Endurant HD
TRSM0950 EN-US
|
October 2024 - A

Primary Drive Gear Replacement

Special Instructions

This procedure provides instructions for replacing the Primary Drive Gear and Rail C Sliding Clutch.

  • Primary Drive Gear (S-3206)
  • Rail C Sliding Clutch (10000557)
  • I-Brake MTM to Main Housing O-ring (13653)
  • I-Brake Main Housing to Clutch Housing O-ring (13834)

Special Tools

  • Rear Housing Alignment Pins (RR1090TR)
  • Upper Countershaft Pilot Tool (RR1071TR)
  • Lower Countershaft Pilot Tool (RR1072TR)
  • Mechanical Diagnostic Kit (RR2011TR)
  • Gasket Sealant (Loctite 5188)
  • Transmission Assembly Lube (Lubegard® Assemblee Goo Firm Tack - Green #19250 or equivalent)
  • Plastic Scraper
  • Gasket Remover (Non-Chlorinated Brake Cleaner)
    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_MainHousing_ID_SpecProc.png

1. Main Housing External Cap Screws (x19) - 16 mm

2. Main Housing

3. Main Housing Internal Cap Screws (x6) - 16mm

4. Rear Housing Alignment Pins (RR 1090TR)

5. Rail C Sliding Clutch

6. Primary Drive Gear

Create a Service Activity Report

Note: If not already created and sent.

  1. Key on with engine off.

  2. Connect ServiceRanger and create a Service Activity Report.

  3. Select “Send to Eaton” (internet connection required)

  4. Disconnect ServiceRanger.

  5. Key off.

Drain Oil

  1. Locate the Oil Drain Plug on the back of the rear housing.

  2. Place a suitable container under the Oil Drain Plug.

    Note: If reusing oil, use a clean container free of contamination and debris.

  3. Remove the Oil Drain Plug with a 6 mm hex key and drain the oil.

    _Graphics/_Raster/TRSM0950_OilDrain_R1.png

  4. If PTO-equipped, remove PTO and drain the oil.

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

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

    Notice
    Do not over-torque drain plug or transmission damage may occur.
    _Graphics/_Raster/TRSM0950_OilDrain_R2.png

Manually Vent Linear Clutch Actuator (LCA)

  1. Key off.

  2. Set vehicle parking brake and chock wheels.

    Warning
    Apply vehicle parking brake and follow vehicle manufacture parking instructions. Failure to follow these instructions could cause unintended vehicle movement and may result in major vehicle component damage, severe injury of death.

  3. Loosen the 4 Linear Clutch Actuator (LCA) cap screws 1-2 turns each with a T45 Torx.

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

    _Graphics/_LineArt/TRSM0950_LCA_Venting_LoosenBolts.png

  4. Tighten the 4 LCA to MTM T45 cap screws and torque to 23-27 Nm (17-21 lb-ft).

Remove Transmission

  1. Disconnect negative battery cable.

  2. Refer to OEM guidelines for transmission removal.

Remove Release Bearing and Clutch Release Yoke

  1. Remove the Release Bearing by sliding the bearing off the input shaft.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Installation3.png

  2. Pull to free the lower Clutch Release Yoke socket from the lower pivot on the clutch housing.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Removal2.png

  3. Pull to free the upper Clutch Release Yoke socket from the Linear Clutch Actuator (LCA) rod end.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Removal3.png

  4. Inspect the plastic socket inserts in the Clutch Release Yoke to verify none of the fingers are missing or damaged.

    Note: If the plastic insert is damaged, replace the Clutch Release Yoke Assembly and the Release Yoke Pivot Pin.

    _Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Removal5.png_Graphics/_Raster/TRSM0950_ReleaseBearingYoke_Removal6.png

Remove Transmission Control Module (TCM)

  1. Unscrew the 4 TCM Cover nuts and remove TCM Cover.

    Note: TCM Cover nuts are 10 or 13 mm.

    _Graphics/_Raster/TRSM0950_TCM_Removal3.png

  2. Unscrew the TCM 7 mm Jackscrew. Lift and remove the TCM from the MTM.

    Notice
    Do not allow contamination into the connectors on the TCM or MTM.
    _Graphics/_Raster/TRSM0950_TCM_Removal4.png

  3. Inspect the TCM Seal for damage.

    Notice
    Replace the TCM Seal if damaged.
    _Graphics/_Raster/TRSM0950_TCM_Installationa.png

Remove Mechatronic Transmission Module (MTM)

  1. Lift the latch on the Output Speed Sensor Harness at the Connector on the Mechatronic Transmission Module (MTM).

    _Graphics/_Raster/IMG_0341.png_Graphics/_Raster/IMG_0342.png

  2. Remove the Output Speed Sensor Harness from the Connector on the MTM.

    _Graphics/_Raster/IMG_0343.png

  3. Remove the 20 MTM cap screws.

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

    _Graphics/_Raster/IMG_0346.png

  4. Separate the MTM from the Main Housing at the 2 pry points.

    _Graphics/_Raster/IMG_0348.png_Graphics/_Raster/IMG_0350.png

  5. Remove the MTM from the transmission housing.

    Caution
    MTM weighs approximately 40 lbs. Keep fingers clear of pinch point between MTM and other surfaces. Dropping MTM could result in component damage and/or personal injury.
    _Graphics/_Raster/TRSM0950_MTM_Removal7.png

Remove Output Speed Sensor

  1. Remove the Output Speed Sensor Harness tie strap at the Harness Bracket.

    _Graphics/_Raster/TRSM0950_OSS_Removal_Harness_tie_strap1.png

  2. Remove the 2 harness press-in retainers from the Main Housing and bracket on Rear Housing.

    _Graphics/_Raster/TRSM0950_OSS_Removal_Harness_tie_strap3.png_Graphics/_Raster/TRSM0950_OSS_Removal_10mmBolt.png

  3. Remove the Output Speed Sensor 10 mm cap screw.

    _Graphics/_Raster/TRSM0950_OSS_Removal_10mmBolt1.png

  4. Remove the Output Speed Sensor from the Rear Housing.

    Note: The sensor may need to be twisted and pulled from the bore.

    _Graphics/_Raster/TRSM0950_OSS_Removal_10mmBolt2.png_Graphics/_Raster/TRSM0950_OSS_Installation.png

Remove Harness Bracket

  1. Remove the Output Speed Sensor Harness tie strap at the Harness Bracket.

    _Graphics/_Raster/TRSM0950_OSS_Removal_Harness_tie_strap1.png

  2. Remove 3 Harness Bracket 10 mm cap screws.

    _Graphics/_Raster/TRSM0950_MSEP_7788.png

  3. Remove Harness Bracket.

    _Graphics/_Raster/TRSM0950_MSEP_7802.png

Secure Transmission (Vertical)

  1. Place transmission in the vertical 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.

    Note: Use a surface with an opening that allows the input shaft to pass through and the clutch housing to sit flat and secure.

    _Graphics/_Raster/IMG_3096.png_Graphics/_Raster/IMG_3097.png

Remove Rear Housing

  1. At the 3 Rear Housing Threaded cap screws, apply paint marks on the Rear Housing to identify location.

    _Graphics/_Raster/IMG_3100.png

  2. Remove 21 Rear Housing and 3 threaded 16 mm cap screws.

    _Graphics/_Raster/IMG_2997.png

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

    Notice
    Failure to install alignment pins results in transmission component damage.
    _Graphics/_Raster/IMG_2999.png

  4. Separate the Rear Housing from the Main Housing at the 2 pry points.

    _Graphics/_Raster/IMG_3007_1.png_Graphics/_Raster/IMG_3010_1.png

  5. Lift and remove Rear Housing Assembly from Main Housing.

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

    Note: Dual PTO Transmissions are equipped with a rear PTO lube tube port on the pump and rear PTO drive splines on the Upper Countershaft.

    _Graphics/_Raster/IMG_3012.png

  6. Place Rear Housing Assembly on bench.

    Warning
    Rear Housing Assembly weighs approximately 170 lbs. Keep fingers clear of pinch point between Rear Housing Assembly and other surfaces. Dropping Rear Housing may result in major vehicle component damage, severe injury or death.
    Notice
    Support the Rear Housing Assembly to prevent damage to Shift Rail E.
    _Graphics/_Raster/TRSM0950_0211.png_Graphics/_Raster/TRSM0950_0213.png

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

Remove Oil Pump Assembly

  1. Remove 18 Oil Pump Assembly 13 mm cap screws.

    _Graphics/_Raster/IMG_2267.png

  2. Remove Oil Pump Assembly.

    _Graphics/_Raster/IMG_0451.png

  3. Remove Oil Pump/Range Spacer with O-ring.

    _Graphics/_Raster/PumpRange Spacer.png

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. Remove 2 Rear Housing 90-degree Lifting Eye 15 mm cap screws from Rear Housing.

    _Graphics/_Raster/IMG_3390.png_Graphics/_Raster/IMG_3392.png

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

    Notice
    Do not over tighten cap screws.

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

    _Graphics/_Raster/MainHsg Lift Eye 1.png_Graphics/_Raster/TRSM0950_AttachLiftingEyesBolts13.png

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

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

  6. 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

Remove Main Shaft and Countershaft

  1. 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

  2. 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

  3. Remove Wave Spring - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0465.png

  4. Remove Thrust Washer - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0466.png

  5. Remove Thrust Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1290.png

  6. Remove Needle Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0475.png

  7. Remove Bearing Race - Rear.

    _Graphics/_Raster/TRSM0950_MHR_0477.png

  8. Remove Primary Drive Gear.

    _Graphics/_Raster/TRSM0950_MHR_0480.png

Install Primary Drive Gear

  1. Install new Primary Drive Gear onto Rail B Synchronizer.

    _Graphics/_Raster/TRSM0950_MHA_1278.png

  2. Install Bearing Race - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1282.png

  3. Install Needle Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1287.png

  4. Install Thrust Bearing - Rear.

    _Graphics/_Raster/TRSM0950_MHA_1290.png

Remove Rail C Sliding Clutch

  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. If necessary, remove Thrust Washer - Rear and Wave Spring - Rear.

  3. Remove Rail C Sliding Clutch.

    _Graphics/_Raster/IMG_2233.png

Install Rail C Sliding Clutch

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

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

  2. 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

  3. 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

  4. 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

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

    _Graphics/_Raster/IMG_3481.png

  6. 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

  7. Remove magnet from Main Shaft Key.

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

Install Main Housing

  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 new I-Brake Main Housing to Clutch Housing O-ring (13834) 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 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 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/TRSM0950_0254.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

Install 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 Mechatronic Transmission Module (MTM)

  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.

    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 the MTM is installed on the transmission with the notch on Rail E facing down, Fault Code 320 (SPN 5942) sets Active and the transmission will not shift out of neutral.

    _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 new I-Brake MTM to Main Housing O-ring (13653) 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 Main Housing and MTM Housing with gasket remover and a plastic scraper. Let air dry then wipe with a clean dry cloth

  20. Apply Gasket Sealant with a bead width of 1.4-2.4 mm (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 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

Connect Output Speed Sensor

  1. Connect the Output Speed Sensor Harness to the Connector on the Mechatronic Transmission Module (MTM) and close the latch.

    _Graphics/_Raster/TRSM0950_OSS_Installation7.png_Graphics/_Raster/TRSM0950_OSS_Installation9.png

Install Transmission Control Module (TCM)

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

  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 and 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/TRSM0950_TCM_Removal4.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/TRSM0950_TCM_Removal3.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 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

  8. Connect the negative battery cable.

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.