Endurant HD
TRSM0950 EN-US
|
February 2025 - A

Main Shaft End-Play Service Procedure

Special Instructions

Main Shaft End-Play must be measured and adjusted after Clutch Housing, Main Housing, Input Shaft, Input Shaft Bearing or Main Shaft Bearing replacement.

Caution
Failure to determine and install the Ideal Main Shaft Selective Washer results in incorrect Main Shaft End-Play resulting in transmission component damage.

Special Tools

  • Torque Wrench
  • 4 Flat Washers (22.3 mm (0.9 in) minimum OD)
  • Dial Indicator
  • 2 Pry Bars
  • 5/32 OD Air Line
  • Front Bearing Capture Plate (RR1085TR-7)
  • Plastic Scraper
  • Non-Chlorinated Brake Cleaner (Gasket Remover)
    Danger
    Do not handle non-chlorinated brake cleaner until all manufacturer precautions have been read and understood. Failure to follow precautions will result in serious personal injury or death.
    Caution
    Avoid contact between non-chlorinated brake cleaner and the transmission plastic components, electrical wiring and connectors. Failure to avoid contact will result in transmission component damage.

Component Identification

_Graphics/_LineArt/TRTS0950_Endplay_ID.png

1. Primary Drive Gear

2. Spherical Washer - Front

3. Bearing Race - Front

4. Needle Bearing - Front

5. Thrust Bearing - Front

6. Thrust Washer - Front

7. Wave Spring - Front

8. Synchronizer Ring

9. Synchronizer Sliding Sleeve

10. Synchronizer Rollers (x3)

11. Synchronizer Springs and Plungers (x3)

12. Lower Lube Tube Cap Screw - 8 mm

13. Lower Lube Tube

14. Upper Countershaft

15. Main Shaft Selective Washer - 6.525 mm (0.257 in), 6.712 mm (0.264 in) or 6.900 mm (0.272 in) (x1)

16. Main Shaft Assembly

17. Wave Spring - Rear

18. Thrust Washer - Rear

19. Thrust Bearing - Rear

20. Needle Bearing - Rear

21. Bearing Race - Rear

22. Upper Lube Tube Cap Screw - 8 mm

23. Upper Lube Tube

24, Lower Countershaft

25. Input Shaft Assembly

26. Countershaft Flat Washers (x2)

27. Countershaft Snap Rings (x2)

28. Input Shaft Snap Ring

Verify Components in the Clutch Housing

Caution
Clutch Housing weighs approximately 50 lbs. Keep fingers clear of pinch point between Clutch Housing and other surfaces. Dropping Clutch Housing could result in component damage and/or personal injury.

  1. Verify Input Shaft Bearing is fully seated in Clutch Housing to ensure a proper Main Shaft End-Play reading.

    _Graphics/_Raster/TRSM0950_ISDA_7396.png

  2. Ensure Input Shaft Snap Ring is installed as instructed in the Clutch Housing to verify that the Input Shaft is fully seated.

    _Graphics/_Raster/TRSM0950_MSEP_1.PNG

  3. Remove Input Shaft Snap Ring and install Front Bearing Capture Plate (RR1085TR-7) and torque to 21-25 Nm (16-19 lb-ft).

    Note: The Input Shaft Bearing must be fully seated against the bearing stop in the Clutch Housing to ensure a proper Main Shaft End-Play reading.

    _Graphics/_Raster/TRSM0950_MSEP_2.PNG

  4. Place and support Clutch Housing on a bench.

    _Graphics/_Raster/TRSM0950_MSEP_7632.png

Install the Main Shaft and Countershaft

  1. On the Secondary Drive Gear, apply paint marks on 2 gear teeth exactly 180-degrees across from each other, if not already marked.

    Note: Paint marks are required for timing the Secondary Drive Gear to the Countershafts.

    _Graphics/_Raster/TRSM0950_MHA_0861.png

  2. Install 3 springs and plungers into Synchronizer hub.

    _Graphics/_Raster/TRSM0950_MHR_0518.png

  3. Install Rail B Synchronizer Sliding Sleeve with bevel facing up.

    Notice
    The tapered side of the sleeve is installed with the bevel facing up.
    _Graphics/_Raster/TRSM0950_MHA_0820.png

  4. Lift and hold the Rail B Synchronizer Sliding Sleeve, install 3 rollers over the 3 springs and plungers and into the sliding sleeve groove.

    _Graphics/_Raster/TRSM0950_MHA_0828.png

  5. Slowly press down the Synchronizer Sliding Sleeve to the neutral position and seat the 3 rollers evenly on the springs and plungers.

    _Graphics/_Raster/TRSM0950_MHA_0830.png

  6. Install Rail B Synchronizer Ring.

    Note: Align the 3 tabs on ring to the 3 openings on the hub at each spring and plunger.

    _Graphics/_Raster/TRSM0950_MHA_0834.png

  7. Install Wave Spring - Front.

    Note: Wave Spring - Front is taller than the Wave Spring - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0529.png

  8. Install Thrust Washer - Front.

    _Graphics/_Raster/TRSM0950_MHR_0527.png

  9. Install Needle Bearing - Front.

    _Graphics/_Raster/TRSM0950_MHA_0838.png

  10. Install Thrust Bearing - Front.

    _Graphics/_Raster/TRSM0950_MHA_0843.png

  11. Install Bearing Race - Front.

    _Graphics/_Raster/TRSM0950_MHR_0497.png

  12. Install Spherical Washer - Front with conical side down.

    _Graphics/_Raster/TRSM0950_MHA_1277.png

  13. Install Lower Countershaft Pilot Tool (RR1071TR) to front section of Lower Countershaft.

    Note: Lower Countershaft has Inertia Brake Splines on the front and Oil Pump drive slot on the rear.

    _Graphics/_Raster/TRSM0950_MHA_0852.png_Graphics/_Raster/TRSM0950_MHA_0850.png

  14. On the Lower Countershaft front drive gear, apply paint marks on the 2 gear teeth marked “0 0".

    Notice
    If the Secondary Drive Gear and countershaft front drive gears are not paint marked correctly, the gearing will not be properly timed and the Main Housing cannot be installed due to countershaft misalignment.

    Note: Paint marks are required for timing the Secondary Drive Gear to the Countershafts.

    _Graphics/_Raster/TRSM0920_MSEP_7899.png

  15. Install Lower Countershaft with Countershaft Pilot Tool (RR1071TR). Ensure timing marks align with Secondary Drive Gear and Lower Countershaft front drive gear.

    Caution
    Countershaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Countershaft and other surfaces. Dropping Countershaft could result in component damage and/or personal injury.
    _Graphics/_Raster/TRSM0950_MHA_0863.png_Graphics/_Raster/TRSM0950_MHA_0865.png

  16. Install Upper Countershaft Pilot Tool (RR1072TR) to front section of Upper Countershaft.

    _Graphics/_Raster/TRSM0950_MHA_0868.png

  17. On the Upper Countershaft front drive gear, apply paint marks on the 2 gear teeth marked “0 0".

    Notice
    If the Secondary Drive Gear and countershaft front drive gears are not paint marked correctly, the gearing will not be properly timed and the Main Housing cannot be installed due to countershaft misalignment.

    Note: Paint marks are required for timing the Secondary Drive Gear to the Countershafts.

    _Graphics/_Raster/TRSM0920_MSEP_7899.png

  18. Install Upper Countershaft with Upper Countershaft Pilot Tool (RR1072TR) into bearing. Ensure timing marks align with Secondary Drive Gear and Upper Countershaft front drive gear.

    Caution
    Countershaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Countershaft and other surfaces. Dropping Countershaft could result in component damage and/or personal injury.
    _Graphics/_Raster/TRSM0950_MHA_0872.png_Graphics/_Raster/TRSM0950_MHA_0876.png

  19. Install Primary Drive Gear with clutching teeth facing up onto Rail B Synchronizer.

    _Graphics/_Raster/TRSM0950_MHA_1278.png

  20. Install Bearing Race - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1282.png

  21. Install Needle Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1287.png

  22. Install Thrust Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1290.png

  23. Apply transmission assembly lube to Wave Spring - Rear and install to Main Shaft.

    Notice
    Wave Spring - Rear is shorter than the Wave Spring - Front.

    Note: Transmission assembly lube holds Wave Spring - Rear in place during Main Shaft Assembly installation.

    _Graphics/_Raster/IMG_3468.png_Graphics/_Raster/IMG_3471.png

  24. Apply transmission assembly lube to Thrust Washer - Rear and install to Main Shaft.

    Note: Transmission assembly lube holds Thrust Washer - Rear in place during Main Shaft Assembly installation.

    _Graphics/_Raster/IMG_3473.png_Graphics/_Raster/IMG_3477.png

  25. Install a magnet onto the Main Shaft Key.

    Note: The magnet holds the key in position during Main Shaft Assembly installation.

    _Graphics/_Raster/TRSM0950_MHA_1302.png

  26. Slide and hold Rail C Sliding Clutch into Secondary Driven Gear.

    _Graphics/_Raster/IMG_3481.png

  27. Install Main Shaft Assembly onto Primary Drive Gear and align gearing.

    Caution
    Main Shaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Main Shaft and other surfaces. Dropping Main Shaft could result in component damage and/or personal injury.
    _Graphics/_Raster/IMG_3484.png

  28. Remove magnet from Main Shaft Key.

    Notice
    Ensure to remove magnet or component damage may occur during assembly.
    _Graphics/_Raster/TRSM0950_MHA_1302.png

  29. Install Upper Lube Tube into Clutch Housing and install 8 mm cap screw and torque to 8–10 Nm (6–13 lb–ft).

    _Graphics/_Raster/TRSM0950_MHA_1315.png_Graphics/_Raster/TRSM0950_MHA_1320.png

  30. Install Lower Lube Tube into Clutch Housing and 8 mm cap screw, torque to 8–10 Nm (6–13 lb–ft).

    _Graphics/_Raster/TRSM0950_MHA_1324.png_Graphics/_Raster/IMG_1327.png

  31. If Clutch Housing, Main Housing, Input Shaft, Input Shaft Bearing or Main Shaft Bearing has been replaced, perform steps to Install the Main Housing without Gasket Sealant before measuring and adjusting Main Shaft End-Play. If these parts have NOT been replaced, perform Install Main Housing .

Install the Main Housing without Gasket Sealant

  1. Clean the sealing surfaces on the Clutch Housing and Main Housing with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  2. Inspect threaded bolt holes for debris and clean if necessary.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened.

  3. Slide O-ring over the Clutch Housing Inertia Brake air passage alignment pin until fully seated in groove.

    Notice
    Failure to install a new O-ring could result in degraded transmission performance.
    _Graphics/_Raster/TRSM0950_MSEP_7381.png_Graphics/_Raster/TRSM0950_MSEP_7375.png

  4. Install Lower Countershaft Pilot Tool (RR1071TR) onto Lower Countershaft above rear bearing race.

    _Graphics/_Raster/TRSM0950_MHA_1338.png

  5. Install Upper Countershaft Pilot Tool (RR1072TR) onto the Upper Countershaft above rear bearing race.

    _Graphics/_Raster/TRSM0950_MHA_1341.png

  6. Install and hand tighten 2 Rear Housing 90-degree Lifting Eyes and 15 mm cap screws to Main Housing.

    Notice
    Do not over tighten Lifting Eye cap screws.

    Note: Install 90-degree Lifting Eyes 180-degrees apart to ensure even lifting.

    _Graphics/_Raster/TRSM0950_AttachLiftingEyesBolts13.png

  7. Install and hand tighten 2 Rear Housing Alignment Pins (RR1090TR) into the Clutch Housing as shown below.

    _Graphics/_Raster/TRSM0950_MHA_1351.png

  8. Lift, align and install Main Housing to Clutch Housing.

    Caution
    Main Housing weighs approximately 50 lbs. Keep fingers clear of pinch point between Main Housing and other surfaces. Dropping Main Housing could result in component damage and/or serious injury.
    Notice
    Use an appropriate lifting device to safely lift component.

    Note: Using a flat tipped screwdriver, rotate the Reverse Idler Gears to align the gearing and allow Main Housing to fully seat onto the Clutch Housing.

    _Graphics/_Raster/TRSM0950_MHA_1366.png

  9. Remove 2 Rear Housing Alignment Pins (RR1090TR).

    _Graphics/_Raster/TRSM0950_HandTightBolts.png

  10. Install 19 external and 6 internal Main Housing 16 mm cap screws and torque to 44–51 Nm (33–38 lb–ft) in a criss-cross pattern.

    Notice
    To avoid internal transmission contamination, keep internal and external Main Housing cap screws separated.
    _Graphics/_Raster/TRSM0950_MHA_1371.png_Graphics/_Raster/TRSM0950_MHA_1374.png

Measure and Adjust the Main Shaft End-Play

Note: The Main Shaft Selective Washer is available in 3 thicknesses: 6.525 mm (0.257 in), 6.712 mm (0.264 in) or 6.900 mm (0.272 in).

Caution
Ensure the Input Shaft Bearing and Main Shaft Bearing are seated in the Clutch Housing and Main Housing. Failure to fully seat bearings in housings will give an incorrect Main Shaft End-Play reading and may cause transmission component damage.
Caution
Ensure the 6.525 mm Main Shaft Selective Washer was installed. Only install a thicker selective washer after end-play has been measured and a thicker selective washer is required to achieve proper end-play or transmission damage may occur.

  1. Install 4 Oil Pump 13 mm cap screws with flat washers (22.3 mm (0.9 in) minimum OD). Torque cap screws to 21-23 Nm (16-18 lb-ft).

    Note: Flat washers are required to ensure the Main Shaft Bearing remains seated in the Main Housing during End-Play measurement.

    _Graphics/_Raster/TRSM0950_MSEP_9.PNG

  2. Thread a Dial Indicator mounting shaft into one of the inner Oil Pump mounting holes around the Main Shaft Bearing.

    Note: The Oil Pump cap screw mounting holes thread pattern: M8 x 1.25 x 30 mm.

    _Graphics/_Raster/TRSM0950_MSEP_3.PNG

  3. Mount the Dial Indicator to the shaft, set the plunger on the Main Shaft, and zero the Dial Indicator.

    Note: Ensure that the Dial Indicator is vertical and zeroed for proper Main Shaft End-Play measurement.

    _Graphics/_Raster/TRSM0950_MSEP_4.PNG

  4. Use two pry bars and slide them between the Reverse Gear and Main Housing at the locations shown below.

    _Graphics/_Raster/TRSM0950_EndPlay_PryBar1.png_Graphics/_Raster/TRSM0950_EndPlay_PryBar2.png

  5. Apply even downward pressure on Reverse Gear with both pry bars and monitor the Dial Indicator between the at-rest position of the Main Shaft and the point where no more downward movement is achieved. Record reading in table.

    _Graphics/_Raster/TRSM0950_MSEP_7.PNG_Graphics/_Raster/TRSM0950_EndPlay_DownwardPressure.png_Graphics/_Raster/TRSM0950_MSEP_8.PNG_Graphics/_Raster/TRSM0950_EndPlay_RangeReading.PNG

  6. Reference the Selective Main Shaft Washer Reference Chart and compare Recorded End-Play to reading in table.

    Note: Main Shaft End-Play specification is 0.000-0.100 mm (0.000-0.004 in). The Selective Washer Chart is only valid for end-play measured with the 6.525 mm (0.257 in) selective washer installed.

    • If end-play is in range, the installed Main Shaft Selective Washer, 6.525 mm (0.257 in), is correct.
    • If end-play is out of range, determine the thicker ideal Main Shaft Selective Washer and record in table. Remove Main Shaft and install the Ideal Main Shaft Selective Washer._Graphics/_Raster/TRSM0950_EndPlay_SelWasherRefChart.PNG_Graphics/_Raster/TRSM0950_EndPlay_IdealSelWasher.PNG
    Caution
    Main Shaft End-Play must be remeasured after replacing Main Shaft Selective Washer or transmission component damage may occur.

Remove Main Housing

  1. Remove the 19 external and 6 internal Main Housing 16 mm cap screws.

    Notice
    To avoid internal transmission contamination, keep internal and external Main Housing cap screws separated.
    _Graphics/_Raster/TRSM0950_RearHousingCapScrews4.png

  2. Install and hand tighten 2 Rear Housing Alignment Pins (RR1090TR) in the internal Main Housing cap screw outer threaded holes.

    _Graphics/_Raster/IMG_0444.png

  3. Separate Main Housing from Clutch Housing at the 2 pry points.

    _Graphics/_Raster/IMG_2261.png_Graphics/_Raster/TRSM0950_MHR_0448.png

  4. Lift and remove Main Housing from Clutch Housing.

    Caution
    Main Housing weighs approximately 50 lbs. Keep fingers clear of pinch point between Main Housing and other surfaces. Dropping Main Housing could result in component damage and/or personal injury.
    Notice
    Use an appropriate lifting device to safely lift component.
    _Graphics/_Raster/TRSM0950_RemoveMainHosuing 2.png

  5. Remove 2 Rear Housing Alignment Pins (RR1090TR).

    Note: Applying sealer when installing Main Housing to Clutch Housing should only be done after proper Main Shaft End-Play has been verified.

    _Graphics/_Raster/IMG_3396.png

  6. Reference the Selective Main Shaft Washer Reference Chart and compare Recorded End-Play to reading in table.

    Note: Main Shaft End-Play specification is 0.000-0.100 mm (0.000-0.004 in). The Selective Washer Chart is only valid for end-play measured with the 6.525 mm (0.257 in) selective washer installed.

    • If end-play is in range, the installed Main Shaft Selective Washer, 6.525 mm (0.257 in), is correct.
    • If end-play is out of range, determine the thicker Ideal Main Shaft Selective Washer and record in table. Remove Main Shaft and install the Ideal Main Shaft Selective Washer._Graphics/_Raster/TRSM0950_EndPlay_SelWasherRefChart.PNG_Graphics/_Raster/TRSM0950_EndPlay_IdealSelWasher.PNG
    Caution
    Main Shaft End-Play must be remeasured after replacing Main Shaft Selective Washer or transmission component damage may occur.

Remove Main Shaft and Countershaft

  1. Remove the Upper Lube Tube 8 mm cap screw.

    _Graphics/_Raster/TRSM0950_RemoveLubeTubeCapScrew 5.png

  2. Remove the Upper Lube Tube.

    _Graphics/_Raster/TRSM0950_UpperLubeTube 3.png

  3. Remove the Lower Lube Tube 8 mm cap screw.

    _Graphics/_Raster/TRSM0950_RemoveLubeTubeCapScrew 3.png

  4. Remove the Lower Lube Tube.

    _Graphics/_Raster/TRSM0950_MHA_1324.png

  5. Install a magnet onto Main Shaft Key to ensure the key stays in place during Main Shaft Removal and Installation.

    _Graphics/_Raster/TRSM0950_MagnetPlace 3.png

  6. Hold Rail C Sliding Clutch against Secondary Driven Gear and lift Main Shaft from Primary Drive Gear.

    Caution
    Main Shaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Main Shaft and other surfaces. Dropping Main Shaft could result in component damage and/or personal injury.

    Note: Spring and Washer may remain attached to the Main Shaft during removal.

    _Graphics/_Raster/TRSM0950_MHR_0461.png

  7. Remove Wave Spring - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0465.png

  8. Remove Thrust Washer - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0466.png

  9. Remove Thrust Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1290.png

  10. Remove Needle Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0475.png

  11. Remove Bearing Race - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0477.png

  12. Remove Primary Drive Gear.

    _Graphics/_Raster/TRSM0950_MHR_0480.png

  13. Remove Lower Countershaft.

    Caution
    Countershaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Countershaft and other surfaces. Dropping Countershaft could result in component damage and/or personal injury.
    _Graphics/_Raster/TRSM0950_MHR_0484.png

  14. Remove Upper Countershaft.

    Caution
    Countershaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Countershaft and other surfaces. Dropping Countershaft could result in component damage and/or personal injury.
    _Graphics/_Raster/TRSM0950_MHR_0488.png

  15. Remove Spherical Washer- Front.

    _Graphics/_Raster/TRSM0950_MHR_0491.png

  16. Remove Bearing Race - Front.

    _Graphics/_Raster/TRSM0950_MHR_0497.png

  17. Remove Needle Bearing - Front.

    _Graphics/_Raster/TRSM0950_MHR_0499.png

  18. Remove Thrust Bearing - Front.

    _Graphics/_Raster/TRSM0950_MHR_0503.png

  19. Remove Synchronizer Ring.

    _Graphics/_Raster/TRSM0950_MHR_0506.png

  20. Slowly lift Synchronizer Sliding Sleeve up until Synchronizer Rollers are free from synchronizer assembly.

    Notice
    Rollers are under spring pressure, ensure to slowly lift sleeve so rollers do not eject from the synchronizer assembly during disassembly.
    _Graphics/_Raster/TRSM0950_MHR_0507.png

  21. Remove 3 Synchronizer Rollers.

    _Graphics/_Raster/TRSM0950_MHR_0511.png

  22. Remove 3 Synchronizer Plungers and Springs from Synchronizer hub.

    _Graphics/_Raster/TRSM0950_MHR_0518.png

  23. Remove Thrust Washer - Front.

    _Graphics/_Raster/TRSM0950_MHR_0527.png

  24. Remove Wave Spring - Front.

    _Graphics/_Raster/TRSM0950_MHR_0529.png

Disassemble the Main Shaft and Replace Main Shaft Selective Washer

Note: This procedure is only required if Main Shaft End-Play is out of range and a thicker Selective Washer is required.

  1. Place Main Shaft Assembly horizontally on a clean flat surface.

    Caution
    Secure Main Shaft Assembly while on flat surface to avoid unexpected movement. Failure to properly secure Main Shaft Assembly could result in component damage and/or personal injury.

  2. Remove Rail C Sliding Clutch.

    _Graphics/_Raster/IMG_2233.png

  3. Place Main Shaft assembly vertically on a clean flat surface.

    Caution
    Secure Main Shaft Assembly while on flat surface to avoid unexpected movement. Failure to properly secure Main Shaft Assembly could result in component damage and/or personal injury.
    _Graphics/_Raster/IMG_2237.png

  4. Remove Main Shaft Key while inserting 5/32 OD air line.

    _Graphics/_Raster/IMG_3533.png

  5. Rotate and remove the Main Shaft Selective Washer above Reverse Gear.

    Note: The Main Shaft Selective Washer above Reverse Gear is available in 3 thicknesses; 6.525, 6.712 or 6.900 mm to control Main Shaft End-Play.

    _Graphics/_Raster/IMG_3525.png

Assemble and Install the Main Shaft with Replaced Main Shaft Selective Washer

  1. Install and rotate the Ideal Main Shaft Selective Washer above Reverse Gear recorded in Step 6 of the Main Shaft End-Play Service Procedure.

    Note: The Main Shaft Selective Washer is available in 3 thicknesses: 6.525, 6.712 or 6.900 mm.

    _Graphics/_Raster/IMG_3525.png

  2. Slide the 5/32 OD air line up to align and hold washer in place.

    _Graphics/_Raster/IMG_3528.png

  3. Install Main Shaft Key at the same spline as the 5/32 OD air line.

    Note: Insert Main Shaft Key while removing air line.

    _Graphics/_Raster/IMG_3533.png

  4. Install a magnet on Main Shaft Key to hold the key in place during final Main Shaft Assembly and installation into transmission.

    Note: Remove magnet from Main Shaft Key after installation of Main Shaft Assembly onto transmission.

    _Graphics/_Raster/IMG_3559.png

  5. Place Main Shaft Assembly horizontally on a clean flat surface.

    Caution
    Secure Main Shaft Assembly while on flat surface to avoid unexpected movement. Failure to properly secure Main Shaft Assembly could result in component damage and/or personal injury.

  6. Install Rail C Sliding Clutch and align the double slot with Main Shaft Key.

    _Graphics/_Raster/TRSM0950_MSEP_7356.png_Graphics/_Raster/IMG_3562.png

  7. Apply transmission assembly lube to Wave Spring - Rear and install to Main Shaft.

    Notice
    Wave Spring - Rear is shorter than the Wave Spring - Front.

    Note: Transmission assembly lube holds Wave Spring - Rear in place during Main Shaft Assembly installation.

    _Graphics/_Raster/IMG_3468.png_Graphics/_Raster/IMG_3471.png

  8. Apply transmission assembly lube to Thrust Washer - Rear and install to Main Shaft.

    Note: Transmission assembly lube holds Thrust Washer - Rear in place during Main Shaft Assembly installation.

    _Graphics/_Raster/IMG_3473.png_Graphics/_Raster/IMG_3477.png

  9. Install a magnet onto the Main Shaft Key.

    Note: The magnet holds the key in position during Main Shaft Assembly installation.

    _Graphics/_Raster/TRSM0950_MHA_1302.png

  10. Slide and hold Rail C Sliding Clutch into Secondary Driven Gear.

    _Graphics/_Raster/IMG_3481.png

  11. Install Main Shaft Assembly onto Primary Drive Gear and align gearing.

    Caution
    Main Shaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Main Shaft and other surfaces. Dropping Main Shaft could result in component damage and/or personal injury.
    _Graphics/_Raster/IMG_3484.png

  12. Remove magnet from Main Shaft Key.

    Notice
    Ensure to remove magnet or component damage may occur during assembly.
    _Graphics/_Raster/TRSM0950_MHA_1302.png

  13. If removed, install Upper Lube Tube into Clutch Housing and install 8 mm cap screw and torque to 8–10 Nm (6–13 lb–ft).

    _Graphics/_Raster/TRSM0950_MHA_1315.png_Graphics/_Raster/TRSM0950_MHA_1320.png

  14. If removed, install Lower Lube Tube into Clutch Housing and 8 mm cap screw, torque to 8–10 Nm (6–13 lb–ft).

    _Graphics/_Raster/TRSM0950_MHA_1324.png_Graphics/_Raster/IMG_1327.png

  15. Perform steps to Install the Main Housing without Gasket Sealant and remeasure Main Shaft End-Play.

    Caution
    Main Shaft End-Play must be remeasured after replacing Main Shaft Selective Washer or transmission component damage may occur.

Install Main Housing

  1. Clean the sealing surfaces on the transmission Main Housing and Rear Housing with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  2. Inspect threaded bolt holes for debris and clean if necessary.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened.

  3. Slide O-ring over the Clutch Housing Inertia Brake air passage alignment pin until fully seated in groove.

    _Graphics/_Raster/TRSM0950_MSEP_7381.png_Graphics/_Raster/TRSM0950_MSEP_7375.png

  4. Apply gasket sealant with a bead width of 1.4-2.4 mm (0.055-0.094 inch) to clutch housing as shown in pattern below.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened.

    Note: Parts must be assembled within 10 minutes of applying gasket sealant.

    _Graphics/_LineArt/TRSM0950_MainHousingInstall_ClutchHousingSealPattern.png

  5. Install Lower Countershaft Pilot Tool (RR1071TR) onto Lower Countershaft above rear bearing race.

    _Graphics/_Raster/TRSM0950_MHA_1338.png

  6. Install Upper Countershaft Pilot Tool (RR1072TR) onto the Upper Countershaft above rear bearing race.

    _Graphics/_Raster/TRSM0950_MHA_1341.png

  7. Install and hand tighten 2 Rear Housing 90-degree Lifting Eyes and 15 mm cap screws to Main Housing.

    Notice
    Do not over tighten Lifting Eye cap screws.

    Note: Install 90-degree Lifting Eyes 180-degrees apart to ensure even lifting.

    _Graphics/_Raster/TRSM0950_AttachLiftingEyesBolts13.png

  8. Install and hand tighten 2 Rear Housing Alignment Pins (RR1090TR) into the Clutch Housing as shown below.

    _Graphics/_Raster/TRSM0950_MHA_1351.png

  9. Lift, align and install Main Housing to Clutch Housing.

    Caution
    Main Housing weighs approximately 50 lbs. Keep fingers clear of pinch point between Main Housing and other surfaces. Dropping Main Housing could result in component damage and/or serious injury.
    Notice
    Use an appropriate lifting device to safely lift component.

    Note: Using a flat tipped screwdriver, rotate the Reverse Idler Gears to align the gearing and allow Main Housing to fully seat onto the Clutch Housing.

    _Graphics/_Raster/TRSM0950_MHA_1366.png

  10. Remove 2 Rear Housing Alignment Pins (RR1090TR).

    _Graphics/_Raster/TRSM0950_HandTightBolts.png

  11. Remove 2 Rear Housing 90-degree Lifting Eyes and 15 mm cap screws from Main Housing.

    _Graphics/_Raster/TRSM0950_AttachLiftingEyesBolts.png

  12. Re-install 2 Rear Housing 90-degree Lifting Eyes to the Rear Housing and torque to 49.6-55.5 Nm (36-40 lb-ft).

    _Graphics/_Raster/IMG_3393.png_Graphics/_Raster/IMG_3394.png

  13. Install 19 external and 6 internal Main Housing 16 mm cap screws and torque to 44–51 Nm (33–38 lb–ft) in a criss-cross pattern.

    Notice
    To avoid internal transmission contamination, keep internal and external Main Housing cap screws separated.
    _Graphics/_Raster/TRSM0950_MHA_1371.png_Graphics/_Raster/TRSM0950_MHA_1374.png

Install the Oil Pump Assembly

  1. Install O-ring to the Oil Pump/Range Spacer.

    _Graphics/_Raster/IMG_3426.png

  2. Install Oil Pump/Range Spacer with O-ring and align tab with groove in Oil Pump Assembly.

    Notice
    Ensure the spacer tab is aligned with the groove and the spacer sits flush in the Oil Pump Assembly.
    _Graphics/_Raster/TRSM0950_MHA_1381.png

  3. While holding the Oil Pump/Range Spacer in place, align oil pump drive key with slot on Lower Countershaft and install Oil Pump Assembly to Main Housing.

    Caution
    Failure to properly install the Oil Pump/Range Spacer and align the oil pump drive key results in transmission component damage during Oil Pump Assembly installation.
    Notice
    Ensure oil pump drive key is aligned with counter shaft drive slot during Oil Pump Assembly installation.
    _Graphics/_Raster/TRSM0950_MHA_1387.png_Graphics/_Raster/TRSM0950_MHA_1383.png

  4. Press Oil Pump Assembly to ensure it sits flat on Main Housing sealing surface.

    _Graphics/_Raster/IMG_3542.png

  5. Install 18 Oil Pump Assembly 13 mm cap screws and torque to 21–23 Nm (16–18 lb–ft) in a criss-cross pattern.

    _Graphics/_Raster/TRSM0950_MHA_1390.png_Graphics/_Raster/TRSM0950_MHA_1394.png

Install the Rear Housing

  1. Clean the sealing surfaces on the transmission Main Housing and Rear Housing with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  2. Inspect threaded bolt holes for debris and clean if necessary.

  3. Apply Gasket Sealant with a bead width of 1.4-2.4 mm (0.055-0.094 inch) to the transmission Main Housing sealing surface following the pattern below.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission housing may be damaged when cap screws are tightened.

    Note: Parts must be assembled within 10 minutes of applying Gasket Sealant.

    _Graphics/_LineArt/TRSM0950_RearHousingInstall_MainHousingSealPattern.png

  4. Install and hand tighten 2 Rear Housing Alignment Pins (RR1090TR) 180-degrees apart.

    Caution
    Failure to install alignment pins results in transmission component damage during Rear Housing Assembly installation.
    _Graphics/_Raster/TRSM0950_0256.png

  5. Lift and install the Rear Housing Assembly on to the Main Housing.

    Warning
    Rear Housing Assembly weighs approximately 170 lbs. Failure to properly secure and lift the Rear Housing may result in major vehicle component damage, severe injury or death.
    Notice
    Use an appropriate lifting device to safely lift component.

    Note: Align the Rear Housing to the alignment pins and align Shift Rail E into the Main Housing during installation.

    Note: Rotate Output Shaft to align gearing and allow Rear Housing Assembly to fully seat on Main Housing.

    _Graphics/_Raster/IMG_8342.png

  6. Install the 3 Rear Housing Threaded 16 mm cap screws at the 3 paint mark locations.

    Note: Two cap screws are used to mount the harness bracket and the third is used by the OEM for additional attachment points.

    _Graphics/_Raster/IMG_3325.png

  7. Remove the 2 Rear Housing Alignment Pins (RR1090TR).

  8. Install the remaining 21 Rear Housing 16 mm cap screws and torque to 44.5 - 51.5 Nm (33-38 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/TRSM0950_0269.png

  9. Lift transmission horizontally onto a bench.

    Warning
    Transmission weighs approximately 550 lbs. Keep fingers clear of pinch point between transmission and other surfaces. Dropping transmission may result in major vehicle component damage, severe injury or death.
    Notice
    Use an appropriate lifting device to safely lift component.

Secure Transmission (Horizontal)

  1. Securely place transmission in the horizontal position with the front side down.

    Warning
    Transmission weighs approximately 550 lbs. Keep fingers clear of pinch point between transmission and other surfaces. Dropping transmission may result in major vehicle component damage, severe injury or death.
    Notice
    Use an appropriate lifting device to safely lift component.

Install the Input Shaft Snap Ring

  1. Remove Front Bearing Capture Plate (RR1085TR-7) from Clutch Housing.

    _Graphics/_Raster/IMG_1855.png

  2. Install Input Shaft Snap Ring.

    Notice
    A new snap ring is required when reinstalling. A used snap ring may detach from Input Shaft and result in transmission component damage.

    Note: The snap ring will not install if Input Shaft is not fully seated into Input Shaft Bearing.

    _Graphics/_Raster/TRSM0950_25_ISSnapRing-R.png

Install the Input Shaft Cover

  1. Clean sealing surfaces on the clutch housing and Input Shaft Cover.

  2. Slide the Input Shaft Cover over the Input Shaft.

    Note: Align “TOP” at 12 o’clock.

    _Graphics/_Raster/IMG_0427.png_Graphics/_Raster/IMG_0428.png

  3. Install the 7 Input Shaft Cover 13 mm cap screws and torque to 21-25 Nm (16-19 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/IMG_0429.png

Install Lower Countershaft Snap Ring and Flat Washer

  1. Install Lower Countershaft Flat Washer and Snap Ring.

    Notice
    A new snap ring is required when reinstalling. A used snap ring may detach from Countershaft and result in transmission component damage.
    _Graphics/_Raster/TRSM0950_MSEP_7746.png_Graphics/_Raster/TRSM0950_MSEP_7752.png

Install the Lower Countershaft Cover and Inertia Brake

  1. Clean sealing surfaces on the Clutch Housing and Inertia Brake Housing.Install the Inertia Brake Cover and Housing as an assembly over the Lower Countershaft, rotate the assembly to align the Friction Discs to the Lower Countershaft splines and seat the assembly to the clutch housing.

    Note: Reference RRMT0027 - Clutch Housing Front Cover Kit for new Inertia Brake Housing part number, additional O-ring part number, and installation instructions.

    _Graphics/_Raster/IMG_0402.png

  2. While holding the Inertia Brake Housing to the clutch housing, remove the Inertia Brake Cover.

    Notice
    Ensure the Friction Discs are splined to the lower countershaft and Wear Guides are fully seated.
    _Graphics/_Raster/IMG_0403.png

  3. Install the Return Spring into the Lower Countershaft.

    _Graphics/_Raster/IMG_0404.png

  4. Install the Piston Pin into the Lower Countershaft.

    _Graphics/_Raster/IMG_0405.png

  5. Install the Inertia Brake Cover onto the housing.

    _Graphics/_Raster/IMG_0406.png

  6. Install the 6 13 mm cap screws and torque to 21-25 Nm (16-19 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/IMG_0407.png

  7. Insert air line in push-to-connect fitting on the Inertia Brake Cover.

    _Graphics/_Raster/IMG_0409.png

Install Upper Countershaft Snap Ring and Flat Washer

  1. Install Upper Countershaft Flat Washer and Snap Ring.

    Notice
    A new snap ring is required when reinstalling. A used snap ring may detach from countershaft and result in transmission component damage.
    _Graphics/_Raster/TRSM0950_MSEP_7717.png_Graphics/_Raster/TRSM0950_MSEP_7727.png

Install the Upper Countershaft Cover

  1. Clean the sealing surfaces on the clutch housing and the Upper Countershaft Cover.

    Note: A new Upper Countershaft Cover Seal is required when reinstalling or an oil leak may occur. Reference RRMT0027 - Clutch Housing Front Cover Kit for new Upper Countershaft Cover part number, additional O-ring part number, and installation instructions.

  2. Insert the Upper Countershaft Cover Seal into the groove until fully seated.

    _Graphics/_Raster/IMG_0390.png_Graphics/_Raster/IMG_0391.png

  3. Install the Upper Countershaft Cover to the Clutch Housing.

  4. Install the six 13 mm cap screws and torque to 21-25 Nm (16-19 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/IMG_0392.png

Install the Harness Bracket

Note: This procedure contains installing the Harness Bracket without the Mechatronic Transmission Module (MTM).

  1. Install Harness Bracket.

    _Graphics/_Raster/TRSM0950_MSEP_7802.png

  2. Install 3 Harness Bracket 10 mm cap screws and torque to 8.8 - 10.4 Nm (6-8 lb-ft).

    _Graphics/_Raster/TRSM0950_MSEP_7788.png

Install the Output Speed Sensor

  1. Clean the sensor bore.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surface.

  2. Apply a light coat of transmission oil to the sensor O-ring.

  3. Install the Output Speed Sensor into the bore.

    Note: The Sensor may need to be twisted and pushed into the bore.

    _Graphics/_Raster/TRSM0950_OSS 3.png

  4. Install the Output Speed Sensor 10 mm cap screw and torque to 8.8-10.4 Nm (6-8 lb-ft).

    _Graphics/_Raster/TRSM0950_OSS_Installation2.png

  5. Press the 2 harness press-in retainers into the Main Housing and the bracket on the rear housing.

    _Graphics/_Raster/TRSM0950_OSS_Installation5.png_Graphics/_Raster/TRSM0950_OSS_Installation4.png

  6. Secure the Output Speed Sensor Harness to the Harness Bracket with a tie strap.

    Caution
    Failure to tie strap the Output Speed Sensor Harness to the Harness Bracket may result in harness damage.
    _Graphics/_Raster/TRSM0950_OSS_Installation6.png

Install the Mechatronic Transmission Module (MTM)

Note: If replacing original equipment MTM with new/replacement MTM locate new/replacement MTM part information tag and record Part Number and Serial Number. Refer to Component Identification section. Part Number and Serial Number are required to properly configure TCM after MTM installation.

  1. Place the transmission in a horizontal position.

    Notice
    The transmission must be in a horizontal position prior to the MTM Installation procedure. Failure to do so causes the sliding clutches to move out of neutral and not align to the shift yokes. If the shift yokes are not aligned to the sliding clutches, position sensor fault codes set Active and the transmission will not shift out of neutral.

  2. Clean the sealing surfaces on the transmission and Mechatronic Transmission Module (MTM) with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  3. Inspect threaded bolt holes for debris and clean if necessary.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened.

  4. Install the Rail B Engagement Tool (RR1088TR) to the Main Housing and hand tighten with 2 MTM cap screws.

    _Graphics/_Raster/IMG_0354.png

  5. Shift the Rail B Synchronizer to neutral.

    _Graphics/_Raster/IMG_0362.png

  6. Remove the Rail B Engagement Tool.

  7. Move Rail C and Rail D sliding clutches to neutral.

    Notice
    The transmission must be in a horizontal position prior to the MTM Installation procedure. Failure to do so causes the sliding clutches to move out of neutral and not align to the shift yokes. If the shift yokes are not aligned to the sliding clutches, position sensor fault codes set Active and the transmission will not shift out of neutral.
    _Graphics/_Raster/IMG_0369.png

  8. Install the Confirm-Neutral Gauge (RR1086TR-2) into the slots of the synchronizer and sliding clutches.

    _Graphics/_Raster/IMG_0355.png_Graphics/_Raster/IMG_0365.png

  9. Install the MTM Alignment Tool (RR1086TR-1) onto the main housing.

    _Graphics/_Raster/IMG_0356.png_Graphics/_Raster/IMG_0366.png

  10. Verify synchronizer and sliding clutches are in neutral by sliding Confirm-Neutral Gauge into the slots of MTM Alignment Tool.

    Note: If the gauge does not slide into the alignment tool slots, neutral is not achieved. Go to Step 4.

    _Graphics/_Raster/IMG_0358.png_Graphics/_Raster/TRSM0950_MTM_Ins6.png

  11. Using the Rail E Lever, move Rail E to neutral.

    _Graphics/_Raster/IMG_0370.png_Graphics/_Raster/TRSM0950_MTM_Ins11.png_Graphics/_Raster/TRSM0950_MTM_Ins12.png

  12. Verify Rail E is in neutral using the Gear Side Actuator end of the Confirm-Neutral Gauge (RR1088TR-2) at Shift Rail E. Rail E is in neutral when end of gauge rests against housing with rail against notch-end of gauge.

    _Graphics/_Raster/IMG_0373.png

  13. Move Shift Rail B in the MTM to neutral. Rail B is in neutral when the ball detent is in the notch of the Rail B yoke assembly.

    _Graphics/_Raster/TRSM0950_MTMRailB_N.png

  14. Move Shift Rails C and D in the MTM to neutral. Rails C and D are in neutral when the shift inter-lock is aligned with the notches of the rail yoke assemblies.

    _Graphics/_Raster/TRSM0950_MTMRailsCD_N.png

  15. Verify MTM is in neutral. Install the MTM Alignment Tool (RR1086TR-1) into the bolt hole and onto Rail B, C, and D Shift Yokes.

    Note: If the MTM Alignment Tool slots do not align with the 3 shift yokes, neutral has not been achieved. Go to Step 13.

    _Graphics/_Raster/IMG_0378.png

  16. Verify notch on Rail E is facing up.

    Note: If MTM is installed on transmission with notch on Rail E facing down, Fault Code/SPN 320/5942 sets Active and transmission does not shift out of neutral.

    _Graphics/_LineArt/TRSM0950_RailENotch.png

  17. Verify Rail E is in neutral using the Fork Side Actuator end of the Confirm-Neutral Gauge (RR1088TR-2) at Shift Rail E. Rail E is in neutral when end of gauge rests against cover with rail against notch-end of gauge.

    Note: If Rail E is not in neutral, slide rail in or out until neutral is achieved.

    _Graphics/_Raster/TRSM0950_MTMRailE_N.png

  18. Slide O-ring over the MTM front alignment pin on the main housing until fully seated in the groove.

    _Graphics/_Raster/TRSM0950_MTM_O-ring.png

  19. Clean the sealing surfaces on the transmission and Mechatronic Transmission Module (MTM) with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  20. Apply gasket sealant with a bead width of 1.4-2.4mm (0.055-0.094 inch) to the transmission housing sealing surface following the pattern below.

    Notice
    Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened.

    Note: Parts must be assembled within 10 minutes of applying Gasket Sealant.

    _Graphics/_LineArt/TRSM0950_MTMRTV.png

  21. Install MTM onto the transmission housing. Align Rail E in the MTM with the Rail E Shift Rail in the Main Housing.

    Caution
    MTM weighs approximately 40 lbs. Keep fingers clear of pinch point between MTM and other surfaces. Dropping MTM could result in component damage and/or personal injury.
    Notice
    If the MTM is installed on the transmission and Rail E in the MTM is not aligned with Rail E in the Main Housing, Fault Code 320 (SPN 5942) sets Active and the transmission will not shift out of neutral.

  22. Install 20 MTM cap screws and torque to 44.5-51.5 Nm (33-38 lb-ft) in a criss-cross pattern.

    Note: 13 mm (x18), 15 mm (x2) cap screws.

    _Graphics/_Raster/IMG_0387.png

Install the Transmission Control Module (TCM)

Notice
Do not allow contamination into the connectors on the TCM or MTM.

Note: TCM can be installed with transmission in-vehicle.

  1. Install the TCM Seal on the 74-Way Harness Connector.

    _Graphics/_Raster/TRSM0950_TCM_Installationa.png

  2. Align the TCM to the 74-Way Harness Connector and TCM studs, then install the TCM.

    _Graphics/_Raster/TRSM0950_TCM_Installationb.png

  3. Torque the TCM 7 mm Jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

    _Graphics/_Raster/IMG_0187.png

  4. Install the TCM Cover over the 4 TCM studs and torque the 4 TCM Cover Nuts to 8.8-10.4 Nm (78-92 lb-in) in a criss-cross pattern.

    Note: TCM Cover nuts are 10 or 13 mm.

    _Graphics/_Raster/IMG_0189.png

Remove the Linear Clutch Actuator (LCA)

  1. Loosen the 4 LCA cap screws 1-2 turns each with a T45 Torx.

    Notice
    Ensure key is off, 20-Way TCM Vehicle and Body Harness Connectors are disconnected, and 5 minutes has passed prior to LCA removal.

    Note: Residual air pressure in the LCA cylinder exhausts between the LCA and MTM housing when the cap screws are loosened.

    _Graphics/_Raster/TRSM0950_LCA_R1.png

  2. Remove the 4 LCA cap screws

  3. Remove the LCA from the MTM.

    Note: LCA piston rod end is seated in the release yoke socket; pull to release rod end from socket.

    _Graphics/_Raster/IMG_8326.png

  4. Inspect the plastic socket insert in the release yoke through the LCA opening using a flashlight to verify none of the fingers are missing or damaged.

    Note: If the plastic insert is damaged, replace the release yoke assembly.

    _Graphics/_Raster/TRSM0950_LCA_R3.png

Reset and Install Linear Clutch Actuator (LCA)

  1. Inspect LCA to determine next steps, reference images below:

    • If LCA is locked in the reset position, go to Install Linear Clutch Actuator (LCA).
    • If LCA is not locked in the reset position, go to Step 2.

    Locked in Reset Position

    Not Locked in Reset Position

    _Graphics/_Raster/ResetLCA_Step1IMG.png

  2. Place LCA push rod on a clean, flat surface. Tightly grasp LCA housing with both hands and push down on push rod to lock LCA into the reset position.

    Caution
    A large amount of force is required to lock the LCA into the reset position. Failure to tightly grasp the LCA housing with both hands while pushing down on push rod may cause unintended movement resulting in personal injury and/or component damage.
    _Graphics/_Raster/ResetLCA_Step2IMG.jpg

  3. Inspect LCA to determine next steps, reference images below:

    • If LCA remains locked in the reset position, go to Step 4.
    • If LCA does not remain locked in the reset position, go to Step 2, repeat reset procedure.

      Note: If LCA cannot be locked into the reset position, replace LCA.

    Caution
    Do not drop LCA. Dropping LCA may cause the LCA to unlock resulting in personal injury and/or component damage.

    Locked in Reset Position

    Not Locked in Reset Position

    _Graphics/_Raster/ResetLCA_Step3IMG.png

  4. Clean all sealing surfaces on the MTM and LCA with a lint free cloth.

    Notice
    Do not use abrasive scrapers or powered tools to clean sealing surfaces or sealing surfaces may be damaged and leak.

  5. Insert the LCA into the MTM.

    _Graphics/_Raster/IMG_8328.png

  6. Install 4 LCA T45 cap screws and torque to 23-28 Nm (17-21 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/TRSM0950_LCA_I2.png

Install the Release Bearing and Clutch Release Yoke

  1. Install the upper Release Yoke socket over the rod end of the Linear Clutch Actuator (LCA) and press until attached.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Removal3.png

  2. Install the lower Release Yoke socket over the lower pivot on the clutch housing and press until attached.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Installation1.png

  3. Slide the Release Bearing over the input shaft and into the Release Yoke.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Installation3.png

Install the Transmission

  1. Refer to OEM guidelines for transmission installation.

  2. Connect negative battery cable.

Fill Oil

Note: Perform the transmission fill procedure with transmission installed in vehicle to ensure proper transmission angle.

  1. Remove the Oil Fill Plug with a 6 mm hex key.

    _Graphics/_Raster/TRSM0950_OilFill_I1_wCallout.png

  2. Place a suitable container under the Oil Check Plug and remove the Oil Check Plug with a 6 mm hex key.

    _Graphics/_Raster/TRSM0950_OilFill_I2.png

  3. Fill the transmission with PS-386 lube until a small amount of oil runs out of the Oil Check Plug hole.

    Note: Fill capacity is approximately 7.5-8.5 liters (16-18 pints) depending on the transmission angle.

    _Graphics/_Raster/TRSM0950_OilFill_I3.png_Graphics/_Raster/TRSM0950_OilFill_I4.png

  4. Inspect Oil Check Plug and O-ring for damage. If damaged, replace the Oil Check Plug; O-ring is serviced with plug.

  5. Install the Oil Check Plug (6 mm) and torque to 24.5-29.5 Nm (18-22 lb-ft).

    Notice
    Do not over-torque the Oil Fill Plug or transmission damage may occur.
    _Graphics/_Raster/TRSM0950_OilFill_I2.png

  6. Inspect Oil Fill Plug and O-ring for damage. If damaged, replace the Oil Fill Plug; O-ring is serviced with plug.

  7. Install the Oil Fill Plug (6 mm) and torque to 24.5-29.5 Nm (18-22 lb-ft).

    Notice
    Do not over-torque the Oil Fill Plug or transmission damage may occur.
    _Graphics/_Raster/TRSM0950_OilFill_I1.png

Clutch and Rail Calibration

To ensure proper operation, the TCM, clutch, MTM and transmission require a Clutch and Rail Calibration. Calibrations are automatically initiated when:

  • LCA is in the reset position
  • Transmission in “N” (Neutral)
  • Key on engine running
  • Vehicle air system pressure at operating range
Notice
Do not use service tool to initiate calibrations. Allow calibrations to automatically initiate.

Note: Vehicle display may indicate a flashing “CC” and “F” in gear display.

  1. Set vehicle parking brake and chock wheels.

  2. Key on with engine running.

  3. Allow vehicle air pressure to build to governor cut-off.

    Note: Clutch and Rail Calibrations automatically initiate when vehicle air pressure reaches approximately 100 psi.

  4. Ensure “N” (Neutral) is selected and engine is running. Wait approximately 2 minutes for calibrations to complete.

    Notice
    If process is interrupted, key off, wait 1 minute and go to Step 2.
    • If vehicle display indicates a solid “N: (Neutral) in gear display, calibrations are complete. Key off, go to Step 6.
    • If vehicle display continues to indicate a flashing “CC” and/or “F” in gear display or service transmission message, go to Step 5.

  5. Key off and wait 1 minute.

  6. Key on with engine off.

  7. Connect ServiceRanger.

  8. Go to “Fault Codes”.

    • If an Active transmission fault code is set, go to Endurant HD Troubleshooting Guide TRTS0950 Diagnostic Procedure.
    • If no Active transmission fault codes are set, select “Clear Eaton Faults” and follow on-screen prompts. Go to Step 9.

  9. Disconnect ServiceRanger.

  10. Key off.

  11. Inspect transmission for a PTO.

    • If not PTO-equipped, process complete.
    • If PTO-equipped, start the engine and run for 1 to 2 minutes to fill the PTO with oil, key off and repeat the Fill Oil Procedure.
    Caution
    Failure to repeat the Fill Oil service procedure to verify proper transmission oil level when equipped with a PTO may result in low transmission oil and component damage.