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SUBJECT DATE
Split Rod Bushing Repair October 2015
Additions, Revisions, or Updates
Publication Number / Title Platform Section Title Change
DDC-SVC-MAN-0140DT12
Transmission
Split Rod Bushing Repair This is a new section.
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2 Split Rod Bushing Repair
NOTE: You may also refer to video on DDCSN
Support/Multimedia/DT12 Transmission Split-Pin Bushing Repairfor
tool usage and procedure.
Required tools - 11.5mm drill bit, 12mm ream bore, and a brass
hammer.
Repair as follows:
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or
allow engine to cool before removingany component.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure
the vehicle is parked on a levelsurface, parking brake is set, and
the wheels are blocked.
1. Shut off the engine, apply the parking brake, chock the
wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting
battery cables. The magneticswitch studs are at battery
voltage.
2. Disconnect the main and auxiliary batteries, if equipped.3.
Remove the transmission. Refer to section "Removal of the
Transmission".4. Remove the Shift Controller. Refer to section
"Removal of the Shift Controller".5. Remove the Shift Actuator.6.
Install drill jig.
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7. Coat a paper rag with heavy grease and place it inside the
transmission housing, in such a way to retain the chipscreated by
drilling out the transmission case.
NOTICE: The original bore diameter is almost the same diameter
of the drill. During the drilling process the bit willhave the
tendency to grab and twist, potentially pointing the drill away
from the intended centerline of the hole.Control the plunge rate
and drill rpm to reduce the risk of damage to the case.
NOTE: The guide block is sized to control the ream diameter; the
drill needs to be visually centered in the blockwhile drilling.
8. Grease the drill bit and bore the hole. Use high revs, keep
the drill centered in the block, and slowly plunge through
thecase.
9. Clear the loose chips and remove the rag.
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10. Grease the reamer and a new catch rag.11. Ream the hole,
using low revs, taking time to clean and re-grease as needed.12.
Clear any loose chips and remove the rag.13. Remove the guide block
and clean the any remaining chips and grease.14. Install the split
bushing, with the split in the 12 o'clock (1), until flush with the
outer surface of the case.
15. Test fit the split rod, to confirm it fits correctly in the
bushing.16. Install the shift actuator.17. Coat the shift pin with
transmission oil and install it.18. Install the shift controller.
Refer to section "Installation of the Shift Controller".19. Install
the transmission. Refer to section "Installation of the
Transmission".
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting
battery cables. The magneticswitch studs are at battery
voltage.
20. Connect the batteries.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure
the vehicle is parked on a levelsurface, parking brake is set, and
the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the
engine in a well-ventilated area.Engine exhaust is toxic.
21. Start the engine and charge the air system.22. Perform the
transmission learn procedure.
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