Key on with engine off.

Connect ServiceRanger and create a Service Activity Report.

Select “Send to Eaton” (internet connection required)

Disconnect ServiceRanger.

Key off.

Key on with engine off.

Connect ServiceRanger.

Go to Service Routines.

Select “Start” XD MTM Service Removal Utility and follow on-screen prompts.

Disconnect ServiceRanger.

Key off.

Key off.

Set vehicle parking brake and chock wheels.

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.

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

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

Place a suitable container under the Oil Drain Plug.

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

Remove the Oil Drain Plug with a 8 mm hex key and drain the oil.

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

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

Install the Oil Drain Plug (8 mm) and torque to 24.5-29.5 Nm (18-22 lb-ft).

Disconnect negative battery cable.

Refer to OEM guidelines for transmission removal.

Unscrew the 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

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

Inspect the TCM Seal for damage.

If replacing the TCM, transfer the TCM Seal to the new TCM.

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

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

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

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.

Determine next steps.

• If Service Routine - XD MTM Service Removal Utility was performed prior to transmission removal, go to Remove the Mechatronic Transmission Module (MTM).
• If Service Routine - XD MTM Service Removal Utility was not performed prior to transmission removal, go to Manually Move Rail E to Forward Position.

Locate Rail E shaft access plug.

Remove Rail E shaft access plug.

Locate Rail E shaft detent plug.

Remove Rail E shaft detent plug with a 6 mm hex key.

Remove Rail E detent spring with a magnet.

Remove Rail E detent using a magnet.

Thread Push Rod Handle (RR1039TR) into the Rail-E Shaft through the access hole.

Push Rail E shaft forward to ensure Rail E is in the forward detent position.

Note: Any soft copper type drift or punch can be used to push Rail-E in the forward position if Push Rod Handle (TR1039TR) is not available.

Install Rail E detent with a magnet.

Install Rail E detent spring with a magnet.

Install Rail E Detent plug with a 6mm hex key and torque to 24.5 - 29.5 Nm (18-22 lb.-ft).

Install the Rail-E access plug with a 6mm hex key and torque to 24.5 - 29.5 Nm (18-22 lb.-ft).

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

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

Remove the two Release Yoke Cover 10 mm cap screws.

Remove the Release Yoke Cover.

Remove the 20 MTM cap screws.

Note: 13 mm (x16), 15 mm (x4).

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

Remove the MTM from the transmission housing.

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

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

Remove the Output Speed Sensor 10 mm cap screw.

Remove the Output Speed Sensor from the Rear Housing.

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

Remove 3 Harness Bracket 10 mm cap screws.

Remove Harness Bracket.

Place transmission in the vertical position with the front side down.

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

Remove Rail E shift range block using 8mm hex key.

Remove 28 Rear Housing and 3 threaded 16 mm cap screws.

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

Separate Rear Housing from Intermediate Housing at the 2 pry points.

Lift and remove Rear Housing Assembly from Intermediate Housing.

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.

Place Rear Housing Assembly on bench.

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

Remove 30 Oil Pump Assembly 13 mm cap screws.

Remove Oil Pump Assembly.

Remove Oil Pump/Range Spacer with O-ring.

Remove the two Rear Upper Main Shaft Lube tube 8 mm cap screws.

Remove Intermediate housing Assembly.

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.

Note: Parts must be assembled within 30 minutes of applying Gasket Sealant.

Install the Intermediate Housing Assembly.

Install the Rear Upper Main Shaft lube tube into the Intermediate Housing.

Install both 8 mm cap screw and torque to 8-10Nm (6-13 lb.-ft).

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

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

Install the Oil Pump Assembly on the Intermediate Housing.

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

Install 30 Oil Pump Assembly 13 mm cap screws and torque to 21–23 Nm (16–18 lb–ft) in a criss-cross pattern.

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

Inspect threaded bolt holes for debris and clean if necessary.

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

Note: Parts must be assembled within 30 minutes of applying Gasket Sealant.

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

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

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.

Install the 28 Rear Housing 16 mm cap screws.

Torque the 28 Rear Housing 16 mm cap screws to 44.5 - 51.5 Nm (33-38 lb-ft) in a criss-cross pattern.

Lift transmission horizontally onto a bench.

Install Rail E shift range block using 8mm hex key and torque to 21.0 - 25.0 Nm (16-19 lb-ft).

Install Harness Bracket.

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

Clean the sensor bore.

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

Install the Output Speed Sensor into the bore.

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

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

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

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

Place the transmission in a horizontal position.

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.

Inspect threaded bolt holes for debris and clean if necessary.

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

Shift the Rail B Synchronizer to neutral.

Remove the Rail B Engagement Tool.

Move Rail C Sliding Clutch to Neutral and Rail D to the fore position.

Move Rail A to the Aft or rear position using a pry bar.

Move Rail A to the forward position.

Install the MTM Alignment tool (RR1116TR) into the slots of the synchronizer and sliding clutches.

Install the Confirm-Neutral Gauge (RR1117TR) onto the main housing.

Verify synchronizer and sliding clutches are in the proper positions by sliding MTM Alignment Gauge into the slots of Confirm Neutral Tool.

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

Using the Rail E Lever, move Rail E to Forward position.

Note: All rails in the transmission case side must be in the correct positions (A: Neutral, B: Neutral, C: Neutral, D: Forward, E: Forward).

Verify Rail E is in Forward position using the Gear Side Actuator end of the MTM Alignment tool (RR1116TR) at Shift Rail E. Rail E is in Forward position when end of gauge rests against housing with rail against notch-end of gauge.

Verify Rail A is in the forward position using the Rail A Gear Side Actuator end of the MTM Alignment Tool (RR1116TR) ensuring the end of the gauge rests against the housing with rail against the notch-end of gauge.

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 (see image below).

Move Shift Rail C in the MTM to neutral. Rail C is in neutral when the shift inter-lock is aligned with the notches of the rail yoke assemblies (see image below).

Move Shift Rail D in the MTM to the fore position. Rail D is in the fore position when the shift inter-lock is aligned off the notches of the rail yoke assemblies (see image below).

Verify MTM shift forks are in the proper positions before installing the Confirm-Neutral Gauge (RR1117TR) 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.

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.

Verify notch on Rail A is facing up.

Note: If the MTM is installed on the transmission with the notch on Rail A facing down, Fault Code 255 (SPN 4218) sets Active and the transmission will not shift out of neutral.

Verify Rail E is in Forward Position using the Fork Side Actuator end of the MTM Alignment Tool (RR1116TR) 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 Forward Position, slide rail in or out until neutral is achieved.

Verify notch on Rail A is facing up.

Note: If the MTM is installed on the transmission with the notch on Rail A facing down, Fault Code 255 (SPN 4218) sets Active and the transmission will not shift out of neutral.

Same CID picture like in above step 21, but of rail A on front side of MTM.

Verify Rail A is in neutral using the Fork Side Actuator end of the MTM Alignment Tool (RR1116TR) at Shift Rail A. Rail A is in neutral when end of gauge rests against cover with rail against notch-end of gauge.

Note: A Rail detent system is very stiff to move, and B Rail shift fork needs to be in the Neutral position before moving A Rail shaft on MTM to the neutral position.

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

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.

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.

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

Install MTM onto the transmission housing. Align Rails A and E in the MTM with Shift Rails A and E in the Main Housing.

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 (x16), 15 mm (x4) cap screws.

Install the Release Yoke Cover.

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

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

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

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

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.

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

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

Remove the 4 LCA cap screws

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.

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.

Inspect LCA to determine next steps, reference images below:

• If LCA is locked in the reset position, go to Step 5 and install Linear Clutch Actuator.
• If LCA is not locked in the reset position, go to Step 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.

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.

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

Insert the LCA into the MTM.

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

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

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

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

Refer to OEM guidelines for transmission installation.

Connect negative battery cable.

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

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

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 12.0 liters (25.4 pints) depending on the transmission angle.

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

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

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

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

Set vehicle parking brake and chock wheels.

Key on with engine running.

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.

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

• 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.

Key off and wait 1 minute.

Key on with engine off.

Connect ServiceRanger.

Go to “Fault Codes”.

• If an Active transmission fault code is set, go to Endurant XD Troubleshooting Guide TRTS0960 Diagnostic Procedure.
• If no Active transmission fault codes are set, select “Clear Eaton Faults” and follow on-screen prompts. Go to Step 9.

Disconnect ServiceRanger.

Key off.

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.