Endurant XD
TRSM0960 EN-US
|
March 2025 - A

Main Shaft End-Play

Special Instructions

Main Shaft End-Play must be measured and adjusted after Intermediate Housing, Main Housing, any Main Shaft Component replacement, 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
  • Main Shaft End Play Kit (RR2015TR)
  • Dial Indicator
  • Main Shaft Repair Kit (RR2016TR)
  • Basic Service Repair Kit (RR2014TR)
  • 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

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1. Extension Shaft Sub-Assembly

2. Main Drive Needle Bearing

3. Main Drive Gear Assembly

4. Synchronizer Ring

5. 1st/2nd/3rd/4th Sliding Sleeve

6. Synchronizer Hub

7. Synchronizer Roller

8. Synchronizer Plunger

9. Compression Spring

10. Compression Spring

11. Thrust Washer (x4)

12. Main Shaft Thrust Bearing

13. Thrust Washer Race

14. Roller Needle Bearing

15. Synchronizer Ring Assembly

16. Welded Main Shaft Gear Assembly

17. Main Shaft Race

18. Spherical Washer

19. Wave Spring

20. Clutch Hub

21. Main Shaft Sliding Clutch

22. Main Shaft Gear (2nd)

23. Main Shaft Washer

24, Main Shaft

25. Main Shaft Gear (1st)

26. Rev Clutch (1st) Hub

27. Reverse Spacer

28. Main Shaft (Reverse) Gear

Measure and Adjust the Main Shaft End-Play

Note: The Main Shaft Selective Washer is available in 4 thicknesses: 6.525 mm (0.257 in), 6.875 mm (0.271 in), 7.225 mm (0.285 in), or 7.575 mm (0.298 in).

Caution
Ensure the Input Shaft Bearing is seated in the Main Housing using Input Bearing Capture Plate (RR1101TR). Failure to fully seat bearings in housings will give an incorrect Main Shaft End-Play reading and may cause transmission component damage.

  1. Place Intermediate Housing on a bench and support housing on the Oil Pump Assembly surface with Input Bearing Guide (RR1095TR).

    _Graphics/_Raster/IMG_0773.png_Graphics/_Raster/IMG_0774.png

  2. Place Input Shaft Bearing Removal and Installation Tool (RR1075TR) and Universal Driver Handle (OE8044-T0) onto Main Shaft Bearing.

    _Graphics/_Raster/IMG_0775.png_Graphics/_Raster/IMG_0777.png

  3. Use a hammer to drive the Main Shaft Bearing out of Intermediate Housing.

    Notice
    Support the Intermediate Housing to avoid damaging the housing and sealing surface.
    _Graphics/_Raster/IMG_0778.png_Graphics/_Raster/IMG_0780.png

  4. Remove Main Bearing O-Ring from Intermediate Housing.

    _Graphics/_Raster/IMG_0782.png

  5. Install the Intermediate Housing to the Main Housing and install 4 long MTM mounting bolts (M10x60x1.5). Torque all 4 bolts to 13-15 NM (10-11 Lb-ft).

    _Graphics/_Raster/IMG_1035.JPG_Graphics/_Raster/IMG_1041.JPG

  6. Remove Main Shaft selective washer to measure Main Shaft End-Play.

    _Graphics/_Raster/IMG_1032.JPG_Graphics/_Raster/IMG_1033.JPG

  7. Make note of what size selective washer is removed. The selective washer part number is stamped onto the selective washer.

    _Graphics/_Raster/IMG_1034.JPG

  8. Pay close attention to the 3 cutaway slots on the Main Bearing shoulder of the Intermediate Housing. Ensure the Dial Indicator shaft will not align to the 3 cutaway slots in the Main Housing when mounting the Main Shaft End-Play measurement tool.

    _Graphics/_Raster/IMG_1045.JPG

  9. Install the Main Shaft End-Play measurement tool assembly with Dial Indicator onto the Intermediate Housing.

    _Graphics/_Raster/IMG_1047.JPG_Graphics/_Raster/IMG_1048.JPG

  10. Install 4 Oil Pump mounting cap screws to secure Main Shaft End-Play measurement tool to Intermediate Housing. Torque all 4 oil pump bolts to 21-23 Nm (19-18 Lb-ft).

    _Graphics/_Raster/IMG_1053.JPG_Graphics/_Raster/IMG_1056.JPG

  11. Install Main Shaft compression tools (RR1109TR Sleeve and RR1108TR Tension Nut) and tighten nut to fully compress Main Shaft and torque to 13-15 Nm (10-11 Lb-ft).

    _Graphics/_Raster/IMG_1058.JPG_Graphics/_Raster/IMG_1060.JPG_Graphics/_Raster/IMG_1062.JPG

  12. Slide dial indicator block to inward slot position and tighten sliding block cap screw. Zero dial indicator on spacer plate (RR1106TR).

    _Graphics/_Raster/IMG_1064.JPG_Graphics/_Raster/IMG_1065.JPG

  13. Slide dial indicator block to outward slot position and tighten block cap screw. Measure Main Shaft End-Play reading by touching the dial indicator shaft on Main Bearing shoulder of the Intermediate Housing. Record reading in table.

    _Graphics/_Raster/IMG_1066.JPG_Graphics/_Raster/IMG_1067.JPG_Graphics/_Raster/TRSM0950_EndPlay_RangeReading.PNG

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

    Main Shaft Selective Washer Reference Chart

    _Graphics/_Raster/MainShaftSelectiveWasherTable_V2.png
    _Graphics/_Raster/SelectiveWasherInputSpace.png

  15. Install the correct Main Shaft Selective washer as directed by the “Main Shaft Selective Washer Reference Chart” above.

    _Graphics/_Raster/IMG_1033.JPG

  16. Install the Main Shaft bearing O-ring into the Intermediate Housing.

    _Graphics/_Raster/IMG_0785.JPG

  17. Locate the bearing lock window in the Intermediate Housing.

    _Graphics/_Raster/IMG_0786.JPG

  18. Set the Main Shaft Bearing lock pin to align with the Intermediate Housing bearing lock window and the ensure the roll pin is in the upward position.

    _Graphics/_Raster/IMG_0789.png

  19. Support the Intermediate Housing using Input Bearing Guide (RR1095TR).

    _Graphics/_Raster/IMG_0790.png

  20. Using Bearing Installer (RR1077TR) and Universal Handle (OE8044-TO) drive the Bearing into the housing until the bearing is fully seated.

    _Graphics/_Raster/IMG_0795.png_Graphics/_Raster/IMG_0796.JPG

Install Intermediate Housing Assembly

  1. 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 30 minutes of applying Gasket Sealant.

    _Graphics/_LineArt/TRTS0960_MainHsgGasketSeal.png

  2. Install the Intermediate Housing Assembly.

    _Graphics/_Raster/TRSM0960_IntermediateHsgAssy_0436.png

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

    _Graphics/_Raster/TRSM0960_IntermediateHsgAssy_0439.png

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

    _Graphics/_Raster/TRSM0960_IntermediateHsgAssy_0442.png

Install the Oil Pump Assembly

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

    _Graphics/_Raster/TRSM0960_OilPumpAssy_0428.png

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

    Caution
    Failure to properly install the Oil Pump/Range Spacer in the Intermediate housing may results in transmission component damage during Oil Pump Assembly installation.
    Notice
    Ensure the spacer tab is aligned with the groove and the spacer sits flush in the Intermediate Housing.
    _Graphics/_Raster/TRSM0960_OilPumpAssy_0671.png

  3. Install the Oil Pump Assembly on the Intermediate Housing.

    _Graphics/_Raster/TRSM0960_OilPumpAssy_0667.png

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

    _Graphics/_Raster/TRSM0960_OilPumpAssy_0665.png

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

    _Graphics/_Raster/TRSM0960_OilPumpAssy_0662.png_Graphics/_Raster/TRSM0960_OilPumpAssy_0424.png

Install the Rear Housing

  1. 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.

    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 Intermediate 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 30 minutes of applying Gasket Sealant.

    _Graphics/_LineArt/TRSM0960_IntermediateHsgGasketSeal.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/TRSM0960_RearHsg_0659.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/TRSM0960_RearHsg_0419.png

  6. Install the 28 Rear Housing 16 mm cap screws.

    _Graphics/_Raster/TRSM0960_RearHsg_0653.png

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

    _Graphics/_Raster/TRSM0960_RearHsg_0650.png

  8. 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.

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

    _Graphics/_Raster/TRSM0960_RearHsg_0410.png