Endurant XD
TRSM0960 EN-US
|
September 2025 - E

Oil Cooler Bypass Cartridge

Special Instructions

The Oil Cooler Bypass Cartridge can be removed and installed with the transmission in-vehicle.

Notice
Oil Cooler Bypass Cartridge Kits are OEM specific. Reference XD Parts Book TRPB0960 for specific parts information.

Note: Refer to OEM regarding External Transmission Oil Cooler and Line installation.

Special Tools

None

Component Identification

_Graphics/_LineArt/TRSM0960_OilCoolerCartridge_ID_v2.png

1. External Transmission Oil Cooler Fitting (2)

2. Oil Cooler Bypass Cartridge

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 8 mm hex key and drain the oil.

    _Graphics/_Raster/TRSM0960_Oil_0357.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 (8 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/TRSM0960_Oil_0359.png

Remove Oil Cooler Port Plugs

  1. Locate both Oil Cooler Port Plugs in the intermediate housing.

    _Graphics/_Raster/OilCooler_PortPlugs.jpg

  2. Place a suitable container under the Oil Cooler Port Plugs.

  3. Remove Oil Cooler Port Plugs with a 6 mm hex key.

    Note: Dispose of both Oil Cooler Port Plugs. Per Joint Industry Council (JIC) fittings in kit will replace Oil Cooler Port Plugs.

    _Graphics/_Raster/OilCooler_RemovePlugs1.jpg_Graphics/_Raster/OilCooler_RemovePlugs3.jpg

Install Oil Cooler Bypass Cartridge

  1. Install Oil Cooler Bypass Cartridge.

    Note: Ensure the plunger and bypass holes face transmission in the Lower Cooler Port of the Intermediate Housing.

    _Graphics/_Raster/OilCooler_BypassCartridge1.jpg_Graphics/_Raster/OilCooler_BypassCartridge2.jpg

  2. Install the lower JIC fitting with the O-ring facing the Intermediate Housing and use (27 mm) hex socket into the intermediate Housing and torque to 54-66 Nm (40-48 lb-ft).

    _Graphics/_Raster/OilCooler_LowerFitting1.jpg_Graphics/_Raster/OilCooler_LowerFitting2.jpg

  3. Install the Upper JIC fitting with the O-ring facing the Intermediate Housing and use (27 mm) hex socket into the intermediate Housing and torque to 54-66 Nm (40-48 lb-ft).

    Note: Purchase cooler and cooler lines through OEM or Aftermarket.

    _Graphics/_Raster/OilCooler_UpperFitting1.jpg_Graphics/_Raster/OilCooler_UpperFitting2.jpg

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/TRSM0960_Oil_0360.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/TRSM0960_Oil_0364.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 12.0 liters (25.4 pints) depending on the transmission angle.

    _Graphics/_Raster/TRSM0960_OilLevel.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/TRSM0960_Oil_0364.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/TRSM0960_Oil_0360.png

  8. 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.