil drain until the oil is at thespecified level.

If the oil level is below the bottom ofthe hole of the fill plug, add thespecified oil.

4. Install and tighten the fill plug to35-50 lb-ft (48-67 N.m).

5. Operate the vehicle for five minutes.Check for correct operation.

Scheduled Maintenance

Every 10,000 Miles (16,000 km) ofVehicle Operation.● Check and adjust the oil level in the

transmission.● Check the condition of the breather

vent.● Check the torque of the fasteners.● Inspect for leaks or damage on the

transmission. Service as necessary.

Every 50,000 Miles (80,000 km) ofVehicle Operation (Approved Pe-troleum Base and Heavy-DutyEngine Oils)● Drain and replace the oil in the trans-

mission with approved petroleum baseand heavy-duty engine oils.

Every 250,000 Miles (400,000 km)of Vehicle Operation (ApprovedFull-Synthetic Oils)● Drain and replace the oil in the trans-

mission with approved full-syntheticoils.

Checking and Adjustingthe Oil LevelSee Figure 2–2.

1. Make sure of the following beforechecking the oil level.

a. The oil is at room temperature

b. Wait ten minutes after the vehicle isparked before checking the level.

c. Make sure the vehicle is parked ona level surface.

2. Clean the area around the fill plug.Remove the fill plug from the side ofthe transmission.

Figure 2–2

FILLPLUG

DRAINPLUGS

OIL LEVEL MUSTBE EVEN WITH

BOTTOM OFFILL PLUG HOLE

Page 22


Inspecting theTransmission for Leaksand DamageInspect the transmission for cracks, leaksand damage. Make sure the leaks aretransmission oil.

CAUTIONRepair all leaks. If leaks are not re-paired, the transmission will be dam-aged.

Inspect the following areas for leaks.● The output yoke and the oil seal in the

output bearing retainer on the auxiliarycase.

● The PTO covers on the main case.● The auxiliary case to main case.● The main case and the clutch housing.● The clutch housing to flywheel hous-

ing.● The auxiliary countershaft covers.● The slave valve to the main case.● The shift lever and tower assembly to

the top cover.● The top cover to the main case.● The fill and the drain plugs.● The output bearing retainer to the

auxiliary case.● The input bearing retainer to the main

case.

● Speedometer bore or electronic speedpick-up in the output bearing retainer.

Figure 2–3

Checking the Torque ofthe FastenersCheck the torque on the following. Seethe torque chart in Section 20, “Specifica-tions”.● Clutch housing to engine flywheel.● Top cover housing to main case.● All electrical switches on the top cover

housing.● Drain and fill plugs.● PTO covers to main case.● Auxiliary case to main case.● Output bearing retainer to auxiliary

case.● Piston housing cover to auxiliary

case.● Auxiliary countershaft cover to

auxiliary case.● Transmission to frame brackets.● Output yoke to output shaft.● Shift cover housing to top cover hous-

ing.

Checking the Condition ofthe Breather VentMake sure the breather vent is not dam-aged. Remove all dirt and oil from thescreen in the breather vent. Figure 2–3.

Page 23


Draining and Replacingthe Transmission Oil

NOTE:Drain the oil when the transmission ishot.

1. Make sure the vehicle is parked on alevel surface. Put a large containerunder the transmission. Put a screenon top of the container.

NOTE:Rockwell recommends replacing themagnetic drain plug each time the oil ischanged. Use the correct part. Pipeplugs will leak if used as a drain plug.

The magnetic drain plug can be reusedif, after cleaning, the plug has a mini-mum pick-up capacity of 1.5 pounds(0.7 kilograms) of low carbon steel.

2. Remove the drain plugs from thebottom of the transmission. Drain anddiscard the oil.

Inspect the O-rings on the drain plugs.Replace worn or damaged O-rings.

Inspect the screen on top of the con-tainer for metal particles and damagedparticles. Service the transmission asnecessary.

3. If the transmission is disassembled orreplaced and an oil cooler is used,remove the cooler. Remove anddiscard the oil from the cooler and theoil lines. Install the oil cooler and thelines. Tighten the fittings to the speci-fied torque of the manufacturer of thevehicle.

4. Install and tighten the drain plug to 35-50 lb-ft (48-67 N.m).

5. Clean the area by the fill plug. Re-move the fill plug from the side of thetransmission.


6. Add the specified transmission oilthrough the hole for the fill plug.

Add the oil until the oil level is evenwith the bottom of the hole of the fillplug. Figure 2–4.

7. Install and tighten the fill plug to 35-50lb-ft (48-67 N.m).

8. Operate the vehicle for five minutes.Check for correct operation.

Figure 2–4

FILLPLUG

DRAINPLUGS

OIL LEVEL MUSTBE EVEN WITH

BOTTOM OFFILL PLUG HOLE

Page 24


Adjusting the Linkage forthe Remote ControlAssemblyCab-Over-Engine (COE) vehicles use aremote control assembly on top of thetransmission. Linkage connects the innershift lever to a shift lever in the cab of thevehicle.

The linkage must be adjusted for correctoperation. See the procedure of the manu-facturer of the vehicle.

Lubricating the RemoteControl AssemblyApply grease to the fittings on the linkageat the interval specified by the manufac-turer of the vehicle. Use the grease speci-fied by the manufacturer of the vehicle.

Page 25

Section 3In-Vehicle Service

WARNINGTo prevent serious eye injury, alwayswear safe eye protection when doingmaintenance or service.

Removing the Shift Leverand Tower Assembly1. Shift the transmission into the NEU-

TRAL position. Remove the air fromthe air supply system.

2. Disconnect the air lines from the shiftknob at the slave valve.

3. Remove the capscrews and the wash-ers that fasten the shift tower housingto the top cover housing.

NOTE:Do not lose any detent springs or ballswhen the shift tower housing is re-moved. If any springs or balls comeout, install the parts in the correct bore.Install the ball before the spring isinstalled.

4. Remove the shift tower housing andlever assembly and the gasket fromthe top cover housing. Discard thegasket Figure 3–1.

5. Remove any gasket material betweenthe shift lever housing and the topcover housing.

Figure 3–2

Installing the Shift Leverand Tower Assembly1. Make sure the transmission is in the

NEUTRAL position. Figure 3–2.

NEUTRALPOSITION

Figure 3–1SHIFT LEVER

AND TOWER ASSEMBLY

Page 26


CAUTIONThe aluminum housing uses a gasketthat is different from the gasket on thecast iron housing. Use the correctgasket. If the wrong gasket is used, thearea between the shift tower housingand the top cover housing will leak.

2. Install a new gasket for the shift towerhousing on the top cover housing.

3. Put the shift tower housing in positionon the top cover housing. Make surethe bottom of the lower shift lever iscorrectly installed between the forksand the sleeves in the top cover hous-ing. Figure 3–1.

4. Install the mounting capscrews andwashers on the shift tower housing.Tighten the capscrews to 35-45 lb-ft(48-61 N.m) in the sequence shown inFigure 3–3 .

5. Install the cover (if used) around theshift tower housing.

6. Operate the vehicle. Make sure thetransmission operates correctly in allgears.

Figure 3–3TORQUE SEQUENCE

Page 27


Removing the Slave ValveSee Figure 3–4.

1. Remove the air from the air supplysystem.

2. Disconnect and mark the air lines fromthe slave valve by pushing on thefitting and pulling on the line.

3. Remove the mounting capscrews andthe washers from the slave valve.Remove the slave valve.

On Design Level 1 Transmissions,remove and replace the gasket be-tween the slave valve and the case.

On Design Level 2 Transmissions, agasket for the slave valve is not used.

4. Remove the actuator pin, the springand the sleeve from the bore in themain case. Figure 3–5.

Installing the Slave ValveSee Figure 3–4.

1. Lubricate the O-rings on the sleevewith a silicone lubricant such as DowCorning #111 Silicone Grease orequivalent.

NOTE:If the part number on the sleeve is2245-H-1126 or 2245-A-1067, replacethe sleeve with part number 2245-U-1165.

2. Install the small end of the sleeve inthe bore in the slave valve.

3. Install the spring on the actuator pin.Install the pin and spring assembly inthe main case Make sure the tip onthe pin is toward the slave valve Fig-ure 3–5.

Figure 3–4

Figure 3–5

4. On Design Level 1 Nine-SpeedTransmissions only, install a newgasket in position on the back of theslave valve. Design Level 2 Nineand Ten-Speed Transmissions donot use a gasket.

5. Install the slave valve and the gasketin position on the main case.

6. Install the mounting capscrews andwashers for the slave valve. Tightenthe capscrews to 85-115 lb-in (10-12N.m).

SLAVEVALVE

ACTUATOR PIN

SLEEVE

SPRING

Page 28


Removing the Air Filterand Regulator AssemblySee Figure 3–7.

Figure 3–6

7. Connect the air lines to the slavevalve. Figure 3–6.

a. Connect the BLACK 1/8 or 5/32inch outer diameter air line to thepilot port fitting (stamped letter 'P'on the valve).

b. Connect the RED 1/8 or 5/32 inchouter diameter air line to the pilotsupply port fitting (stamped letters'PS' on the valve).

c. Connect the RED 1/4 or 5/16 inchouter diameter air line to the supplyfitting (stamped letter 'S').

d. Connect the BLACK 1/4 or 5/16inch outer diameter air line to theLO range fitting (stamped letter'L' ).

e. Connect the BLUE 1/4 or 5/16 inchouter diameter air line to the HIrange fitting (stamped letter 'H').

8. Operate the vehicle. Check the airshift system for correct operation.

Figure 3–7


2. Disconnect and mark the air lines onthe filter and regulator assembly.

3. Remove the mounting capscrews andthe washers from the filter and regula-tor assembly. Remove the filter andregulator assembly.

4. On thirteen-speed transmissions,remove the O-ring from between thefilter and regulator assembly and thepiston housing cover. Figure 3–8.

RED AIR LINE-TO SUPPLY PORT

('PS')

RED AIR LINE-TO SUPPLY

('S')

BLUE AIR LINE-TO HI RANGE

('H)

BLACK AIRLINE-TO

LO RANGE ('L')

BLACK AIRLINE-TO

PILOT PORT ('P')

FILTER ANDREGULATORASSEMBLYSUPPLY

PORT

DELIVERYPORT

Page 29


Figure 3–8

Removing the OutputYoke and the Oil Seal

NOTE:Before replacing the oil seal, make sureof the following:

1. The oil seal leaks. The lip of the oilseal is packed with grease. Undernormal conditions, the area be-tween the lip of the oil seal and theyoke is “wet”. To check if the sealleaks, clean the area around theseal (Make sure the oil is at thespecified level.). If drops of oilappear, the seal must be replaced.If the area between the lip of theseal and the yoke is “wet”, do notreplace the oil seal.

2. The correct oil is in the transmis-sion. If the wrong oil is used, theoil seal will be damaged and leak.See “Transmission Oil Specifica-tions” in Section 20.

3. The yoke is not worn or damaged.If the yoke is worn or damaged,replace the yoke. Do not repairyokes.

Figure 3–9

Installing the Air Filter andRegulator Assembly

See Figure 3–7.

1. On thirteen-speed transmissions,lubricate the O-ring with a siliconlubricant such as Dow Corning #111Silicone Grease or equivalent. Put theO-ring for the filter and regulator as-sembly in the port in the piston hous-ing cover. Figure 3–7.

1. Put the filter and regulator assemblyon the top of the range cylinder.

2. Install the mounting capscrews andwashers. Tighten the capscrews to85-115 lb-in (10-12 N.m).

3. Connect the RED air line to the DELIV-ERY port on the filter and regulatorassembly. Connect the air line fromthe air supply system to the SUPPLYport on the slave valve (stamped letter“S” on the valve. Figure 3–9.

4. Operate the vehicle. Check the airshift system for correct operation.

O-RING

FILTER ANDREGULATORASSEMBLY

FILTER ANDREGULATORASSEMBLY

SUPPLYPORT

DELIVERYPORT

Page 30


4. Use the correct tool and the correctprocedure to install the seal. UseSeal Driver Tool, Rockwell PartNumber 3256-Z-1014 or Kent-MoorePart Number J-39161 to install theseal. Do not remove the outputbearing retainer to install the seal.If the correct tool and/or the correctprocedure is not used, the seal willleak.

WARNING

Do not work under a vehicle supportedonly by jacks. Jacks can slip or fall overand cause serious personal injury.Support the vehicle with safety stands.Block the wheels to prevent the vehiclefrom moving.

1. Put the transmission in NEUTRAL .Make sure the parking brake isapplied.

2. Disconnect the driveshaft from theoutput yoke of the transmission.

3. Put a holding tool, such as Kent-MooreTool, J-3453, Flange/Yoke HoldingBar, or equivalent, on the yoke.

4. Put a 2-3/4 inch socket on the nut thatfastens the yoke to the output shaft.Remove and discard the nut.Figure 3–10.

5. Remove the yoke from the outputshaft. Remove the speedometer tonering or drive gear from the yoke. Re-place the yoke if worn or damaged.

6. Use a slide hammer and puller, suchas Snap-On Light Duty Puller Set,CG2400B, or equivalent, to remove theseal from the retainer. Discard theseal. Figure 3–11.

Installing the Oil Seal andthe Output Yoke

1. Inspect the bore for the seal in theoutput bearing retainer and the sealjournal on the output yoke for wear ordamage. Replace the retainer if wornor damaged.

2. Lubricate the outer surface of theoutput bearing retainer where the sealis installed with the oil that is used inthe transmission.

Figure 3–11

OIL SEAL

PULLER

HOLDINGTOOL

YOKE

Figure 3–10

Page 31


CAUTIONHold the seal only on the outer diame-ter. Do not touch the inner diameter ofthe seal. Touching contaminates theinner diameter of the seal and causes aleak between the shaft and the seal.

3. Install the oil seal in the output bearingretainer.

CAUTIONUse only the specified seal driver tool.If a different driver tool is used, the sealwill not be installed at the correct depthand will leak.

4. Use seal driver tool, Rockwell PartNumber 3256-Z-1014 or Kent-MoorePart Number J-39161, to install theseal. Clean and inspect the tool.Replace the tool if the area thattouches the seal is worn or damaged.Figure 3–12.

5. Clean the seal driver tool. Put the oilseal on the seal driver tool so that thespring is away from the tool. Makesure the seal is flat against the surfaceof the tool. Figure 3–13.

6. Drive the seal into the retainer until theflange on the tool touches the retainer.Make sure there are no gaps betweenthe tool and the retainer.

CAUTIONUse a cleaning solvent to clean theyoke. Do not use a crocus cloth topolish the journal of the yoke. If acrocus cloth is used, the seal will leak.

7. Clean the yoke with a cleaning solvent.Lubricate the journal and splines in theyoke with the oil that is used in thetransmission.

CAUTIONMake sure the speedometer drive gearor tone ring is correctly installed or theoutput shaft seal may be damagedwhen the yoke is installed.8. Install the speedometer drive gear or

tone ring on the yoke.

Figure 3–12

SEALDRIVERTOOL

On 115 and 125 Series transmission,use the sleeve inside the seal drivertool.

On 135, 145 and 155 Series transmis-sions, remove the sleeve from theinside of the seal driver tool.

Figure 3–13SPRING

Page 32


9. Install the yoke on the output shaft.Put a holding tool on the yoke. Figure3–14.

CAUTIONDo not tighten the yoke nut more than500 lb-ft (677 N.m) or the output bearingwill be damaged.10. Install a new nut that fastens the yoke

on the output shaft. Tighten the nut to450-500 lb-ft (610-677 N.m). Figure3–14.

11. Connect the driveshaft to the outputyoke. Install and tighten the fastenersaccording to the specifications andprocedures of the manufacturer of thevehicle.

12. Operate the vehicle. Make sure the oilseal does not leak.

Figure 3–14

HOLDINGTOOL

YOKE

Page 33


To adjust the distance, loosen the jamnuts and move the rod to the correctdistance. Tighten the jam nuts to 35-50 lb-ft (47-67 N.m).

8. Adjust the linkage according to theprocedure of the manufacturer of thevehicle.

9. Operate the vehicle and check forcorrect operation.

Removing and Installingthe Remote ControlAssembly

NOTE:See the recommended procedure fromthe manufacturer of the vehicle. Thefollowing is a general procedure toremove and install the remote controlassembly.

1. Raise the cab according to the proce-dure of the manufacturer of the ve-hicle.

2. Measure the length of the adjustingrod from the centerline of each ballsocket as shown in Figures3–15 and 3–16. Mark the location ofthe adjusting rod and the ball sockets.

3. Disconnect the linkage to the remotecontrol assembly.

4. Remove the capscrews that fasten theremote control housing to the top coverhousing. Remove the housing. Re-move and discard the gasket. Removeany gasket material between theremote control housing and the topcover housing.

5. Install a new gasket on the transmis-sion.

6. Put the remote control housing inposition. Install and tighten the cap-screws to 35-45 lb-ft (47-61 N.m).

7. Connect the linkage to the outer shiftlever of the remote housing. Installand tighten the nut to 12-18 lb-ft (17-24 N.m).

8. Adjust the length of the adjusting rodto the distance measured in step 2 orto the distance specified by the manu-facturer of the vehicle. Figures 3–15and 3–16.

Figure 3–15

Figure 3–16

ONE-PIECEADJUSTING

ROD

ADJUST TOSPECIFICATIONS

OF VEHICLEMANUFACTURER

ADJUST TOSPECIFICATIONS

OF VEHICLEMANUFACTURER

TWO-PIECEADJUSTING

ROD

Page 34

Section 4Removing and Installing the Transmission

Removing theTransmissionSee the recommended procedure from themanufacturer of the vehicle to remove thetransmission. Some vehicles require thatthe engine is supported when the trans-mission is removed. The following is ageneral procedure to remove the transmis-sion.


2. Put a large container under the trans-mission. Remove both drain plugs(and if necessary, the cooler lines).Drain and discard the oil. Figure 4-1.

Figure 4-1


3. Remove the shift lever from the trans-mission. If necessary, remove the shifttower assembly from the transmission.

4. Put marks on the yoke or the flange ofthe driveshaft and the output shaft ofthe transmission. The marks on thedriveshaft and the output shaft makesure the driveshaft is correctly rein-stalled.

5. Remove the driveshaft.

6. Disconnect all the electrical connec-tions (if used) for the back-up lampswitches, the neutral safety switch andthe temperature indicator.

7. Disconnect and mark all the air linesfrom the transmission.

8. Disconnect the speedometer connec-tions from the output bearing retainer.

9. If used, remove the spring from theclutch lever on the transmission. Markand disconnect the clutch linkage fromthe clutch housing on the transmission.

10. If a hydraulic system is used on theclutch, disconnect the push rod andthe spring from the release fork. Re-move the hydraulic cylinder from thebracket on the transmission. Usewires to support the cylinder on theframe.

WARNINGMake sure the transmission is securelysupported on the overhead hoist or thejack. If the transmission is not securelysupported, the transmission may falland cause serious personal injury ordamage.

11. Support the transmission with an overhead hoist or with a transmission jack.Make sure the transmission is securelysupported.

12. Remove the fasteners that attach thetransmission to the brackets on theframe.

OIL LEVEL MUST BE EVENWITH BOTTOM OF FILL

PLUG HOLE

DRAINPLUG

FILLPLUG

Page 35

Section 4Removing and Installating the Transmission

CAUTIONMake sure the transmission does nothang by the input shaft. The clutchassembly and the pilot bearing will bedamaged if the transmission is sup-ported by the input shaft.

10. Remove the bolts and the washers thatattach the clutch housing to the en-gine. Pull the transmission straight outfrom the flywheel housing. Removethe transmission from the vehicle.Figure 4-2.

11. If used, remove the clutch brake as-sembly from the input shaft of thetransmission. Inspect transmissioninput bearing retainer surface forexcessive wear which can affect theclutch adjustment. Figure 4-3.

Figure 4-3

Figure 4-2

TRANSMISSION-PULL

TRANSMISSIONSTRAIGHT OUT

INPUT SHAFT-MAKE SURE

TRANSMISSIONIS NEVER

SUPPORTEDBY INPUT SHAFT

CLUTCHBRAKE

Page 36


Installing theTransmission

See the recommended procedure from themanufacturer of the vehicle to install thetransmission. The following is a generalprocedure to install the transmission.

1. Inspect the clutch housing for wearand damage. Replace worn anddamaged housings.

2. Inspect the cross shaft bores in thehousing. Make sure plugs are in thebores that are not used. If the boresare not plugged, dirt and contaminantsgo into the clutch housing and damagethe clutch. Figure 4-4.

Figure 4-4

Figure 4-5

3. Make sure an inspection cover isinstalled on the bottom of the clutchhousing. If an inspection cover is notused, dirt and contaminants go into theclutch housing and damage the clutch.Figure 4-5.

Figure 4-6

4. Inspect the input bearing retainer onthe transmission. Check the areawhere the clutch brake touches theretainer. Replace worn or damagedretainers.

5. Measure the distance from the top ofthe splines on the input shaft to the topof the bearing retainer as shown inFigure 4-6. If the distance is morethan 8.72 inches (221.48 mm), theinput bearing retainer is worn and mustbe replaced.

MAKE SURETHE UNUSEDBORES AREPLUGGED

IF DIMENSION 'A' ISMORE THAN

8.72 INCHES (221.48 mm),REPLACE THE INPUTBEARING RETAINER

INSPECTION COVER

Page 37


6. Inspect the shaft and the release fork.Make sure the release fork is straightand the tips of the fork are not worn ordamaged. Replace forks that are wornor damaged. Figure 4-7.

Figure 4-7

Figure 4-8

7. Make sure the cross shafts rotatefreely in the clutch housing. Makesure the shaft does not have anyexcessive radial (side-to-side) move-ment in the housing. Inspect thebushings for the shaft in the housing.Replace bushings and shafts that areworn or damaged.

8. Inspect the splines on the input shaft.Make sure the splines are not worn ordamaged. Inspect the area of travelfor the release bearing for damage.Use an emery cloth to remove smallscratches from the input shaft. Re-place input shafts that are worn ordamaged. Figure 4-8.

9. Inspect the end of the input shaftwhere the pilot bearing is installed. Ifthe end is worn or damaged, replacethe input shaft and the pilot bearing.Figure 4-8.

Figure 4-9

10. Inspect the clutch brake. If the tabs orthe body is worn or damaged, replacethe clutch brake. Inspect the liningmaterial on the clutch brake. Replacethe clutch brake if the lining is worn ordamaged. Figure 4-9.

11. If removed, install the clutch brake onthe input shaft of the transmission.Make sure the large part of the brakeis toward the input bearing retainerand the tabs on the brake engage theslots in the input shaft. Figure 4-9.

CROSS SHAFTMUST ROTATE

FREELY

TIPS ONFORK MUST

NOT BEWORN ORDAMAGED

MAKE SURE SPLINESARE NOT DAMAGED

CLUTCHBRAKE

Page 38


supported by the clutch or the discs.The clutch or the discs are damagedwhen the transmission is not correctlyinstalled.

15. Install the transmission according tothe following procedure. Figure 4-10.

a. Put the transmission so that theinput shaft is aligned with the pilotbearing.

b. Move the input shaft into the clutchhousing. Make sure the two tips ofthe release fork are installed be-tween the release bearing assem-bly and the clutch cover.

c. If necessary, rotate the output shaftof the transmission to align thesplines on the input shaft with theteeth in the hubs of the clutchdiscs.

12. Put the transmission in gear.

WARNINGMake sure the transmission is securelysupported on the overhead hoist orjack. If the transmission is not securelysupported, the transmission may falland cause serious personal injury ordamage.

13. Put the transmission on a transmissionjack or an overhead hoist.

14. If installed, remove the inspectioncover from the clutch housing.

CAUTIONBe careful when installing the inputshaft of the transmission in the hubs ofthe disc. If the transmission is forcedor jammed, the clutch discs or theclutch housing will be damaged. Also,do not let the transmission hang or be

Figure 4-10

SEE VIEW A VIEW A

INPUT SHAFTMUST BEALIGNED

WITH PILOTBEARING TIPS OF RELEASE FORK

MUST BE INSTALLEDBETWEEN RELEASE

BEARING AND CLUTCH

Page 39


Install and tighten the fasteners ac-cording to the specifications and theprocedure of the manufacturer of thevehicle.

24. Connect the shift lever assembly to thetransmission. If removed, install theshift tower assembly on the transmis-sion.

25. Lubricate the clutch housing, the crossshaft bushings and the release bearinghousing. See the procedure of themanufacturer of the vehicle.

26. Adjust the clutch and/or the linkage.See the procedure of the manufac-turer of the vehicle

CAUTIONMake sure the inspection cover on theclutch housing is used. If an inspec-tion cover is not used, dirt and con-taminants get into the clutch housingand damage the clutch.

27. Install the inspection cover. Install andtighten the capscrews. Tighten thecapscrews to the specified torque ofthe manufacturer of the vehicle.

CAUTIONUse the specified oil. Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. The wrong oil will damagethe transmission.

28. Clean the area by the fill plug. Re-move the fill plug from the transmis-sion. Add the specified oil until the oillevel is even with the bottom of the

d. Push the transmission against theflywheel housing.

16. Install the capscrews that fasten theclutch housing on the transmission tothe flywheel housing. Tighten thecapscrews to the specified torque andthe sequence specified by the manu-facturer of the vehicle.

17. Align the transmission with the brack-ets on the frame. Install the fastenersthat hold the transmission on thebrackets. Tighten the fasteners to thetorque specified by the manufacturerof the vehicle.

18. Remove the transmission jack or liftingdevice from the transmission.

19. If a hydraulic assist system is used forthe clutch, install the slave cylinder inthe bracket on the transmission. Con-nect the push rod to the release leveron the transmission. Connect thespring to the release lever.

20. Connect the clutch linkage to therelease lever on the transmission.Connect the spring to the releaselever.

21. Connect the air lines to the transmis-sion.

22. Connect the electrical connectors tothe transmission.

23. Connect the driveshaft to the outputyoke on the transmission. Make surethe alignment marks on the outputyoke and the driveshaft that weremade during removal are aligned.

Page 40


Figure 4-11hole of the fill plug. Figure 4-11.

See “Transmission Oil Capacities” and“Transmission Oil Specifications” inSection 20, “Specifications”.

Install and tighten the fill plug to 35-50lb-ft (48-67 N.m).

29. Operate the vehicle. Check for correctoperation.

OIL LEVEL MUST BE EVENWITH BOTTOM OF FILL

PLUG HOLE

FILLPLUG

DRAINPLUG

Page 41

Section 5Overhauling the Shift Lever and Tower Assembly

WARNINGTo prevent serious eye injury, always wear safe eye protection when doing main-tenance or service.

Disassembling the Aluminum Shift Lever and TowerAssemblySee Figure 5–1.

Figure 5–1

CLAMP

BOOT

CLAMP

SNAPRING

UPPERRETAINERPLATE

LEVER

LOWERRETAINERPLATE

HOUSING

SETSCREW

SPRINGWASHERS

Page 42


NOTE:If an aluminum shift tower assembly isreplaced, replace the entire assemblywith a cast iron shift tower assembly.Make sure the gasket between the shifttower housing and the top cover hous-ing is replaced. A different gasket isused on the aluminum than on the castiron housing.

1. Remove the shift lever and towerassembly as described in Section 3,“In–Vehicle Service”.

2. If necessary, separate the upper shiftlever from the lower shift lever. Seethe following.

a. If clips are used, remove one clip.Remove the clip and pin assemblyfrom the lever. Remove the bush-ings. Figure 5–2.

b. If a bolt and nut is used, removethe nut and the bolt.

c. Remove the upper shift lever fromthe lower shift lever. Figure 5–2.

Figure 5–2

Figure 5–3

4. Put the assembly in a vise with brassjaws. Make sure the inside of thehousing is away from you.

5. Remove the snap ring that fastens theupper retainer plate and the lever inthe housing. Figure 5–3.

6. Remove the set screws from the sideof the housing. Remove the lowerretainer from the housing. Figure 5–4.

Figure 5–4

NUT

BUSHINGPIN

CLIP

BOLT

SNAPRING

SETSCREW

HOUSING

3. Remove the clamps that fasten theboot to the housing. Remove the bootfrom the housing and the lower shiftlever.

Page 43


7. Lift on the lever to remove the leverand the upper retainer plate from thehousing. Figure 5–5.

NOTE:Two or three spring washers may beused in the housing. Make sure thesame number of washers are installed.

8. Remove the spring washers from thehousing. Figure 5–6.

9. Inspect all parts. See “Repairing orReplacing the Parts” in Section 1.

Figure 5–5

Figure 5–6

Assembling the AluminumGear Shift Lever andTower HousingSee Figure 5–1.

NOTE: If an aluminum housing is being re-placed, replace the entire assemblywith a cast iron shift tower housing.

1. Put the housing in a vise with brassjaws. Make sure the outside of thehousing is toward you.

NOTE:Two or three spring washers may beinstalled in the housing. Make sure thesame number of washers are installed.

2. Install the spring washers in the bot-tom of the housing. Make sure thelarge ends of the washers touch andthe bevels of the washers are installedaway from each other as shown inFigure 5–7 .

UPPERRETAINER

LEVER

WASHERS(2)

Figure 5–7

WASHERS(2)

Page 44


3. Install the lower retainer plate in thehousing. Make sure the tabs of theretainer are in the slots in the housing.

4. Install the lever so that the slots in thelever are installed over the pins. Fig-ure 5–8.

5. Install the upper retainer plate over thelever and in the housing. Make surethe tabs on the plate are installed inthe slots in the housing. On somehousings, make sure the pins in theplate are aligned with the slots in theball on the lever. Figure 5–8.

Figure 5–9

Figure 5–10

SNAPRING

HOUSING

SETSCREW

Figure 5–8

6. Install the snap ring that fastens theupper retainer plate and the lever inthe housing. Figure 5–9.

7. Install and tighten the set screw thatfastens the upper retainer plate in thehousing. Figure 5–10.

LEVER

UPPERRETAINER

8. Install the boot on the housing. Makesure the lip on the boot is installed inthe groove in the housing. Install theclamps or cable ties that fasten theboot to the lower lever and the hous-ing. Figure 5–11.

Page 45


NUT

BUSHINGPIN

CLIP

BOLT

Figure 5–11

9. If removed, connect the upper shiftlever assembly to the lower lever. Seethe following: Figure 5–12 .

a. Install the upper shift lever assem-bly on the lower lever. Make surethe bores for the retainers arealigned.

Figure 5–12

b. If clips are used, install a bushing ineach side. Install a clip on one endof the pin. Install the pin in thebores. Install the clip on the otherend of the pin.

c. If a bolt and nut is used, install thebolt in the bores. Install and tightenthe nut to 8-12 lb-ft (11-16 N.m).

BOOT

Page 46


Figure 5–13

Disassembling theCast Iron Shift Lever andTower AssemblySee Figure 5–13.1. Remove the shift lever and tower

assembly as described in Section 3,“In–Vehicle Service”.

2. If necessary, separate the upper shiftlever from the lower shift lever. Seethe following.

a. If clips are used, remove one clip.Remove the clip and pin assemblyfrom the lever. Remove the bush-ings. Figure 5–14.

b. If a bolt and nut is used, removethe nut and the bolt. Figure 5–14.

c. Remove the upper shift lever fromthe lower shift lever.

3. Remove the clamps that fasten theboot to the housing. Remove the bootfrom the housing and the shift lever.

4. Put the assembly in a vise with brassjaws. Make sure the inside of thehousing is toward you.

5. Remove the spiral snap ring thatfastens the spring, the spacer and thelower lever in the housing.

WARNINGTo prevent serious eye injury, al-ways wear safe eye protection whendoing maintenance or service.

6. Lift on the lower lever to remove thelever. Remove the spring and thespacer from the lower lever.

7. Inspect all parts. See “Repairing orReplacing the Parts” in Section 1.

CLAMP

BOOT

SPIRALSNAP RING

SPRING

SPACER

LEVER

HOUSING

Page 47


NUT

BUSHINGPIN

CLIP

BOLT

Assembling the Cast IronShift Lever and TowerAssembly

See Figure 5–13

1. Put the housing in a vise with brassjaws. Make sure the outside of thehousing is toward you.

2. Install the lower lever in the housing.Make sure the slots on the ball of thelever are aligned with the pins in thehousing.

Figure 5–14 3. Install the spacer over the lower lever.Install the assembly in the housing.

4. Install the spring over the lower leverin the housing.

5. Install the spiral snap ring over thelower lever in the housing. Make surethe snap ring is completely installed inthe groove in the housing.

6. Install the boot on the housing. Makesure the lip on the boot is installed inthe groove in the housing. Install newcable ties that fasten the boot to thehousing.

7. If removed, connect the upper lever tothe lower lever. See the following:Figure 5–14 .

a. Install the upper lever of the lowerlever. Make sure the bores for theretainers are aligned.

b. If clips are used, install a bushing ineach side. Install a clip on one endof the pin. Install the pin in thebores. Install the clip on the otherend of the pin.

c. If a bolt and nut is used, install thebolt in the bores. Install and tightenthe nut to 8-12 lb-ft (11-16 N.m).

Page 48

Section 6Overhauling the Remote Control Assembly

Disassembling theRemote Control Assembly

Refer to Figure 6–1.

1. Remove the set screw that fastens theouter shift lever to the shaft. Removethe lever.

2. Remove and discard the two tie strapsthat fasten the boot to the housing.Remove the boot.


3. Remove the lockwire and the setscrew that fasten the inner shift leverto the shaft. Remove the shaft and theinner shift lever.

4. Inspect the bushings in the housing. Ifworn or damaged, use a driver tool toremove the bushings.

5. If necessary, loosen the sockets andremove the adjusting rod.

Figure 6–1HOUSING

SHAFT

STRAP

SET SCREW

OUTERSHIFTLEVER

ADJUSTING ROD(ONE-PIECE SHOWN)

BUSHINGS

BOOTSTRAP

SETSCREW

LOCKWIRE

INNER SHIFTLEVER

SOCKET

Page 49

Section 6Overhauling the Remote Control Assembly

Assembling the RemoteControl Assembly

1. Do the following to the set screws thatfasten the levers to the shaft.

a. Clean the threads of the set screwswith Loctitie® Safety Solvent(Rockwell part number 2297-P-6412) or equivalent. Make sure alldirt is removed from the threads.

NOTE:See the specifications of the sealantmanufacturer for the “cure” time.

b. Apply Loctite® #242 (Rockwell partnumber 2297-V-2430) or equivalentto the threads of the set screws.

2. Lubricate the bushings with a lithium12-hydroxy stearate grease such asMulti-Purpose grease, Rockwell speci-fication O-617-A or equivalent.

3. If removed install the adjusting rodassembly in the housing. Tighten thesocket to 35-50 lb-ft (47-68 N.m).

4. If removed, use a driver tool to installthe bushings.

5. Fill the area between the bushings withmulti-purpose grease.

6. Put the inner shift lever in position inthe housing. Install the shaft in thelever. Install and tighten the set screwto 32-40 lb-ft (44-54 N.m). Install thelockwire.

7. Install the boot over the shaft and onthe housing. Install new tie straps.

8. Put the outer shift lever on the shaft.Make sure the outer shaft lever isaligned with the inner shaft lever.Install and tighten the set screw to 32-40 lb-ft (44-54 N.m). Figure 6–2.

Figure 6–2

LEVERS MUSTBE ALIGNED

Page 50

Section 7Removing and Installing the Top Cover Assembly


Removing the Top CoverAssembly

NOTE:Four different top cover assemblies areavailable. See Figure 7–1.

● Standard position top cover with astandard shift pattern.

● Standard position top cover with an“x” shift pattern.

● Forward position top cover with astandard shift pattern.

Figure 7–1

● Forward position top cover with an“X” shift pattern.

Standard position top covers have thedetent balls and springs under the shiftlever housing.

Forward position covers have the de-tent springs and balls under a platebehind the shift lever housing.

Top covers with an “X” shift patternhave a stud and a nut that fastens therocking lever assembly to the topcover.

1. Shift the transmission into the NEU-TRAL position.

2. Remove the transmission (if neces-sary) and the shift lever and towerassembly as described in Section 3,“In–Vehicle Service”.

STANDARD POSTIONTOP COVER

—STANDARD SHIFT PATTERN

STANDARD POSTIONTOP COVER

—"X" SHIFT PATTERN

FORWARD POSTIONTOP COVER

—"X" SHIFT PATTERN

FORWARD POSITIONTOP COVER

—STANDARD SHIFT PATTERN

INDICATES"X" BAR

Page 51

Section 7Removing and Installating the Top Cover Assembly

NOTE:If a heavy-duty detent spring is used,the spring (different color) is in thebore on the slave valve side of thetransmission.

3. Remove the three detent springs fromthe top cover from the holes in the topcover. Figure 7–2.

4. Use a magnet to remove a detent ballfrom the each of the three holes.Figure 7–2.

5. Remove the mounting capscrews andwashers from the top cover.

CAUTIONUse a rubber mallet or “dead blow”hammer to separate the top cover fromthe transmission case. Do not use prybars or screwdrivers to separate thecover from the case. Pry bars or screw-drivers may damage the cover and casemounting surfaces. If the cover is stilldifficult to remove, remove the slavevalve and the interlock pin from themain case.

6. Remove the top cover from the trans-mission case. Figure 7–3.

7. Use a scraper to remove the sealantmaterial from the top cover and thetransmission case.

Figure 7–2

Figure 7–3

DETENTSPRING

HEAVY-DUTYSPRINGLOCATION(IF USED)

DETENTBALL

TOPCOVER

Page 52

Section 7Removing and Installing the Top Cover Assembly

Installing the Top CoverAssembly1. Inspect the tips of the forks. If the tips

of the forks are worn or damaged,replace the forks.

Inspect the shift sleeves. If thesleeves are worn or damaged, replacethe sleeves.

To replace the fork or the sleeve, seeSection 8, “Overhauling the TopCover”.

2. Inspect the set screws, if the setscrews are loose, see the following:

a. Clean the threads of the setscrews. Make sure all dirt isremoved from the threads.

NOTE:See the specifications of the sealantmanufacturer for the “cure” time.

b. Apply Loctite® #242 (Rockwell PartNumber (2297-V-5430) orequivalent to the threads of thecapscrews

c. Tighten the capscrews to thetorque in the “Torque SpecificationsChart”.

3. Inspect the lockwire. If the lockwire ismissing or damaged, see the following:

a. Install the new lockwire.

b. Bend the wire towards thecapscrew.

c. Twist the wire at least oncebetween the parts. On the 1-2sleeve and fork assembly, the wirecan be wrapped around the shaft.

4. Make sure the transmission is in theNEUTRAL position.

5. Use Loctite® Master Gasket Sealant®,#5699 (Rockwell Part Number2297-A-7021) and a sealant dispenser,to put a new 1/8 inch (2 mm) sealantpattern for the top cover on the case.See “Gasket Sealant” in Section 1.Figure 7–4.

Figure 7–4

TRANSMISSION CASE

FOUR HOLESSURROUNDEDBY SEALANT

NOTE:If the top cover is difficult to install,remove the slave valve and the inter-lock pin from the main case.

6. Install the top cover. Make sure thecover is in the NEUTRAL position.Make sure the forks of the coverengage the collars in the transmissioncase. Figure 7–5.

Page 53

Section 7Removing and Installating the Top Cover Assembly

Figure 7–6

HEAVY-DUTYSPRINGLOCATION(IF USED)

DETENTBALL

DETENTSPRING

Figure 7–5TOP

COVER

7. Install the mounting capscrews andwashers for the top cover. Tighten thecapscrews to 25-35 lb-ft (34-47 N.m).

8. Install a detent ball in each of the threeholes in the top cover. Figure 7–6.

NOTE:Replace the detent springs as a set.Use the “yellow” spring (Rockwell partnumber 2258-D-1278) in all the holes.

NOTE:If a heavy-duty detent spring is used,install the spring (different color) in thebore on the slave valve side of thetransmission.

9. Install a spring on top of each detentball in the holes in the top cover.Figure 7–6.

Page 54

Section 8 Standard PatternOverhauling the Top Cover Assembly Top Cover

SPRING

Disassembling the Standard and Forward PositionTop Cover AssemblySee Figures 8–1 and 8–2.

Figure 8–1REVERSE

SWITCHPLUG

BREATHERVENT

BALL

LONG PINNEUTRAL SWITCH

PLUG

SHORT PIN

FORWARDPOSITION HOUSING

STANDARDPOSITIONHOUSING

(FOR FORWARDPOSITIONHOUSINGSEE BOX)

OILSCOOP

OILSCOOP

GASKET

COVERPLATE

REVERSESWITCHPLUG

Page 55

Standard Pattern Section 8Top Cover Overhauling the Top Cover Assembly

Figure 8–2

NOTE:The standard position top cover andthe forward position top cover usedifferent housings. The forward posi-tion housing uses a plate and a gasketinstalled over the detent balls andsprings.1. Remove the top cover from the trans-

mission case as described in thissection. Make sure the top cover is inthe NEUTRAL position. Figure 8–3.


Figure 8–3 SLEEVES INNEUTRALPOSITION

LOCKWIRE INSTALLATION NOTES:1. Trim excess wire to 1/4 inch (6mm).2. Bend the wire towards the capscrew.3. Twist the wire at least once between parts.4. On the 1-2 sleeve, the wire can be

wrapped around the shaft.5. Make sure the wire does not interfere with

the movement of the rail.

CLIP

BALL SPRING LOW REVERSEFORK

SPRINGPLUNGER

1-2 SLEEVE

3-4 SLEEVE

NEUTRALCHECK SHAFT

3-4 SLEEVE

3-4 FORKLOCKWIRE

SETSCREW

1-2FORK

1-2 SHAFT BALL

LOWREVERSE

SHAFT

PIN

BALL

Page 56


2. On forward top covers, remove thecapscrews that fasten the spring coverplate (if installed) to the top cover.Remove the plate and the gasket.

NOTE:If a heavy-duty detent spring is used,the spring (different color), is in thebore on the slave valve side of thetransmission.

3. If installed, remove the three detentsprings and balls from the top of thehousing. Figure 8–4.

Figure 8–4

BALL ANDSPRING

CAUTIONDo not damage the machined surface ofthe case. If the surface is damaged, thecase will leak

4. Put the top cover on the bench so thatthe forks are toward you or in a visewith brass protectors on the jaws.

5. Remove the capscrews that fasten thelarge and the small oil scoops to thecover. Figure 8–5.

6. Cut and remove the lock wire on thefork, sleeve and set screw assembly.Figure 8–5.

Figure 8–5

OILSCOOPS

7. Remove the set screws that fasten theshift fork and sleeve assembly to theshift shafts. Figure 8–6.

Figure 8–6

8. Remove the 3-4 shift shaft from thehousing. Remove the 3-4 shift sleeve.Remove the 3-4 shift fork. Figure 8–7.

Page 57


3-4 SHIFTSHAFT

Figure 8–7 3-4 SHIFTSLEEVE

9. On Design Level 1, nine-speedtransmissions, if necessary, disas-semble the 3-4 shift sleeve. Removethe clip that fastens the 3-4 plunger inthe housing. Remove the plunger.Figure 8–8.

Figure 8-8 PLUNGER ANDSPRING

CLIP

10. Remove the interlock ball from thebottom of the top bore of the first set ofbores at the rear of the housing. Fig-ure 8–9.

Figure 8–9

BALL

11. Remove the 1-2 shift shaft, the 1-2shift fork and the 1-2 shift sleeve fromthe housing. Remove the pin interlockfrom the end of the 1-2 shift shaft.Figure 8–10.

Figure 8–10 1-2 SHIFTSLEEVE

1-2SHIFTFORK

PIN

12. Remove the interlock ball from thebottom of the middle bore in the firstset of bores in the housing. Figure8–11.

3-4 SHIFTFORK

1-2 SHIFTSHAFT

Page 58


Figure 8–11

13. Remove the neutral check shaft fromthe top cover. Figure 8–12.

BALL

Figure 8–12NEUTRALCHECKSHAFT

NOTE:On standard position top covers, one ortwo reverse switches may be used. Onforward position top covers, one re-verse switch is used.

14. Remove the reverse switch(es) orplugs from the top of the housing.Remove the long pin(s) from eachbore. Figure 8–13.

Figure 8–13REVERSE

SWITCH BORES LONG PIN

BREATHERVENT

15. Remove the low-reverse shift shaft.Remove the low-reverse shift sleeveand fork assembly. Figure 8–14.

Figure 8–14

16. If necessary, disassemble the low-reverse sleeve and fork assembly.Remove the clip that fastens theplunger in the housing. Remove theplunger and the spring. Remove thespring and the ball from the bore nextto the plunger bore. Figure 8–15.

LOW-REVERSESHIFT SHAFT

LOW-REVERSEFORK AND

SLEEVE

Page 59


Figure 8–16 Figure 8–15

17. If necessary, remove the breather fromthe top of the cover. Figure 8–16.

18. Remove the neutral safety switch orplug. Remove the short pin from thebore. Figure 8–17.

19. Inspect all parts. See Section 1, “Re-pairing and Replacing the Parts”.

CLIP

PLUNGERAND

SPRING

Figure 8–17 NEUTRALSWITCHBORE

SHORTPIN

BREATHER

Page 60


Assembling the Standardand Forward Position TopCover AssemblySee Figures 8–1 and 8–2.

NOTE:The standard position and the forwardposition top covers use different hous-ing. The forward housing also uses aplate and a gasket installed over thedetent balls and springs.

1. Lubricate all the parts of the top coverwith the oil that is used in the transmis-sion.

2. Do the following to the set screws thatfasten the shift sleeves and/or forks tothe shift shafts and the capscrews forthe oil scoops.

a. Clean the threads of the fasten-ers with Loctite ® Safety Solvent#755 (Rockwell part number2297-P-6412) or equivalent.Make sure all dirt is removedfrom the threads.

NOTE:See the specifications of the sealantmanufacturer for the "cure" time.

b. Apply Loctite® #242 (Rockwellpart number 2297-V-5430) orequivalent to the threads of thefasteners.

3. Install the top cover in a vise withbrass jaws. Make sure the low-re-verse bore holes are toward the bot-tom of the vise.

4. Install the short pin in the bore for theneutral safety switch. Install the switchor plug and tighten to 35-50 lb-ft (48-67 N.m). Figure 8–18.

5. Install the breather vent in the topcover. Tighten to 15-20 lb-ft (21-27N.m). Figure 8–18.

NOTE:On standard position top covers, one ortwo reverse switches may be used. Onforward position top covers, one re-verse switch is used.

6. Install the larger pin(s) in the bore(s)for the reverse switch. Install theswitches or plugs and tighten to 35-50lb-ft (48-67 N.m). Figure 8–18.

Figure 8–18

7. If disassembled, install the plungerassembly in the low-reverse shift 7fork.See the following. Figure 8–19.

a. Put the fork in a vise with brassjaws.

b. Install the spring and the ball in thebore next to the plunger.

c. Install the plunger and the spring inthe bore of the fork.

d. Install the snap ring that holds theassembly in the fork.

LARGE PINS(REVERSE SWITCH)

SHORT PIN (NEUTRAL SAFETY SWITCH)

Page 61


Figure 8–19

8. Assemble the low-reverse shift shaftassembly. See the following proce-dure.

NOTE:The low-reverse shaft is the shortest ofthe three shafts.

a. Put the low-reverse shift shaft inthe bottom bore of the housing.Make sure the boss on the end ofthe shaft is toward the rear of thehousing. Make sure the detentgrooves in the rail are aligned withthe detent ball holes in the housing.Figure 8–20.

b. Put the low-reverse shift fork as-sembly in the top cover so that theplunger of the fork is toward you.Make sure the bore of the fork andsleeve assembly is aligned with thebore in the housing. Figure 8–20.

c. Push the shift shaft through thelow-reverse sleeve and fork assem-bly.

d. Push the shaft through the assem-bly until the holes in the fork andshaft are aligned.

Figure 8–20

Figure 8–21

CAUTIONAfter the setscrews with the Loctite®sealant (see step 2) are tightened to thespecified torque, do not loosen ortighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the setscrews may loosen during operation.

e. Install the set screw with the Loc-tite® sealant (see step 2) thatfasten the fork in position on theshaft. Tighten the set screw to 35-45 lb-ft (47-54 N.m). Figure 8–21 .

CLIP

PLUNGERAND

SPRING

LOW-REVERSE

SHAFT

LOW-REVERSE

FORK

SET SCREW

Page 62


Figure 8–22

10. Put the large interlock ball in the bot-tom of the middle bore of the first setof bores on the rear of the housing.Figure 8–23.

11. Assemble the 1-2 shift rail assembly.See the following procedure.

NOTE:The 1-2 shift rail is the same size as the3-4 shift rail and has a hole drilledthrough the rail.

NOTE:Move the low-reverse shift shaft assem-bly so that the interlock ball is com-pletely installed in the bore. Move thelow-reverse shaft assembly so that the1-2 rail can be installed.

a. Put the 1-2 shift shaft in the middlebore of the housing. Make sure theidentification on the end of the shaftis toward the front of the housing.Make sure the detent grooves inthe shaft are aligned with the de-tent ball holes in the housing.Figure 8–24.

b. Put the interlock pin in the holedrilled in the side of the 1-2 shiftshaft. Figure 8–24.

Figure 8–23

Figure 8–24

f. Install the lock wire in the holes inthe capscrew and the fork andsleeve assembly. Figure 8–21.

9. Install the neutral check shaft in thebore on the top of the housing. Makesure the round end of the shaft isinstalled toward the low-reverse shiftshaft. Make sure the end of the neu-tral check shaft touches the slot in theLow/Reverse shaft. Figure8–22.

NEUTRALCHECKSHAFT

1-2SLEEVE

PIN

1-2SHAFT

BALL

Page 63


c. Put the 1-2 shift sleeve in thehousing. Make sure the bore of thesleeve is aligned with the bore inthe housing. Make sure thethreaded hole in the sleeve istoward the rear of the housing.Figure 8–24.

d. Push the shift shaft through the 1-2shift sleeve. Figure 8–24 .

e. Put the 1-2 shift fork in the housing.Make sure bend on the fork isinstalled toward the middle set ofshift rail bores in the top coverhousing. Make sure the bore of thefork is aligned with the bore in thehousing. Figure8–25.

f. Push the shift shaft through the 1-2fork. Figure 8–25.

Figure 8–25

g. Push the shaft through the assem-bly until the holes in the fork andthe sleeve are aligned with theholes in the shaft.

CAUTIONAfter the set screws with the Loctite®sealant (see step 2) are tightened to thespecified torque, do not loosen ortighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the cap-screws may loosen during operation.

h. Install the set screw with the Loc-tite® sealant (see step 2) thatfasten the fork and the sleeve inposition on the shaft. Tighten theset screw to 35-45 lb-ft (47-54N.m).

i. Install the lock wire in the holes inthe set screws.

12. Put the interlock ball in the bottom ofthe top bore of the first set of bores atthe rear of the housing. Figure 8–26.

Figure 8–26

13. Make sure the low-reverse sleeve andthe 1-2 sleeve are in the NEUTRALposition. The slots in the sleeve mustbe aligned. Figure 8–27.

1-2FORK

BALL

Page 64


Figure 8–27 NOTE:On R-ratio transmissions, the bill ofmaterial refers to the 3-4 shift fork asthe O/D (Overdrive) shift fork and the3-4 shift sleeve as the O/D shift sleeve.

15. Assemble the 3-4 shift rail assembly.See the following procedure.

NOTE:The 3-4 shift shaft has a slot on oneside

NOTE:Move the 1-2 shift shaft assembly sothat the interlock ball is completelyinstalled in the bore. Move the 1-2shaft assembly so that the 3-4 shaft canbe installed.

a. Put the 3-4 shift shaft in the topbore of the housing. Make sure theinterlock slot on the end of the railis toward the rear of the housing.Make sure the detent grooves inthe shaft are aligned with the de-tent ball holes in the housing.Figure 8–29.

Figure 8–29

14. If removed, install the plunger assem-bly in the 3-4 shift sleeve. Put thesleeve in a vise with brass jaws. In-stall the spring (if used) and theplunger in the sleeve. Install the snapring that holds the assembly in thefork. Figure 8–28.

Figure 8–28

3-4SLEEVE

3-4SHAFT

SLEEVES INNEUTRALPOSITION

CLIP

PLUNGER ANDSPRING

Page 65


b. Put the 3-4 shift sleeve in thehousing. Make sure the bore of thefork and sleeve assembly is alignedwith the bore in the housing. Makesure the slot pin in the 3-4 sleeve isaligned with the hole in the 1-2sleeve. Figure 8–30.

Figure 8–30

c. Push the shift shaft through the 3-4shift sleeve.

e. Put the 3-4 shift fork in the housing.Make sure the bend on the fork isinstalled toward the last set ofbores in the housing. Make surethe bore of the fork is aligned withthe bore in the housing. Figure 8-29.

f. Push the shift shaft through the 3-4fork.

g. Push the shaft through the assem-bly until the holes in the fork andthe sleeve are aligned with theholes in the shaft.

CAUTIONAfter the set screws with the Loctite®sealant (see step 2) are tightened to thespecified torque, do not loosen ortighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the setscrews may loosen during operation.

h. Install the set screws with theLoctite® sealant (see step 2) thatfastens the 3-4 fork and the sleeveto the rail. Tighten the set screw to35-45 lb-ft (47-54 N.m).

i. Install the lock wire in the cap-screws, the sleeve and the fork.

15. If removed, install the large oil scoopon the housing. Install and tighten thecapscrews with the Loctite® sealant(see step 2) to 10-13 lb-ft (13-17 N.m).Figure 8–31.

16. If removed, install the small scoop onthe housing. Install and tighten thecapscrews with the Loctite® sealant(see step 2) to 10-13 lb-ft (13-17 N.m).Figure 8–31.

Figure 8–31

3-4FORK

OILSCOOPS

Page 66

Section 8 “X” BarOverhauling the Top Cover Assembly Top CoverDisassembling the Standard and the Forward Position“X” Bar Top Cover Assembly

See Figures 8–32 and 8–33.

Figure 8–32

BREATHERVENT

REVERSESWITCH

PLUG

BALL

SPRING

BALL

REVERSESWITCH

PLUG

LONG PIN

FORWARD POSITIONHOUSING

STANDARDPOSITION HOUSING

(FOR FORWARDPOSITION HOUSING

SEE BOX)

OILSCOOP

SPACERPLATE

ROCKINGLEVER

GUIDEPIN

NEUTRAL SWITCHPLUG

SHORTPIN

OILSCOOP

COVERPLATE

GASKET

Page 67

“X” Bar Section 8Top Cover Overhauling the Top Cover Assembly

Figure 8–33

NOTE:The standard position “X” bar top coverassembly and the forward position “X”top cover assembly use different hous-ings. The forward housing also uses aplate and a gasket installed over thedetent balls and springs.

1. Remove the top cover assembly asdescribed in this section. Make surethe top cover assembly is in the NEU-TRAL position. Figure 8–34.


Figure 8–34NEUTRALPOSITION

LOCKWIRE INSTALLATION NOTES:1. Trim excess wire to 1/4 inch (6mm).2. Bend the wire towards the capscrew.3. Twist the wire at least once between parts.4. On the 1-2 sleeve, the wire can be

wrapped around the shaft.5. Make sure the wire does not interfere with

the movement of the rail.

LOW-REVERSESHAFT

CLIP

BALL

PLUNGER

SPRING

LOW-REVERSEFORK

1-2 SLEEVE

3-4 SLEEVE

NEUTRALCHECKSHAFT

3-4 SHAFT

3-4 FORK3-4SHIFT

SLEEVESHAFT

3-4X-BAR

SLEEVE

LOCKWIRE

SETSCREW

1-2FORK

1-2SHAFT

PINBALL

BALL

Page 68

Section 8 “X” BarOverhauling the Top Cover Assembly Top Cover

2. On forward top covers, remove thecapscrews that fasten the detentspring cover plate (if installed) to thetop cover assembly. Remove the plateand the gasket.

NOTE:If a heavy-duty detent spring is used,the spring (different color) in the boreon the slave valve side of the transmis-sion.

3. If installed, remove the three detentsprings and balls from the top of thehousing. Figure 8–35.

Figure 8–35

SPRINGBALL

NOTE:On standard position top cover assem-blies, two reverse switches may beused. On forward position housings,one reverse switch is used.

4. Remove the reverse switches or plugsfrom the housing. Remove the longpins from each bore. Figure 8–36.

Figure 8–36

5. If necessary, remove the breather fromthe top of the cover. Figure 8–37.

6. Remove the neutral safety switch orplug. Remove the short pin from thebore. Figure 8–37.

Figure 8–37

CAUTIONDo not damage the machined surface ofthe case. If the surface is damaged, thecase will leak.

7. Put the top cover assembly on thebench so that the forks are toward youor in a vice with brass protectors onthe jaws of the vise.

NEUTRAL SAFETYSWITCH BORE

REVERSESWITCH BORES

LONG PIN

SHORTPIN

Page 69


8. Remove the capscrews that fasten thelarge and the small oil scoops to thecover. Figure 8–38.

Figure 8–38

9. Remove the lock wire from the follow-ing. Figure 8–39.

• 3rd-4th fork.• 3rd-4th shift sleeve.• 1st-2nd shift fork.• 1st-2nd shift sleeve.• LOW-Reverse shift fork.

Figure 8–39

10. Remove the set screw from the 3rd-4thfork and the 3rd-4th shift fork shaftfrom the housing. Remove the 3rd-4thfork. Figure 8–40 .

Figure 8–403-4

SHIFT FORK

11. Remove the set screw and remove the3-4 shift sleeve shaft from the housing.Remove the 3-4 X-bar sleeve. Figure8–41.

Figure 8–41

12. Remove the interlock ball from thebottom of the top bore of the first set ofbores at the rear of the housing. Fig-ure 8–42.

3-4SLEEVE

3-4SHIFTERSHAFT

3-4X-BAR

SLEEVE

LARGE OILSCOOP

SMALL OILSCOOP

3-4SHIFT FORK

SHAFT

Page 70


Figure 8–42

13. Remove the interlock pin from the endof the 1-2 shift shaft. Figure 8–43.

BALL

Figure 8–43

PIN

14. Remove the set screws and removethe 1-2 shift shaft, the 1-2 shift forkand the 1-2 shift sleeve from thehousing. Figure 8–44.

Figure 8–44

1-2 SHIFTFORK

1-2 SHIFTSLEEVE 1-2 SHIFT

SHAFT

15. Remove the interlock ball from thebottom of the middle bore in the firstset of bores in the rear of the housing.Figure 8–45.

Figure 8–45

BALL

Page 71


Figure 8–47CAUTION

Remove the O-ring on the guide pinbefore removing the rocking lever andthe spacer plate or the O-ring will bedamaged.

16. Remove the nut and the washer thatfasten the guide pin and the rockinglever assembly to the housing. Re-move the O-ring from the guide pin.Remove the rocking lever and thespacer plate. Figure 8–46.

Inspect the O-ring on the guide pin.Replace the O-ring if worn or dam-aged.


Figure 8–49

GUIDEPIN

O-RING

ROCKINGLEVER

LOW-REVERSESHIFT SHAFT

LOW-REVERSESHIFT FORK

PLUNGERAND

SPRING

CLIP

NEUTRALCHECKSHAFT

SPACERWASHER

17. Remove the neutral check shaft fromthe top cover assembly. Figure 8–47.

18. Remove set screws and remove thelow-reverse shift shaft. Remove thelow-reverse shift sleeve and fork as-sembly. Figure 8–48.

19. If necessary, disassemble the low-reverse sleeve and fork assembly.Remove the clip that fastens theplunger in the housing. Remove theplunger and the spring. Remove thespring and the ball from the bore nextto the plunger bore. Figure 8–49.

20. Inspect all parts. See Section 1, “Re-pairing or Replacing the Parts”.

Page 72


Assembling the Standardand the Forward Position“X” Bar Top CoverAssemblySee Figure 8–32 and 8–33.

NOTE:The standard position “X” bar top coverassembly and the forward position “X”bar top cover assembly uses differentcovers. The forward cover also uses aplate and a gasket installed over thedetent balls and springs.

1. Lubricate all the parts of the top coverwith the oil that is used in the transmis-sion.

2. Do the following to the set screws thatfasten the shift sleeves and/or forks tothe shift shafts and the capscrews forthe oil scoops.

a. Clean the threads of the fasten-ers with Loctite ® Safety Solvent#755 (Rockwell part number2297-P-6412) or equivalent.Make sure all dirt is removedfrom the threads.

NOTE:See the specifications of the sealantmanufacturer for the "cure" time.

b. Apply Loctite® #242 (Rockwellpart number 2297-V-5430) orequivalent to the threads of thefasteners.

3. If disassembled, install the plungerassembly in the low-reverse fork as-sembly. See the following.Figure 8–50.

a. Put the fork in a vise with brassjaws.

b. Install the ball and the spring in thebore next to the plunger.

c. Install the plunger and the spring inthe bore of the fork.

d. Install the snap ring that holds theassembly in the fork.

Figure 8–50

4. Assemble and install the rocking leverassembly according to the followingprocedure. Figure 8–51.

a. Install the guide pin through therocking lever.

b. Install the spacer plate on the guidepin.

CAUTIONInstall the O-ring on the guide pin afterinstalling the rocking lever and thespacer plate or the O-ring will bedamaged.

c. Install a new O-ring on the guidepin.

d. Install the assembly so that thelong part of the spacer plate istoward the center of the housing.

PLUNGERAND

SPRING

CLIP

Page 73


e. Install a new nut and a new washerthat fasten the guide pin to thehousing. Tighten to 35-45 lb-ft (47-54 N.m).


d. Install the set screw with theLoctite® sealant (see step 2) thatfasten the fork in position on theshaft. Tighten the set screw to35-45 lb-ft (47-54 N.m).

e. Install the lock wire in the holesin the set screw and the forkassembly.

Figure 8–52

6. Install the neutral check shaft in thebore on the top of the housing. Makesure the round end of the shaft isinstalled toward the low-reverse shiftrail. Make sure the end of the shafttouches the slot in the rail. Figure8–53.

Figure 8–51

5. Install the low-reverse fork assemblyaccording to the following procedure.Figure 8–52.

a. Put the low-reverse shift shaft inthe bottom bore in the rear of thehousing. Make sure the twodetent grooves are toward therear of the housing. Make surethe detent grooves in the shaftare aligned with the detent ballholes in the housing.

b. Put the low-reverse shift forkassembly in the housing so thatthe lower lever slot is toward thecenter of the assembly. Makesure the bore of the fork isaligned with the bore in thehousing.

c. Push the shift shaft through thefork and sleeve assembly untilthe holes in the fork and shaftare aligned.

GUIDEPIN

O-RING

ROCKINGLEVER LOW-REVERSE

SHIFT SHAFT

LOW-REVERSESHIFT FORK

SPACERWASHER

Page 74


Figure 8–53

7. Put the large interlock ball in the bot-tom of the middle bore of the first setof bores on the rear of the housing.Figure 8–54.

Figure 8–54

8. Assemble the 1-2 shift shaft assembly.See the following procedure.

NOTE:The 1-2 shift shaft is the same size asthe 3-4 shift shaft and has a hole drilledthrough the shaft.

NOTE:Move the low-reverse shift shaft assem-bly so that the interlock ball is com-pletely installed in the bore. Move thelow-reverse shaft assembly so that the1-2 shaft can be installed.

a. Put the 1-2 shift shaft in the middlebore of the housing. Make sure thepart identification on the end of theshaft is toward the front of thehousing. Make sure the detentgrooves in the shaft are alignedwith the detent ball holes. Figure8–55.

b. Put the 1-2 shift sleeve in thehousing. Make sure the bore of thesleeve is aligned with the bore inthe housing. Make sure thethreaded hole in the sleeve istoward the rear of the housing.Figure 8–55.

c. Push the shift shaft through the 1-2shift sleeve. Figure 8–55 .

d. Put the 1-2 shift fork in the housing.Make sure bend on the fork isinstalled toward the middle set ofbores. Make sure the bore of thefork is aligned with the bore in thehousing. Figure 8–55.

Figure 8–55

1-2 SHIFTSLEEVE

NEUTRALCHECKSHAFT

1-2 SHIFTFORK

1-2 SHIFTSHAFT

BALL

Page 75


e. Push the shift shaft through the 1-2fork. Figure 8–55.

f. Push the rail through the assemblyuntil the holes in the fork and thesleeve are aligned with the holesin the shaft.


g. Install the set screws with theLoctite® sealant (see step 2) thatfastens the 1-2 fork and the sleeveto the rail. Tighten the set screwsto 35-45 lb-ft (47-54 N.m).

h. Install the lock wire in the holes inthe set screws and the fork and thesleeve. Wrap the lock wire aroundthe barrel of the shaft.

i. Put the interlock pin in the holedrilled in the end of the 1-2 shiftshaft. Figure 8–56.

9. Put the interlock ball in the bottom ofthe top bore of the first set of bores atthe rear of the housing. Figure 8–57.

Figure 8–57

10. Make sure the low-reverse sleeve andthe 1-2 sleeve are in the NEUTRALposition. The slots in the sleeve mustbe aligned.

NOTE:On R-ratio transmissions, the bill ofmaterial refers to the 3-4 shift fork asthe O/D (Overdrive) shift fork and the3-4 “X” bar sleeve as the O/D shiftsleeve.

11. Assemble the 3-4 shift sleeve andshaft assembly. See the followingprocedure.

NOTE:The 3-4 shift sleeve shaft has a slot onone side

NOTE:Move the 1-2 shift shaft assembly sothat the interlock ball is completelyinstalled in the bore. Move the 1-2shaft assembly so that the 3-4 shiftsleeve shaft can be installed.

BALL

Figure 8–56

PIN

Page 76


a. Put the 3-4 shift sleeve shaft in thetop bore of the housing. Make surethe interlock slot on the end of theshaft is toward the rear of thehousing. Make sure the detentgrooves in the shaft are alignedwith the detent ball holes in thehousing. Figure 8–58.

b. Put the 3-4 shift sleeve in thehousing. Make sure the bore of thesleeve is aligned with the bore inthe housing. Make sure the slot inthe 3-4 shift sleeve is aligned withthe slot in the 1-2 sleeve. Figure8–58.

c. Push the shift shaft through the 3-4shift sleeve.

e. Put the 3-4 “X” bar sleeve in thehousing. Make sure the slot is inthe sleeve is aligned over therocking lever assembly. Make surethe bore of the sleeve is alignedwith the bore in the housing. Fig-ure 8–58.

f. Push the shift shaft through the 3-4“X” bar sleeve.

g. Push the shaft through the assem-bly until the holes in the sleevesare aligned with the holes in theshaft.


h. Install the set screws with theLoctite® sealant (see step 2) thatfastens the sleeves to the shaft.Tighten the set screws to 35-45 lb-ft (47-54 N.m).

i. Install the lock wire in the holes inthe sleeves and the set screws.

NOTE:On R-ratio transmissions, the bill ofmaterial refers to the 3-4 shift fork asthe O/D (Overdrive) shift fork and the3-4 “X” bar sleeve as the O/D shiftsleeve.

12. Install the 3-4 fork and 3-4 shift forkshaft according to the following proce-dure.

a. Put the 3-4 shift fork shaft in the topbore at the front of the housing.Figure 8–59.

b. Put the 3-4 shift fork in the housing.Make sure the slot on the fork isaligned with the rocking leverassembly. Make sure the bore ofthe fork and sleeve assembly isaligned with the bore in the hous-ing. Figure 8–59.

Figure 8–58 3-4SLEEVE

3-4SHIFTERSHAFT

3-4X-BAR

SLEEVE

Page 77


Figure 8–60

NOTE:On standard position top covers assem-blies, one or two reverse switches maybe used. On forward position top cov-ers, one reverse switch is used.

14. Install the larger pin(s) in the bore(s)for the reverse lamp switch. Install theswitches or plugs and tighten to 35-50lb-ft (48-67 N.m). Figure 8–61.

Figure 8–61

LARGE OILSCOOP

SMALL OILSCOOP

REVERSESWITCH BORES

LONG PIN

Figure 8–59

c. Push the shift shaft through the 3-4fork.


d. Install the set screw with the Loc-tite® Sealant (see step 2) thatfastens the 3-4 fork to the shaft.Tighten the set screw to 35-45 lb-ft(47-54 N.m).

e. Install the lock wire in the holes inthe set screws and the fork.

13. If removed, install the large and smalloil scoops on the housing. Install andtighten the capscrews with the Loctite®sealant (see step 2) to 10-13 lb-ft (14-17 N.m). Figure 8–60.

3-4SHIFT FORK

SHAFT

3-4SHIFT FORK

Page 78


15. Install the short pin in the bore for theneutral safety switch. Install the switchor plug and tighten to 35-50 lb-ft (48-67 N.m). Figure 8–62.

16. Install the breather vent in the topcover. Tighten to 15-20 lb-ft (21-27N.m). Figure 8–62.

Figure 8–62 NEUTRAL SAFETYSWITCH BORE

SHORT PINBREATHER

VENT

Page 79

Section 9Removing and Installing the Input Shaft


Removing the Input ShaftAssembly

NOTE:The input shaft can be removed withoutdisassembling the transmission .

1. Remove the transmission from thevehicle. See the procedure in thissection.

CAUTIONUse a rubber mallet or “dead blow”hammer to separate the top cover fromthe transmission case. Do not use prybars or screwdrivers to separate thecover from the case. Pry bars or screw-drivers may damage the cover and casemounting surfaces. If the cover is stilldifficult to remove, remove the slavevalve and the interlock pin from themain case.

2. Remove the capscrews and thewashers that fasten the input bearingretainer to the main case. Removethe input bearing retainer. Figure 9–1.

3. Use a scraper to remove the sealantmaterial between the input bearingretainer and the main case.

NOTE:A black shipping seal may be on theinput shaft. Remove and discard theseal.

4. Remove the inner snap ring that holdsthe bearing on the input shaft. Figure9–2.

Figure 9–2

INNERSNAPRING

5. Remove the bearing from the shaft.The use of Owatonna tool set,OTC-7070 (as shown in Figure 9–3) ,or G&W Tool, G-38, Input Shaft Bear-ing Driver (as shown in Figure 9–4) , orequivalent, makes the removal of thebearing from the shaft easier. The toolis attached to the outer snap ring onthe bearing to pull the bearing from theshaft.

If the snap ring is not out far enoughfor the tool to grip, pull the input shaftout until the tool can be installed onthe snap ring. Figure 9–5.

INPUT BEARINGRETAINER

Figure 9–1

Page 80


Figure 9–3

Figure 9–4

Figure 9–5

SNAPRING

6. Remove the spacer from the inputshaft. Figure 9–6.

Figure 9–6

SPACER

7. Remove the snap ring from the gearthat holds the input shaft in the gear.Figure 9–7.

Figure 9–7

SNAPRING

8. Remove the input shaft. Figure 9–8.

Page 81


Figure 9–8

Installing the Input Shaft

NOTE:The input shaft can be installed withoutdisassembling the transmission.

1. Lubricate all the parts in the oil that isused in the transmission.

2. Align the splines of the input shaft withthe splines inside the main drive gear.Install the input shaft in the main drivegear. Install the snap ring that holdsthe input shaft in the main drive gear.Install the spacer on the input shaft.Figure 9–9.

Figure 9-–9

3. Install the outer snap ring in the grooveon the bearing. Figure 9–10.

Figure 9–10

CAUTIONPut the tool or tube on the inner race ofthe bearing. If tools are used in anyother place on the bearing, the bearingwill be damaged.

4. Put the bearing over the input shaftand in the case. Use a rubber orplastic mallet and G & W Tool, G-35,Input Shaft Bearing Driver,to install thebearing on the input shaft. The bear-ing is correctly installed when the snapring touches the case. Figure 9–11.

Figure 9–11

OUTERSNAPRING

SPACER

Page 82


5. Install the inner snap ring that fastensthe bearing on the input shaft.Figure 9–12

6. Use Loctite® Master Gasket Sealant,#00203 or equivalent, and a sealantdispenser to put a new sealant patternfor the input bearing retainer on thecase in the pattern shown inFigure 9–13.See ‘Gasket Sealant’ in Section 1.

7. Install the bearing retainer on the case.Make sure the oil passage in theretainer is aligned with the oil hole inthe case. Figure 9–14.

8. Install the capscrews and washers forthe retainer. Tighten the capscrews to65-85 lb-ft (89-115 N.m). Figure 9–14.

9. Install the top cover and the transmis-sion. See the procedure in thissection.

10. Operate the vehicle. Check for correctoperation.

Figure 9–13

Figure 9–14 INPUTBEARINGRETAINER

SEALANTPATTERN

BOLT HOLEOIL SLOT

INNERSNAPRING

Figure 9–12

Page 83

Section 10Removing and Installing the Clutch Housing


Removing the ClutchHousingFigure 10–1.

1. Remove the transmission as describedin Section 1, “In-Vehicle Service.”

2. Remove the nuts, the capscrews andthe washers that fasten the clutchhousing to the main case.

3. Remove the clutch housing.

4. Use a scraper to remove all sealantmaterial from the clutch housing andthe main case.

Figure 10–1

Installing the ClutchHousingNOTE:Clutch housings for Design Level 1transmissions cannot be used on De-sign Level 2 transmissions. Clutchhousings for Design Level 2 transmis-sions can be used on Design Level 1transmissions. See the chart in Figure10–2 to choose the correct clutchhousing.

Original Design Replacement DesignPart Number Level Clutch Housing Type Part Number LevelA-3282-G-1021 1 SAE#1, Iron-Standard A-3282-E-1045 1,2A-3282-H-1022 1 SAE#1, Iron-Symmetrocal Nodal A-3282-G-1047 1,2A-3282-J-1024 1 SAE#1, Aluminum-Standard A-3282-F-1046 1,2A-3282-K-1025 1 SAE#1, Aluminum-Symmetrical Nodal A-3282-H-1048 1,2

Clutch Housing Assembly - Below Centerline Clutch Release Shaft

Clutch Housing Assembly - Above Centerline Clutch Release Shaft

Original Design Replacement DesignPart Number Level Clutch Housing Type Part Number LevelA-3282-M-1001 1 SAE#1, Iron-Standard A-3282-Z-1040 1,2A-3282-T-1008 1 SAE#1, Iron-Symmetrical Nodal A-3282-X-1038 1,2A-3282-V-1010 1 SAE#1, Aluminum-Standard A-3282-V-1036 1,2A-3282-X-1012 1 SAE#1, Aluminum-Symmetrical Nodal A-3282-B-1042 1,2A-3282-P-1030 1 SAE#2, Iron-Standard A-3282-D-1044 1,2

Figure 10–2

Page 84

Section 10Removing and Installing the Clutch Housing

1. Use Loctite® RTV Sealant™, #5699(Rockwell part number 2297-A-7021)or equivalent, to put a new sealantpattern for the clutch housing on thetransmission case. Make sure thesealant is installed in the patternshown in Figure 10–3. See ‘GasketSealant’ in Section 1.

2. Install the clutch housing on the trans-mission case.

3. Install the mounting nuts and washerson the studs on the clutch housing.Tighten the nuts to 150-190 lb-ft (204-257 N.m).

4. Apply Loctite® #222 (Rockwell partnumber 2297-B-6112) or equivalent tothe threads of the capscrews thatfasten the clutch housing to the maincase.

5. Install the mounting capscrews andwashers and tighten to 65-85 lb-ft (89-115 N.m).

6. Install the transmission as described inSection 2, “In-Vehicle Service”.

Figure 10–3

NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD.

CLUTCH HOUSING-TO-TRANSMISSION CASE GASKET PATTERN• PUT THE PATTERN ON THE TRANSMISSION CASE

MAKE SURE THE PATTERNIS ON THE TRANSMISSION CASEAND NOT ON THE RETAINER

Page 85

Nine–Speed and Section 11Ten–Speed Removing and InstallingTransmissions the Auxiliary Case

Figure 11–1

Figure 11–2


Removing the AuxiliaryCase – Nine-Speed andTen-Speed Transmissions1. If necessary, remove the transmission

and the output yoke as described inthis section.

If the auxiliary case is removed withthe transmission installed in thevehicle, do the following:

a. If necessary, remove the outputyoke as described in this section.

b. Remove the air from the air supplysystem.

c. Put a large container under thetransmission. Remove both drainplugs. Drain and discard the oil.

2. Disconnect and mark the air lines.Disconnect the BLACK tube from theLO range port. On the piston housingcover, disconnect the BLUE tube fromthe HI range port. From the supplyport of the filter and regulatorassembly, disconnect the RED tube.Figure 11–1.

NOTE:The auxiliary case must be in the LOrange so that the case can be removed.

3. Use an air gun to apply air pressure tothe LO range port in the pistonhousing to put the auxiliary case intothe LO range. If necessary, rotate theoutput shaft while applying airpressure. Figure 11–2.

4. On gear driven speedometers,remove the driven gear from theoutput bearing retainer and the drivegear from the output shaft.

On electronic speedometers,remove the sensor from the outputbearing retainer and the rotor from theoutput shaft or disconnect the sensorat the connector.

LORANGEPORT

SUPPLYPORT

LO RANGEPORT

DELIVERYPORT

BLUE

BLACKHIRANGEPORT

RED

Page 86

Section 11 Nine–Speed andRemoving and Installing Ten–Speedthe Auxiliary Case Transmissions

5. Remove the mounting capscrews andwashers from the covers of the auxil-iary countershafts. Remove the cov-ers. Use a scraper to remove thegasket material on the cover and thecase.

CAUTIONInstall holding cover plates or lift brack-ets on each auxiliary countershaft. Ifnot used, the countershafts will fallwhen the auxiliary cover is removed.

6. Install Holding Cover Plates, 3305-W-1141 on each counter shaft. See thefollowing. Figures 11–3 and 11–4.

a. Put the Holding Cover Plate inposition on the cover over thecountershaft.

NOTE:One or two holes for the holding coverplate may be in the top of the counter-shaft.

b. Rotate the output shaft so that theholes in the countershaft arealigned with the holes in the hold-ing cover plate.

c. Use capscrews to fasten the coverplates to the countershafts.

NOTE:Holding cover plate templates are foundin Section 20, Specifications. The pat-tern for the cover plate is shown inFigure 11–4.

Figure 11 –3

Figure 11–4

HOLDING COVERPLATE 3305-W-1141

1.25 INCH(32.00 mm)

0.25 INCH(6.35 MM)

0.437 INCH(11.11 MM)DIAMETER

2.25 INCH(57.15 MM)

4.5 ± 0.11 INCH(114.30 ± 3.00 mm)

0.50 INCH(12.70 mm)

1.62 INCH(41.15 mm)

1.0 INCH(25.4 mm)

0.375 INCH(9.53 mm)

Page 87


d. On Design Level 2 Transmis-sions only , install two lifting brack-ets and two capscrews on eachauxiliary countershaft. Install thebrackets opposite each other asshown in Figure 11–5 .

Figure 11–5

CAUTIONIf required, remove the dowel pins fromthe case side. Do not hit the taperedends of the dowel pins. If the ends ofthe dowel pins are damaged, the auxil-iary case will be difficult to separatefrom the main case. Also, the lowerdowel pin cannot be removed from theyoke side of the auxiliary case.

7. Clean the dowels pins. Remove paint,rust and dirt from the pins so that theauxiliary case can be removed. Lubri-cate the dowel pins with new oil that isused in the transmission.

Make sure the dowel pins are notdamaged. Replace damaged dowelpins after the auxiliary case is re-moved.

8. Remove the mounting capscrews andwashers from the auxiliary case.

9. Clean the puller holes in the auxiliarycase. Install a 3/8"-16 x 1-1/2" UNCcapscrew into the three puller holes.Evenly tighten each capscrew toseparate the auxiliary case from thetransmission case. Figure 11–6.

Figure 11–6

WARNINGWhen using a hammer and a steel drift,wear safe eye protection and make surethe tools are in safe condition. Do notuse tools that are worn or damaged(“mushroomed”). If the tools are not insafe condition, pieces can break andcause serious personal injury.

If the auxiliary case is difficult to re-move or the dowel pins are damaged,use a hammer and a steel drift toremove one or both of the pins fromthe main case. Drive the pins towardthe yoke. Make sure the case is se-curely when the pins are removed.

LIFTINGBRACKET

HOLDING COVERPLATE 3305-W-1141

PULLER HOLES

Page 88


10. Remove the puller screws from theauxiliary case.

11. Use an overhead hoist and brackets ora transmission jack and a bracket toremove the auxiliary case from thetransmission case. See the followingprocedure.

Overhead Hoist

a. Install lifting brackets of the auxil-iary case. If necessary, use a prybar to separate the case from thecase enough to install a liftingbracket. Figure 11–7 .

b. Connect an overhead hoist to thelifting bracket. Figure 11–7 .

c. Use an overhead hoist to removethe auxiliary case from the trans-mission case.

Transmission Jack

a. Remove the bottom two capscrewsfrom the output bearing retainer.Install a bracket from the transmis-sion jack. Figure 11–8 .

b. Connect a transmission jack to thebracket.

Figure 11–7

Figure 11–8

c. Use the transmission jack to re-move the auxiliary case from thetransmission case.

NOTE:Sometimes the bearing cups for theauxiliary countershafts will remain inthe bores in the main transmissioncase. Remove the cups. Mark eachcup for the correct location. However,if “slip” fit cups are installed, the cupsmust be removed and replaced with“press” fit cups.

BOTTOM TWOCAPSCREWS

Page 89


Figure 11–9

12. Use a slide hammer and a puller toremove the bearing cups for the auxil-iary countershaft from the main case.Mark the cups. The cups must beinstalled in the original location. Figure11–9.

13. On Design Level 1 Transmissions ,remove the snap rings in the bores for

Figure 11–10

the cups for the auxiliary counter-shafts. (Design Level 2 Transmis-sions do not use snap rings in thislocation.) Figure 11–10.

14. Use a scraper to remove the gasketmaterial from the transmission caseand the auxiliary case.

SLIDEHAMMER

CUP

SNAP RING

Page 90


Installing the AuxiliaryCase–Nine-Speed andTen-Speed Transmissions

NOTE:The auxiliary case must be in the LOrange so that the case can be installedwith the gears timed correctly.

1. Use an air gun to apply air pressure tothe LO range port in the piston hous-ing to put the case in the LO range.

2. On Design Level 1 Transmissions, ifremoved, install the snap rings in thebores for the cups for the auxiliarycountershafts in the main case.Figure 11–11.

3. If removed, install the bearing cups forthe auxiliary countershaft in the boresin the main case. Clean the outerdiameter of the cups.

On Design Level 1 Transmissions,make sure the cup is against the snapring. Figure 11–11.

On Design Level 2 Transmissions,make sure the cup is against the stepin the bore. Figure 11–12.

Figure 11–11

Figure 11–12

AUXILIARYCOUNTER-SHAFTCUP

SNAPRING

CUP

Page 91

Nine–Speed and Section 11Ten–Speed Removing and InstallingTransmissions the Auxiliary Case Figure 11–13

4. Use a sealant dispenser and Loctite®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) to put a newsealant pattern for the auxiliary caseon the transmission case a 1/8 inch(2 mm) bead in the pattern shown inFigure 11–13. Put a sealant patternaround each puller hole in the auxiliarycase as shown in Figure 13. See‘Gasket Sealant’ in Section 1.


5. If the dowels have been removed, usea steel drift and a hammer to install thedowels. Install the dowels from theback of the main case flange. Installthe dowels until the end of the dowelsare 2.5 inches (64 mm) from theflange. Figure 11–14.

Figure 11–14

6. Lubricate the dowel pins with new oilthat is used in the transmission.

7. Connect a lifting bracket to theauxiliary case.

If a transmission jack is used, removethe bottom two capscrews from theoutput bearing retainer. Usecapscrews to connect a bracket for thejack to the retainer. Figure 11–15.

AUXILIARY COVER-TO-TRANSMISSION CASE GASKET PATTERN• PUT THE PATTERN ON THE TRANSMISSION CASE AND THE AUXILIARY COVER

TRANSMISSION CASE GASKET PATTERN

TRANSMISSION CASE

AUXILIARY COVER GASKET PATTERN


BEAD

BOLT HOLE

BOLT HOLE

REARCOVER

2.5 INCHES(64 mm)

Page 92


Figure 11–15

If an overhead hoist is used, connectbrackets to the bores for the transmis-sion case capscrews. Figure 11–16.

Figure 11–16

8. Connect a lifting device to the liftingbracket(s).

NOTE:The auxiliary section must be in the LOrange and the main case must be ingear to install the auxiliary case.

9. Install the auxiliary case. Make surethe dowel holes in the auxiliary caseare aligned with the dowels in the maincase and that the auxiliary case isevenly installed on the dowels. Rotatethe input shaft so that the teeth on theauxiliary drive gear align with the teethon the countershaft driven gears.Figure 11–17.BOTTOM TWO

CAPSCREWS

Figure 11–17

10. Remove the lifting bracket(s) and thelifting device from the auxiliary case.

11. Install the auxiliary case against thetransmission case. If necessary, use arubber or plastic mallet to push theauxiliary case against the main case.Figure 11–18.

12. Install the mounting capscrews andwashers for the auxiliary case.Tighten the capscrews to 35-45 lb-ft(47-61 N.m). Figure 11–18.

Page 93


buttons on the top of the fittings auto-matically lock the air lines in position.

15. Connect the BLUE air line to the HIrange port of the piston housing.Connect the BLACK air line to the LOrange port of the piston housing.Connect the RED air line to the supplyport of the filter and regulatorassembly. Figure 11–19.

16. Install the transmission as described inSection 4, “Removing and Installingthe Transmission”.

17. Fill the transmission with the specifiedoil to the specified level. See“Checking and Adjusting the Oil Level ”in Section 2.

Figure 11–18

13. Check and adjust the end play ofeach auxiliary countershaft. Do theprocedure described in Section 18,“Auxiliary Countershaft End PlayAdjustment”. When the correct endplay of 0.002-0.006 inch(0.050-0.152 mm) is obtained, go tostep 14 of this procedure.

14. If removed, install the filter andregulator assembly. See theprocedure described in Section 3,“In-Vehicle Service”.

NOTE:To install the air lines, push the airlines into the fittings until the linestouch the bottom of the fittings. The

Figure 11–19

SUPPLYPORT

LO RANGE PORT

DELIVERYPORT

RED

BLUE

BLACKHI

RANGEPORT

Page 94

Section 11Removing and Installing the Thirteen–SpeedAuxiliary Case Transmissions

Removing the AuxiliaryCase–Thirteen-SpeedTransmissions1. If necessary, remove the transmission

and the output yoke as described inthis section.

If the auxiliary case is removed withthe transmission installed in the ve-hicle, do the following:

a. If necessary, remove the outputyoke as described in this section.

b. Remove the air from the air supplysystem.

c. Put a large container under thetransmission. Remove both drainplugs. Drain and discard the oil.

2. Disconnect and mark these air tubes:Figure 11–20.

a. BLACK tube from the LO rangeport on the piston housing.

b. BLUE tube from the HI range porton the piston housing cover.

c. RED tube from the supply port ofthe filter and regulator assembly.

d. Splitter tube on piston housingcover.

Figure 11–20WARNING

To prevent serious eye injury, alwayswear safe eye protection when doingmaintenance or service.

NOTE:The auxiliary case must be in the LOrange so that the case can be removed.

3. Use an air gun to apply air pressure tothe LO range port in the piston hous-ing to put the auxiliary case into theLO range. If necessary, rotate theoutput shaft while applying air pres-sure. Figure 11–21.

Figure 11–21 LORANGEPORT

HI RANGEPORT

SPLITTERPORT

SUPPLYPORT

LORANGEPORT

RED

BLACK

BLUE

Page 95

Section 11Thirteen–Speed Removing and InstallingTransmission the Auxiliary Case

4. On gear driven speedometers,remove the driven gear from the out-put bearing retainer and the drive gearfrom the output shaft.

On electronic speedometers, removethe sensor from the output bearingretainer and the rotor from the outputshaft or disconnect the sensor at theconnector.

5. Remove the mounting capscrews andwashers from the covers of the auxil-iary countershafts. Remove the cov-ers. Use a scraper to remove thegasket material.

CAUTIONInstall Holding Cover Plates on eachauxiliary countershaft. If not used, thecountershafts will fall when the auxil-iary case is removed.

6. Install Holding Cover Plates, 3305-W-1141 on each counter shaft. See thefollowing Figure 11–22.

a. Put the Holding Cover Plate inposition on the cover over thecountershaft.

NOTE:One or two holes for the holding coverplate may be in the top of the counter-shaft.

b. Rotate the output shaft so that theholes in the countershaft arealigned with the holes in the Hold-ing Cover Plate.

c. Use capscrews to fasten the coverplates to the countershafts and thecover.

NOTE:Holding Cover Plate templates arefound in Section 20, Specifications.

Holding Cover Plates can be madefrom the pattern shown in Figure 11–23.

Figure 11–22

Figure 11–23

4.5 ± 0.11 INCH(114.30 ± 3.00 mm)

1.25 INCH(32.00 mm)

1.62 INCH(41.15 mm)

0.50 INCH(12.70 mm)

1.0 INCH(25.4 mm)

0.375 INCH(9.53 mm)

2.25 INCH(57.15 MM)

0.25 INCH(6.35 MM)

0.437 INCH(11.11 MM)DIAMETER

HOLDING COVERPLATE

3305-W-1141

Page 96


CAUTIONIf required, remove the dowel pins fromthe case side. Do not hit the ends ofthe dowel pins. If the ends of the dowelpins are damaged, the auxiliary casewill be difficult to separate from themain case. Also, the lower dowel pincannot be removed from the yoke sideof the auxiliary case.

7. Clean the dowels pins. Remove paint,rust and dirt from the pins so that theauxiliary case can be removed. Lubri-cate the dowel pins with new oil that isused in the transmission.

Make sure the dowel pins are notdamaged. Replace damaged dowelpins after the auxiliary case is re-moved.

8. Remove the mounting capscrews andwashers from the auxiliary case.

9. Clean the puller holes in the auxiliarycase. Install a 3/8"-16 x 1-1/2" UNCcapscrew into the three puller holes.Evenly tighten each capscrew toseparate the auxiliary case from thetransmission case. Figure 11–24.


If the auxiliary case is difficult to re-move or the dowel pins are damaged,use a hammer and a steel drift toremove one or both of the pins fromthe main case. Drive the pins towardthe yoke. Make sure the case is se-cure when the pins are removed.

10. Remove the puller screws from theauxiliary case.

11. Use an overhead hoist and brackets ora transmission jack and a bracket toremove the auxiliary case from thetransmission case. See the followingprocedure.

Overhead Hoista. Install lifting brackets of the auxil-

iary case. If necessary, use a prybar to separate the case from thecase enough to install a liftingbracket. Figure 11–25 .

b. Connect an overhead hoist to thelifting bracket. Figure11– 25 .

c. Use an overhead hoist to removethe auxiliary case from the trans-mission case.

Figure 11–24PULLERHOLES

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Transmission Jack

a. Remove the bottom two capscrewsfrom the output bearing retainer.Install a bracket from the transmis-sion jack. Figure 11–26 .

b. Connect a transmission jack to thebracket.

Figure 11–25 c. Use the transmission jack to re-move the auxiliary case from thetransmission case.

NOTE:Sometimes the bearing cups for theauxiliary countershafts will remain inthe bores in the transmission case.Remove the cups. Mark each cup forcorrect location. However, if “slip” fitcups are installed, the cups must beremoved and replaced with “press” fitcups.

12. Use a slide hammer and a puller toremove the bearing cups for the auxil-iary countershaft from the case. Markthe cups. The cups must be installedin the original location. Figure 11–27.

Figure 11–26

Figure 11–27 CUP

SLIDEHAMMER

BOTTOM TWOCAPSCREWS

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Section 11Removing and Installing the Thirteen–SpeedAuxiliary Case Transmissions13. On Design Level 1 Transmissions ,

remove the snap rings in the bores forthe cups for the auxiliary counter-shafts. (Design Level 2 Transmis-sions do not use snap rings in thislocation.) Figure 11–28.

14. Use a scraper to remove the gasketmaterial from the transmission caseand the auxiliary case.

Figure 11–28

SNAP RING

Installing the AuxiliaryCase –Thirteen-SpeedTransmissions

NOTE:The auxiliary case must be in the LOrange so that the case can be installedwith the gears timed correctly.

1. Use an air gun to apply air pressure tothe LO range port in the piston hous-ing to put the case in the LO range.

2. On Design Level 1 Transmissions, ifremoved, install the snap rings in thebores for the cups for the auxiliarycountershafts in the main case. Fig-ure 11–29.

3. If removed, install the bearing cups forthe auxiliary countershaft in the boresin the main case. Clean the outerdiameter of the cups.

On Design Level 1 Transmissions,make sure the cup is against the snapring. Figure 11–29.

On Design Level 2 Transmissions,make sure the cup is against the stepin the bore. Figure 11–30.

Figure 11–30

Figure 11–29

SNAPRING


CUP

Page 99


Figure 11–31

4. Use a sealant dispenser and Loctite®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) to put a newsealant pattern for the auxiliary caseon the transmission case a 1/8 inch (3mm) bead in the pattern shown inFigure 11–31. Put a sealant patternaround each puller hole in the auxiliarycase as shown in Figure 11-31. See‘Gasket Sealant’ in Section 1.


5. If the dowels have been removed, usea steel drift and a hammer to install thedowels. Install the dowels from theback of the main case flange. Installthe dowels until the end of the dowelsare 2.5 inches (64 mm) from theflange. Figure 11–32.

Figure 11–32

6. Lubricate the dowel pins with new oilthat is used in the transmission.

7. Connect a lifting bracket to the auxil-iary case.

If a transmission jack is used, removethe bottom two capscrews from theoutput bearing retainer. Use cap-screws to connect a bracket for thejack to the retainer. Figure 11–33.

AUXILIARY COVER-TO-TRANSMISSION CASE GASKET PATTERN• PUT THE PATTERN ON THE TRANSMISSION CASE AND THE AUXILIARY COVER

TRANSMISSION CASE GASKET PATTERN

TRANSMISSION CASEBOLT HOLE

AUXILIARY COVER GASKET PATTERN

BOLT HOLE


BEAD

REARCOVER

2.5 INCHES(64 mm)

Page 100


Figure 11–33

If an overhead hoist is used, connectbrackets to the bores for the transmis-sion case capscrews. Figure 11–34.

Figure 11–34

8. Connect a lifting device to the liftingbracket(s).

NOTE:The auxiliary section must be in the LOrange to install the auxiliary case.

9. Install the auxiliary case. Make surethe dowels holes in the auxiliary caseare aligned with the dowels in the maincase and that the auxiliary case isevenly installed on the dowels. Rotatethe input shaft so that the teeth on theauxiliary drive gear align with the teethon the countershaft driven gears.Figure 11–35.

Figure 11–35

10. Remove the lifting bracket(s) and thelifting device from the auxiliary case.

11. Install the auxiliary case against thetransmission case. If necessary, use arubber or plastic mallet to tap theauxiliary case against the main case.Figure 11–36.

12. Install the mounting capscrews andwashers for the auxiliary case.Tighten the capscrews to 35-45 lb-ft(47-61 N.m). Figure 11–36.

BOTTOM TWOCAPSCREWS

Page 101


Figure 11–36

13. Check and adjust the end play ofeach auxiliary countershaft. Do theprocedure described in Section 18,“Auxiliary Countershaft End PlayAdjustment”. When the correct endplay of 0.002-0.006 inch (0.050-0.152mm) is obtained, go to step 14 ofthis procedure.

14. If removed, install the filter and regula-tor assembly. See the procedure inSection 3, “In-Vehicle Service”.

NOTE:To install the air lines, push the airlines into the fitting until the linestouch the bottom of the fittings. Thebuttons on the top of the fittings auto-matically lock the air lines in position.

15. Connect the following air tubes: Fig-ure 11–37.

a. BLACK tube to the LO range porton the piston housing.

b. BLUE tube to the HI range port onthe piston housing cover.

c. RED tube to the supply port of thefilter and regulator assembly.

d. Splitter tube to the fitting on thepiston housing cover.

16. Install the transmission as described inthis section.

17. Fill the transmission with the specifiedoil to the specified level. See “Check-ing and Adjusting the Oil Level ” inSection 2.

Figure 11–37

SUPPLYPORT

HI RANGEPORT

LORANGEPORT

SPLITTERPORT

RED

BLUE

BLACK

Page 102

Section 11Removing and Installing the AllAuxiliary Case Transmissions

Figure 11–40

Figure 11–39Removing the AuxiliaryDrive Gear1. Remove and discard the snap ring that

fastens the auxiliary drive gear to themainshaft. Figure 11–38.

2. Use pry bars to separate the auxiliarydrive gear from the mainshaft. Re-move the gear. Figure 11-39.

3. Remove and discard the two O-ringsfrom the gear. Figure 11-40.

Figure 11–38

SNAP RING

Page 103

Section 11All Removing and InstallingTransmissions the Auxiliary Case

Installing the AuxiliaryDrive Gear

1. Lubricate all parts with new oil that isused in the transmission.

2. Lubricate new O-rings with new oil thatis used in the transmission. Installnew O-rings on the gear.

3. Install the auxiliary drive gear assem-bly on the mainshaft and in the rear ofthe case. Figure 11–41.

4. Install a new snap ring that fastens theauxiliary drive gear on the mainshaft.Figure 11–42.

Figure 11–41

Figure 11–42

SNAP RING

Page 104

Section 12Overhauling the Main Case


Figure 12–2

Removing the Mainshaft

NOTE:If the auxiliary drive gear is removed,go to step 5.

1 Remove the capscrews that fasten thebearing retainer of the auxiliary drivegear to the transmission case. Figure12–1.

2. Remove and discard the snap ring thatfastens the auxiliary drive gear to themainshaft. Figure 12–1.

3. If a round retainer is used for theauxiliary drive gear, clean the pullerholes and install a 3/8"-16 x 1.00"capscrew in the three puller holes inthe bearing retainer of the auxiliarydrive gear. Evenly tighten the threecapscrews to remove the auxiliarydrive gear from the mainshaft. Ifnecessary, tap on the mainshaft with arubber or plastic mallet to separate thegear from the mainshaft. Remove theround retainer. Figure 12–3.

Figure 12–3

Figure 12–1

3. If a two-piece retainer is used for theauxiliary drive gear, use pry bars toseparate the auxiliary drive gear fromthe mainshaft. Remove the gear.Remove and discard the O-rings fromthe gear. Remove the two-pieceretainer Figure 12-2.

PULLER SCREWS

AUXILIARY DRIVE GEAR

SNAP RING

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NOTE:The ball bearing assembly for the auxil-iary drive gear will sometimes come outwhen the auxiliary drive gear is re-moved. If necessary, pull on the as-sembly to separate the gear from thebearing.

4. Put a pry bar under the snap ring onthe ball bearing assembly for theauxiliary drive gear. Remove thebearing. Figure 12–4.

Figure 12–4

5. Remove the auxiliary drive gear thrustwasher from the mainshaft. Figure12–5.

6. Remove the snap ring from the re-verse gear on the mainshaft. Figure12–6.

7. Slide the clutch collar into the low orfirst gear. Move the reverse gearagainst the low or first gear. Figure12–7.

Figure 12–5

Figure 12–6

Figure 12–7

SNAPRING

THRUST WASHER

REVERSEGEAR

LOW ORFIRST GEAR

SNAP RING

Page 106


8. Put a pry bar between the case andthe end of the idler shaft to keep thereverse idler shaft for the upper coun-tershaft from moving. Remove the nutand the washer that fastens the gearon the shaft. Figure 12–8.

Figure 12–8

9. Remove the upper reverse idler shaftfrom the rear of the case. Remove thereverse idler gear, the two spacerwashers, the bearing race and theneedle bearing assembly while remov-ing the shaft. Figure 12–9.

Figure 12–9

CAUTIONThe mainshaft must be supported whenthe countershaft is serviced. If notsupported, the timing marks fall out ofalignment. The weight of the mainshaftwill also damage the thrust washersbetween the gears.

10. Install the auxiliary drive gear andbearing assembly so that themainshaft is supported in the case.

11. On Design Level 1 Transmissions,remove the selective snap ring for thefront upper countershaft bearings inthe case. Mark the snap ring for cor-rect installation. Figure 12–10.

PRYBAR

UPPER IDLERGEAR

SPACER

GEAR

NEEDLEBEARING

ASSEMBLY

RACE

Figure 12–10

12. On Design Level 2 Transmissions ,remove the Allen-head screws thatfasten the front upper countershaftretainer to the case. Remove theretainer and the shims. Figure 12–11.

SNAPRING

Page 107



Figure 12–13

NOTE:Two types of rear countershaft bearingretainers are used on Design Level 2transmissions. One retainer is used ontransmissions with serial numbersLB93017865 and below. The otherretainer is used on transmissions withserial numbers LB93017866 and above.Make sure the correct part is used.

CAUTIONUse hand tools to rotate the forcingscrew of the bearing puller tool. Ifpower tools are used, the tool will bedamaged.

13. Remove the front upper countershaftbearing cup and cone. Use BearingPuller Tool, Rockwell Part Number A-3256-W-1037, or Kent-Moore Number,J-41086 or equivalent to remove thecup and cone. Make sure the correctkeys of the tool for transmission designlevel are installed between the jaws ofthe puller and the countershaft. Fig-ure 12–12.

If the cup is removed easily, the cup isa “loose” fit cup. Discard and replacewith a “press” fit cup and cone assem-bly. Make sure the correct parts areused.

14. On Design Level 1 Transmissions,remove the selective snap ring for therear upper countershaft bearing in thecase. Mark the snap ring for correctinstallation. Figure 12–13.

BEARINGCUP AND CONE

PULLER TOOLJ41086

(A-3256-W-1037)

SNAP RING

CUP

SHIM

RETAINER

Page 108


15. On Design Level 2 Transmissions ,remove the fasteners for the rearupper countershaft retainer. Removethe retainer. Figure 12–14.

Figure 12–14

Figure 12–15

17. Move the upper countershaft assemblyforward and to the side of the case.Make sure the countershaft is sepa-rated from the mainshaft assembly.

18. Remove the auxiliary drive gear fromthe mainshaft.

19. Remove the mainshaft. See the fol-lowing procedure.

a. Make sure the reverse gear isagainst the low gear.

WARNINGThe mainshaft assembly weighs morethan 50 pounds. Use a lifting device toinstall the mainshaft into the case toavoid serious personal injury.

b. Put a rope or a lifting hook underthe first-second collar. Slide themainshaft assembly to the rear ofthe case. Figure 12–16.

CAUTIONUse hand tools to rotate the forcingscrew of the countershaft bearingpusher tool. If power tools are used,the tool will be damaged.

16. Install Countershaft Bearing PusherTool, Rockwell Part Number 3256-D-1044 or G&W Tool Number G-28 orequivalent, on the front of the counter-shaft. Rotate the forcing screw untilthe rear countershaft bearing cup canbe removed from the case. Make surethe countershaft does not push againstthe mainshaft. Figure 12–15.

If the cup is removed easily, the cup isa “loose” fit cup. Discard and replacewith a “press” fit cup and cone assem-bly. Make sure the correct part isused.

RETAINER

COUNTERSHAFTBEARINGPUSHER TOOL

Page 109



CAUTIONHold the reverse gear when removingthe mainshaft. If not secured, the gearcan fall from the shaft.

c. Tilt the front of the mainshaft upand lift the mainshaft assemblyfrom the case. Figure 12–17.

FIRST GEARCOLLAR

Page 110


Removing the Input ShaftThe top cover, the mainshaft and theauxiliary drive gear must be removed toremove the input shaft.

1. Remove the mounting capscrews andwashers from the input bearing re-tainer. Remove the retainer. Figure12–18.

Figure 12–18

2. Use a scraper to remove the sealantmaterial from the transmission caseand the input bearing retainer.

3. Remove the input shaft. See thecorrect procedure.

Design Level 1 Transmissionsa. Remove the snap ring on the outer

race of the input bearing. Figure12–19.

b. Use a rubber mallet to drive theinput shaft, the bearing assemblyand the main drive gear from thecase. Figure 12–20.

Figure 12–19

Figure 12–20

c. If necessary, disassemble the inputshaft assembly as described instep 4.

Design Level 2 Transmissions

a. Remove the snap ring that retainsthe input shaft in the bearing.Figure 12–21.

INPUT BEARINGRETAINER

SNAPRING

Page 111


Figure 12–21

b. Remove the input shaft from thecase. If necessary, use a rubbermallet to drive the input shaft fromthe case. Figure 12–22.

Figure 12–22

c. Remove the input bearing from thecase. If necessary, remove thesnap ring from the bearing. Figure12–23.

Figure 12–23

d. Remove the main drive gear andthe spacer from the case. Figure12–24.

Figure 12–24

4. On Design Level 1 Transmissions, ifrequired, disassemble the input shaft.See the following procedure. Figure12–25.

INPUTSHAFT

SNAP RING INPUTBEARING

MAINDRIVEGEAR

Page 112


Figure 12–25

a. Remove the snap ring from theside of the input bearing.

b. Use a press and a sleeve to re-move the input shaft from thebearing. Figure 12–26.

c. Remove the spacer from the top ofthe gear.

Figure 12–26

d. Remove the input shaft from themain drive gear. Remove the snapring from the groove inside themain drive gear.

e. If worn or damaged, use a pullertool to remove the bushing frominside the input shaft.

f. Inspect all parts. See “Inspectingthe Parts” in Section 1.

BEARING

SPACER

MAINDRIVEGEAR

BUSHING

SNAPRING

SNAPRING

INPUTSHAFT

Page 113


Removing theMain Countershafts1. Remove the auxiliary drive gear and

mainshaft as described in this section.See “Removing the Mainshaft”.

2. Remove the input shaft and the maindrive as described in this section. See“Removing the Input Shaft”.

3. If installed, remove the long capscrewsor the T-Handle Tools (3256-Y-1013)from the countershafts.

4. Push the countershaft assemblies tothe rear of the case. Tilt the front ofthe countershaft up and remove thecountershaft. Remove the upper andlower countershafts from the case.Mark the countershafts for correctinstallation. Figure 12–27.

Figure 12–27

Page 114


Removing the ReverseIdler Gear Assembly1. Remove the upper reverse idler gear

assembly and the mainshaft as de-scribed in “Removing the Mainshaft” inthis section.

2. Remove the input shaft as described in“Removing the Input Shaft ” in thissection.

3. Remove the main countershafts asdescribed in “Removing the MainCountershafts” in this section.

4. Put a pry bar between the case andthe end of the idler shaft to keep thelower reverse idler shaft from moving.Remove the nut and the washer thatfastens the gear on the shaft. Figure12–28.

5. Remove the reverse idler gear, the twospacer washers, the bearing race andthe needle bearing assembly whileremoving the shaft. Figure 12–29.

Figure 12–28

Figure 12–29

IDLERGEAR

NUT

BEARINGASSEMBLY

GEAR RACE

SPACER

Page 115


Removing the Oil Pump1. Remove the auxiliary drive gear, the

mainshaft, the input shaft and thecountershafts as described in thissection.

2. Remove the Allen-head capscrewsand washers that fasten the pump tothe case. Figure 12–30.

3. Remove the bracket for the pick-uptube from the case.

4. Remove the pump. If necessary, hitthe pump with a plastic or rubberhammer to separate the pump fromthe case.

5. Clean the pick-up screen on the tube.If the tube or screen is damaged,replace the pich-up tube assembly.

6. If used, inspect the pump-to-case O-ring on the front of the pump. If wornor damaged, replace the O-ring.

7. Remove the cover and inspect thepump. Replace the O-ring if worn ordamaged. Replace the pump if therotors are worn or damaged. Figure12–31.

Figure 12–30

Figure 12–31

ROTOR

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Removing the Magnets1. Remove the auxiliary drive gear, the

mainshaft, the input shaft and thecountershafts as described in thissection.

2. Remove the magnets from the bottomof the case. Figure 12–32.

Figure 12–32

Removing the PTO Covers1. Drain the lubricant from the transmis-

sion. See “Draining and Replacing theTransmission Oil” in Section 2, “Lubri-cation and Maintenance”.

2. Remove the capscrews that fasten thePTO covers to the side and the bottomof the case. Remove the covers.Figure 12–33.

3. Use a scraper to remove the sealantmaterial from the PTO covers and thecase.

Figure 12–33

MAGNETS

PTOCOVERS

Page 117


Figure 12–34

Figure 12–35

Figure 12–36

Installing the PTO Covers1. Use a sealant dispenser and Loctite®,

RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent toput a sealant pattern for the PTOcovers on the case. Put a gasketsealant on the case. See “Installingthe Sealant” in Section 1, “GeneralInformation”.

See Figure 12–34 for the pattern forthe bottom cover. See Figure 12–35for the pattern for the side cover.

2. Install the 8-hole PTO cover on thebottom of thecase. Install the mount-ing capscrews and washers. Tightenthe capscrews to 35-45 lb-ft(47-61 N.m).

3. Install the 6-hole PTO cover on theside of the case. Install the mountingcapscrews and washers. Tighten thecapscrews to 35-45 lb-ft (47-61 N.m).

MAGNETS



TRANSMISSIONCASE


BOLTHOLE



PUT BEADAROUND HOLE

TRANSMISSIONCASE


SIDE COVER

BOLTHOLE

Installing the Magnets1. Use a weak alkaline solution or a

commercial cleaning solvent to removeall oil and dirt from the case. Dry thecase before installing the magnets.

2. Remove all dirt and metal particlesfrom the magnets. Put an adhesive,such as Loctite®, RTV Sealant™,#5699 (Rockwell Part Number2297-A-7021) or equivalent on thebottom of the magnets. Install the fourmagnets in the bottom of the case.Figure 12–36 .

3. Install the main countershafts, theinput shaft and the mainshaft asdescribed in this section.

Page 118


Installing the Oil PumpSee Figure 12–37.


2. Install the pump in the case. Install thecapscrews and the washers. Tightenthe capscrews to 7-10 lb-ft (10-13N.m).

3. Connect the pick-up tube bracket tothe case. Install and tighten the cap-screw.

4. Install the main countershafts, theinput shaft and the mainshaft asdescribed in this section.

Figure 12–37

Installing the ReverseIdler Gear Assemblies1. Lubricate all parts with new oil that is

used in the transmission.

2. Install the needle bearing assemblyinside the lower reverse idler gear.Figure 12–38.

3. Install the inner race inside the needlebearing assembly. Figure 12–38.

4. Install a spacer washer on each side ofthe reverse idler gear. Figure 12–38.

Figure 12–38

5. Put the lower reverse idler gear inposition in the bottom of the case.

6. From the auxiliary cover side of thetransmission case, install the shaftthrough the reverse idler gear assem-bly.

7. Install the nut and the washer thatfastens the lower reverse idler gearassembly in the case. Hold the end ofthe shaft with a screwdriver. Tightenthe nut to 75-100 lb-ft (101-135 N.m).Figure 12–39.

Figure 12–39

IDLERGEAR

NUT

GEAR BEARINGASSEMBLY RACE

SPACER

Page 119


8. Install the countershafts, the inputshaft and the mainshaft as describedin this section. The procedure toinstall the upper reverse idler gearassembly is in “Installing the Main-shaft” in this section.

e. Install the spacer on top of thegear.

Figure 12–40

Installing the Input Shaft1. Use paint to put a timing mark on one

tooth of the main driven gear on theinput shaft. Put another paint markdirectly opposite (180o) the first mark.Figure 12–40.

Figure 12–41

f. Use a press and a sleeve to installthe bearing on the input shaft.Support the bearing on the pressso that the main drive gear istoward the top of the press. Presson the gear until the bearingtouches the spacer. Make sure thebearing rotates after the shaft isinstalled. Figure 12–42.

g. Install the snap ring that fastens thebearing on the input shaft.

Figure 12–42

MAINDRIVE GEAR—MARK ONE TOOTH


BEARING

SPACER

MAIN DRIVEGEAR

BUSHING

SNAPRING

SNAPRING

INPUTSHAFT

2. On Design Level 1 Transmissions, ifrequired, disassemble the input shaft.See the following procedure. Figure12–41.

a. Lubricate all the parts with new oilthat is used in the transmission.

b. If removed, install a new bushing inthe end of the input shaft. Use ahammer and the correct driver toolto install the bushing.

c. Install the snap ring in the grooveinside the main drive gear.

d. Align the splines of the input shaftwith the splines inside the maindrive gear. Install the main drivegear over the input shaft.

TIMINGMARKS

Page 120


Figure 12–443. On Design Level 1 Transmissions,install the input shaft. See the follow-ing.

a. If installed, remove the outer snapring from the input bearing.

b. Install the input shaft assemblythrough the inside of the case.

c. Use a rubber mallet to tap the inputshaft assembly in position. Theinput shaft assembly is correctlyinstalled when there is a slightclearance between the main drivegear and the transmission case.Figure 12–43.

Figure 12–43

d. Install the snap ring in the grooveon the input shaft bearing. Figure12–44.

4. On Design Level 2 Transmissions,install the input shaft. See the follow-ing procedure.

a. Lubricate all parts with new oil thatis used in the transmission

b. If removed, install the snap ringinside the main drive gear.

c. Install the main drive gear in posi-tion in the case. Figure 12–45.

Figure 12–45

d. If removed, install a new bushing inthe end of the input shaft. Use ahammer and the correct driver toinstall the bushing.

e. Install the input shaft through themain drive gear. The shaft iscorrectly installed when the groovefor the snap ring on the shaft istowards the outside the case.Figure 12–46 .

MAINDRIVEGEAR

SNAPRING

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g. If removed, install the outer snapring on the bearing.

h. Install the bearing over the shaftand in the case. Figure 12–48.

Figure 12–47

f. Install the spacer on the input shaft.Figure 12–47.

CAUTIONPut the tube on the inner race of thebearing. If tools are used in any otherplace on the bearing, the bearing willlbe damaged.

i. Put the bearing over the input shaftand in the case. Use a rubber orplastic mallet and G&W Tool, G-35,Input Shaft Bearing Driver to installthe bearing on the input shaft. Thebearing is correctly installed whenthe snap ring touches the case.Figure 12–49.

INPUTSHAFT

SPACER

SNAP RING

Figure 12–49

INPUT SHAFTBEARING DRIVER

BEARING

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j. Install the snap ring in the grooveon the input shaft bearing. Figure12–50.

Figure 12–50

5. Use a sealant dispenser and Loctite®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021), to put a newsealant pattern on the case for theretainer in the pattern shown in Figure12–51. See “Gasket Sealant” inSection 1.

6. Put the input bearing retainer on thecase. Install the mounting capscrewsand washers. Tighten the capscrewsto 25-35 lb-ft (34-47 N.m).Figure 12–52 .

Figure 12–51

Figure 12–52INPUT BEARING

RETAINER

SNAP RING

INPUT BEARING RETAINER-TO-TRANSMISSIONCASE GASKET PATTERN

• PUT THE PATTERN ON THE INPUT BEARING RETAINER


OIL SLOT

BOLT HOLE


RETAINER

Page 123


Installing the MainCountershafts

NOTE:The bearing cup and the bearing conemust be replaced as an assembly. Donot replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manufac-turer.


2. Use paint to put a timing mark on twoteeth of each countershaft driven gear.Make sure the timing mark is alignedwith the slot for the key and the “O”stamping on the countershaft. Fig-ure 12–53.

Figure 12–53

3. Use paint to put a timing mark on onetooth of the main drive gear on theinput shaft. Put another paint markdirectly opposite (180o) the first mark.Figure 12–54.

4. Install the lower countershaft so thatthe large gears are toward the front ofthe case. Move the countershafttoward the side of the case. Figure12–55.

Figure 12–54

Figure 12–55

5. Install the upper countershaft assem-bly in the case. The large gears mustbe toward the front of the case. Movethe countershaft toward the side of thecase. Figure 12–56.

MAIN DRIVE GEAR—MARK ONE TOOTH


TIMINGMARKS

COUNTERSHAFT DRIVEN GEAR—MARK TWO TEETH OVER

THE SLOT FOR THE KEYOR THE "O" STAMPING

TIMINGMARK

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Install a long capscrew or T-HandleTool, 3256-Y-1013, in the hole in thefront of the upper countershaft. Thetool or the capscrew makes the coun-tershaft easier to move.

Figure 12–56

6. Rotate the input shaft and move thelower countershaft assembly so thatthe timing marks are aligned. Figure12–57.

7. Install the mainshaft as described inthis section.

Figure 12–57

MAIN DRIVE GEAR TIMING MARKCOUNTERSHAFT DRIVEN GEAR TIMING MARK

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Installing the Mainshaft

WARNINGWear safe eye protection and make surethe tools are in safe condition. If thetools are worn or damaged(“mushroomed”), pieces can break andcause serious personal injury.

To install the mainshaft, the input shaft andthe main countershafts must be installed inthe case.

NOTE:Apply Loctite #242 (Rockwell Part Num-ber 2297-V-5430) or equivalent on thethreads of the fasteners.


NOTE:The rear bearing cone must be installedon the upper countershaft.

Figure 12–58

2. Move the upper countershaft towardthe side of the case. Figure 12–58.

Install a long capscrew or T-HandleTool, 3256-Y-1013, in the hole in the

Figure 12–59

front of the upper countershaft. Thetool or the capscrew makes the coun-tershaft easier to move.

3. Rotate the input shaft and move thelower countershaft assembly so thatthe timing marks are aligned. Figure12–59.

4. Remove the snap ring to remove theauxiliary drive gear assembly from themainshaft.

T-HANDLETOOL


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CAUTIONThe mainshaft must be supported whenthe countershaft is serviced. If notsupported, the timing marks fall out ofalignment. The weight of the mainshaftwill also damage the thrust washersbetween the gears.

8. Install the auxiliary drive gear andnearong assembly so that themainshaft is supported in the case.

9. Align the timing marks on the maindrive gear of the input shaft with thetiming marks on the upper counter-shaft. Use the T-Handle Tool or thelong capscrew to move the counter-shafts. Figure 12–62.

Remove the T-Handle Tool or longcapscrews from the countershafts.

NOTE:The bearing cone must be installed onthe rear of the countershaft.

5. Remove the snap ring that fastens thereverse gear to the mainshaft. Slidethe reverse gear forward until the geartouches the low gear. Figure 12–60.

6. Install the sliding collar on the front ofthe mainshaft. Figure 12–60.

7. Put lifting hooks or a rope under themainshaft assembly. Install the main-shaft assembly in the case. Make surethe front of the mainshaft is installed inthe bushing in the input shaft. Tempo-rarily install the auxiliary drive gear tosupport the rear of the mainshaft.Remove the lifting hooks or rope.Figure 12–61.

SLIDINGCOLLAR

REVERSE GEARMUST TOUCH

LOW GEAR

Figure 12–60

Figure 12–61

Figure 12–62


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Figure 12–64

d. Use a hammer and a bearing drivertool to install the upper front coun-tershaft cone. The cone is correctlyinstalled when the cone touchesthe countershaft. Figure 12–65.

COUNTER SHAFTBEARINGPUSHER TOOL

Figure 12–63

GROOVE

install the upper rear bearing cup andthe upper front bearing cup and coneon the countershaft. See the followingprocedure.

a. Put the cup in the bore for theupper rear countershaft. Use aplastic hammer to install the cup inthe bore.

b. Use a hammer and a bearing drivertool to install the upper rear coun-tershaft cup. The cup is correctlyinstalled when the cup is past thesnap ring groove. Figure 12–63.

CAUTIONUse hand tools to rotate the forcingscrew of the countershaft bearingpusher tool. If power tools are used,the tool will be damaged.

c. Install Countershaft Bearing PusherTool, Rockwell Part Number 3256-D-1044 or G&W Tool Number G-28or equivalent, on the front of thecountershaft. Rotate the forcingscrew until the rear countershaftbearing cup is against the snapring. Figure 12–64.

Figure 12–65BEARINGCONE

10. On Design Level 1 transmissions,

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WARNINGWear safe eye protection and make surethe tools are in safe condition. If thetools are worn or damaged (“mush-roomed”), pieces can break and causeserious personal injury.

e. Use a hammer and a bearing drivertool to install the upper front coun-tershaft cup. The cup is correctlyinstalled when the cup is past thesnap ring groove. Figure 12–66.

Figure 12–66

f. Install the thinnest snap ring (0.068inch or 1.73 mm), Rockwell partnumber 1229-C-4215 in the borefor the front countershaft. Thesnap ring is used as a gauge.Figure 12–67.

g. Install T-Handle Tool, Rockwell partnumber, 3256-Y-1013, or a longcapscrew in the front of the coun-tershaft. Figure 12–68.

h. Pull the countershaft and front coneassembly into the cup until the frontcup is against the snap ring. Fig-ure 12–68.

i. Remove the T-Handle Tool or thelong capscrew.

Figure 12–67

NOTE:The bearing cone must be installed onthe rear of the countershaft.

11. On Design Level 2 transmissions,install the upper rear bearing cup andthe upper front bearing cup and coneon the countershaft. See the followingprocedure.

a. Put the cup in the bore for theupper rear countershaft. Use aplastic hammer to install the cup inthe bore.

GROOVE

THINNEST SNAP RING-0.068 INCH (1.73 MM)

Figure 12–68

T-HANDLETOOL

CUP MUST TOUCHSNAP RING

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WARNINGWear safe eye protection and makesure the tools are in safe condition. Ifthe tools are worn or damaged (“mush-roomed”), pieces can break and causeserious personal injury.

NOTE:The Piloted Bearing Driver Tool mustinstall the cup so that the cup extendsat least 0.125 or 1/8 inch (3 mm) abovethe surface of the case. Make sure theDriver Tool does not touch the any partof the bearing cone or the cone will bedamaged.

b. Use a hammer and a PilotedBearing Driver to install the rearcup in the bore. The cup is cor-rectly installed when the cup ex-tends 0.125 or 1/8 inch (3 mm)above the surface of the case.Figure 12–69.

CAUTIONUse a new hardened countershaft bear-ing retainer to install the rear counter-shaft cup. If a retainer that is not hard-ened is used, the transmissions will bedamaged.

d. Put a new hardened countershaftrear bearing retainer in position onthe main case. Install the cap-screws. Alternately and evenlytighten the capscrews to 35 lb-ft (47N.m) until the retainer touches themain case. Figure 12–70.

Figure 12–69

c. Clean three capscrews that fastenthe countershaft rear bearingretainer to the main case. ApplyLoctite®#242 (Rockwell Part Num-ber 2297–V–5430) or equivalent tothe threads of the capscrews.

DRIVER1/8 INCH(3MM)

Figure 12–70

TORQUESEQUENCE


e. Use a hammer and a bearing drivertool to install the upper front coun-tershaft cone. The cone is cor-rectly installed when the bottom ofthe cone is against the counter-shaft. Figure 12–71.

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Figure 12–71

f. Put the cup in the bore for theupper front countershaft. Use aplastic hammer to start installingthe cup in the bore.


g. Use a hammer and a bearing drivertool to install the upper front coun-tershaft cup. The cup is correctlyinstalled when the cup touches thebearing cone. Figure 12–72.

Figure 12–72

h. Use a hammer and a PilotedBearing Driver to install the frontcup in the bore. The cup is cor-rectly installed when the cup ex-tends 0.125 inch (3 mm) above thesurface of the case.

CAUTIONMake sure the retainer and the shimsare correctly installed against the case.Make sure the retainer does not pushthe shims against the cup or the endplay will not be correct.

i. Install the shims in the bore for theupper front countershaft bearing.Replace any worn or damagedshims. Make sure the slot for theoil passage on the shims arealigned with the oil passage hole.Install the one of following shimselections. Figure 12-73.

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• The shims that were removedduring disassembly.

• A 0.005 inch (0.127 mm) shim,Rockwell part number, 2803-R-2826.

• A 0.0075 inch (0.190 mm) shim,Rockwell part number, 2803-S-2827.

CAUTIONMake sure the retainer and the shimsare correctly installed against the case.Make sure the retainer does not pushthe shims against the cup or the endplay will not be correct.

j. Install a new retainer for the upperand lower front countershaft bear-ings. Install the Allen-head cap-screws. Alternately and evenlytighten the capscrews to 120 lb-in(14 N.m). Figure 12–74.

Figure 12–75

TORQUESEQUENCE

RETAINER

SPACER

GEAR

RACE

NEEDLEBEARING

ASSEMBLY

OIL SLOT

12. Check the end play on the upperand lower main countershafts asdescribed in Section 17, “MainCountershaft End Play Adjust-ment”. When the end play is be-tween 0.002-0.006 inch (0.050-0.152mm), go to step 13.

13 Install the upper reverse idler gearassembly in the top of the case. Seethe following procedure.

a. Install the needle bearing assemblyinside the gear. Figure 12–75.

SHIM

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b. Install the inner race inside theneedle bearing assembly. Figure12–75.

c. Install a spacer washer on eachside of the reverse idler gear.Figure 12–75.

d. Put the reverse idler gear in posi-tion in the top of the case.

e. From the auxiliary cover side of thetransmission case, install the shaftthrough the reverse idler gearassembly.

f. Install the nut and the washer onthe upper reverse idler gear as-sembly. Hold the end of the shaftwith a screwdriver. Tighten the nutto 75-100 lb-ft (100-135 N.m).Figure 12–76.

Figure 12–76

14. Move the reverse gear to the rear ofthe mainshaft. Remove the auxiliarydrive gear. Figure 12–77.

Figure 12–77

15. Install a new snap ring that fastens thereverse gear on the mainshaft. Makesure the snap ring is completely in-stalled in the groove. Figure 12–78.

Figure 12–78

16. Install the thrust washer on the main-shaft. Figure 12–79.

17. Install the auxiliary drive gear assem-bly on the mainshaft and in the rear ofthe case. See the following.

PRYBAR

UPPER IDLERGEAR

REVERSEGEAR

SNAPRING

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Round Retainer–Figure 12–80

a. Install the retainer, the bearing andgear assembly on the mainshaft.Make sure the groove for the snapring on the shaft is visible.

b. Rotate the retainer so that theholes in the retainer are alignedwith the bores in the case.

c. Install and tighten the capscrews to35-45 lb-ft (47-61 N.m)

Two-Piece Retainer-Figure 12–81

a. Install the bearing assembly in thecase over the mainshaft.

b. Install the two-piece retainer on thecase.

c. Install and tighten the capscrews to35-45 lb-ft (47-61 N.m).

d. Install the auxiliary drive gear onthe mainshaft. Make sure thegroove for the snap ring on theshaft is visible.


Figure 12–81

SNAP RING

THRUST WASHER

TWO-PIECERETAINER

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Section 13Overhauling the Auxiliary Drive Gear

Figure 13–1

Disassembling theAuxiliary Drive GearAssembly1. Remove the auxiliary case. See

Section 11, “Removing and Installingthe Auxiliary Case”.

2. Remove the capscrews that fasten thebearing retainer of the auxiliary drivegear to the transmission case. Figure13–1.

3. Remove and discard the snap ring thatfastens the auxiliary drive gear to themainshaft. Figure 13–1.

4. If a two-piece retainer is used for theauxiliary drive gear, use pry bars toseparate the auxiliary drive gear fromthe mainshaft. Remove the gear.Remove the two-piece retainer Figure13–2.

5. If a round retainer is used for theauxiliary drive gear, clean the pullerholes and install a 3/8"-16 x 1.00"capscrew in the three puller holes inthe bearing retainer of the auxiliarydrive gear. Evenly tighten the threecapscrews to remove the auxiliarydrive gear from the mainshaft.

If necessary, tap on the mainshaft witha rubber or plastic mallet to separatethe gear from the mainshaft. Removethe round retainer. Figure 13–3.


Figure 13–2

Figure 13–3

SNAP RING

PULLER SCREWS

AUXILIARY DRIVE GEAR

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NOTE:The ball bearing assembly for the auxil-iary drive gear is sometimes come outwhen the auxiliary drive gear is re-moved. If necessary, pull on the as-sembly to separate the gear from thebearing.

5. If necessary, remove the ball bearingassembly from the main case. Put apry bar under the snap ring on the ballbearing assembly for the auxiliarydrive gear. Remove the bearing.Figure 13–4.

Figure 13–4

6. If worn or damaged, remove andreplace the two O-rings from the bot-tom grooves of the auxiliary drive gear.

7. Inspect the teeth of the auxiliary drivegear. Replace the gear if the teeth areworn or damaged. Figure 13–5.

Figure 13–5

8. Inspect the synchronizer surface onthe auxiliary drive gear. If the surfaceis discolored, worn or damaged re-place the gear and the synchronizer.For synchronizer service procedures,see Section 16, “Overhauling theAuxiliary Case”. Figure 13–6.

9. Inspect the ball bearing. Make surethe bearing rotates in the race and thatthe outer race is not worn or damaged.Replace worn or damaged bearings.

Figure 13–6SNAP RING

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Assembling the AuxiliaryDrive Gear Assembly1. Lubricate all the parts with new oil that

is used in the transmission.

2. If removed, install two, new O-rings inthe bottom grooves of the auxiliarydrive gear. Make sure the O-rings arelubricated with new oil that is used inthe transmission. Figure 13–7.

Figure 13–8

Figure 13–7

Figure 13–9

3. Install the auxiliary drive gear assem-bly on the mainshaft and in the rear ofthe case. See the following.

Round Retainer–Figure 13–8a. Install the retainer, the bearing and

gear assembly on the mainshaft.Make sure the groove for the snapring on the shaft is visible.

b. Rotate the retainer so that theholes in the retainer are alignedwith the bores in the case.

c. Install and tighten the capscrews to35-45 lb-ft (47-61 N.m)

Two-Piece Retainer-Figure 13–9a. Install the bearing assembly in the

case over the mainshaft.b. Install the two-piece retainer on the

case.

c. Install and tighten the capscrews to35-45 lb-ft (47-61 N.m).

d. Install the auxiliary drive gear onthe mainshaft. Make sure thegroove for the snap ring on theshaft is visible.


5. Install the auxiliary case. See Section11, “Removing and Installing theAuxiliary Case”.

SNAP RING

TWO-PIECERETAINER

Page 137

Section 14Overhauling the Mainshaft

Disassembling the MainshaftSee Figure 14–1.

Figure 14–1

SNAPRING

THRUSTWASHER

SLIDINGCOLLAR

THRUSTWASHER

SPACER

THRUSTWASHER

SPACER

FIRST GEAR➀ ➁ ➂

ORSECOND GEAR

➄

THRUSTWASHER

SPACERSLIDINGCOLLAR

THRUSTWASHER

SPACER

REVERSEGEAR

SNAPRING

ROLLPIN

KEY

MAINSHAFT

SNAPRING

SECOND GEAR➀ ➁ ➂

ORTHIRD GEAR

➄ SPACER

SLIDINGCOLLAR

SNAPRING

LOW OR FIRSTGEAR ➀ ➁ ➂

ORFIRST GEAR

➄

APPLICATIONS➀ 9-SPEED DIRECT DRIVE TRANSMISSIONS 9-SPEED “R” RATIO OVERDRIVE TRANSMISSIONS➁ 9-SPEED “A” RATIO OVERDRIVE TRANSMISSIONS ➄ 10-SPEED OVERDRIVE TRANSMISSIONS➂ 9-SPEED “B” RATIO OVERDRIVE TRANSMISSIONS 13-SPEED TRANSMISSIONS

6

4

4

6

4

64

6

7

7

7

THIRD GEAR ➀ OROVERDRIVE GEAR

➁ ➂ ➄OR FOURTH GEAR

47

6

10-SPEED DIRECT DRIVE TRANSMISSIONS7

Page 138


d. Remove the spacer and the thrustwasher.

e. Remove the reverse gear.f. Remove the clutch collar.g. Remove the thrust washer, the

spacer and the low or the first gear.h. Remove the first or the second

gear.i. Remove the spacer and the thrust

washer.j. Remove the clutch collar .k. Remove the thrust washer, the

spacer and the second or the thirdgear.

m. Remove the overdrive or the thirdgear.

n. Remove the spacer and the thrustwasher.

NOTE:Remove the roll pin, only if the pin isworn or damaged. The roll pin is diffi-cult to remove.

4. If worn or damaged, remove andreplace the roll pin.

5. If worn or damaged, remove andreplace the snap rings from inside thegears. Figure 14–2.

6. Inspect all parts. See “Inspecting theParts” in Section 1.


NOTE:The thrust washer on the mainshaft,the snap ring in the reverse gear andthe front sliding collar are removedwhen the mainshaft is removed fromthe transmission.

1. If installed, remove the 3rd-4th slidingcollar from the mainshaft.

2. Put the mainshaft in a vise with brassjaws. Make sure the auxiliary drivegear end of the shaft is toward you.

3. Remove the following parts of themainshaft in this order. Keep all partstogether after disassembly.

NOTE:See Figure 14–1 to identify the compo-nents of the mainshaft assembly for thetransmission models.

a. Remove the snap ring from thesecond groove from the top of theshaft.

b. Use a small punch to push the keyaway from the roll pin at the bottomof the shaft.

c. Remove the key from the top of theshaft.

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Figure 14–2

Assembling the MainshaftSee Figure 14–1.

NOTE:See Figure 14–1 to identify the compo-nents of the mainshaft assembly for thetransmission models.

CAUTIONUse the correct snap ring in the gearsor the transmissions will not operatecorrectly. Transmissions with serialnumbers LB93021753 and below, usepart number 1229–X–4418. Transmis-sions with serial numbers LB93021754and above, use part number 1229–W-4625.

1. If removed, install the snap rings in thegears. Figure 14–2


2. If removed, use a hammer and a steeldrift to install a new roll pin. Figure14–3.

Figure 14–3

3. Lubricate all the parts of the mainshaftwith the same oil used in the transmis-sion.

4. Install the mainshaft in a vise withbrass jaws. Make sure the slot for thekey is toward you.

SNAPRING

ROLLPIN

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CAUTIONUse the correct selective washer. Donot mix washers or the transmissionwill not operate correctly.

5. Choose the correct selective thrustwasher for the third or overdrive gear.See the following.

• If the selective washers are notreplaced , use the original washers.

• If the selective washers are re-placed , install the medium size ofwasher.

For transmissions with serial num-bers LB93021753 and below, use a0.220 inch (5.60 mm) washer.

For transmissions with serial num-bers LB93021754 and above, usea 0.275 inch (7.00 mm) washer.

6. Install the selective thrust washer forthe third or overdrive gear. See thefollowing. Figure 14–4.

a. Install the washer on the shaft.Make sure the smooth side istowards you.

b. Slide the washer to the grooveabove the roll pin.

c. Move the washer so that the teethof the washer are directly over thesplines of the shaft. The washermust not slide down the shaft.

NOTE:The key will be removed and installedduring this procedure. Mark the groovewhere the roll pin is installed.

7. Install the key in the slot where the rollpin is installed. Make sure the keytouches the roll pin. Figure 14–5.

8. Install the spacer on top of the washer.Figure 14–5.

Figure 14–4

Figure 14–5

9. Install the third or the overdrive gearon the shaft. Make sure the splines inthe gear engage the teeth on thespacer and the snap ring is against thespacer. Figure 14–6.

KEY

SELECTIVETHRUST

WASHER-TEETHDIRECTLY

OVER SHAFTSPLINES

SPACER

Page 141


CAUTIONMake sure the selective washers do notmove when the key is removed. If thewashers move, the gears will fall andthe assembly must be disassembledand assembled.

12. Remove the key.

13. Choose the correct selective thrustwasher for the second or third gear.See the following.


• If the selective washers are re-placed , install the thinnest size ofwasher.



14. Install the selective thrust washer forthe second or third gear. See thefollowing. Figure 14–8.

Figure 14–6

10. Install the second or the third gear.Make sure the snap ring is towards thethird or overdrive gear. Figure 14–7.

11. Install a spacer. Make sure the teethof the spacer engage the splines of thegear. Figure 14–7.

Figure 14–7

Figure 14–8

THIRD, FOURTHOR OVERDRIVEGEAR

SPACER

SECONDOR THIRDGEAR

DOT

SELECTIVE THRUST WASHER-TEETH DIRECTLY OVER SHAFT SPLINES

Page 142


a. Install the washer on the shaft.Make sure the chamfered side withthe dot is towards you.

b. Slide the washer to the secondgroove above the roll pin.


If necessary, put a small screw-driver in the dot to move thewasher. Figure 14–8.

15. Check the clearance between the thirdand the second gears or the overdriveand the third gears. See the followingprocedure.

a. Put two screwdrivers across fromeach other between the gears.Figure 14–9.

b. Lightly push on the screwdrivers toevenly spread the gears. Makesure the gears are parallel to eachother. Figure 14–9.

Figure 14–9

NOTE:Do not push on the screwdrivers whenthe feeler gauges are installed.

c. Put two small feeler gauges be-tween the hubs. Each feeler gaugemust be opposite the other. Theclearance must be 0.006-0.012inch (0.152 mm-0.304 mm). Fig-ure 14–10.

Figure 14–10

CLEARANCE BETWEEN GEARS;0.006-0.012 INCH90.152-0.304 MM

d. If the clearance is less than 0.006inch (0.152 mm), install a thinnerselective thrust washer in thesecond or the third gear.

If the clearance is more than 0.012inch (0.304 mm), install a thickerselective thrust washer.

Three sizes of thrust washers areavailable.

For transmissions with serial num-bers LB93021753, the sizes are:0.216, 0.220 and 0.224 inch (5.50,5.60 and 5.70 mm).

For transmissions with serial num-bers LB93021754 and above, thesizes are: 0.272, 0.275 and 0.279inch (6.90, 7.00 and 7.10 mm).

FEELERGAUGES

Page 143


e. Remove the screwdrivers andfeeler gauges.

17. Install the sliding collar. Make sure theslot in the collar is installed over thekey. Figure 14–11.

Figure 14–11

SLIDINGCOLLAR

SLOTFOR KEY


18. Choose the correct selective thrustwasher for the first or second gear.See the following.





19. Remove the key. Install the selectivethrust washer for the first or secondgear. See the following. Figure 14–12.


b. Slide the washer to the third grooveabove the roll pin.


Figure 14–12


20. Install the key in the slot where the rollpin is installed. The key must touchthe roll pin. Figure 14–13.


Page 144


Figure 14–13

22. Install the first or second gear on theshaft. Make sure the splines of thegear engage the teeth on the spacerand the snap ring is against thespacer. Figure 14–14.

Figure 14–14

FIRST ORSECOND GEAR

KEY

23. Install the low or first gear. Make surethe snap ring is towards the first orsecond gear. Figure 14–15.

24. Install a spacer. Make sure the teethof the spacer engage the splines of thegear. Figure 14–15.

Figure 14–15

SPACER

LOW ORFIRST GEAR

CAUTIONMake sure the selective washers do notmove when the key is removed. If thewashers move, the gears will fall andthe assembly must be disassembledand assembled.

25. Remove the key.

26. Choose the correct selective thrustwasher for the low or first gear. Seethe following.


• If the selective washers are re-placed , install the thinnest size ofwasher.



SPACER

Page 145


27. Install the selective thrust washer forthe low or first gear. See the following.Figure 14–16.

a. Install the washer on the shaft.Make sure the chamfered side withthe dot is towards you.

b. Slide the washer to the fourthgroove above the roll pin.


If necessary, put a small screw-driver in the dot on the washer tomove the washer. Figure 14–16.

Figure 14–16

28. Check the clearance between the lowor the first and the first or secondgears. See the following procedure.

a. Put two screwdrivers across fromeach other between the first andlow or the second and the firstgears. Figure 14–17.

b. Lightly push on the screwdrivers toevenly spread the gears. Makesure the gears are parallel. Figure14–17.

NOTEDo not push on the screwdrivers whenthe feeler gauges are installed.

c. Put two feeler gauges between thehubs. Each feeler gauge must beopposite the other. The clearancemust be 0.006-0.012 inch (0.152mm-0.304 mm). Figure 14–18.

Figure 14–18

Figure 14–17

CLEARANCE BETWEEN GEARS;0.006-0.012 INCHCO. 152-0.304 MM

USE TWOSCREWDRIVERSTO SEPARATEGEARS


DOT

USE AFEELERGAUGEON EACHSIDE

Page 146



28. Choose the correct selective thrustwasher for the reverse gear. See thefollowing.





29. Remove the key. Install the selectivethrust washer for the reverse gear.See the following. Figure 14–20.


b. Slide the washer to the fifth grooveabove the roll pin.


d. If the clearance is less than 0.006inch (0.152 mm), install a thinnerselective washer.

If the clearance is more than 0.012inch (0.304 mm), install a thickerselective washer.





27. Install the sliding collar on the shaft.Make sure the slot in the collar isinstalled over the key. Figure 14–19.

Figure 14–19

SLOT FORKEY

SLIDINGCOLLAR

Page 147


Figure 14–20

30. Install the key in the slot where the rollpin is installed. Make sure the keytouches the roll pin. Figure 14–21.

Figure 14–22

Figure 14–23

33. Install the snap ring in the second snapring groove from the top of the main-shaft. Make sure the opening of thesnap ring is opposite (180o) the key.Figure 14–24.

Figure 14–21


REVERSE GEAR

SPACER

KEYTOUCHESROLLPIN


32. Install the reverse gear on the shaft.Make sure the splines in the gearengage the teeth in the spacer and thesnap ring is against the spacer. Fig-ure 14–23.

Page 148


Figure 14–24

34. Install the thrust washer for the auxil-iary drive gear on the mainshaft in thesecond groove from the top of themainshaft. Figure 14–25.

Figure 14–25

35. Install the auxiliary drive gear assem-bly on the mainshaft. Make sure thebearing is installed toward the main-shaft. Figure 14–26.

36. Install the snap ring that fastens theauxiliary drive gear to the mainshaft.Figure 14–26.

Figure 14–26

37. Check the clearance between theauxiliary drive gear and the reversegear. See the following procedure.

a. Lift on the auxiliary drive gear andpush on the reverse gear. Makesure the auxiliary drive gear isparallel to the reverse gear. Makesure the snap rings are correctlyinstalled. Figure 14–27.

Figure 14–27

AUXILIARYDRIVE GEAR

SNAP RING

THRUSTWASHER

SNAP RING-INSTALL 180 o

FROM ROLLPIN

Page 149


b. Put a two feeler gauges betweenthe hubs. The clearance must be0.006-0.012 inch (0.152 mm-0.304mm). Figure 14–28.





38. Remove the mainshaft assembly fromthe vise.

39. Install the sliding collar over the roll pinon the top of the mainshaft.

CAUTIONBe careful when moving the mainshaftassembly. The movement of the gearscan damaged the washers.

Figure 14–29

c. If the clearance is less than 0.006inch (0.152 mm), install a thinnerselective washer in the reversegear.

d. If the clearance is more than 0.012inch (0.304 mm), install a thickerselective washer in the reversegear.

CLEARANCE MUST BE:0.006-0.012 INCH(0.152-0.304 MM)

Page 150

Section 15Overhauling the Main Countershafts

THIRD GEAROR

OVERDIVE GEAR

Disassembling the Upper and the Lower MainCountershaft AssembliesSee Figure 15–1.

Figure 15–1

FRONTCONE

DRIVEGEAR

PTOGEAR

SECOND GEAR

ORTHIRD GEAR

FIRST GEAR

ORSECOND GEAR

REARCONE

ROLLPIN

COUNTERSHAFTKEY

➀ ➄

APPLICATIONS➀ 9-SPEED DIRECT DRIVE TRANSMISSIONS 9-SPEED “R” RATIO OVERDRIVE TRANSMISSIONS➁ 9-SPEED “A” RATIO OVERDRIVE TRANSMISSIONS ➄ 10-SPEED OVERDRIVE TRANSMISSIONS➂ 9-SPEED “B” RATIO OVERDRIVE TRANSMISSIONS 9-SPEED DESIGN LEVEL 1 TRANSMISSIONS

13-SPEED TRANSMISSION

➁ ➂ ➄

➀ ➁ ➂

➀ ➁ ➂

➄

7

7

4

4

6

7

4

4

6

7

Page 151

Section 15Overhauling the Main Countershaft

Figure 15–3

Figure 15–4

that fits inside the diameter of thecountershaft. Press the counter-shaft from the cone. Discard thecone. Figure 15–3.

NOTE:The upper and lower main counter-shafts are serviced in the same way.NOTE:See Figure 15–1 to identify the compo-nents of the countershaft assembly forthe transmission models.

1. If necessary, remove the front and rearcountershaft bearings. See the follow-ing.a. Puller Method-Rear Bearing.

Put a step plate on the counter-shaft. Install a puller tool so thatthe jaws of the puller are under therace of the cone. Remove anddiscard the cone. Figure 15–2.

Figure 15–2

b. Press Method-Front Bearing.Do steps 2 and 3 of this procedure.

c. Press Method-Rear Bearing.Put a splitter tool under the race ofthe cone. Support the countershafton the splitter tool. Put a sleeve


2. Put the countershaft in a press so thatthe main drive gear is toward the top ofthe press. Support the countershaft onthe third or overdrive gear assembly.Figure 15–4.

3. Put a sleeve on the top of the shaft.Press the shaft from the third or theoverdrive gear, the PTO gear and themain drive gear. Figure 15–4.

THIRD OROVERDRIVEGEAR

Page 152


4. Support the countershaft on the first orsecond gear. Put a sleeve on top ofthe shaft. Press the shaft from thesecond or the third gear and the first orthe second gear. Figure 15–5.

Figure 15–5

5. Remove the key from the groove in theshaft. Figure 15–6.

6. On Design Level 1 Transmissions,remove the roll pin from the shaft.Design Level 2 Transmissions donot use a roll pin. Figure 15–6.


Figure 15–6

Assembling the Upper andthe Lower Main Counter-shaft Assemblies

NOTE:The upper and lower countershafts areeach serviced in the same way.

NOTE:See Figure 15–1 to identify the compo-nents of the countershaft assembly forthe transmission models.1. Lubricate all the parts with new oil that

is used in the transmission.

2. On Design Level 1 Transmissions,install the roll pin in the hole in thegroove for the key. Figure 15–6.

WARNINGWear safe eye protection and makesure the tools are is safe condition. Ifthe tools are worn or damaged (“mush-roomed”), pieces can break and causeserious personal injury.

3. Use a punch and a hammer to installthe key in the groove. On DesignLevel 1 Transmissions, make surethe taper on the end of the key isinstalled toward the roll pin. Figure15–6.

4. Put the first or the second gear on apress so that the hub is toward thebottom of the press. Put the shaft inthe gear. Make sure the slot in thegear is aligned with the key. Put asleeve on the top of the shaft. Pressthe shaft until the first gear touches thegear on the countershaft. Figure 15–7.

FIRST ORSECONDGEAR

KEY

ROLLPIN

Page 153

Section 15Overhauling the Main Countershaft

Figure 15–7

Figure 15–8

5. Put the second or the third gear on apress. Put the shaft in the gear. Makesure the slot in the gear is aligned withthe key. Put a sleeve on the shaft.Press the shaft until the hub of thesecond gear touches the hub of thefirst gear. Figure 15–8.

Figure 15–9

6. Put the third or the overdrive gear on apress so that the hub is away from thetop of the press. Put the shaft in thegear. Make sure the slot in the gear isaligned with the key. Put a sleeve onthe shaft. Press the shaft until thehub of the third gear touches the hubof the second gear. Figure 15–9.

7. Put the PTO gear on the press so thatthe chamfered side of the teeth aretoward from the top of the press. Putthe shaft in the gear. Make sure theslot in the gear is aligned with the keyin the shaft. Press the PTO gear on theshaft until the PTO hub touches thehub of the third or overdrive gear.

8. Put the main drive gear on a press sothat the large hub of the gear is towardthe PTO gear. Put the shaft in thegear. Make sure the slot in the gear isaligned with the key in the shaft. Put asleeve on the top of the shaft. Pressthe shaft into the gear until the hub ofthe main drive gear touches the hub ofthe PTO gear. Figure 15–10.

FIRST ORSECOND

GEAR

THIRD OROVERDRIVEGEAR

SECOND ORTHIRDGEAR

Page 154


Figure 15–10

CAUTIONUse the bearing inner race for installa-tion. If pressure is applied to the bear-ing cage, the bearing will be damaged.

9. Install the front and rear countershaftbearing cones in one of the followingways.

• Use a sleeve or a bearing installa-tion tool to install the cones. Make

sure the bottom of the conetouches the shoulder on the shaft.Figure 15–11.

WARNINGFollow the instructions of the manufac-turer of the bearing heater. The heatedcones can burn you.

• Use a bearing heater to install thecones on the shaft. Make sure thebottom of the cone touches theshoulder on the shaft.

Figure 15–11

PTOGEAR

MAINDRIVEGEAR

PRESS ONLYON INNERRACE

Page 155

Nine–Speed and Ten–Speed Section 16Transmissions Overhauling the Auxiliary Case

Disassembling the Auxiliary Case - Nine- and Ten-SpeedTransmissionsSee Figure 16–1.

Figure 16–1

COUNTERSHAFTCOVER

OUTPUTBEARINGRETAINER

RANGECYLINDERASSEMBLY

OIL SEAL

AIRFILTER/REGULATOR

ASSEMBLY

HI-LOFORK

SYNCHRONIZERASSEMBLY

AUXILIARYCASE

AUXILIARYCOUNTERSHAFT

ASSEMBLY

1

OUTPUT SHAFTASSEMBLY

CASE CUPAND CONEASSEMBLY

DESIGN LEVEL 1

2

1

2

1

1 1

1

DESIGN LEVEL 22

Page 156

Section 16 Nine–Speed and Ten–SpeedOverhauling the Auxiliary Case Transmissions


1. If necessary, remove the air filter/regulator assembly from the rangecylinder cover.

2. Remove the capscrews and washersfrom the range cylinder cover . Re-move the range cylinder cover. Fig-ure 16–2.

Figure 16–2

3. Remove and discard the gasket be-tween the range cylinder cover andthe range cylinder housing. Figure16–3.

4. Remove the nut from the piston in therange cylinder housing. Figure 16–3.

Figure 16–3

WARNINGIf necessary, use a safe amount of airpressure at the LO range port to re-move the piston from the range cylin-der. If too much air pressure is used,the piston will come out of the housingwith enough force to cause seriouspersonal injury.

5. Remove the piston from the bore ofthe range cylinder. Inspect the largeO-ring on the outer diameter of thepiston. If worn or damaged, removeand replace the O-ring . Figure 16–4.

Inspect the small O-ring in the innerdiameter of the piston bore. If worn ordamaged, remove and replace the O-ring . Figure 16–4.

Inspect the piston, especially the outerdiameter for wear and damage. Ifworn or damaged, replace the pistonand the housing as an assembly.

RANGECYLINDER

COVER

GASKET

PISTONNUT

Page 157


Figure 16–4

NOTE:An O-ring is used between the rangecylinder housing and the auxiliarycover on Design Level 1 Nine-SpeedTransmissions. Replace with gasketsealant during assembly.

6. Remove the range cylinder housingfrom the cover. Inspect the O-ring inthe bore for the shift shaft. Replace, ifdamaged. If used, remove and re-place the O-ring between the housingand the auxiliary case with sealant withsealant during assembly. Figure 16–5.

Inspect the range cylinder housing,especially the bore for wear and dam-age. If worn or damaged, replace thepiston and the housing as an assembly

7. Remove the mounting capscrews andwashers from the output bearingretainer to the auxiliary cover. Re-move the retainer. Use a scraper toremove the sealant material from thecover and the retainer. Figure 16–6.

8. Inspect the oil seal in the output bear-ing retainer. If the seal is worn ordamaged, remove and replace theseal. Figure 16–6.

Figure 16–5

Figure 16–6

Remove the plugs from the outputbearing retainer. Inspect the O-ringson the plugs. Replace worn or dam-aged O-rings.

9. If a mechanical speedometer is used,inspect the speedometer bushinginside the output bearing retainer. Ifworn or damaged, remove the bush-ing.

10. Remove the capscrews and the wash-ers that fasten the holding cover toolson the auxiliary countershafts. Re-move the holding cover tools.

PISTON O-RING

RANGECYLINDERHOUSING


Page 158


11. On Design Level 1 Nine-SpeedTransmissions, remove the snap ringthat fastens the upper and lower coun-tershafts in the cover. Remove therear bearing cups. Mark the snaprings and cups for the correct location.Figure 16–7.

Figure 16–8

NOTE:If a pin and a clip is used to fasten theHI-LO fork to the shift shaft, replacewith a nut and shoulder bolt duringassembly.

12. Remove the shoulder bolt and the nut(or pin and clip) that fastens the HI-LO fork to the shift shaft. Figure 16–9.

Figure 16–7

On Design Level 2 Nine-Speed andTen-Speed Transmissions, removethe spacers for the upper and lowercountershafts. Remove the rear bear-ing cups. Mark the spacers and thecups for correct installation. Figure16–8

Figure 16–9

SPACERWASHER

SHOULDERBOLT

CUP SNAPRING

Page 159



13. If necessary, use a hammer and asteel drift to remove the shift shaft fromthe HI-LO fork. Figure 16–10.

14. Remove the HI-LO fork from the syn-chronizer collar. Figure 16–10.

Figure 16–10

15. Remove the upper and lower auxiliarycountershafts from the cover. Figure16–11.

16. Remove the synchronizer assemblyfrom the output shaft. Figure 16–11.

Figure 16–11

Figure 16–12

17. If worn or damaged, disassemble thesynchronizer assembly. See thefollowing procedure.

NOTE:When separating the synchronizers,put a towel over the synchronizers tokeep the springs from flying out.

a. Pull up on the high synchronizer toseparate the high synchronizerfrom the low synchronizer. Do notlose the springs when the synchro-nizers are separated. Figure 16–12.

SHIFTSHAFT

HI-LOFORK

AUXILIARYCOUNTERSHAFTS


PULLUP

➡

Page 160


Figure 16–15

Figure 16–16

b. Remove the springs from the holesin the high synchronizer. Figure16–13.

Figure 16–13

Figure 16–14

c. Remove the collar from the lowsynchronizer. Figure 16–14.

18. If worn or damaged, remove the frontand rear bearing cones from the upperand lower auxiliary countershafts. Usea puller to remove the cones from thecountershaft. Make sure the jaws ofthe puller are under the bearing races.Figure 16–15.

19. If necessary, remove the output shaftand the low gear assembly from theauxiliary cover. See the followingprocedure.

a. Support the auxiliary cover on thelow gear in a press. Make sure theoutput shaft is toward the top of thepress. Figure 16–16.

b. Put a sleeve on the top of theoutput shaft. Press the output shaftfrom the low gear assembly andthe cover. Figure 16–16.

SPRING

COLLAR

LOWSYNCHRONIZER

Page 161


Figure 16–17

Figure 16–18

20. If necessary, remove the inner and theouter bearing cups for the output shaftfrom the auxiliary cover. See thefollowing procedure. Figure 16–19.

a. Support the case on a press. Makesure the inner surface of the caseis toward the top of the press.

b. Put a sleeve on the outer race ofthe inner bearing cup.

c. Press the inner and the outer cupsfrom the cover. Discard the cups.

Figure 16–19

21. On Design Level 1, Nine-SpeedTransmissions, remove the toothedspacer from the output shaft or frominside the low gear. Remove thethrust washer from the top of the gear.

c. Remove the outer bearing coneand the spacer from the cover.Figure 16–17.

d. Remove the cover from the press.Remove the auxiliary low gear andthe inner bearing cone from thecover. Figure 16–18.

OUTERBEARING

CONE

COVER

INNERBEARING

CONE

LOWGEAR

Page 162


Figure 16–20NOTE:115 and 125 series transmissions useone spacer on the output shaft. 135,145, 155 and 165 series transmissionsuse two spacers on the output shaft.

22. Remove the spacer(s) from the top ofthe output shaft. Figure 16–20.


SPACER

TOOTHEDWASHER

(DESIGN LEVEL 1)

OUTPUTSHAFT

LOW GEAR

THRUST WASHER(DESIGN LEVEL 1)

Page 163


Assembling theAuxiliary Case —Nine– and Ten–SpeedTransmissionsSee Figure 16–1.

NOTEThe bearing cup and the bearing conemust be replaced as an assembly. Donot replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manu-facturer.

1. Lubricate all the parts of the auxiliarycover with the oil used in the transmis-sion

2. On Design Level 1 Nine-SpeedTransmissions, if removed, install thesnap ring in the groove inside theauxiliary low gear. Make sure theround side of the snap ring is installedtoward the gear. Figure 16–21.

3. Put timing marks on the auxiliary lowgear. Mark one tooth with paint. Marka second tooth opposite (180o) the firsttooth. Figure 16–21.

Figure 16–21

4. Use paint to put timing marks next toeach other on two teeth of each coun-tershaft low gear. Make sure themark is aligned with the “O” stampingon the counter shaft. Figure 16–22.

Figure 16–22

TIMINGMARKS

SNAPRING

TIMINGMARKS

“O”STAMPING

Page 164


5. Assemble the output shaft and lowgear assembly according to the follow-ing procedure: Figure 16–23.

a. Put the output shaft on the workbench. Make sure the threadedend of the shaft is up.

b. On Design Level 1, Model 115and 125 Transmissions , install theoutput shaft spacer with the shoul-der. Make sure the spacer isinstalled with the large sectiontoward the bottom of the shaft.

On Design Level 1, Model 135and 145 Transmissions , install theoutput shaft spacer with the shoul-der. Make sure the spacer isinstalled with the large sectiontoward the bottom of the shaft.Install the small spacer on top ofthe spacer with the shoulder.

On Design Level 2, Model 115and 125 Transmissions , install theflat output shaft spacer on theshaft.

Figure 16–23 TOOTHEDSPACER-DESIGNLEVEL 1

ONLYSPACERS

-DESIGN LEVEL 1SHOWN

OUTPUTSHAFT

LOW GEAR

SNAP RING-DESIGN LEVEL 1

ONLY

THRUSTWASHER-DESIGN

LEVEL 1 ONLY

DESIGN LEVEL 1MODELS 115

AND 125

DESIGN LEVEL 2MODELS

115 AND 125

DESIGN LEVEL 2MODELS

155 AND 165

SPACER

LARGESPACER

DESIGN LEVEL 1MODELS 135

AND 145

FLATSPACER

SMALLSPACER

SPACERWITH

SHOULDER

SPACERWITH

SHOULDER

Page 165


On Design Level 1, Model 135,145, 155 and 165 Transmissions ,install the large output shaft spaceron the shaft. Install the smalloutput shaft spacer on top of thelarge spacer.

c. One Design Level 1 Nine-SpeedTransmissions, install the toothedspacer in the low gear.

d. One Design Level 1 Nine-SpeedTransmissions, install the snapring in the low gear.

e. Install the auxiliary low gear on theoutput shaft. Figure 16–23.

f. On Design Level 1 Nine-SpeedTransmissions, install the thrustwasher on top of the low gear.Figure 16–23.

6. Install the bearing cone on the outputshaft and low gear assembly. See thefollowing procedure. Figure 16–24.

Figure 16–24

BEARINGCONE

WARNINGA bearing heater can be used to installthe bearing cone. Follow the instruc-tions of the manufacturer of the bearingheater. The heated cones can burn you.

a. Put the output shaft and low gearassembly on a press. Support theshaft on the bottom of the shaft.Make sure the threads on the shaftare toward the top of the press.

b. Install a bearing cone on the shaft.Make sure the large diameter of thegear is toward the cone.

c. Put a sleeve on the cone. Pressthe cone on the shaft until the conetouches the thrust washer or thelow gear. Make sure the gear andthe bearing cone rotates on theshaft.

d. Install the spacer on the shaft.Figure 16–25.

Figure 16–25

SPACER

7. If removed, install the bearing cups forthe output shaft in the auxiliary cover.See the following procedure.

a. Put the cover in a press so that theoutside is toward the top of thepress. Support the cover under theoutput shaft bore. Figure 16–26.

b. Put the inner bearing cup in thecover. Make sure the letters on thecup are toward you. Install asleeve or a bearing installation toolon the race of the bearing. Figure16–26.

Page 166


c. Press the inner cup into the cover.Figure 16–26.

d. Put the outer cup on top of theinner cup. Make sure the slots ofthe outer cup are against the innercup. Figure 16–27.

Figure 16–26INNER

BEARINGCUP

Figure 16–27OUTER

BEARINGCUP

e. Put a sleeve or installation tool onthe top of the outer cup. Pressboth cups into the bore. The cupsare correctly installed when theouter cup touches the shoulder inthe bore of the cover. Figure 16–28.

Figure 16–28

8. If removed, install the bearing coneson the auxiliary countershafts. See thefollowing procedure. Figure 16–29.

CAUTIONA bearing heater can be used to installthe bearing cone. Follow the instruc-tions of the manufacturer of the bearingheater. The heated cones can burnyou.

a. Put the countershaft in a press sothat the front of the countershaft istoward the top of the press. Sup-port the countershaft on the gear.

b. Put the front cone on the counter-shaft so that the bottom of the coneis toward the gear.

c. Put a sleeve on the inner race ofthe cone. Press the cone on thecountershaft. The cone is correctlyinstalled when the bottom of thecone touches the gear.

d. Turn the shaft over so that theopposite end is toward the top ofthe press. Repeat steps a-c toinstall the rear cone.

Page 167


Figure 16–29

9. Install the auxiliary cover on the outputshaft and low gear assembly and theauxiliary countershafts. See the fol-lowing procedure.

a. Put the output shaft and low gearassembly in a press. Make surethe threads on the shaft are towardthe top of the press. Figure 16–30.

b. Put each auxiliary countershaftnext to the output shaft. Make surethe timing marks on each counter-shaft and the low gear are aligned.Figure 16–30.

Figure 16–30

TIMING MARKS ON AUXILIARY LOW GEARSTIMING MARKS ON COUNTERSHAFT LOW GEARS

c. Put the auxiliary cover on theoutput shaft and low gear assemblyand the auxiliary countershafts.Figure 16–31.

Figure 16–31

d. Install the outer bearing cone onthe output shaft. Make sure theletters on the cone are toward thetop of the press.

e. Install a sleeve on the outer bearingcone. Press the cone on the shaftand into the cup in the bore of thecover. Figure 16–32.

Figure 16–32

Page 168


10. Assemble the synchronizer assembly.

a. Put the low synchronizer on thetable so that the pins are towardyou.

b. Install the synchronizer collar overthe pins on the low synchronizer.Make sure the chamfered holes inthe collar are over the pins andtowards the low synchronizer.Make sure the low synchronizertouches the collar. Figure 16–33.

Figure 16–33

c. Install the springs into the holes inthe high synchronizer. Use greaseto retain the springs. Use a multi-purpose lubricating grease withNLGI Number 2 rating. Figure 16–34.

d. Install the high synchronizer on thepins of the low synchronizer cone.Rotate the high synchronizer sothat the springs are against the sideof the pins of the low synchronizer.Figure 16–34.

COLLAR

LOWSYNCHRONIZER

Figure 16–34

NOTE:Put a towel under the low synchronizerto keep the assembly from movingwhen the high synchronizer is installed.

e. Push down on the high synchro-nizer so that the pins of the lowsynchronizer are installed in theholes in the high synchronizer.Figure 16–35.

Figure 16–35

SPRING

PUSHDOWN➡

Page 169


11. Support the output shaft so that thecover is in the upright position.

12. Make sure the timing marks on the lowgear and each auxiliary countershaftare in alignment.

13. Install the synchronizer assembly onthe output shaft inside the auxiliarycover. Make sure the high synchro-nizer is toward you. Figure 16–36.

Figure 16–36

NOTE:The cup was marked during disassem-bly. Make sure the cup is installed inthe correct location.

14. Install the correct cup on the rearbearing of the upper auxiliary counter-shaft. Figure 16–37.

15. Install the correct cup on the rearbearing of lower auxiliary countershaft.Figure 16–37.


AUXILIARYCOUNTERSHAFTS

Figure 16–37

16. On Design Level 1 Nine-SpeedTransmissions, do the following:

a. Install the snap ring that retains thecups in the case. Use the snapring that was removed duringdisassembly.

b. install Holding Cover Tools, 3305-R-1214 on each countershaft. Usecapscrews to fasten the cover toolsto the countershafts and the cover.Figure 16–38.

On Design Level 2 Nine-Speed andTen-Speed Transmissions, do thefollowing:

a. Install the selective washers in frontof the cups. Make sure the tabs onthe washers are in the slots in thecase. Figure 16–38.

b. Install Holding Cover Tools, 3305-R-1214 on each countershaft. Usecapscrews to fasten the cover toolsto the countershafts and the cover.Figure 16–38.

CUP

Page 170


Figure 16–38

17. If removed, use the correct driver toolto install a new bushing for the speed-ometer gear inside the output bearingretainer.

18. Use a sealant dispenser and Loctite ®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent tomake a 1/8 inch (2 mm) sealant patternfor the output bearing retainer. Makesure the sealant material does notcover the oil passage. SeeFigure 16–39 for the sealant pattern.See “Installing the Sealant” in Section 1.

HOLDINGCOVER TOOLS

3305-R-1214

19. Install the output bearing retainer onthe auxiliary cover. Make sure the oilpassage in the retainer is aligned overthe oil hole in the cover.Figure 16–40.

20. Install the mounting capscrews for theoutput bearing retainer. Tighten thecapscrews to 35-45 lb-ft (47-71 N.m).

21. If removed, install the oil seal in theoutput bearing retainer. See the fol-lowing procedure. Figure 16–41.

CAUTIONHold the seal only on the outer diame-ter. Do not touch the inner diameter ofthe seal. Touching contaminates theinner diameter of the seal and causes aleak between the shaft and the seal.

a. Lubricate the outer diameter of theseal. Put the oil seal in the cover.Make sure the letters on the sealare installed away from the re-tainer.

Figure 16–39 SEALANTPATTERN


Figure 16–40

OILSLOT

OILSLOT

Page 171


CAUTIONUse the correct tool to install the oilseal. If the correct tool is not used, theseal will leak.

b. Use seal driver tool, 3256-Z-1014,(Kent-Moore Tool NumberJ-39161) to drive the seal intothe cover. The seal is correctlyinstalled when the outer flange ofthe seal touches the retainer.

Figure 16–41

22. Put the HI-LO shift fork in position sothat the fork engage the synchronizercollar. Make sure the bore of the forkis aligned with the bore of the rangecylinder. Make sure the hole in thefork is installed away from the cover.Figure 16–42.

23. Install the HI-LO shift shaft from insidethe front of the auxiliary cover. Makesure the threads on the end of theshaft are installed first. Figure 16–42.

SEAL DRIVERTOOL

Figure 16–42

NOTE:If a pin and a clip was used to fasten theHI-LO fork to the shaft, replace the pinand the clip with a nut (NL-25-1)andshoulder bolt (10-X-1534).

24. Align the hole of the shaft with the holeof the shift fork. Install the bolt and thelock nut. Tighten the nut to 8-12 lb-ft(11-16 N.m). Figure 16–43.

Figure 16–43

SHIFTSHAFT

HI-LOFORK

SHOULDERBOLT

Page 172


Figure 16–45

27. Lubricate the O-rings for the pistonwith a silicone lubricant such as DowCorning #111 Silicone Grease orequivalent. Install the O-rings on theouter diameter and the inner diameterof the piston. Figure 16–46.

SEALANTPATTERN

Figure 16–46

CAUTIONDo not use too much silicone lubricanton the O-rings and the bore of therange cylinder housing. If too muchlubricant is used, the range may shiftslowly.

25. Lubricate the O-rings and the bore ofthe range cylinder housing with the asilicone lubricant such as Dow Corning#111 Silicone Grease or equivalent.Install the O-ring in the groove in thebore of the range cylinder housing.Figure 16–44.

Figure 16–44

26. Use a sealant dispenser and Loctite ®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent tomake a 1/8 inch (2 mm) sealant pat-tern for the range cylinder housing.See Figure 16–45 for the sealantpattern. See “Installing the Sealant” inSection 1. Install the range cylinderhousing on the auxiliary cover.

O-RINGGROOVES

O-RINGS

Page 173


28. Install the piston on the shaft in therange cylinder. Install the nut thatfastens the piston on the shaft.Tighten the nut to 35-50 lb-ft (48-67N.m). Figure 16–47.

29. Install the gasket between the rangecylinder cover and the range cylinderhousing. Install the cover.

30. Install the capscrews and the washersthe fasten the range cylinder cover tothe auxiliary cover. Tighten the cap-screws to 35-45 lb-ft (47-61 N.m).

31. Put the auxiliary cover in the LO range.

32. Clean the outer diameter of the cupsfor the front bearing cones of theauxiliary countershafts. Put the cupsin the correct bores in the transmissioncase. Figure 16–48.

Figure 16–47

Figure 16–48

PISTON

GASKETRANGE

CYLINDERCOVER

CUP

Page 174

Section 16 13–SpeedOverhauling the Auxiliary Case Transmission

Disassembling the Auxiliary Case — Thirteen–SpeedTransmissionsSee Figure 16–49.

Figure 16–49

OUTPUTOIL

SEAL

CASE CUP ANDCONE ASSEMBLY

AIRFILTER/REGULATOR

ASSEMBLY

PISTONHOUSING

AUXILIARYCASE

AUXILIARYCOUNTER SHAFT

ASSEMBLY

OUTPUTSHAFT

ASSEMBLY

HUB ANDLO GEAR

ASSEMBLY


SPLITTERFORK

HI-LOFORK

12

2

1

1

2 DESIGN LEVEL 2

DESIGN LEVEL 1

Page 175

13–Speed Section 16Transmission Overhauling the Auxiliary Case


1. Put the auxiliary cover in a holdingfixture, such as an axle repair stand.

2. Remove the capscrews and washersthat fasten the piston housing cover tothe auxiliary cover. Remove the coverand the gasket. If necessary, removethe fitting and the shuttle valve fromthe cover. Figure 16–50.

3. Remove the nuts and the washers thatfasten the pistons to the shift shafts.Discard the nut. Figure 16–50.

Figure 16–50

4. Remove the piston housing and thepistons as an assembly. Inspect theO-rings on the pistons. Replace wornor damaged O-rings. Figure 16–51.

Figure 16–51

5. Use a scraper to remove the gasketmaterial from between the cover andthe housing.

6. Inspect the O-rings in the shaft boresof the piston housing. If worn or dam-aged, replace the O-rings. Figure 16–52.

Figure 16–52

PISTONHOUSING

PISTONS

O-RINGS

PISTONS

SHUTTLEVALVE

PISTONHOUSING COVER

Page 176


7. Remove the mounting capscrews andwashers from the output bearingretainer. Remove the retainer. Use ascraper to remove the gasket material.Remove the speedometer gear fromthe shaft.

8. Inspect the oil seal in the output bear-ing retainer. If the seal is worn ordamaged, remove and replace theseal. Figure 15–53.

9. If a mechanical speedometer is used,inspect the speedometer bushinginside the output bearing retainer. Ifworn or damaged, remove the bush-ing. Figure 16–53.

Figure 16–53

10. Move the assembly in the repair standso that the inside of the cover is towardyou.

NOTE:If a pin and a clip is used to fasten theHI-LO fork to the shift shaft, replacewith a nut and shoulder bolt duringassembly.

11. Remove the shoulder bolt and the nut(or pin and clip) that fastens the HI-LO fork to the shift shaft. Figure 16–54.

Figure 16–54


12. If necessary, use a hammer and abrass drift to remove the shift shaftfrom the HI-LO fork. Figure 16–55.

13. Remove the HI-LO fork from the syn-chronizer collar. Figure 16–55.

Figure 16–55

BUSHING

OIL SEAL

SHOULDER BOLTAND NUT

HI-LOFORK

SHAFT

Page 177


NOTEInstall a capscrew to fasten the plate tothe cover to keep the gears from mov-ing when the nut is removed. Figure 57.

14. Remove and discard the nut andwasher that fasten the LO gear andsynchronizer assembly to the outputshaft. Figure 16–56.

Figure 16–56

15. Remove the capscrews and washersthat fasten the holding plates on thecountershafts and cover. DO NOTCHANGE THE POSITION OF THEAUXILIARY COVER IN THE REPAIRSTAND. Remove the holding plates.Figure 16–57.

16. On Design Level 1 Transmissions,Remove the snap rings that fastensthe upper and lower auxiliary counter-shafts in the cover. Remove the rearbearing cups. DO NOT CHANGE THEPOSITION OF THE COVER IN THEREPAIR STAND. Mark the snap ringsand cups for correct installation. Fig-ure 16–58.

Figure 16–57

Figure 16–58

17. Remove the LO gear and synchronizerassembly. See the following proce-dure. Figure 16–59.

a. Move the splitter shaft so that thesplitter fork will not touch the LOgear during removal.

b. Move each countershaft away fromthe LO gear.

c. Lift the LO gear and couplingasssembly out of the cover.

NUT

LO GEAR ANDHUB ASSEMBLY

SNAPRINGCUP

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Figure 16–59

d. Remove the splitter fork and shaftassembly and the clutch collar asan assembly Figure 16–60.

18. Remove the upper and lower auxiliarycountershafts from the cover. Figure16–60.

Figure 16–60

19. If worn or damaged, disassemble theLO gear and synchronizer assembly.See the following procedure.

a. Remove the low synchronizerassembly from the LO gear as-sembly. Figure 16–61 .

Figure 16–61

NOTE:When separating the synchronizers,put a towel over the synchronizers tokeep the springs from flying out.

b. Pull up on the high synchronizer toseparate the high synchronizerfrom the low synchronizer. Do notlose the springs when the synchro-nizers are separated. Figure 16–62.

Figure 16–62

LO GEARAND SYNCHRONIZERASSEMBLY

SPLITTERSHAFT



SPLITTER FORKAND SHAFT

COUNTERSHAFTS

PULLUP

➧

Page 179


c. Remove the springs from the holesin the high synchronizer. Figure16–63.

Figure 16–63

d. Remove the collar from the lowsynchronizer. Figure 16–64.

Figure 16–64

e. Remove the snap ring and washerthat fastens the LO gear on thecoupling. Remove the thrustwasher and the coupling. Figure16–65.

Figure 16–65

20. If necessary, disassemble the splitterfork and shaft assembly. Figure 16–66.

a. Cut and discard the lock wire onthe capscrew. Remove the cap-screw.

b. Remove the splitter fork from theshaft.

Figure 16–66

SNAP RING

WASHER

HUB LO GEAR

LOCKWIRE

CAPSCREW

SHAFT

SPLITTERFORK

SPRING

COLLAR

LOWSYNCHRONIZER

Page 180


21. If worn or damaged, remove the frontand rear bearing cones and the splittergear from the upper and lower auxil-iary countershafts.

Use a puller to remove the front cone.Make sure the jaws of the puller areunder the bearing races. Figure 16–67.

Figure 16–67

Remove the rear cone and splittergear as an assembly. Support thesplitter gear in a press so that the rearcone is toward the top of the press.Put a sleeve on the countershaft.Press the countershaft from the coneand gear. Remove the key from thecountershaft. Figure 16–68.

22. If necessary, remove the output shaftand the OD gear assembly from the

Figure 16–68

auxiliary cover. See the followingprocedure. Figure 16–69.

a. Support the auxiliary cover in apress. Make sure the output shaftis toward the top of the press.

b. Put a sleeve on the top of theoutput shaft. Press the output shaftand OD gear assembly from thecover.

c. Remove the outer bearing conefrom the cover.

d. Remove the cover from the press.

Figure 16–69

FRONTCONE

REARCONE

SPLITTERGEAR

OUTPUTSHAFT

OUTERBEARING

CONE

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13–Speed Section 16Transmission Overhauling the Auxiliary Case23. If necessary, remove the inner and the

outer bearing cups for the output shaftfrom the auxiliary cover. See thefollowing procedure. Figure 16–70.

a. Support the case on a press. Makesure the inner surface of the caseis toward the top of the press.

b. Put a sleeve on the outer race ofthe outer bearing cup.

c. Press the inner and the outer cupsfrom the cover. Discard the cups.

24. If worn or damaged, remove the innerbearing cone from the output shaft andOD gear assembly. See the following.

a. Remove the spacer from the shaft.Figure 16–71.

b. Support the assembly in the pressby the gear. Make sure the threadsare toward the top of the press.

c. Put a sleeve on top of the outputshaft. Press the shaft out of thecone and gear. Discard the cone.Figure 16–72.

25. Remove the spacer from the outputshaft. Figure 16–73.


Figure 16–70

Figure 16–71

Figure 16–72

Figure 16–73

SPACER

SPACER

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Assembling the AuxiliaryCase—Thirteen–SpeedTransmissions

See Figure 16–49.

1. Lubricate all the parts of the auxiliarycover with new oil used in the trans-mission

2. Put timing marks on the OD gear.Mark one tooth with paint. Mark asecond tooth opposite (180o) the firsttiming mark. Figure 16–74.

Figure 16–74

3. Put the output shaft on the workbench. Make sure the splined end ofthe shaft is up.

4. Install the spacer on the output shaft.Make sure the small shoulder of thespacer is toward the splined end of theshaft for the output yoke. Figure 16–75.

Figure 16–75

5. Install the auxiliary OD gear on theoutput shaft. Figure 16–76.

Figure 16–76

6. Install the bearing cone on the outputshaft and OD gear assembly. See thefollowing procedure. Figure 16–77.

a. Put the output shaft and OD gearassembly on a press. Support theshaft on the bottom of the shaft.Make sure the large threads on theshaft are toward the top of thepress.

TIMINGMARKS

ODGEAR

SPACER

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b. Install a bearing cone on the shaft.Make sure the letters on the coneassembly are toward the gear.

c. Put a sleeve on the cone. Pressthe cone on the shaft until the conetouches the gear. Make sure thegear and the bearing cone rotateson the shaft.

d. Install the spacer on the shaft.Figure 16–78.

Figure 16–77

Figure 16–78

7. If removed, install the bearing cups forthe output shaft in the auxiliary cover.See the following procedure.

a. Put the auxiliary cover in a press sothat the outside of the cover istoward the top of the press.

b. Put the inner bearing cup in thecover. Make sure the letters on thecup are toward you. Install asleeve or a bearing installation toolon the race of the bearing.

c. Press the inner cup into the coveruntil the top of the cup is 3/8 inchbelow the outer surface of thecover. Figure 16–79.

Figure 16–79

d. Put the outer cup on top of theinner cup. Make sure the letters onthe cup are toward you. Figure16–80.

e. Put a sleeve or installation tool onthe top of the outer cup. Pressboth cups into the bore. The cupsare correctly installed when theflange on the outer cup touches theshoulder in the bore of the cover.Figure 16–80.

CONE

AUXILIARYOD GEAR

INNER CUP–3/8 INCH FROMCOVER OUTER

SURFACE

Page 184



8. Install the auxiliary cover on the outputshaft and OD gear assembly. See thefollowing procedure. Figure 16–81.

a. Put the output shaft and OD gearassembly in a press. Put a supportunder the gear. Make sure thelarge threads on the shaft aretoward the top of the press.

b. Put the auxiliary cover on theoutput shaft assembly. Rotate thecover to make sure the output shaftinner bearing cone is installed inthe cup.

c. Install the spacer on the top of theinner bearing cone of the outputshaft.

d. Install the outer bearing cone onthe output shaft. Make sure theletters on the cone are toward thetop of the press.

e. Install a sleeve on the outer bear-ing cone. Press the cone on theshaft and into the cup in the bore ofthe cover.

9. Put the gear and cover assembly on abench. Make sure the inside of thecover is toward you.

10. Use paint to put timing marks on twoteeth of each countershaft OD gear.Make sure the mark is aligned with thedot on the counter shaft. Figure 16–82.

Figure 16–82

11. If necessary, assemble the splitter forkand shaft assembly. Figure 16–83.

a. Install the shaft in the fork. Makesure the holes in the shaft and thefork are aligned.

OUTERCUP CONE

ODGEAR

TIMINGMARK

Page 185


b. Install the capscrew. Tighten to 35-45 lb-ft (47-61 N.m).

c. Install a new lock wire in the cap-screw and fork.

Figure 16–83

12. Assemble the LO gear and synchro-nizer assembly.

a. Install the snap ring in the grooveinside the LO gear and hub assem-bly. Make sure the round side ofthe snap ring is installed away fromthe gear. Install the washer insidethe gear. Figure 16–84.

Figure 16–84

b. Put the low synchronizer on thetable so that the pins are towardyou.

c. Install the synchronizer collar overthe pins on the low synchronizercone. Make sure the chamferedholes in the collar are over the pins.Make sure the cone touches thecollar. Figure 16–85.

Figure 16–85

d. Install the springs in the holes inthe high synchronizer. Put greaseon the springs. Use a multi-pur-pose lubricating grease with NLGINumber 2 rating. Figure 16–86.

Figure 16–86WASHER

SNAPRING

LOGEARHUB

CAPSCREW

SHAFT

SPLITTERFORK

LOCKWIRE

COLLAR

LOWSYNCHRONIZER

SPRING

Page 186


e. Install the high synchronizer on thepins of the low synchronizer cone.Move the high synchronizer so thatthe springs are against the side ofthe pins of the low synchronizer.Figure 16–87.

NOTEPut a towel under the low synchronizerto keep the assembly from movingwhen the high synchronizer is installed.

f. Push down on the high synchro-nizer so that the pins of the lowsynchronizer are installed in theholes in the high synchronizer.Figure 16–87.

Figure 16–87

g. Install the low synchronizer on thehub and LO gear assembly. Fig-ure 16–88.

13. If removed, install the bearing conesand the splitter gear on the auxiliarycountershafts. See the followingprocedure.

a. Put the countershaft in a press sothat the auxiliary gear is toward thebottom of the press. Support thecountershaft on the gear.

Figure 16–88

Figure 16–89

b. Put the key in the groove on theshaft.

c. Put the splitter gear on the shaft.Make sure the key is aligned withthe slot in the gear.

d. Put a sleeve on the gear and pressthe gear on the shaft. Figure 16–89.

e. Put the rear cone on the counter-shaft so that the bottom of the coneis toward the gear.

SPLITTER GEAR(MAKE SURE KEY

IS INTALLEDIN GEAR)

➧PUSHDOWN



Page 187


f. Put a sleeve on the inner race ofthe cone. Press the cone on thecountershaft. The cone is correctlyinstalled when the bottom of thecone touches the gear. Figure 16–90.

Figure 16–90

g. Turn the countershaft over so thatthe splitter gear is toward thebottom of the press.

h. Put the front cone on the counter-shaft so that the bottom of the coneis toward the gear.

i. Put a sleeve on the inner race ofthe cone. Press the cone on thecountershaft. The cone is correctlyinstalled when the bottom of thecone touches the gear. Figure 16–91.

14. Install the auxiliary countershafts in thecover. Make sure the timing marks onthe OD gears are aligned. Make surethe countershaft bearing is completelyinstalled in the cover. Figure 16–92.

Figure 16–91

Figure 16–92

15. Install the collar on the output shaft.Install the splitter fork and shaft as-sembly on the splitter gear assembly.Move the fork so that the fork will nottouch the splitter gear assemblyduring installation. Figure 16–93.

FRONTCONE

REARCONE

COUNTERSHAFTS

TIMINGMARKS

Page 188


Figure 16–93

16. Install the LO gear and synchronizerassembly on the output shaft insidethe auxiliary cover. Make sure thehigh synchronizer is toward you. Makesure the timing marks on all the gearsare aligned. Figure 16–94.

NOTEThe end play of the auxiliary counter-shaft is checked when the auxiliarycover is installed on the transmission.

17. On Design Level 1 Transmissions,install the cups on the cones of theauxiliary countershafts. Install thecorrect selective snap rings that fas-tens the cups in the cover. Make surethe snap ring is completely installed inthe groove. Figure 16–95.

On Design Level 2 Transmissions ,install the cups on the cones of theauxiliary countershafts. Install thecorrect selective washers in front of thecups. Make sure the tabs in the wash-ers are in the slots in the case.

Figure 16–94

Figure 16–95

COUNTERSHAFTTIMING MARKS

SPLITTER FORKAND SHAFT

COLLAR

TIMINGMARKS

SPLITTERSHAFT

LO GEARAND HUB

ASSEMBLY

➧ A➧ A

VIEW FOR ARROW A

CUP

SNAPRING

Page 189


18. Put the holding plates on both auxiliarycountershafts. Use capscrews tofasten the plates to the countershaftand the cover. DO NOT CHANGE

Figure 16–97

20. Put the HI-LO shift fork in position sothat the fork engages the synchronizercollar. Make sure the bore of the forkis aligned with the bore of the pistonhousing. Make sure the lock pin holein the fork is installed away from thecover. Figure 16–98.

21. Install the HI-LO shift shaft from theinside the front of the auxiliary cover.Make sure the threads on the end ofthe shaft are installed first. Rotate theshaft while pushing the shaft throughthe O-ring. Figure 16–98.

NOTE:If a pin and a clip was used to fasten theHI-LO fork to the shaft, replace the pinand the clip with a nut (NL-25-1) andshoulder bolt (10-X-1534).

22. Align the hole of the shaft with the holeof the shift fork. Install the bolt and thelock nut. Tighten the nut to 8-12 lb-ft(11-16 N.m). Figure 16–98.

Figure 16–98

NUT

LO-GEARAND HUB

ASSEMBLY

SHOULDERBOLTHI-LO

FORK

SHAFT

Figure 16–96

19. Install a new nut and the washer thatfasten the LO gear to the output shaft.Tighten the nut to 220-260 lb-ft(299-352 N.m). Figure 16–97.

THE POSITION OF THETRANSMISSION IN THE REPAIRSTAND. Figure 16-96.

Page 190


23. Move the cover in the fixture so thatthe outside of the cover is toward you.

24. If removed, use the correct tool toinstall a new bushing for thespeedometer gear inside the outputbearing retainer.

25. If removed, install a new oil seal in theoutput bearing retainer. See thefollowing procedure. Figure 16–99.

Figure 16–99

CAUTIONHold the seal only on the outer diameter.Do not touch the inner diameter of theseal. Touching contaminates the innerdiameter of the seal and causes a leakbetween the shaft and the seal.

a. Lubricate the outer diameter of theseal. Put the oil seal in the cover.Make sure the letters on the sealare installed away from the retainer.

CAUTIONUse the correct tool to install the oilseal. If the correct tool is not used, theseal will leak.

b. Use seal driver tool, 3256-Z-1014,(Kent-Moore Tool NumberJ-39161) to drive the seal into thecover. The seal is correctly in-stalled when the flange of the sealtouches touches the retainer.

26. Use a sealant dispenser and Loctite�RTV Sealant, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent tomake a 1/8 inch (2 mm) gasket patternon the cover for the output bearingretainer. See Figure 16–100 for thegasket pattern. See “Installing theSealant” in Section 1.

27. Install the output bearing retainer onthe auxiliary cover. Make sure the oilpassage in the retainer is aligned overthe oil hole in the cover. Figure 16–100.

SEAL DRIVERTOOL

Figure 16–100OIL

SLOT

SEALANTPATTERN

OILSLOT

Page 191


28. Install the mounting capscrews for theoutput bearing retainer. Tighten thecapscrews to 35-45 lb-ft (47-61 N.m).Figure 16–101.

29. Lubricate the O-rings and the bores ofthe piston housing with the a siliconelubricant such as Dow Corning #111Silicone Grease or equivalent. Installthe O-rings in the grooves in the boresof the piston housing. Figure 16–101.

Figure 16–101

30. Use a sealant dispenser and Loctite�RTV Sealant�, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent tomake a gasket pattern on the pistonhousing. See Figure 16–102 for thegasket pattern. See “Installing theSealant” in Section 1.

31. Install piston housing on the auxiliarycover. Make sure the shafts are in thecorrect bores. Figure 16–103.

32. Lubricate the O-ring for the pistonswith a silicone lubricant such as DowCorning #111 Silicone Grease orequivalent. Install the O-rings on theouter diameter and in the bore of thepistons. Figure 16–103.

Figure 16–103

Figure 16–102

33. Install the pistons on the shafts in thepiston housings. Make sure the pis-tons are install on the correct shafts.Figure 16–103.

34. Install a new nut and the washer thatfasten the pistons on the shafts.Tighten the nut to 35-50 lb-ft(48-67 N.m). Figure 16–104.

O-RINGS

GASKETPATTERN

SPLITTERPISTON

RANGEPISTON

Page 192


Figure 16–104

35. If removed, install the shuttle valve.

Lubricate the O-rings on the shuttlevalve with a silicone lubricant such asDow Corning #111 Silicone Grease orequivalent.

Install the shuttle valve. Make sure therod of the valve is toward the piston.Install and tighten the fitting. Figure16–104.

Figure 16–105

36. Install a new gasket between thepiston housing and the piston housingcover.

37. Install the capscrews and the washersthe fasten the piston housing cover tothe piston housing. Tighten the cap-screws to 35-45 lb-ft (47-61 N.m).

38. Install the cups for the rear bearingcones of the auxiliary countershafts.Put the cones in the correct bores inthe transmission case. Figure 16–105.

SNAPRING


PISTONHOUSING

COVER

PISTONS

SHUTTLEVALVE

Page 193

Section 17Main Countershaft End Play Adjustment


Checking and Adjustingthe End Play of theMain Countershafts

NOTE:Check the end play on one counter-shaft at a time.

1. Put the transmission in NEUTRALFigure 17–1.

Figure 17–1

2. Install Countershaft End Play CheckingTool, Rockwell Part Number 3256-C-1043, or Kent-Moore Tool Number J-41335 on the upper countershaft. Seethe following procedure. Figure 17–2.

Figure 17–2

a. Put the Shaft Plug Adapter inposition on the countershaft. Installand tighten the screws that fastenthe adapter to the countershaft.

b. Install the (short) shaft plug with5/16 inch threads into the adapter.Tighten the plug.

c. Install the 3/8 inch base into one ofthe mounting holes for the clutchhousing.

d. Install the actuator arm so that the“forked” end of the arm is in thegroove of the shaft plug.

e. Align the holes in the actuator armwith the hole in the base. Installthe pivot pin.

NEUTRALPOSITION

ARM

BASESHAFT

PLUG ADAPTER(SHORT)

Page 194


NOTE:Runout measurement will not occurwhen the output shaft is rotated if thedial indicator and the Countershaft EndPlay Checking Tool are correctlyinstalled. If runout occurs make surethe tip of the dial indicator and thealignment mark on the shaft plugare aligned.

3. Install a dial indicator so that the tip ofthe indicator is in the center of theshaft plug. Make sure the tip of thedial indicator is also aligned with thealignment mark on the shaft plug.Figure 17–3.

4. Install a torque wrench in the end ofthe actuator arm. The torque wrenchmust be installed in a straight line withthe actuator arm. Figure 17–3.

Figure 17–3

5. Measure the upper countershaft endplay. See the following procedure.

NOTEIf you do not apply proper torque,repeat the procedure.

a. Use the torque wrench to apply aforce of 25 lb-ft or 300 lb-in (34N.m) in one direction.Figure 17–4.

b. Put reference marks on the inputshaft and the main case. When theinput shaft is rotated in this proce-dure, the “starting” and “stopping”positions of rotation must be in thesame location.

c. Rotate the input shaft at least four(4) complete turns in a clockwisedirection. Make sure the “starting”and “stopping” positions of rotationare at the same location.Figure 17–4.

d. Set the dial indicator to “zero” (0).

e. Change the direction of force ap-plied in step “a” to the oppositedirection.

f. Rotate the input shaft at least four(4) complete turns in a counter-clockwise direction. Make surethe “starting” and “stopping” posi-tions of rotation are at the samelocation. Figure 17–5.

g. Record the reading on the dialindicator.

DIAL INDICATORTORQUE WRENCH

CLOCKWISEROTATION

Figure 17–4

DIRECTIONOF FORCE

Page 195


Figure 17–5

6. The correct end play specification is0.002-0.006 inch (0.050-0.152 mm).

If the reading is 0.002-0.006 inch(0.050-0.152 mm), go to step 14.

For Design Level 1 Transmissions ,If the reading is less than 0.002 inch(0.050 mm) or more than 0.006 inch(0.152 mm), see steps 7-8.

For Design Level 2 Transmissions ,If the reading is less than 0.002 inch(0.050 mm) or more than 0.006 inch(0.152 mm), see steps 9-14.

7. For Design Level 1 Transmissions ,if the reading is 0.002 inch or less,check the following:

● Check the cover of the main coun-tershaft for damage. Replacedamaged covers. Repeat steps 1-5.

● Check for dirt or other contami-nants between the rear bearing cupand the case. Repeat steps 1-5.

● Remove the auxiliary case andcheck that the cup for the maincountershaft is correctly installed inthe main case. Make sure the cupis installed correctly. Repeat steps1-5.

8. For Design Level 1 Transmissions ,if the reading is more than 0.006inch (0.152 mm) , remove the 0.068inch (1.73 mm) snap ring (Rockwellpart number 1229-C-4215) from thefront bore of the main countershaft.

Use the reading to find the correctsnap ring in the chart in Figure 17–6 .Install the correct snap ring in the frontbore for the main countershaft. Figure17–7.

Figure 17–6

END PLAY SNAP RING MEASUREMENT THICKNESS PART

INCH MM. INCH MM NUMBER COLOR0.007-0.011 0.153-0.279 0.073 1.86 1229-D-4216 Orange0.012-0.016 0.280-0.406 0.078 1.99 1229-E-4217 White0.017-0.021 0.407-0.533 0.083 2.12 1229-F-4218 Blue0.022-0.026 0.534-0.660 0.088 2.25 1229-G-4219 Yellow0.027-0.032 0.661-0.812 0.094 2.38 1229-H-4220 Green0.033-0.037 0.813-0.939 0.099 2.51 1229-J-4222 Green/White0.038-0.042 0.940-1.067 0.104 2.64 1229-K-4223 Blue/White0.043-0.047 1.068-1.194 0.109 2.77 1229-L-4224 Orange/White

COUNTERCLOCKWISEROTATION

DIRECTIONOF FORCE

Page 196


Figure 17–7

Repeat steps 1-5 to make sure the endplay is correct. When the end play iscorrect, go to step 14.

9. On Design Level 2 Transmissions, ifthe reading is less than 0.002 inch(0.050 mm), or there is no reading,move the cup 0.125 inch (3 mm)toward the outer surface of the case.See the following procedure.

a. Remove the Allen-head capscrewsand remove the retainer.

b. Use a yoke bar (puller bridge),washer and a long 5/16 inch x 18capscrew to move the cup. Figure17–8.

c. After the cup is moved, go to step13 (the procedure for if the readingis 0.020 inch or more)

Figure 17–8

10. On Design Level 2 Transmissions, ifthe reading is 0.007-0.011 inch(0.177-0.279 mm), see the following:


b. Remove the 0.005 inch (0.127 mm)shim (Rockwell part number 2803-R-2826).

c. Install the retainer. Instal the Allen-head capscrews. Alternately andevenly tighten the capscrews to120-140 lb-in (14-16 N.m).

d. Check the end play as described insteps 1-5 of this procedure.



b. Remove the 0.0075 inch (0.190mm) shim (Rockwell part number2803-S-2827).

SNAPRING

YOKEBAR

WASHER

CAPSCREW

COUNTERSHAFT

Page 197


c. Install the retainer. Instal the Allen-head capscrews. Alternately andevenly tighten the capscrews to120-140 lb-in (14-16 N.m).

d. Check the end play as described insteps 1-5 of this procedure.



b. Remove the 0.005 inch (0.127 mm)shim (Rockwell part number 2803-R-2826).

c. Remove the 0.0075 inch (0.190mm) shim (Rockwell part number2803-S-2827).

d. Install the retainer. Instal the Allen-head capscrews. Alternately andevenly tighten the capscrews to120-140 lb-in (14-16 N.m).

e. Check the end play as described insteps 1-5 of this procedure.

13. On Design Level 2 Transmissions, ifthe reading is 0.020 inch (0.483 mm)or more , see the following:


b. Remove and discard all the shims,including the original shims.

NOTE:Shim KIT 5364 uses the followingshims:

● Two 0.0050 inch (0.127 mm) shims.● Two 0.0075 inch (0.190 mm) shims.● One 0.0175 inch (0.444 mm) shim.● One 0.0325 inch (0.825 mm) shim.

The total shim pack thickness is 0.075inch (1.903 mm)

c. Install shim KIT 5364 in the bore forthe front countershaft bearing.Make sure the slots for the oilpassage on the shims are alignedwith the oil passage hole.

d. Install the retainer for the frontcountershaft bearings. Install theAllen-head capscrews. Alternatelyand evenly tighten the capscrewsto 120-140 lb-in (14-16 N.m).

e. Check the end play as described insteps 1-5 of this procedure.

f. Find the end play measurementdetermined in step 5 of this proce-dure in the “Main Countershaft EndPlay Chart for Shim KIT 5364” inFigure 17–9 . Remove shims to getthe specified end play of 0.002-0.006 inch (0.050-0.152 mm).

g. Check end play again. Make surethe front cup touches the retainer.If the reading is 0.002-0.006 inch(0.050-0.152 mm), the end play iscorrect. See step 14.

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Main Countershaft End Play Chart for Shim KIT 5364

REMOVE THESE SHIMS2803-R-2826 2803-S-2827 2803-W-2831 2803-C-2837

END PLAY MEASUREMENT (0.0050 INCH (0.0075 INCH (0.0175 INCH (0.0325 INCHINCHES MM. OR 0.127 MM) OR 0.190 MM) OR 0.444 MM) OR 0.825 MM)

0.002-0.007 0.050-0.177 ----- ----- ----- -----0.008-0.010 0.178-0.254 1 ----- ----- -----0.011-0.012 0.255-0.304 ----- 1 ----- -----0.013-0.015 0.305-0.381 2 ----- ----- -----0.016-0.017 0.382-0.431 1 1 ----- -----0.018-0.020 0.432-0.508 2 ----- ----- -----0.021-0.022 0.509-0.558 ----- ----- 1 -----0.023-0.025 0.559-0.635 2 2 ------ ------0.026-0.027 0.636-0.685 1 1 ----- -----0.028-0.030 0.686-0.762 ----- 1 1 -----0.031-0.032 0.763-0.812 1 ----- 1 -----0.033-0.035 0.813-0.889 1 1 1 -----0.036-0.037 0.890-0.939 ----- ----- ----- 10.038-0.040 0.940-1.016 2 1 1 -----0.041-0.042 1.017-1.066 1 ----- ----- 10.043-0.045 1.067-1.143 ----- 1 ----- 10.046-0.047 1.144-1.193 2 ----- ----- 10.048-0.050 1.194-1.270 1 1 ----- 10.051-0.052 1.271-1.320 ----- 1 ----- 20.053-0.055 1.321-1.397 ----- ----- 1 10.056-0.057 1.398-1.447 1 2 ----- 10.058-0.060 1.448-1.524 1 ----- 1 10.061-0.062 1.525-1.574 ----- 1 1 10.063-0.065 1.575-1.651 2 ----- 1 10.066-0.067 1.652-1.701 1 1 1 10.068-0.070 1.702-1.778 ----- 2 1 10.071-0.072 1.779-1.828 2 1 1 10.073-0.075 1.829-1.905 1 2 1 1

0.076 and above 1.906 and above 2 2 1 1

Figure 17–9

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14. Repeat steps 1-5 and check the endplay of the other main countershaft.

15. On Design Level 1 Transmissions,when the end play is 0.002 -0.006 inch(0.050-0.152 mm) on each counter-shaft, repeat steps 1-5 on each coun-tershaft to make sure the end play iscorrect.

If end play is correct, return to step 13in Section 12, “Overhauling the MainCase”. If end play is not correct,repeat the procedure in this section.

16. On Design Level 2 Transmissions,when the end play is 0.002 -0.006 inch(0.050-0.152 mm) on each counter-shaft, do the following:

a. Remove the Allen-head capscrewsthat fasten the retainer to the maincase.

b. Apply Loctite® #222 or equivalentto the threads of the capscrews.

c. Install the capscrews. Alternatelyand evenly tighten the capscrewsto 120-140 lb-in (14-16 N.m) Fig-ure 17–10 .

Figure 17–10

d. Repeat steps 1-5 of this procedureto make sure the end play is cor-rect.

e. If end play is correct, return to step13 in Section 12, “Overhauling theMain Case). If end play is notcorrect, repeat the procedure in thissection.

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Section 18Auxiliary Countershaft End Play Adjustment


Figure 18–1

Checking and Adjustingthe End Play of theAuxiliary Countershaft

NOTE:Check the end play on one counter-shaft at a time.

1. Install the auxiliary case on the maincase as described in Section 11,“Removing and Installing the AuxiliaryCase”.

2. On Design Level 1 Transmissions,discard the selective snap ring that isused to fasten the cup in the bore.Install a spacer washer to adjust theend play.

3. Remove the capscrews and the wash-ers that fasten the Holding CoverPlates and/or lift brackets on the coun-tershaft and cover. Remove the covertool.

CAUTIONUse spacer washer, Part Number 1229-N-4538 (with blue color) to check theend play of the auxiliary countershaft.If the wrong spacer washer is used, theend play reading will not be correct.

4. Install the thinnest spacer washer,Rockwell Part Number 1229-N-4538(with blue color), in the bore on top ofthe cup. Make sure the tab of thewasher is aligned with the slot in thecase. Figure 18–1 .

5. Make sure the bearing cup and thespacer washer are in the correct posi-tion. See the following procedure.Figure 18–2.

Figure 18–2

a. Install the cover for auxiliary coun-tershaft.

b. Install the capscrews and washersthat fasten the cover to the auxiliarycase.

SPACER WASHER1229-N-4538

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Section 18 Auxiliary Countershaft End Play Adjustment

c. Alternately and evenly tighten thecapscrews until the countershaftcover touches surface of the auxil-iary cover. DO NOT TIGHTENMORE THAN 35 LB-FT (47 N.M).

d. Remove the capscrews, the wash-ers and the countershaft cover.

NOTE:Two designs of countershafts are used:a single-hole design and a two-holedesign. The Countershaft End PlayChecking Tool is installed differentlyon each design.

6. Install Countershaft End Play CheckingTool, Rockwell Part Number 3256-C-1043, or Kent-Moore Tool Number J-41335 on the countershaft. See thefollowing procedure.

Two-Hole Design Countershaft

See Figure 18–3.

b. Install the (short) shaft plug with5/16 inch threads into the adapter.Tighten the plug.

c. Install the 3/8 inch base for two-hole countershafts into one of themounting holes for the countershaftcover.

d. Install the actuator arm so that the“forked” end of the arm is in thegroove of the shaft plug.

e. Align the holes in the actuator armwith the hole in the base. Installthe pivot pin.

Single-Hole Design Countershaft

See Figure 18–4.

Figure 18–4

a. Install the (short) shaft plug with 3/8inch threads into the countershaft.Tighten the plug.

b. Install the 3/8 inch base for single-hole countershafts into one of themounting holes for the countershaftcover.

c. Install the actuator arm so that the“forked” end of the arm is in thegroove of the shaft plug.

Figure 18–3

a. Put the Shaft Plug Adapter inposition on the countershaft. Installand tighten the screws that fastenthe adapter to the countershaft.

PLUG

ADAPTOR

ARM

BASE

PLUG

BASE

ARMPIVOT

PIN

PIVOTPIN

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d. Align the holes in the actuator armwith the hole in the base. Installthe pivot pin.

NOTE:Runout measurement will not occurwhen the output shaft is rotated if thedial indicator and the Countershaft EndPlay Checking Tool are correctly in-stalled. If runout occurs make sure thetip of the dial indicator and the align-ment mark on the shaft plug arealigned.

7. Install a dial indicator so that the tip ofthe indicator is in the center of theshaft plug. Make sure the tip of thedial indicator is also aligned with thealignment mark on the shaft plug.Figure 18–5.

8. Install a torque wrench in the end ofthe actuator arm. The torque wrenchmust be installed in a straight line withthe actuator arm. Figure 18–5.

Figure 18–5

9. Measure the auxiliary countershaft endplay. See the following procedure.

CAUTIONApply the force on the torque wrenchuntil after the end play is checked. Ifthe force is released, the proceduremust be repeated.

a. Use the torque wrench to apply aforce of 25 lb-ft or 300 lb-in (34N.m) in one direction. Figure 18–6.

Figure 18–6

b. Put reference marks on the outputshaft and the auxiliary case. Whenthe output shaft is rotated in thisprocedure, the “starting” and “stop-ping” positions of rotation must bein the same location.

c. Rotate the output shaft at least four(4) complete turns in a clockwisedirection. Make sure the “starting”and “stopping” positions of rotationare at the same location. Figure18–6.

CLOCKWISE ROTATION

DIRECTION OF FORCE

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Figure 18–7

d. Set the dial indicator to “zero” (0).

e. Change the direction of forceapplied in step “a” to the oppositedirection.

f. Rotate the output shaft at least four(4) complete turns in a counter-clockwise direction. Make surethe “starting” and “stopping” posi-tions of rotation are at the samelocation. Figure 18–7.

g. Record the reading on the dialindicator.

10. The correct end play specification is0.002-0.006 inch (0.050-0.152 mm).

If the reading is less than 0.002 inch(0.050 mm) or there is no reading onthe dial indicator, see step 11.

If the reading is 0.007 inch (0.177 mm)or more, see step 12.

If the reading is 0.002-0.006 inch(0.050-0.152 mm), the end play iscorrect. See step 13.

11. If the reading is less than 0.002 inch(0.050 mm), or there is no reading,move the cup 0.125 inch (3 mm)toward the outer surface of the case.Use a yoke bar (puller bridge), washerand a long 5/16 inch x 18 capscrew tomove the cup. Figure 18–8 .

Figure 18–8

If the reading is less than 0.002 inch(0.050 mm), or there is no reading,check the following.

● Check the cover of the auxiliarycountershaft for damage. Replacedamaged covers. Repeat steps 6-9.

● Check for dirt or other contami-nants between the rear bearing cupand the case. Repeat steps 6-9.

● Remove the auxiliary case andcheck that the front cup for theauxiliary countershaft is correctlyinstalled in the main case. Checkthe cover of the auxiliary counter-shaft for damage. Make sure thecup is installed correctly. Repeatsteps 6-9.

COUNTER-CLOCKWISEROTATION

DIRECTION OF FORCE

COUNTERSHAFT

WASHER

CAPSCREW

YOKEBAR

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12. If the reading is 0.007 inch (0.177 mm)or more, the end play must be ad-justed. See the following.

a. Choose the correct spacer washeraccording to the dial indicatorreading in step 9. See the chart inFigure 18–9 to choose the correctspacer washer.

b. Remove the Countershaft End PlayChecking Tool.

c. Remove the blue spacer washer(Part Number 1229-N-4538) thatwas used to check the end play.

Figure 18–9

End Play Spacer Spacer Washer Spacer Measurement Washer Thickness Washer

Inch MM. Color Inch MM. Part Number

0.002-0.006 0.050-0.176 Blue 0.253 6.426 1229-N-4538

0.007-0.012 0.177-0.329 Green 0.258 6.553 1229-P-4540

0.013-0.017 0.330-0.456 Yellow 0.264 6.705 1229-Q-4541

0.018-0.022 0.457-0.583 White 0.269 6.832 1229-R-4542

0.023-0.027 0.584-0.710 Purple 0.274 6.956 1229-S-4543

0.028-0.032 0.711-0.837 Orange 0.279 7.086 1229-T-4544

0.033-0.038 0.838-0.989 White/Blue 0.284 7.213 1229-U-4545

0.039-0.043 0.990-1.116 White/Green 0.290 7.366 1229-V-4546

0.044-0.048 1.117-1.243 White/Yellow 0.295 7.493 1229-W-4547

0.049-0.053 1.244-1.370 White/Purple 0.300 7.620 1229-X-4548

0.054-0.058 1.371-1.497 White/Orange 0.305 7.747 1229-Y-4549

0.059 and 1.498 and * ---- ----- -------above above

NOTES * If the reading is 0.059 inch (1.498 mm), or there is no reading, check the following.

● Check for dirt or other contaminants between the rear bearing cup and the case.

● Remove the auxiliary case and check that the front cup for the auxiliary countershaftis correctly installed in the main case. Check the cover of the auxiliary countershaftfor damage. Make sure the cup is installed correctly.

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d. Install the correct spacer washer inthe bore on top of the cup. Makesure the tab of the washer isaligned with the slot in the case.Figure 18–10 .

h. Remove the capscrews, thewashers and the countershaftcover.

i. Again check the end play for theauxiliary countershaft. See steps2-9.

13. Use a sealant dispenser and Loctite®RTV Sealant™, #5699 (Rockwell PartNumber 2297-A-7021) or equivalent,to put a 1/8 ind (2 mm) new sealantpattern for the cover of the auxiliarycountershaft in the pattern shown inFigure 18–11. See ‘Gasket Sealant’

Figure 18–10

e. Install the cover for auxiliarycountershaft.

f. Install the capscrews and washersthat fasten the cover to the auxiliarycase.

g. Alternately and evenly tighten thecapscrews until the countershaftcover touches surface of the auxil-iary cover. DO NOT TIGHTENMORE THAN 35 LB-FT (47 N.M).

Figure 18–11

in Section 1.

14. Install the cover for the auxiliarycountershaft on the auxiliary case.Install the capscrews and the washers.Tighten the capscrews to 25-35 lb-ft(34-47 N.m). Figure 18–12.

SPACER WASHER1229-N-4538

AUXILIARYCASE

SURROUND ALLHOLES WITH SEALANT

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Figure 18–12 NOTE:Different end play measurements ofeach countershaft are a normal condi-tion.

15. Repeat steps 2-12 and check the endplay of the other auxiliary countershaft.

16. When the end play of 0.002 - 0.006inch (0.050-0.152 mm) is obtained, dothe following:

• On Nine–Speed and Ten–SpeedTransmissions, go to step 14under “Installing the Auxiliary Cover— Nine–Speed and Ten–SpeedTransmissions” in Section 11,Removing and Installing the Auxil-iary Cover”.

• On Thirteen–Speed Transmis-sions, go to step 14 under “Install-ing the Auxiliary Cover — Thirteen–Speed Transmissions” in Section11, Removing and Installing theAuxiliary Cover”.

1

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Section 19Troubleshooting

General Information

When checking a problem with the manualtransmission, the first thing to do is tomake sure of the service condition. Talk tothe driver, the mechanic or the servicemanager. If possible, take the vehicle for aroad test.

There are three types of problems:

● Leaks.

● Noise and/or vibration.

● Operating conditions.

Oil Leaks

Check the transmission for transmission oilleaks. If you find oil on or under thetransmission, verify that the leak istransmission oil and not engine oil, coolantor other lubricants. Note that under normalconditions, the area around the oil seal,yoke and rear bearing retainer is moist.This moist condition is not a transmissionleak or an oil seal leak. (Refer to Section 3,"Removing the Output Yoke and the OilSeal," for instructions on how to determinean oil seal leak.)

On New Transmissions

The following conditions can be found onnew transmissions and are not consideredoil leaks:

● Lubricants applied to the yoke duringassembly can make the seal areaappear moist or "leaking."

● All output seals are pre-lubed withgrease that melts at low temperatures.When the grease melts, it comes out ofthe seals, and the seals only appear tobe "leaking."

Vibration

When checking a noise or a vibration, findout when the problem occurs.

● When the transmission is in NEUTRALor in gear.

● During upshifts or downshifts.

● In all gears or specific gears.

● In the HI range or the LO range.

● In the DIR range or the OD range.(Thirteen-Speed Transmission Only)

● During coast or acceleration.

● With the vehicle loaded or unloaded.

Noise

If a noise is the problem, find out the soundof the noise.

● Growling, humming or grinding.

● Hissing, thumping or bumping.

● Rattles.

● Squealing.

● Whining.

Operation Problems

When the transmission is not operatingcorrectly, find out when the problemoccurs.

● In NEUTRAL or in gear.

● During upshifts or downshifts.

● In the HI range or the LO range.

● In the DIR range or the OD range.(Thirteen-Speed Transmission Only)

Also, find out what the transmission doesduring the problem.

● Does not stay in the selected gear.

● Does not stay in the selected range.

● Does not select all gears.

● Does not select all ranges.

● Overheats.

● Does not operate.

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Troubleshooting Other SystemsSee the following chart to make sure the transmission is the cause of the problem.

SYSTEM CHECK FOR REPAIRSEngine Systems 1. Loose or missing fasteners. 1. Replace missing fasteners.

Tighten to specified torque.2. Engine idle speed out-of- 2. Adjust idle speed to the specified

specifications. range.3. Loose or damaged engine mounts. 3. Tighten the fasteners to the specified

torque. Replace damaged mounts.4. Out-of-balance fan. 4. Replace fan.5. Damaged engine fan. 5. Repair or replace as required.

Clutch Systems. 1. Loose or missing fasteners. 1. Replace missing fasteners.Tighten to specified torque.

2. Clutch out-of-adjustment. 2. Adjust clutch3. Clutch assembly out-of-balance. 3. Replace clutch assembly.4. Worn or damaged pilot bearing. 4. Replace pilot bearing.

Driveshaft 1. Driveshaft system requires 1. Lubricate driveshaft system.Systems. lubrication.

2. Worn or damaged U-joints and/or 2. Replace U-joints and/or yokes.yokes.

3. Driveshaft out-of-balance. 3. Balance driveshaft correctly orreplace driveshaft.

4. Center bearings not installed 4. Install center bearings correctly orcorrectly or damaged. replace.

5. Driveline angles not correct. 5. Adjust driveline angles tomanufacturer's specifications.

Suspension 1. Loose or missing fasteners. 1. Replace missing fasteners. TightenSystems. to specified torque.

2. Damaged suspension components. 2. Repair or replace damagedsuspension components.

3. Driveline touching frame. 3. Adjust so that driveline does not touchframe.

4. Loose or damaged cab mounts. 4. Tighten loose fasteners to thespecified torque. Replace damagedmounts.

5. Leaks in air suspension system. 5. Repair leaks. Check all valves forcorrect operation.

Power Take-Off 1. PTO does not engage or 1. Repair or replace PTO assembly.(PTO) Systems disengage correctly.Wheels and Tires 1. Wheels and tires out-of-balance. 1. Balance or replace wheels and and

tires.2. Tires do not match on each side of 2. Install tires of the same size on all

the vehicle. sides of the vehicle.Remote Shift 1. Low lubricant level. 1. Fill to specified level.Systems 2. Linkage out-of-adjustment. 2. Adjust linkage.

3. Linkage binding or unable to move. 3. Lubricate, repair or replace linkage.

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Troubleshooting VibrationsBefore troubleshooting a vibration condition, make sure of the following:

1. The engine idle speed is within the specified range.2. The engine is operating correctly.3. The U-joints, yokes and driveshaft are in good condition. Check the driveline angles. Correct as neces-

sary.4. The U-joints, the yokes and the driveshafts are correctly aligned and/or balanced. Correct as necessary

5. Check air bag height. Correct as necessary

.

CONDITION CAUSE REPAIRVibration - In- 1. Fasteners do not remain tight. 1. Tighten fasteners. If fasteners do notVehicle Repair. remain tight, replace fasteners or

housing.Vibration - 1. Damaged bearings. 1. Replace bearings.Remove and 2. Broken or loose synchronizer 2. Replace synchronizer.Disassemble pins.Transmission.

NOTES:If the transmission does not shift correctly into the selected range, broken or loose synchronizer pins arethe result of the vibration condition.

Troubleshooting LeaksBefore troubleshooting a leak condition, make sure of the following:

1. Clean the outside of the transmission to remove all dirt.2. Operate the vehicle to make sure the leak is coming from the transmission.3. Verify that the fluid is transmission oil.4. The transmission housings are not cracked or broken.

CONDITION CAUSE REPAIRLeaks - In-Vehicle 1. Missing fasteners. 1. Replace missing fasteners.Repair. Tighten to specified torque.

2. Loose fasteners. 2. Tighten to specified torque.3. High oil level. 3. Drain to specified level. See

"overheating" in "Operating Conditions".4. Unspecified oil in transmission. 4. Drain oil. Install specified oil.5. Clogged or dirty breather vent. 5. Clean breather vent.6. Damaged yoke. 6. Replace yoke.7. Damaged output shaft seal. 7. Replace output shaft seal.8. Worn or damaged sealing tape on 8. Install new sealing tape on electronic

electronic speed sensor. speed sensor.Leaks - Remove 1. Damaged gaskets or sealing 1. Replace gaskets or sealing material.and Disassemble material.Transmission. 2. Cracked or broken housing. 2. Replace housing.

3. Oil leaking from breather vent. 3. Replace O-ring in piston housing.

NOTES:If the transmission continues to leak and the output shaft seal and the yoke have been replaced, removeand replace the output shaft assembly.Put the transmission in the LO range and operate the vehicle. If air leaks from the breather vent, the O-

1

1

2

2

1

3

3

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Troubleshooting NoisesFor all noise conditions, check the following before disassembling the transmission:

1. Check that the oil level is even with the bottom of the fill plug hole.2. Make sure the correct oil is used.3. Make sure the driveline angles of the transmission are correct.4. Make sure the transmission is correctly installed.5. Remove the drain plug. Check for any metal shavings, gasket material or any other material in the oil.

In some noise conditions, there are additional repairs to perform. These repairs will be explained in thefollowing charts.See the following charts to troubleshoot the clutch.

CONDITION CAUSE REPAIRGrowling, 1. Worn or damaged gears. 1. Replace gears.Humming or 2. Worn bearings (Humming only). 2. Replace bearings.Grinding 3. End play out-of-specifications. 3. Check and adjust end play.Hissing, 1. Damaged bearings (Hissing only). 1. Replace bearings.Thumping or 2. Damaged gear teeth (Thumping or 2. Replace gears.Bumping bumping only).Rattles - 1. Engine idle speed not within 1. Adjust idle speed to specified RPM.In-Vehicle specifications.Repair 2. Engine does not operate on all 2. Adjust or repair engine.

cylinders.3. Clutch intermediate or center 3. Repair or replace intermediate

plate binding in housing. or center plate.4. Other systems. 4. Make sure the transmission is the

source of the rattle condition.5. Incorrect shim installation on the 5. Install correct shims on PTO unit.

PTO unit.Rattles - 1. Damaged washers between 1. Replace washers betweenRemove and mainshaft gears. mainshaft gears.DisassembleTransmission.Squealing or 1. Incorrect shim installation on 1. Install correct shims on PTO unit.Whining - In- PTO unit.Vehicle RepairSquealing or 1. Damaged bearings 1. Replace bearings.Whining - 2. End play of countershafts not 2. Adjust countershaft end playRemove and within specifications. withing specifications.DisassembleTransmission

NOTES:Growling and humming are associated with the first stages of the condition. Grinding is associated withthe severe stages of the condition.

Hissing is associated with the first stages of the condition. Thumping and bumping are associated withthe severe stages of the condition.

If the noise occurs when the clutch is engaged and stops when the clutch is disengaged, the the interme-diate or center plate is the cause of the rattle.

Whining is a medium pitched noise. Squealing is a high pitched noise.

1

2

3

4

4

1

2

3

4

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Troubleshooting Operating ConditionsCONDITION CAUSE REPAIRTransmission 1. Loose air lines and fitings. 1. Tighten air lines and fittings.Slips Out of the 2. Obstructions in air lines. 2. Change routing or replace air lines.Selected Range - 3. Check operation of filter/regu- 3. Replace filter/regulator assembly ifIn-Vehicle lator assembly. pressure at delivery port is not withinRepair 60-65 psi.

4. Damaged O-ring on piston in 4. Replace O-ring on piston.range shift cylinder.

5. Loose or missing nut that fastens 5. Tighten or replace nut.piston to shift shaft in range shiftcylinder.

Transmission 1. Worn teeth in sliding clutch. 1. Replace sliding clutch.Slips Out of the 2. Bent or worn shift fork. 2. Replace shift fork.Selected Range - 3. Worn collar on range shift fork. 3. Replace collar on range shift fork.Remove andDisassembleTransmissionTransmission is 1. Loose or leaking air lines and 1. Tighten or replace air lines orSlow to Shift or fittings. fittings.Unable to Shift 2. Obstructions in the air lines. 2. Change routing or replace air lines.into the Selected 3. Filter/regulator assembly does not 3. Replace filter/regulator assembly ifRange - In-Vehi- operate correctly. pressure at delivery port is notcle Repair 60-65 psi.

4. Spool binding in slave valve. 4. Replace slave valve.5. Leakage at slave valve. 5. Replace slave valve.6. Damaged piston and/or O-rings 6. Replace O-rings and/or piston in

in piston housing. piston housing.7. Worn or damaged neutral interlock 7. Replace pin.

pin.8. Damaged shift knob/selector valve. 8. Replace shift knob/selector valve.9. Damaged exhaust disc in slave valve. 9. Replace disc in slave valve.

Transmission is 1. Damaged output shaft. 1. Replace output shaft.Slow to Shift or 2. Broken or missing synchronizer 2. Replace synchronizer springs orUnable to Shift springs or pins. syncnronizer.into the Selected 3. Damaged synchronizer. 3. Replace synchronizer.Range - Remove 4. Bent or broken shift shaft in range 4. Replace shift shaft.and Disassemble cylinder.Transmission. 5. Bent or broken shift fork in range 5. Replace shift fork.

cylinder.6. Dirt between splines and gears. 6. Drain oil. Flush inside of housing.

Fill to specified level with new fluid.7. Missing HI/LO fork pin and nut 7. Replace HI/LO fork pin and nut.

NOTES:To check leakage at the range cylinder, first put the selector valve in the LO range. Disconnect the airline to the HI range port on the piston housing. Operate the vehicle to charge the air system. If air leaksare heard, the O-ring or the piston must be replaced.When the nut is loose or missing at the end of the shift shaft, the transmission will shift into the HI rangebut not into the LO range.To check leakage at the slave valve, first put the selector valve in the LO range. Disconnect the air lineson the slave valve that goes to the HI range port of the piston housing. Operate the vehicle to chargethe air system. If air is heard leaking inside the slave valve, the valve is the cause of the leak.To check for leaks at the piston housing, disconnect the air lines at the piston housing. Apply air pres-sure to each port, one port at a time. If air leaks past the piston, the O-ring and/or the piston must bereplaced. If the piston does not move, the shift shaft or the shift assembly is damaged.

1

2

3

4

1

2

3

4

Page 212

Section 19TroubleshootingTroubleshooting Operating Conditions (Cont'd)

CONDITION CAUSE REPAIRTransmission 1. Incorrect clutch use. 1. Make sure driver uses clutchSlips Out of the correctly.Selected Gear - 2. LInkage binding or does not move 2. Lubricate, repair or replace linkage.In-Vehicle freely.Repair. 3. Clutch out-of-adjustment. 3. Adjust clutch. Make sure clutch

engages and releases correctly.4. Remote shift linkage out-of- 4. Adjust remote shift linkage.

adjustment.5. Loose or damaged engine 5. Tighten fasteners of loose mounts to

and/or cab mounts. specified torque. Replace damagedmounts.

6. Incorrect driveline angles. 6. Adjust driveline angles.7. Weak or broken detent spring 7. Replace detent spring in top cover

in top cover assembly. assembly.Transmission 1. Worn pads on shift fork. 1. Replace shift fork.Slips Out of the 2. Worn teeth in sliding clutch. 2. Replace sliding clutch.Selected Gear - 3. Worn fork slot on sliding clutch. 3. Replace sliding clutch.Remove and 4. Broken key on mainshaft. 4. Replace key and/or mainshaft.Disassemble 5. Twisted mainshaft. 5. Replace mainshaft.TransmissionTransmission 1. Incorrect vehicle operation. 1. Make sure driver operates vehicleIs Hard to Shift correctly.or Unable to 2. Clutch out-of-adjustment. 2. Adjust clutch. Make sure clutchShift Into the engages and releases correctly.Selected Gear - 3. Remote shift linkage binding 3. Lubricate, repair or replace remoteIn-Vehicle or unable to move. shift linkage.Repair 4. Loose and/or damaged cab 4. Tighten fasteners of loose mounts to

and/or engine mounts. specified torque. Replace damagedmounts.

5. Detent spring too strong or broken. 5. Replace detent spring.Transmission 1. Bent shift shaft in top cover 1. Replace shift shaft.Is Hard to Shift assembly.or Unable to 2. Burr on shift shaft in top cover 2. Replace shift shaft.Shift into the assembly.Selected Gear - 3. Cracked top cover assembly. 3. Replace top cover assembly.Remove and 4. Twisted mainshaft. 4. Replace mainshaft.Disassemble 5. Broken key on mainshaft. 5. Replace key and/or mainshaft.Transmission 6. Broken or bent shift fork on 6. Replace fork.

sliding clutch.Transmission 1. Driver does not operate vehicle 1. Make sure driver operates vehicleGrinds on Initial correctly. correctly.Engagement - 2. Clutch out-of-adjustment. 2. Adjust clutch. Make sure clutchIn-Vehicle engages and releases correctly.Repair. 3. Worn, damaged or missing 3. Replace clutch brake. Make sure

clutch brake. clutch engages and releasescorrectly.

4. Clutch and/or remote shift 4. Lubricate, repair or replace linkage.housing linkage binding or unableto move

5. Worn bushings in side of clutch 5. Replace bushings in the clutchhousing. housing.

Page 213


Troubleshooting Operating Conditions (Cont'd)

CONDITION CAUSE REPAIRShift Lever Locks 1. Remote shift linkage out-of- 1. Adjust remote shift linkage.or Sticks In Gear adjustment.- In-Vehicle 2. Clutch linkage needs adjustment. 2. Adjust clutch linkage.Repair. 3. Linkage binding or unable to move. 3. Lubricate, repair or replace linkage.

4. Loose or damaged cab and/or 4. Tighten fasteners of loose mounts toengine mounts. specified torque. Replace damaged

mounts.5. Damaged balls or rails in top cover 5. Replace balls or rails.

assembly.Shift Lever Locks 1. Bent shift fork in top cover. 1. Replace shift forkor Sticks In Gear 2. Damaged shift shaft in top cover. 2. Replace shift shaft.- Remove and 3. Damaged mainshaft. 3. Replace mainshaft.DisassembleTransmissionTransmission 1. Incorrect oil level. 1. Fill to specified level.Overheats - 2. Incorrect oil. 2. Drain oil. Use specified oil.-In-Vehicle 3. Damaged temperature gauge. 3. Replace temperature gauge.

Transmission 1. Missing or damaged interlock ball 1. Replace interlock ball in topDoes Not Operate in top cover. cover.- Remove and 2. Free running gears are locked. 2. Replace gears.Disassemble 3. Mismatched gear sets. 3. Install correct gear sets.Transmission 4. Timing marks on gears not aligned. 4. Align timing marks on gears.

5. Broken shafts. 5. Replace shafts.

NOTES:If a noise is present along with the overheating condition, see the "Troubleshooting Noise" chart toidentify and service the noise.

If the oil is at the specified level and the specified oil is used, but the transmission overheats and the oilsmells burnt, the transmission must be disassembled and inspecged.

If the oil does not have a burnt smell and the temperature gauge indicates overheating, remove andreplace the gauge.

75 6

5

6

7

Page 214

Section 20Specifications

Transmission Oil Capacities *TransmissionModel U.S Pints LitersRM9-115A 20.0 9.5RM9-125A 20.0 9.5RM9-135A 20.5 9.7RM9-145A 20.5 9.7RM9-155A 20.5 9.7RMO9-125A 20.0 9.5RMO9-135A 20.5 9.7RMO9-145A 20.5 9.7RMX9-125A 20.0 9.5RMX9-135A 20.5 9.7RMX9-145A 20.5 9.7RMO9-115B 20.0 9.5RMO9-125B 20.0 9.5RMO9-135B 20.5 9.7RMO9-145B 20.5 9.7RMX9-115B 20.0 9.5RMX9-125B 20.0 9.5

TransmissionModel U.S Pints LitersRMX9-135B 20.5 9.7RMX9-145B 20.5 9.7RMX9-155B 20.5 9.7RMX9-115R 20.0 9.5RMX9-125R 20.0 9.5RMX9-135R 20.5 9.7RMX9-145R 20.5 9.7RM10-115A 20.0 9.5RM10-125A 20.0 9.5RM10-135A 20.5 9.7RM10-145A 20.5 9.7RMX10-115A 20.0 9.5RMX10-125A 20.0 9.5RMX10-135A 20.5 9.7RMX10-145A 20.5 9.7RMX10-155A 20.5 9.7RMX-10-165A 20.5 9.7RMO-13-145A 22.0 10.4

*Oil capacities are approximate. Fill the transmission to the bottom of the fill plug hole.On transmissions equipped with an oil pump and/or oil cooler, operate the engine with thetransmission in NEUTRAL and the clutch engaged for five minutes after the initial fill andcheck the oil level again.

Transmission Oil Specifications

Lubricant Type Grade (SAE) Outside Temperature

Full-Synthetic Oil 50 AllRockwell Specification 0-81*

Heavy Duty Engine Oil, 50 Above 10oF (-12o C)A.P.I.-CD, -CE, -SF or -SG 40 Above 10oF (-12o C)(Current A.P.I. Designations 30 Above -15oF (-26o C)Acceptable) *MIL-2104B, C, D or E *

Mineral Oil with Rust and 90 Above 10oF (-12o C)Oxidation Inhibitor, A.P.I.-GL-1 * 80 Above -15oF (-26o C)

* Use only the specified type of single weight oils. Do not use multi-viscosity and EP(Extreme Pressure) GL-5 gear oils. Multi-viscosity and EP gear oils may damagecomponents. The use of multi-viscosity or EP gear oils void the warranty.

Page 215


Fastener Torque Locations- Nine-Speed and Ten-Speed Transmissions

TOP VIEW SIDE VIEW

FRONT VIEWWITH CLUTCH HOUSING

FRONT VIEWWITHOUT CLUTCH HOUSING

DESIGN LEVEL 2

12

6

5

11 1312

3 4

7

1098

14 14

Page 216


Fastener Torque Locations- Nine-Speed and Ten-Speed Transmissions (Continued)

REAR VIEWWITH AUXILIARY

COVER

REAR VIEWWITHOUT AUXILIARY COVER

DESIGN LEVEL 2WITH ROUND RETAINER


DESIGN LEVEL 2WITH TWO-PIECE RETAINER

TOP COVERSTANDARD X-BAR SHOWN

15

16

17

18

22

20

2324

23

23

25

26

27

21

19

24

23

26

Page 217


Fastener Torque Locations- Nine-Speed and Ten-Speed Transmissions (Continued)

MAIN CASEREVERSE IDLER GEAR

MAIN CASEOIL PUMP

28

29

30

AUXILIARY CASE

31

32

REMOTE CONTROL HOUSING

33

35

34

37

36

38

40

39

B SECTION A-ASECTION B-B

SIDE VIEW

AA

B

Page 218


Size Torque RangeItem Description (Inch) Lb-Ft N.m

1 Back-Up Lamp Switch to Top Cover Housing 9/16-18 UNF 35-50 47-672 Top Cover Housing to Main Case Capscrew 3/8-16 UNC x 1-1/4 25-35 34-473 Neutral Safety Switch to Top Cover Housing 3/4- 16 UNF 35-50 47-674 Breather Vent 3/8-18 NPT 15-20 21-275 Slave Valve Air Fittings 1/8 NPT 15-20 21-276 Slave Valve to Transmission Case 1/4-20 UNC 1-1/2 85-115 10-12

Capscrew lb-in7 Shift Tower to Top Cover 3/8-16 UNC x 1-1/4 35-45 47-60

Housing8 Inspection Cover to Clutch Housing Capscrew 3/8-16 UNC x 5/8 25-35 34-479 PTO Cover to Case Capscrew – 8-Hole 7/16-14 UNC x 3/4 35-45 47-6110 Drain and Fill Plugs to Main Case 1-1/16 -12 UN 35-50 47-6711 Clutch Housing to Main Case Nut 5/8-18 UNF 150-190 204-25712 Clutch Housing to Main Case 1/2-13 UNC x 1-1/2 65-85 89-115

Capscrew 1/2-13 UNC x 3-1/2 65-85 89-11513 Input Bearing Retainer to Main Case 3/8-16 UNC x 1-1/4 25-35 34-47

Capscrew14 Front Cup Retainer to Main Case ------- 120-140 14-15

Allen-head Capscrew in-lbs15 Countershaft Cover to Auxiliary Case 3/8-16 UNC x 1 25-35 34-47

Capscrew16 Range Cylinder Cover to Auxiliary Case 3/8-16 UNC x 2-3/4 35-45 47-61

Capscrew17 Air Filter/Regulator End Cap ------ 20-25 2.3-2.8

lb-in18 Air Filter/Regulator to Auxiliary Case 1/4-20UNC x 2 85-115 10-12

Capscrew lb-in19 Auxiliary Cover to Main Case Capscrew 3/8-16 UNC x 1-1/2 35-45 47-6120 Output Bearing Retainer to Main Case 3/8-16 UNC x 3 35-45 47-61

Capscrew21 Yoke to Output Shaft Nut 2-16 UN 450-500 610-67722 PTO Cover to Case Capscrew – 6-Hole 3/8-16 UNC x 3/4 35-45 47-6123 Auxiliary Drive Gear to Main Case 3/8-16 x 1 35-45 47-61

Capscrew24 Rear Bearing Retainer to 3/8-16 UNC x 1 25-35 34-47

Main Case Capscrew25 Rocking Lever Assembly Pin guide to Top 1/2-20 UNF 35-45 47-61

Cover Housing Nut26 Oil Scoop to Top Cover Housing 1/4-20 x 1/2 UNC 10-13 13-17

Capscrew27 Shift Fork to Shift Rail Set Screw 7/16-20 UNF 35-45 47-6128 Reverse Idler Gear to Shaft Nut 5/8-18 UNF 75-100 101-13529 Oil Pump to Main Case Capscrew 1/4-20 UNC x 1-1/2 7-10 10-13

Fastener Torque Chart - Nine-Speed and Ten-SpeedTransmissions

See NOTES on the following page.

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

2

1

1

Page 219


Fastener Torque Chart - Nine-Speed and Ten-SpeedTransmissions Chart (Continued)

Size Torque RangeItem Description (Inch) Lb-Ft N.m30 Oil Pump Pick-up Tube Bracket to 3/8-16 UNC x 1/2 5-10 7-13

Transmission Case Capscrew31 HI/LO Shift Fork to HI/LO Shift Shaft 5/16-18 UNC 8-12 11-16

Shoulder Bolt32 Piston to Shift Shaft Nut 7/16-20 UNF 35-50 48-6733 Remote Control Housing to Top Cover ----- 35-45 47-61

Capscrew34 Remote Control Housing Adjusting Rod 1/2-13 UNC 35-50 47-67

Jam Nut35 Remote Control Housing Outer Shift Lever 7/16-14 UNC 32-40 44-54

Set Screw36 Remote Control Housing Outer Shift 7/16-20 UNF 12-18 17-24

to Linkage Nut37 Remote Control Housing Adjusting Rod 1/2-13 UNC 65-85 89-115

to Linkage Nut38 Remote Control Housing Socket 1/2-13 UNC 35-50 47-67

39 Remote Control Housing Adjusting Rod 1/2-20 UNF 60-75 82-101to Linkage Nut

40 Remote Control Housing Inner Shift Lever 7/16-14 UNC 32-40 44-54Set Screw

NOTES:On fasteners with threads 1/4 inch (7mm) or smaller, put Loctite ® 222 (Rockwell Part Number 2297-B-6112) or equivalent on the threads. On fasteners with threads greater than 1/4 inch (7mm) threads orsmaller, put Loctite ® 242 (Rockwell Part Number 2297-V-2430) or equivalent on the threads. Put a newapplication of Loctite ® or equivalent if any of the following occur.a. A new fastener is installed.b. The sealant is removed from the threads.c. The fastener is removed the third time from the transmission.Requires Loctite ® 242 (Rockwell Part Number 2297-V-2430) or equivalent and lockwire. After thecapscrews are tightened to the specified torque, do not loosen or tighten the capscrews. If the cap-screws are loosened or tightened, the capscrews must be removed, cleaned and new sealant applied orthe capscrews may loosen during operation.When installing lockwire, do the following:a. Trim excess wire to a 1/4 inch (6 mm) length.b. Bend the wire towards the capscrew.c. Twist the wire at least once between parts.d. On the 1-2 sleeve, the wire can be wrapped around the shaft.Do not tighten more than the specified torque or the output bearing may be damaged.

1

1

1

2

3

Page 220


Fastener Torque Locations- Thirteen-Speed Transmissions

FRONT VIEWWITH CLUTCH HOUSING

14 14

11 12 13

1

3 54

2

98 10

67

FRONT VIEWWITHOUT CLUTCH HOUSING

DESIGN LEVEL 2

TOP VIEW SIDE VIEW

Page 221


Fastener Torque Locations- Thirteen-Speed Transmissions (Continued)


DESIGN LEVEL 2WITH ROUND RETAINER


DESIGN LEVEL 2WITH TWO-PIECE RETAINER

2324

23

24

23

23

25

26

27

26

TOP COVERSTANDARD X-BAR

SHOWN

REAR VIEWWITH AUXILIARY COVER

15

16

17

18

22

2021

19

Page 222


Fastener Torque Locations- Thirteen-Speed Transmissions (Continued)

MAIN CASEREVERSE IDLER GEAR

MAIN CASEOIL PUMP

28

29

30

40

AUXILIARY CASE

32

33

34

31

35

37

3638

REMOTE CONTROL HOUSING

A

B SECTION A-A

A

SIDE VIEW

B

SECTION B-B

3941

42

Page 223


Size Torque RangeItem Description (Inch) Lb-Ft N.m

1 Back-Up Lamp Switch to Top Cover Housing 9/16-18 UNF 35-50 47-672 Top Cover Housing to Main Case Capscrew 3/8-16 UNC x 1-1/4 25-35 34-473 Neutral Safety Switch to Top Cover Housing 3/4- 16 UNF 35-50 47-674 Breather Vent 3/8-18 NPT 15-20 21-275 Slave Valve Air Fittings 1/8 NPT 15-20 21-276 Slave Valve to Main Case Capscrew 1/4-20 UNC x 1-1/2 85-115 10-12

lb-in7 Shift Tower to Top Cover Housing 3/8-16 UNC x 1-1/4 25-35 34-478 Inspection Cover to Clutch Housing Capscrew 3/8-16 UNC x 5/8 25-35 34-479 PTO Cover to Case Capscrew – 8-Hole 7/16-14 UNC x 3/4 35-45 47-61

10 Drain and Fill Plugs to Main Case 1-1/16-12 UN 35-50 47-6711 Clutch Housing to Main Case Nut 5/8-18 UNF 150-190 204-25712 Clutch Housing to Main Case 1/2-13 UNC x 1-1/2 65-85 89-115

Capscrew 1/2-13 UNC x 3-1/2 65-85 89-11513 Input Bearing Retainer to Main Case 3/8-16 UNC x 1-1/4 25-35 34-47

Capscrew14 Front Cup Retainer to Main Case ------- 120-140 14-15

Allen-head Capscrew in-lbs15 Countershaft Cover to Auxiliary Case 3/8-16 UNC x 1 25-35 34-47

Capscrew16 Piston Housing to Auxiliary Case Capscrew 3/8-16 UNC x 3 35-45 47-6117 Air Filter/Regulator End Cap ------ 20-25 2.3-2.8

lb-in18 Filter and Regulator to Auxiliary Case Capscrew 1/4-20UNC x 3/4 85-115 10-12

lb-in19 Auxiliary Cover to Main Case Capscrew 3/8-16 UNC x 1-1/2 35-45 47-6120 Output Bearing Retainer to Main Case 3/8-16 UNC x 3 35-45 47-61

Capscrew21 Yoke to Output Shaft Nut 2-16 UN 450-500 610-67722 PTO Cover to Case Capscrew – 6-Hole 3/8-16 UNC x 3/4 35-45 47-6123 Auxiliary Drive Gear to Main Case 3/8-16 x 1 35-45 47-61

Capscrew24 Rear Bearing Retainer to 3/8-16 UNC x 1 25-35 34-47

Main Case Capscrew25 Rocking Lever Assembly Pin guide to Top 1/2-20 UNF 35-45 47-61

Cover Housing Nut26 Oil Scoop to Top Cover Housing 1/4-20 x 1/2 UNC 10-13 13-17

Capscrew27 Shift Fork to Shift Rail Set Screw 7/16-20 UNF 35-45 47-6128 Reverse Idler Gear to Shaft Nut 5/8-18 UNF 75-100 101-13529 Oil Pump to Main Case Capscrew 1/4-20 UNC x 1-1/2 7-10 10-1330 Oil Pump Pick-up Tube Bracket to 3/8-16 UNC x 1/2 5-10 7-13

Transmission Case Capscrew

Fastener Torque Chart- Thirteen-Speed Transmission

See NOTES on the following page.

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

2

1

1

1

Page 224


NOTES:On fasteners with threads 1/4 inch (7mm) or smaller, put Loctite ® 222 (Rockwell Part Number 2297-B-6112) or equivalent on the threads. On fasteners with threads greater than 1/4 inch (7mm) threads orsma1ller, put Loctite ® 242 (Rockwell Part Number 2297-V-2430) or equivalent on the threads. Put anew application of Loctite ® or equivalent if any of the following occur.a. A new fastener is installed.b. The sealant is removed from the threads.c. The fastener is removed the third time from the transmission.Requires Loctite ® 242 (Rockwell Part Number 2297-V-2430) or equivalent and lockwire. After thecapscrews are tightened to the specified torque, do not loosen or tighten the capscrews. If the cap-screws are loosened or tightened, the capscrews must be removed, cleaned and new sealant applied orthe capscrews may loosen during operation.When installing lockwire, do the following:a. Trim excess wire to a 1/4 inch (6 mm) length.b. Bend the wire towards the capscrew.c. Twist the wire at least once between parts.d. On the 1-2 sleeve, the wire can be wrapped around the shaft.Do not tighten more than the specified torque or the output bearing may be damaged.

Fastener Torque Chart - Thirteen-Speed Transmission(Continued)

Size Torque RangeItem Description (Inch) Lb-Ft N.m31 Output Shaft to Synchronizer Nut 7/8-14 UNF 220-260 299-35232 HI/LO Shift Fork to HI/LO Shift Shaft 5/16-18 UNC 8-12 11-16

Shoulder Bolt33 Splitter Fork to Shaft Capscrew 7/16-20 UNF 35-45 47-6134 Piston to Shift Shaft Nut 7/16-20 UNF 30-45 41-6035 Remote Control Housing to Top Cover ----- 35-45 47-61

Capscrew36 Remote Control Housing Adjusting Rod 1/2-13 UNC 35-50 47-67

Jam Nut37 Remote Control Housing Outer Shift Lever 7/16-14 UNC 32-40 44-54

Set Screw38 Remote Control Housing Outer Shift 7/16-20 UNF 12-18 17-24

to Linkage Nut39 Remote Control Housing Adjusting Rod 1/2-13 UNC 65-85 89-115

to Linkage Nut40 Remote Control Housing Socket 1/2-13 UNC 35-50 47-67

41 Remote Control Housing Adjusting Rod 1/2-20 UNF 60-75 82-101to Linkage Nut

42 Remote Control Housing Inner Shift Lever 7/16-14 UNC 32-40 44-54Set Screw

1

1

1

1

2

3

Page 225


Air Line Locations - Nine-Speed and Ten-Speed Transmissions

2 (RED)

3 (YELLOW)

1 (BLACK)

MAIN VIEW

4 (RED)

3 (YELLOW)

1 (BLACK)

2 (RED)

SELECTOR VALVE

1(BLACK)

SLAVE VALVE

FILTER/REGULATOR ASSEMBLYAND

RANGE CYLINDER

5 (BLACK)6 (BLUE)

4 (RED)

5(BLACK)

4 (RED)

2 (RED)

6 (BLUE)

Page 226


Air Line Identification Chart - Nine-Speed and Ten-Speed TransmissionsHose Hose Outer

Item Description Color Diameter Specification

1 Pilot Fitting on Selector Valve to Pilot Black 5/32 inch SAE J844 Fitting on Slave Valve or 1/8 inch Type A

2 Pilot Supply Fitting on Selector Valve to Red 5/32 inch SAE J844Pilot Supply Fitting on Slave Valve or 1/8 inch Type A

3 Exhaust Fitting on Selector Valve Yellow 5/32 inch SAE J844Type A

4 Supply Fitting on Filter/Regulator to Red 5/16 inch SAE J844Supply Fitting on Slave Valve Type A

5 LO Range Port on Slave Valve to Black 5/16 inch SAE J844LO Range Port on Range Cylinder Type A

6 HI Range Port on Slave Valve to Blue 5/16 inch SAE J844HI Range Port on Range Cylinder Type A

NOTES:

Color or hose diameter may vary by vehicle manufacturer.

If 1/4 inch air lines and fittings are used, replace the lines and fittings with 5/16 inch air linesand fittings.

1

1

1

1

2

2

2

1

2

Page 227


Air Line Locations - Thirteen-Speed Transmissions

SLAVE VALVEFILTER AND REGULATIORASSEMBLY PISTON HOUSING

SELECTOR VALVE

2A4A

3

4B

7B

6B

5A1A

2B

5B

7A

1B

6A

1

2

3

4

76

5

Page 228


Air Tube Identification Chart - Thirteen-Speed TransmissionsTube

Tube OuterItem Description Color Diameter Specification

1 Pilot Fitting on Selector * 5/32 inch SAE J844Valve (1A) to Pilot Fitting or Type Aon Slave Valve (1B) 1/8 inch

2 Pilot Supply Fitting on Selector * 5/32 inch SAE J844Valve (2A) to Pilot Supply Fitting or Type Aon Slave Valve (2B) 1/8 inch

3 Exhaust Fitting on Selector * 5/32 inch SAE J844Valve or Type A

1/8 inch

4 Splitter Fitting on Selector * 5/32 inch SAE J844Valve (4A) to Splitter Fitting or Type Aon Piston Housing Cover (4B) 1/8 inch

5 Supply Fitting on Filter * 1/4 inch SAE J844and Regulator (5A) to Supply Type AFitting on Slave Valve (5B)

6 LO Range Port on Slave * 1/4 inch SAE J844Valve (6A) to LO Range Port Type Aon Piston Housing (6B)

7 HI Range Port on Slave * 1/4 inch SAE J844Valve (7A) to HI Range Port Type Aon Piston Housing Cover (7B)

* See the specifications of the manufacturer of the vehicle for the color of the tube.

Page 229


Holding Cover Template3305-W-1141

➛

➛

➛ 0.25 INCH(6.35 mm)

➛

➛

➛

➛

➛

➛

➛

➛

➛

➛

➛

+-4.5 0.11 INCH(114.30 3.00 mm)+-

1.0 INCH(25.4 mm)

1.62 INCH(41.15 mm)

1.25 INCH(32.00 mm) 0.5 INCH

(12.70 mm)

2.25 INCH(57.15 mm)

➛

➛

0.075 INCH(9.53 mm)

0.437 INCH(11.11 mm)DIAMETER

Page 230


Tool Description Tool Number Tool ManufacturerBearing Puller Tool 3256-W-1037 Rockwell

J-41086 Kent-Moore

Bearing Cup Seating Tool 3256-T-1034 Rockwell

Bearing Cup Seating Tool J-41085 Kent-Moore

Bearing Service Set OTC-7070 Owatonna(Input Shaft Removal)

Countershaft Bearing 3256-D-1044 RockwellPusher Tool G-28 G&W

Countershaft End Play 3256-C-1043 RockwellChecking Tool J-41335 Kent-Moore

Flange/Yoke Holding J-3453 Kent-MooreTool

Holding Cover Plate 3305-W-1141 Rockwell

Input Shaft Bearing G-38 G&WRemover

Input Shaft Bearing G-35 G&WDriver

Input Shaft Installer J-39942 Kent-Moore

Seal Remover CG2400B Snap-On(Light Duty Puller Set)

Seal Driver J-39161 Kent-Moore

Seal Driver 3256-Z-1014 Rockwell

Spacer Washer 1229-N-4538 Rockwell

T-Handle Tool 3256-Y-1013 Rockwell

Special Tools

NOTES:Rockwell tools are available wherever Rockwell parts are sold.

Order Kent-Moore Tools from Kent-Moore Heavy Duty Division, 29874 Little Mack,Roseville, MI 48066-2298.Order Owatonna Tools from OTC Tool and Equipment Division, 655 Eisenhower Drive,Owatonna, MN 55060.

Contact your local Snap-On tool distributor.Order G&W Tools from G&W Tool Company, 1105 E. Louisville, Broken Arrow, OK74012

1

2

1

2

3

1

4

1

2

2

1

2

2

1

1

1

1

2

3

4

5

4

5

5

Page 231

Air Filter and Regulator AssemblyInstalling, 29Removing, 28

Air LineIdentification (9-,10-Speed), 226Identification (13-Speed), 228Location (9-,10-Speed), 225Location (13-Speed), 227

Auxiliary CaseAssembling (9-, 10-Speed), 163Assembling (13-Speed), 181Disassembling (9-,10-Speed), 155Disassembling (13-Speed), 173Installing (9-,10-Speed), 90Installing (13-Speed), 98Removing (9-,10-Speed), 85Removing (13-Speed), 94

Auxiliary CountershaftAssembling (9-,10-Speed), 166Assembling (13-Speed), 185Disassembling (9-,10-Speed), 160Disassembling (13-Speed), 179End Play, 199-205Installing (9-,10-Speed), 166Installing (13-Speed), 186Removing (9-,10-Speed), 159Removing (13-Speed), 177Timing (9-,10-Speed), 163Timing (13-Speed), 183

Auxiliary Drive GearAssembling, 136Disassembling, 134Installing, 103Removing, 102

Auxiliary Low GearTiming Mark, 163

Bearing Cone and CupInspecting, 15-18Replacement Chart, 15

Bearing Cone, Auxiliary Countershaft,Installing (9-,10-Speed), 166Installing (13-Speed), 185Removing (9-,10-Speed), 160Removing (13-Speed), 179

IndexBearing Cone, Main Countershaft,Front, LowerInstalling,Removing,

Bearing Cone, Main Countershaft,Front, UpperInstalling, 126-129Removing, 106-107

Bearing Cone, Main Countershaft,Rear, LowerInstalling,Removing,

Bearing Cone, Main Countershaft,Rear, UpperInstalling, 154Removing, 151

Bearing Cup, Auxiliary Countershaft,FrontInstalling (9-,10-Speed),90, 172Installing (13-Speed), 191Removing (9-,10-Speed), 89Removing (13-Speed), 97

Bearing Cup, Auxiliary Countershaft,RearInstalling (9-,10-Speed), 168-169Installing (13-Speed), 187Removing (9-,10-Speed), 158Removing (13-Speed), 176

Bearing Cup, Main Countershaft, Front,LowerInstalling,Removing, 106-107

Bearing Cup, Main Countershaft, Front,UpperInstalling, 126-130Removing, 108

Bearing Cup, Main Countershaft, Rear,LowerInstalling,Removing,

Bearing Cup, Main Countershaft, Rear,UpperInstalling,Removing,

Breather Vent, 22

Page 232

IndexCleaning

Ground Parts, 19Polished Parts, 19Rough Parts, 19

Clutch HousingInstalling, 83Removing, 83

Corrosion, 19

Description, 5

Dowel PinInstalling, 91, 99Removing, 87, 97

Drying Parts, 19

End PlayAuxiliary Countershaft, 199Main Countershaft, 192

Identification,6

General Information, 5

GasketInstalling, 12Patterns, 13-14Removing, 12Specifications, 12

General Information, 5

HI-LO ForkInstalling (9-,10-Speed), 170-171Installing (13-Speed), 187-188Removing (9-,10-Speed), 158-159Removing (13-Speed), 175

Holding Cover Template, 229

Input ShaftInstalling, 81, 119Removing, 79, 110

Inspecting Parts, 15

In-Vehicle Service, 25

Leaks, 22, 209

Lubrication, 20

Main Case, 104-133

Main CountershaftAssembling, 152Disassembling, 150End Play, 192Installing, 123Removing, 113

MainshaftAssembling, 139Disassembling, 137Installing, 125Removing, 104

Maintenance, 20Scheduled, 21

MagnetsInstalling, 117Removing, 116

Noises, 210

OD (Overdrive) GearTiming Marks, 181

Oil Capacities, 214

Oil Coolers, 20

Oil Draining, 23

Oil LevelAdjusting, 21Checking, 21

Oil PumpInstalling, 118Removing, 115

Oil Replacing, 23

Oil SealInstalling, 30Removing, 29

Oil Specifications, 20, 214

Operating Conditions, 211

Output ShaftAssembling (9-,10-Speed), 164Assembling (13-Speed), 181Disassembling (9-,10-Speed), 161Disassembling (13-Speed), 177Installing (9-,10-Speed), 166Installing (13-Speed), 183Removing (9-,10-Speed), 160Removing (13-Speed), 176

Output YokeInstalling, 30Removing, 29

PistonInstalling (9-,10-Speed), 172Installing (13-Speed),190Removing (9-,10-Speed), 156Removing (13-Speed), 174

Page 233

Index

Piston HousingInstalling, 190-191Removing, 174

PTO CoversInstalling, 117Removing, 116

Range CylinderInstalling, 171-172Removing, 156

Repairing Parts, 19

Replacing Parts, 19

Remote Control AssemblyAdjusting, 24Installing, 33Lubricating, 24Removing, 33

Remote Shift HousingAdjusting, 24Installing, 33Lubricating, 24Removing, 33

Reverse Idler GearInstalling, 118Removing, 104

Rust,19

Scheduled Maintenance, 21

SealInstalling, 30Removing, 29

SealantInstalling, 12Patterns, 13-14Removing, 12Specifications, 12

Shift Lever and Tower AssemblyAssembly (Aluminum), 43Assembly (Cast Iron), 47Disassembly (Aluminum), 41Disassembly (Cast Iron), 46Installing, 25Removing, 25

Shim KIT 5376 Chart, 197

Shuttle ValveInstalling, 191Removing, 174

Slave ValveInstalling, 27Removing, 27

Snap Ring Chart, 194

Special Tools, 230

Splitter ForkAssembling, 183-184Disassembling, 178Installing, 186-187Removing, 177

SynchronizerAssembling, 167, 184Disassembling, 159, 177Installing, 168, 187Removing, 159, 176

Timing, 9

Top CoverAssembling (Standard), 60Assembling (“X” Bar), 72Disassembling (Standard), 54Disassembling (“X” Bar), 66Identification, 50Installing, 52Removing, 50

Torque, 22, 215-224

TransmissionInstalling, 36Removing, 34

YokeInstalling, 30Removing, 29

North American Truck Systems information contained in this publication was in effect at the time the publication was approvedRockwell International Corporation for printing and is subject to change without notice or liability. Rockwell International reserves the2135 West Maple Road right to revise the information presented or discontinue the production of parts described at any time.Troy, MI 48084 USA(800) 535-5560 © Copyright 1996 Revised 2-96

Rockwell International Printed in U.S.A. MM26A (47865/24240)

Automotive

Information contained in this publication was in effect at the time the publication was approvedfor printing and is subject to change without notice or liability. Rockwell International reserves theright to revise the information presented or discontinue the production of parts described at any time.

Manual de Servicio Transmisiones Rockwell 9-10 y 13 Marchas.

Documents

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serial numbers

serial numbers

hot solution

remote control

auxiliary

weak alkaline

piloted bearing