Endurant HD
TRSM0950 EN-US
|
October 2024 - A

RRMT0027 - Clutch Housing Front Cover Kit

Special Instructions

K-4491 should be installed on transmissions built prior to July 29th, 2019 serial number Z0123456 whenever a transmission is removed. Contact the Roadranger Call Center at 1-800-826-4357 for warranty guidelines. K-4491 will be added to new production transmissions targeted to be built 07/19/2021.

Special Tools

  • ServiceRanger
  • Transmission Assembly Lube (Lubegard® Assemblee Goo Firm Tack - Green #19250 or equivalent)
    Notice
    Only use the specified transmission assembly lube indicated above. Other types of assembly lube or grease reduce O-ring effectiveness.
  • 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/InputShaft_Countershaft_CvrKit_4.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).

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: Original oil is not to be reused.

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

    _Graphics/_Raster/TRSM0950_OilDrain_R1.png

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

  5. 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

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 Cover.

    _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

Remove Upper Countershaft Cover

  1. Remove the 6 Upper Countershaft Cover 13 mm cap screws and remove cover.The original Upper Countershaft Cover and Front Seal are not to be reused.

    _Graphics/_Raster/IMG_0388.png_Graphics/_Raster/IMG_0389.png

Install Upper Countershaft Cover Countershaft Bearing O-ring

  1. Clean any residual oil from the Upper Countershaft Bearing outer diameter using Non-Chlorinated Brake Cleaner.

  2. Install the Upper Countershaft Cover Countershaft Bearing O-ring (10004217) onto the Upper Counter- shaft Bearing.

    Note: O-ring may fall out of position after installation. Ensure to clean any residual oil from the bearing and roll the O-ring on to the bearing using the tips of your fingers pushing on the inner diameter of the O-ring. If necessary, apply a small amount of transmission assembly lube at the 3, 6, 9 and 12 o'clock positions to the outer diameter of the bearing.

    _Graphics/_Raster/Install Upper Countershaft Cover CS Bearing Oring_1.jpg_Graphics/_Raster/Install Upper Countershaft Cover CS Bearing Oring_2.jpg

Install Upper Countershaft Cover

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

    Note: The new Upper Countershaft Cover has a chamfer that is required for the bearing O-ring.

    _Graphics/_Raster/Install Upper Countershaft Cover.jpg

  2. Install new Countershaft Cover front seal (10001048) into the groove of the new Upper Countershaft Cover (10004215) until fully seated

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

  3. Install the new Upper Countershaft Cover and six 13 mm cap screws to the clutch housing and torque to 21-25 Nm (16-19 lb-ft) in a criss-cross pattern.

    _Graphics/_Raster/IMG_0392.png

Remove Lower Countershaft Cover and Inertia Brake

  1. Depress and hold collar on air line fitting and disconnect the air line from the Inertia Brake Cover.

    _Graphics/_Raster/IMG_0399.png_Graphics/_Raster/IMG_0400.png

  2. Remove the 6 Inertia Brake Cover 13 mm cap screws.

    _Graphics/_Raster/IMG_0401.png

  3. Remove the Inertia Brake Cover and Housing as an assembly. The original Inertia Brake Housing and seals are not to be reused.

    _Graphics/_Raster/IMG_0402.png

  4. Ensure the Inertia Brake Piston Pin and Return Spring remain in the Lower Countershaft.

    _Graphics/_Raster/TRSM0950_LowerCountershaftCvrBrake_Removal6.png

Disassemble Inertia Brake

  1. Remove the clutch pack from the Inertia Brake Housing.

    _Graphics/_Raster/TRSM0950_LCIB_DisA2.png

  2. Remove the 2 wear guides from the Inertia Brake Housing.

    _Graphics/_Raster/TRSM0950_LCIB_DisA3.png

Assemble Inertia Brake

  1. Clean sealing surfaces on the clutch housing and the new Inertia Brake Housing.

    Note: The new Inertia Brake Housing (10004216) has a chamfer on the Clutch Housing side that is required for the bearing O-ring.

    _Graphics/_Raster/IMG_8323.png_Graphics/_Raster/Install Inertia Brake.jpg

  2. Insert the new Inertia Brake Rear Seal (10001049) into the groove on the rear of the new Inertia Brake Housing (10004216) until fully seated.

    _Graphics/_Raster/TRSM0950_LCIB_Assembly.png

  3. Insert the new Inertia Brake Housing Front Seal (10001048) into the new Inertia Brake Housing (10004216) until fully seated.

    _Graphics/_Raster/TRSM0950_LCIB_Assembly1.png

  4. Install the 2 original Wear Guides into the new Inertia Brake Housing (10004216).

    _Graphics/_Raster/TRSM0950_LCIB_Assembly2.png

  5. Install the original inertia brake clutch pack in the order shown below:

    • 1 Steel Disc,
    • 1 Friction Disc,
    • 2 Steel Discs,
    • 1 Friction Disc,
    • 2 Steel Discs,
    • 1 Friction Disc, and
    • 1 Steel Disc.

    Note: Steel Discs align with Wear Guides. Friction Discs spline to the lower countershaft.

    _Graphics/_LineArt/TRSM0950_IB.png_Graphics/_Raster/TRSM0950_LCIB_A8.png_Graphics/_Raster/TRSM0950_LCIB_A10.png

  6. Place Inertia Brake Cover and Piston on the Housing. Align the bolt holes.

Install Inertia Brake Housing Countershaft Bearing O-ring

  1. Clean any residual oil from the Lower Countershaft Bearing outer diameter using Non-Chlorinated Brake Cleaner.

  2. Install the Inertia Brake Housing Countershaft Bearing O-ring (10004217) onto the Lower Countershaft Bearing.

    Note: O-ring may fall out of position after installation. Ensure to clean any residual oil from the bearing and roll the O-ring on to the bearing using the tips of your fingers pushing on the inner diameter of the O-ring. If necessary, apply a small amount of transmission assembly lube at the 3, 6, 9 and 12 o'clock positions to the outer diameter of the bearing.

    _Graphics/_Raster/Install Inertia Brake Housing CS Bearing Oring_1.jpg_Graphics/_Raster/Install Inertia Brake Housing CS Bearing Oring_2.jpg

Install Inertia Brake Cover and Housing

  1. Install the Inertia Brake Cover and the new 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.

    _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. If removed, install the Return Spring into the Lower Countershaft.

    _Graphics/_Raster/IMG_0404.png

  4. If removed, 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 six 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

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

  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.