UltraShift DM3 and AutoShift AS3

Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT0021 or call 1-800-826-HELP (4357).

Note: The use of lubricants not meeting these requirements will affect warranty coverage.

Note: For lubrication change and inspection intervals see TCMT0021.

Note: Please refer to CLSM0200 for clutch lubrication and service guidelines.

Buy From a Reputable Dealer

For a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013, Kalamazoo, MI 49003

Transmission Operating Angles

If the transmission operating angle is more than 12°, improper lubrication will occur. The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12°, the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication.

Transmission filters should be changed during regular lubrication intervals. Inspection of the transmission filter should be conducted during preventative maintenance checks for damage or corrosion. Replace as necessary.

Operating Temperatures with Oil Coolers

Transmissions must not be operated at temperatures above 250°F (121°C). Operation at temperatures above this limit causes loaded gear tooth temperatures to exceed 350°F (177°C) which will ultimately destroy the heat treatment of the gears. If the elevated temperature is associated with an operating condition that will recur, a cooler should be added, or the capacity of the existing cooling system increased.The following conditions, in any combination, can cause operating temperatures of over 250°F (120°C):

• Operating consistently at high loads/slow speeds
• High ambient temperatures
• Restricted air flow around the transmission
• Exhaust system too close to the transmission
• High horsepower operation
• Engine retarders

External oil coolers are available to reduce operating temperatures when the above conditions are encountered. Eaton oil cooler systems must meet a minimum requirement of 3/4” ID cooler lines and 8 GPM system flow at 1500 RPM. The end user is ultimately responsible for maintaining transmission lube temperatures below 250°F (121°C).

UltraShift™ ASW Models

Note: For a list of Eaton-approved synthetic lubricants, see TCMT0021 or call 1-800-826-HELP (4357).

Note: The use of lubricants not meeting these requirements will affect warranty coverage.

Note: For lubrication change and inspection intervals, see TCMT0021.

Buy From a Reputable Dealer

For a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013, Kalamazoo, MI 49003

Synthetic Dextron III ATF

Synthetic Dextron III ATF must be used in the wet clutch portion of the transmission.

CD-50

CD-50 must be used in the gearbox portion of the transmission.

Maintenance and Lubricant Change Intervals

Transmission inspections and lubricant changes are outlined below.

For a list of Eaton Roadranger-approved lubricants, order publication TCMT0020.

Checking Wet Clutch Lubricant

The wet clutch portion is checked using a dipstick located in the engine compartment.

Proper Wet Clutch Lubricant Level

Wet clutch lubricant level should be checked when idling in neutral for at least 2 minutes, with the transmission temperature between 60° F and 120° F (15.5° C and 48.8° C). Proper level is obtained when the lubricant is between the cold Add mark and the cold Full marks on the dipstick. Due to thermal expansion of the lubricant, it is not recommended to check the level when the transmission is above 120° F (48.8° C).

Checking Gearbox Lubricant

The gearbox portion is checked at the lubricant fill plug located on the right side of the gear case.

Cooler

A Transmission Clutch Cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the requirements specified in TRIG0930.

Proper Gearbox Lubricant Level

The gearbox lubricant is at the proper level when it is even with bottom of the fill hole. When you remove the plug to check the lubricant level, lubricant should seep out. Do not use your finger to feel for the lubricant. Even if you can touch the lubricant, it may not be at the proper level. In a transmission, 1 inch of lubricant level equals about 1 gallon of lubricant.

Drain the Transmission Gearbox and Wet Clutch Housing

• Locate drain plugs at the bottom of the transmission gear case and clutch housing oil pan.
• Place a drain pan under each drain plug.
• Remove both drain plugs. Allow the lubricants to drain completely.
• Disconnect both cooler lines at the wet clutch housing.
• Pressurize one line with 20 PSI until all lubricant is forced out of the cooler.
• Reconnect both cooler lines.

Change Wet Clutch Filters

Change the lubricant filters when the transmission lubricant is changed. Detailed information can be found on removal and replacement of the oil filters in this service manual.

Transmission filters should be changed during regular lubrication intervals. Inspection of the transmission filter should be conducted during preventative maintenance checks for damage or corrosion. Replace as necessary.

Fill the Transmission

• Install the Transmission Gearbox Drain Plug and tighten to 45-55 lb-ft. (60-73 Nm). Sealant is not required on the drain plug threads.
• Install the Clutch Housing Oil Pan Drain Plug and torque to 34-48 lb-ft. (45-64 Nm). Sealant is not required on the drain plug thread.
• Fill the Transmission Gearbox with the recommended lubricant until the it seeps out of the fill hole.
• Install the fill plug and torque to 25-35 lb-ft. (33-47 N•m).
• Slowly fill the clutch through the dipstick tube with an initial fill of 18 pints (8.5 liters) of the recommended lubricant.
• Place the transmission in neutral position apply the parking brakes. Start the engine and let idle for 5 minutes. This allows oil to fill the wet clutch system and cooling system. Add oil as needed to obtain a level at the proper temperature range. Total oil quantity at this time varies depending on the cooling system capacity.
• Increase the engine idle slowly to 1500 RPM for 2 minutes. Now, recheck the oil level at normal idle speed in neutral, again adding oil to obtain a level at the proper temperature range.
• Install the dipstick and tighten securely.

Clutch Calibration

The ASW system automatically provides for clutch wear. The system will initiate a clutch calibration once per vehicle power up, when certain vehicle conditions are right. Of these conditions, the most important ones include:

• When the engine is running at idle speed.
• During normal operating temperature.
• When the vehicle is stopped.
• When neutral is selected on the Shift Control.

During calibration, the clutch is partially engaged until the engine begins to slightly lug down. It will then disengage the clutch and repeat this process several times. The calibration process usually takes as little as 30 seconds, but can take as long as 2 minutes. The calibration will be aborted when any position other than neutral is selected on the Shift Control.

If the vehicle is not engaging smoothly from a stop, it is possible the clutch needs to be re-calibrated. If it was not calibrated during the current power up, stop the vehicle with the engine idling at normal operating temperature and place the Shift Control in neutral. Wait 2 minutes. If the calibration is being performed, you should hear the engine slightly lug down and then return to its no-load condition several times.

If calibration does not occur, a power down or power up will initiate a calibration.