Page 1 Service Manual Endurant 12-Speed ™ Automated Transmission TRSM0950 EN-US March 2019...
Page 3: Table Of Contents
Change Log ....... .243 Rear Housing Assembly Disassembly/Assembly . . .117 Clutch Housing Disassembly/Assembly ..129 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 4: Warnings And Cautions
60 - 140 PSI. Refer to OEM guidelines regarding vehicle system operation and service. Failure to follow OEM guidelines may result in major vehicle component damage, severe injury or death. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 5 To avoid damage to the transmission during towing: • Sit in the driver’s seat. When towing a vehicle equipped with the Endurant Trans- • Confirm vehicle parking brake is applied. mission, do not allow the output shaft of the transmission to rotate.
Page 6: How To Use This Manual
Installation. Below the Component Identification diagram is a numerical listing for each part with the part name. Appendix This section contains information such as Lubrication Specifications, Inspection, Tool Specifications, and Torque Specifications. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 8: Serial Tag Information And Model Nomenclature
(XX * 100 + 50 ft-lb) Serial Number The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the number down as it may be needed. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 10: Oil Drain Procedure
TRSM0950 Removal | Oil Drain Procedure Oil Drain Procedure Special Instructions Special Tools None None Component Identification 1. Oil Drain Plug - 6 mm Hex 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 11 Oil Drain Plug, O-ring is serviced with plug. 6. Install the Oil Drain Plug and torque to 24.5-29.5 Nm (18-22 lb-ft). NOTICE: Do not over-torque drain plug or transmission damage may occur. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 12: Linear Clutch Actuator (Lca) Removal
Special Tools Drain the vehicle air system. None Component Identification 1. Mechatronic Transmission Module (MTM) Housing 2. Linear Clutch Actuator (LCA) 3. LCA Cap Screws (x4) - T45 Torx 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 13 Harness is disconnected prior to removing the LCA from the MTM. Note: LCA piston rod end is seated in the release yoke socket; pull to release rod end from socket. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 14 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 16: Transmission Control Module (Tcm) Removal
1. Transmission Control Module (TCM) Cover - 10 or 13 mm Nuts 2. Transmission Control Module (TCM) 3. Mechatronic Transmission Module (MTM) 4. Transmission Control Module (TCM) Jackscrew - 7 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 17 1. Connect ServiceRanger and create a Service Activity Report. 2. Key off. 3. Disconnect the negative battery cable. NOTICE: Leaving battery cable connected may damage TCM. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 18 Note: TCM Cover nuts are 10 or 13 mm. 8. If replacing the TCM, transfer the TCM Seal to the new 6. Unscrew the 7 mm jackscrew, lift and remove the TCM TCM. from the MTM. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 20: Transmission Removal
2 cap screws and washers (M10 x 1.5 x 30 mm, minimum class 8.8) Component Identification Procedure – Removal 1. Perform “Manually Vent Linear Clutch Actuator (LCA)” on page 219. 2. Refer to OEM guidelines for transmission removal. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 22: Clutch Removal
Component Identification 1. Clutch Cover Cap Screws (x12) - 15 mm 2. Clutch Cover 3. Driven Disc Assembly 4. Engine Flywheel 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 23 2. Install and hand tighten the 4 stand-off bolts 6. Remove the pilot bearing if the clutch assembly or the (RR1063TR-4) in place of the removed Clutch Cover input shaft wear sleeve are being replaced. cap screws. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 24: Fluid Pressure Sensor (Fps) Removal
TRSM0950 Removal | Fluid Pressure Sensor (FPS) Removal Fluid Pressure Sensor (FPS) Removal Special Instructions Special Tools None None Component Identification 1. Fluid Pressure Sensor (x1) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 25 TRSM0950 Procedure – Removal 1. Unlatch and disconnect the OEM 3-Way Transmission Fluid Pressure Sensor (FPS) Connector. 2. Remove the Transmission FPS (24 mm) threaded into the main housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 26: Output Speed Sensor Removal
Output Speed Sensor Removal Special Instructions Special Tools None None Component Identification 1. Output Speed Sensor Harness 2. Harness Retainers (x2) 3. Cap Screw - 10 mm 4. Output Speed Sensor Connector 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 27 1. Lift the latch on the Output Speed Sensor Harness at the Connector on the Mechatronic Transmission Mod- ule (MTM). 3. Remove the Output Speed Sensor Harness tie strap at the Harness Bracket. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 28 Housing and bracket on Rear Housing. Housing. Note: The sensor may need to be twisted and pulled from the bore. 5. Remove the Output Speed Sensor 10 mm cap screw. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 30: Mechatronic Transmission Module (Mtm) Removal
2. MTM Cap Screws, Special (x2) - 15 mm 3. MTM Cap Screws (x14) - 13 mm 4. Mechatronic Transmission Module (MTM) 5. Main Housing 6. Output Speed Sensor 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 31 5. Lift the latch on the Output Speed Sensor Harness at the Connector on the Mechatronic Transmission Mod- ule (MTM). 7. Remove the 20 MTM cap screws. Note: 13 mm (x18), 15 mm (x2). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 32 9. 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 34: Release Bearing And Clutch Release Yoke Removal
Removal | Release Bearing and Clutch Release Yoke Removal Release Bearing and Clutch Release Yoke Removal Special Instructions Special Tools None None Component Identification 1. Release Bearing 2. Clutch Release Yoke 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 35 2. Remove the Release Bearing by sliding the bearing off the input shaft. 3. Pull to free the lower Clutch Release Yoke socket from the lower pivot on the clutch housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 36 5. Inspect the plastic socket inserts in the Clutch Release Yoke to verify none of the fingers are missing or dam- aged. Note: If the plastic insert is damaged, replace the Clutch Release Yoke assembly. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 38: Upper Countershaft Cover Removal
Upper Countershaft Cover Removal Special Instructions Special Tools None None Component Identification 1. Upper Countershaft Cover Cap Screws (x6) - 13 mm 2. Upper Countershaft Cover 3. O-ring 4. Upper Countershaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 39 2. Perform “Release Bearing and Clutch Release Yoke Removal” on page 31. 3. Remove the 6 Upper Countershaft Cover 13 mm cap screws and remove cover. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 40: Input Shaft Cover Removal
Special Instructions Special Tools None None Component Identification 1. Input Shaft Cover Cap Screws (x7) - 13 mm 2. Input Shaft Cover 3. Seal 4. O-ring 5. Input Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 41 2. Perform “Release Bearing and Clutch Release Yoke Removal” on page 20. 3. Remove the 7 Input Shaft Cover 13 mm cap screws. 4. Remove the Input Shaft Cover. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 42: Removal
1. Inertia Brake Cover Cap Screws (x6) - 13 mm 2. Inertia Brake Cover 3. Inertia Brake Cover O-ring 4. Inertia Brake Housing 5. Inertia Brake Housing O-ring 6. Piston Pin 7. Return Spring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 43 4. Depress and hold collar on air line fitting and discon- nect the air line from the Inertia Brake Cover. 6. Remove the Inertia Brake Cover and Housing as an assembly. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 44 Removal | Lower Countershaft Cover and Inertia Brake Removal 7. Remove Piston Pin from the end of the lower counter- shaft. 8. Remove the Return Spring from the end of the lower countershaft using a magnet. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 46: Output Yoke Removal
Removal | Output Yoke Removal Output Yoke Removal Special Instructions Special Tools None None Component Identification 1. Retainer Bolt - 27 mm 2. Retainer Plate 3. Output Yoke 4. Output Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 47 3. Remove the Output Yoke. Note: There is an interference fit between the Output Yoke and output shaft splines that may require an out- put yoke puller. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 48: Rear Bearing Cover Removal
None None Component Identification 1. Output Shaft 2. Thrust Washer 3. O-Ring 4. Rear Bearing Cover 5. Wear Sleeve and Dust Cover 6. Cap Screws (x8) - 13 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 49 3. Remove the 8 Rear Bearing Cover 13 mm Cap Screws. 4. Using a pry bar, separate the Rear Bearing Cover from the rear housing. Note: Two pry points located at 12 and 6 o’clock. 6. Remove the O-ring. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 52: Harness Bracket Removal
TRSM0950 Removal | Harness Bracket Removal Harness Bracket Removal Special Instructions Special Tools None None Component Identification 1. Harness Bracket 2. Harness Bracket Cap Screws (x3) - 10 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 53 Procedure – Removal 1. Remove the Output Speed Sensor Harness tie strap at the Harness Bracket. 2. Remove 3 Harness Bracket 10 mm cap screws. 3. Remove Harness Bracket. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 54: Rear Housing Assembly Removal
1. Rear Housing Cap Screws (x21) - 16 mm 2. Rear Housing Threaded Cap Screws (x3) - 16 mm 3. 90-Degree Lifting Eyes (x2) 4. Rear Housing 5. Rear Housing Alignment Pins (x2) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 55 Removal” on page 27. component. 5. Perform “Output Speed Sensor Removal” on page 23. 6. Perform “Harness Bracket Removal” on page 49. 7. Perform “Output Yoke Removal” on page 43. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 56 10. Remove 21 Rear Housing and 3 threaded 16 mm cap screws. 12. Separate the Rear Housing from the Main Housing at the 2 pry points. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 57 PTO lube tube port on the pump and rear PTO drive splines on the Upper Countershaft. 15. Remove the 2 Rear Housing Alignment Pins (RR1090TR) from the Main Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 58: Bolt Pto Cover Removal
Removal | 4-Bolt PTO Cover Removal 4-Bolt PTO Cover Removal Special Instructions Special Tools None None Component Identification 1. O-ring 2. 4-Bolt PTO Cover 3. Cap Screws (x4) - 18 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 59 2. Using a soft-faced hammer at the 3 o’clock position, lightly tap to separate the PTO cover from the Rear Housing. CAUTION: Keep fingers clear to avoid personal injury. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 60: Oil Pump Removal
Oil Pump Removal Special Instructions Special Tools None None Component Identification 1. Oil Pump Assembly Cap Screws (x18) - 13 mm 2. Oil Pump Assembly 3. O-ring 4. Oil Pump/Range Spacer 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 61 7. Perform “Output Yoke Removal” on page 43. 8. Perform “Rear Housing Assembly Removal” on page 51. 9. Remove 18 Oil Pump Assembly 13 mm cap screws. 10. Remove Oil Pump Assembly. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 62: Main Housing Removal
1. Main Housing External Cap Screws (x19) - 16 mm 2. Main Housing 3. Main Housing Internal Cap Screws (x6) - 16 mm 4. Rear Housing Alignment Pins (RR1090TR) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 63 7. Perform “Output Yoke Removal” on page 43. 9. Perform “Rear Housing Assembly Removal” on page 51. 10. Remove 2 Rear Housing Alignment Pins (RR1090TR). 11. Perform “Oil Pump Removal” on page 57. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 64 Main Housing cap screws separated. 13. Install and hand tighten 2 Rear Housing Alignment Pins (RR1090TR) in the internal Main Housing cap screw outer threaded holes. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 65 Eyes and 15 mm cap screws to Main Housing. pry points. NOTICE: Do not over tighten cap screws. Note: Install 90-degree Lifting Eyes 180-degrees apart to ensure even lifting. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 66 Dropping Main Housing could result in component damage and/or personal injury. NOTICE: Use an appropriate lifting device to safely lift component. 18. Remove 2 Rear Housing Alignment Pins (RR1090TR). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 68 Removal | 8-Bolt PTO Cover Removal 8-Bolt PTO Cover Removal Special Instructions Special Tools None None Component Identification 1. 8-Bolt PTO Cover 2. PTO Cover Cap Screws (x8) - 18 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 69 1. Perform “Oil Drain Procedure” on page 7. 2. Remove 8 PTO Cover 18 mm cap screws. 3. Separate 8-Bolt PTO Cover from Main Housing at the 2 pry points. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 70: Main Shaft And Countershaft Removal
25. Countershaft Flat Washers (x2) 8. Synchronizer Ring 17. Thrust Washer - Rear 26. Countershaft Snap Rings (x2) 9. Synchronizer Sliding Sleeve 18. Thrust Bearing - Rear 27. Input Shaft Snap Ring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 71 13. Perform “Lower Countershaft Cover and Inertia Brake 10. Remove Upper Countershaft Snap Ring and Flat Removal” on page 39. Washer. NOTICE: A new snap ring is required when reinstalling. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 72 15. Perform “Rear Housing Assembly Removal” on page 51. 20. Remove the Lower Lube Tube. 16. Perform “Main Housing Removal” on page 59. 17. Remove the Upper Lube Tube 8 mm cap screw. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 73 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. 25. Remove Thrust Bearing - Rear. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 74 CAUTION: Countershaft weighs approximately 35 lbs. Keep fingers clear of pinch point between Countershaft and other surfaces. Dropping Countershaft could result in component damage and/or personal injury. 28. Remove Primary Drive Gear. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 75 Main Shaft and Countershaft Removal | Removal TRSM0950 31. Remove Spherical Washer- Front. 34. Remove Thrust Bearing - Front. 32. Remove Bearing Race - Front. 35. Remove Synchronizer Ring. 33. Remove Needle Bearing - Front. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 78: Output Seal Assembly
Note: RR1001TR-2 is part of Output Seal Driver Kit (RR1001TR) and may have already been purchased to support prior transmission models. Component Identification 1. Rear Bearing Cover 2. Output Shaft Seal 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 79 2. Place the Output Seal Driver (RR1001TR-8) onto the Output Seal Driver Handle (RR1001TR-2). 3. Place the Output Seal onto the Output Seal Driver (RR1001TR-8). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 80: Inertia Brake Disassembly/Assembly
1. Inertia Brake Cover 2. Inertia Brake Piston 3. Steel Discs (x6) 4. Friction Discs (x3) 5. O-ring - Front 6. Wear Guides (x2) 7. Inertia Brake Housing 8. O-ring - Rear 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 81 1. Remove the clutch pack from the Inertia Brake Hous- ing. 4. Remove O-ring from the rear of the Inertia Brake Hous- ing. 2. Remove the 2 wear guides from the Inertia Brake Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 82 1. Insert the O-ring into the groove on the rear of the Iner- tia Brake Housing until fully seated. 2. Insert the O-ring into the groove on the front of the Inertia Brake Housing until fully seated. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 83 • 1 Steel Disc. Note: Steel Discs align with Wear Guides. Friction Discs spline to the lower countershaft. 5. Place Inertia Brake Cover and Piston on the Housing. Align the bolt holes. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 84: Disassembly/Assembly
Wear Sleeve Installer (RR1061TR) Snap Ring Installer (RR1061TR-1) Wear Sleeve Driver (RR1061TR-2) Component Identification 1. Spiral Snap Ring 2. Pilot Bearing Wear Sleeve 3. Wear Sleeve Alignment Pin 4. Input Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 85 (RR1062TR) over the flats on the Pilot Bearing Wear 1. Perform “Transmission Removal” on page 17. Sleeve. 2. Remove the Spiral Snap Ring from the input shaft with a pick. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 86 Disassembly/Assembly | Input Shaft Pilot Bearing Wear Sleeve Disassembly/Assembly 4. Tighten the 13 mm jackscrew on the Input Shaft Pilot 5. Remove the Wear Sleeve Alignment Pin. Bearing Wear Sleeve Puller (RR1062TR) to remove Wear Sleeve. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 87 Wear Sleeve Alignment Pin in place. 3. Slide the Wear Sleeve Alignment Pin into the groove on the input shaft. NOTICE: Chamfered end of alignment pin must face forward. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 88 6. Use the Wear Sleeve Driver (RR1061TR-2) to fully seat the Pilot Bearing Wear Sleeve onto the input shaft. 8. Install a new Spiral Snap Ring onto the Snap Ring Installer (RR1061TR-1). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 89 10. While holding the Snap Ring Installer (RR1061TR-1) Snap Ring Installer (RR1061TR-1). against the input shaft, slide the Wear Sleeve Driver (RR1061TR-2) forward and fully seat the Spiral Snap Ring into the snap ring groove. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 90: Input Shaft Cover Disassembly/Assembly
Output Shaft Installer/Input Shaft Seal Driver (RR1070TR) Component Identification 1. Input Shaft Cover Cap Screws (x7) - 13 mm 2. Input Shaft Cover 3. Seal 4. O-ring 5. Input Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 91 2. Place the Input Shaft Cover into a vice equipped with from the Input Shaft Cover. soft-faced jaw pads with the drain back port at the 8 o'clock position. Note: Do not over-tighten the vice jaws. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 92 TRSM0950 Disassembly/Assembly | Input Shaft Cover Disassembly/Assembly 5. Clean and inspect the Input Shaft Seal bore. If seal bore is damaged, replace the Input Shaft Cover. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 93 2. Place Output Shaft Installer/Input Shaft Seal Driver (RR1070TR) onto the Input Shaft Seal and drive until seal is seated into the cover. Note: Fully seat Seal into Input Shaft Cover 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 94: Main Shaft Disassembly/Assembly
2. Reverse Gear 3. Main Shaft Washer (x4) 4. Rail D Sliding Clutch 5. Primary Driven Gear 6. Secondary Driven Gear 7 Main Shaft Assembly 8. Rail C Sliding Clutch 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 95 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 96 9. Rotate and remove standard Main Shaft Washer above Primary Driven Gear. 7. Rotate and remove standard Main Shaft Washer above Rail D Sliding Clutch. 10. Remove Primary Driven Gear. 8. Remove Rail D Sliding Clutch. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 97 Main Shaft Disassembly/Assembly | Disassembly/Assembly TRSM0950 11. Rotate and remove standard Main Shaft Washer above Secondary Driven Gear. 12. Remove Secondary Driven Gear. 13. Rotate and remove last standard Main Shaft Washer. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 98 Main Shaft Assembly could result in component damage and/or personal injury. 3. Install a 5/32 OD air line into the main shaft spline to align and hold washer in place. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 99 5. Install and rotate a standard Main Shaft Washer (6.525 7. Install Primary Driven Gear on Main Shaft with clutch- mm) above Secondary Driven Gear. ing teeth facing up. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 100 9. Slide the 5/32 OD air line up to align and hold washer 11. Install and rotate a standard Main Shaft Washer (6.525 in place. mm) above Rail D Sliding Clutch. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 101 OD air line. Note: Insert Main Shaft Key while removing air line. 14. Install and rotate the Selective Main Shaft Washer (6.525, 6.712, or 6.900 mm) above Reverse Gear. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 102 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 104: Input Shaft Disassembly/Assembly
Overhaul Tool Kit (RR2012TR) and may have already been purchased to support prior transmission models. Component Identification 1. Input Shaft Assembly 2. Clutch Housing 3. Input Shaft Bearing 4. Input Shaft Snap Ring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 105 Input Shaft Press (RR1085TR)” on page 221. 5. Place Clutch Housing in press with flywheel housing side of the Clutch Housing down. NOTICE: Support the Clutch Housing to avoid damag- ing the housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 106 Disassembly/Assembly | Input Shaft Disassembly/Assembly 6. Place Input Shaft Bearing Removal and Installation Tool (RR1075TR) and Universal Driver Handle (OE8044-T0) onto Input Bearing. 7. Press Input Shaft Bearing from Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 107 4. Press Input Shaft Bearing into Clutch Housing. NOTICE: Do not over press bearing into Clutch Hous- ing. Over pressing could result in component damage. 5. Verify Input Shaft Bearing is fully seated in Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 108 A used snap ring may detach from Input Shaft and result in transmission component damage. Note: The snap ring will not install if Input Shaft is not fully seated into Input Shaft Bearing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 110: Main Housing Disassembly/Assembly
5. Reverse Idler Gear Thrust Washers (x2) 2. Reverse Idler Gear Shaft (x2) 6. Reverse Idler Gear Needle Bearings (x2) 3. Rear Countershaft Bearings (x2) 7. Reverse Idler Gear (x2) 4. Main Housing 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 111 3. Remove Lower Reverse Idler Gear Shaft from Main Housing by pushing shaft up. 5. Remove Upper Reverse Idler Gear Shaft from Main Housing by pushing shaft up. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 112 8. Place Countershaft Bearing Installer (RR1076TR) and Universal Driver Handle (OE8044-T0) onto Rear Upper Countershaft Bearing. 9. Press Rear Upper Countershaft Bearing out of Main Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 113 15. Press Rear Lower Countershaft Bearing out of Main Housing. NOTICE: Support the Main Housing to avoid damaging the housing and sealing surface. NOTICE: Support the Main Housing to avoid damaging the housing and sealing surface. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 114 Over pressing could result in component damage. 7. Place Rear Lower Countershaft Bearing into Main Housing. 8. Place Countershaft Bearing Installer (RR1076TR) and Universal Driver Handle (OE8044-T0) onto Rear Lower Countershaft Bearing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 115 NOTICE: Support the Main Housing to avoid damaging the housing and sealing surface. NOTICE: Do not over press bearing into Main Housing. Over pressing could result in component damage and/or personal injury. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 116 19. Install Upper Reverse Idler Gear Shaft by pushing shaft into housing, through washers, bearing and gear. 17. Install and hold Upper Reverse Idler Gear upper washer into Main Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 117 23. While holding the upper washer, install Lower Reverse Idler Gear, bearing and lower washer into Main Hous- ing. 21. Install bearing into Lower Reverse Idler Gear. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 118 25. Align pin with passage in housing until pin is fully seated into passage. Note: If necessary, use a soft faced hammer to lightly tap shaft into housing. 26. Perform “Fluid Pressure Sensor (FPS) Installation” on page 159. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 120: Rear Housing Assembly Disassembly/Assembly
8. Output Bearing 4. Shift Rail E 9. Cap Screw (x1) - 8 mm 5. Reaction Plate Alignment Pins (x2) 10. Rear PTO Lube Tube (Dual PTO model only) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 122 6. Install 2 Reaction Plate Alignment Pins (RR1091TR) onto Reaction Plate dowels. NOTICE: Failure to use Reaction Plate Alignment Pins (RR1091TR) results in component damage. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 123 NOTICE: Use an appropriate lifting device to safely lift component. Note: Rotate Sun Gear to ease removal. 10. After Range Synchronizer Assembly clears the hous- ing, remove Shift Rail E. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 124 Shaft Assembly weighs approximately 60 lbs. Keep fin- gers clear of pinch point between Rear Housing and other surfaces. Dropping Rear Housing and Planetary Output Shaft Assembly could result in component damage and/or personal injury. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 125 NOTICE: Support the Rear Housing to avoid damaging the housing and sealing surface. 17. Place Output Bearing Removal and Installation Tool (RR1089TR) and Universal Driver Handle (OE8044-T0) onto Output Bearing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 126 3. Place Output Bearing Removal and Installation tool (RR1089TR) onto Output Bearing. NOTICE: Do not over press bearing into Rear Housing. Over pressing could result in component damage. 4. Press Output Bearing into Rear Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 127 Dropping Planetary Output Shaft Assembly could result in component damage and/or personal injury. 9. Place Input Shaft Bearing Removal and Installation Tool (RR1075TR) onto Planetary Output Shaft Assem- bly. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 128 Tube and 8 mm cap screw into Rear Housing and torque to 8.8 - 10.4 Nm (6-8 lb-ft). 16. Inspect plastic Oil Slinger to ensure it is locked into place by three locking tab pins. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 129 21. Remove Range Assembly Removal and Installation tool (RR1065TR). 19. Install and hold Shift Rail E to Range Synchronizer Assembly. Note: Ensure the notched end of Shift Rail E is facing 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 130 21 - 25 Nm (16 - 19 lb-ft). 25. Torque detent plug to 24.5 - 29.5 Nm (16-19 lb-ft). NOTICE: Do not over-torque detent plug or transmis- sion damage may occur. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 132: Clutch Housing Disassembly/Assembly
6. 90-Degree Air Line Fitting 2. Countershaft Bearings (x2) 7. Inspection Cover 3. Clutch Housing 8. Cap Screws (x2) 4. Input Shaft Bearing 9. Release Yoke Pivot Pin 5. Input Shaft Snap Ring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 133: 2018 Eaton Cummins Automated Transmission Technologies. All Rights Reserved
“Input Shaft Disassem- bly/Assembly using Input Shaft Press (RR1085TR)” on page 221. 5. Mark Clutch Housing case to indicate airline inlet direc- tion with a paint mark. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 134 10. Press Input Shaft Bearing from Clutch Housing. 11. Place Countershaft Bearing Installer (RR1076TR) and Universal Driver Handle (OE8044-T0) onto Lower Countershaft Bearing. 12. Press Lower Countershaft Bearing from Clutch Hous- ing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 135 14. Press Upper Countershaft Bearing from Clutch Hous- ing. 15. Place Input Shaft Bearing Removal and Installation Tool (RR1075TR) and Universal Driver Handle (OE8044-T0) onto Input Shaft Bearing. 16. Press Input Shaft Bearing from Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 136 Over pressing could result in component damage. 9. Verify Lower Countershaft Bearing is fully seated in Clutch Housing. 5. Verify Upper Countershaft Bearing is fully seated in Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 137 NOTICE: Support the Clutch Housing to avoid damag- 13. Verify Input Shaft Bearing is fully seated in Clutch ing the housing. Housing. 17. Install Input Shaft into Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 138 Housing. Over pressing could result in component result in transmission component damage. damage. Note: The snap ring will not install if Input Shaft is not fully seated into Input Shaft Bearing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 139 22. Install and hand tighten Inertia Brake 90-degree airline elbow (15 mm) aligning airline inlet with paint mark. 23. Install Release Yoke Pivot Pin (30 mm) and torque to 130-140 Nm (95-101 lb-ft). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 140: Rear Bearing Cover Installation
Gasket Remover (Loctite SF 7631) Component Identification 1. Output Shaft 2. Thrust Washer 3. O-Ring 4. Rear Bearing Cover 5. Wear Sleeve and Dust Cover 6. Cap Screws (x8) - 13 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 141 3. Slide the Output Shaft Thrust Washer over the output shaft and seat it against the Output Bearing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 142 6. Slide the Rear Bearing Cover over the output shaft. Note: Align the two pry points at 12 and 6 o’clock posi- tions. 9. Perform “Oil Fill Procedure” on page 213. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 144: Output Yoke Installation
Installation | Output Yoke Installation Output Yoke Installation Special Instructions Special Tools None None Component Identification 1. Retainer Bolt - 27 mm 2. Retainer Plate 3. Output Yoke 4. Output Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 145 WARNING: A new Retainer Bolt is required during Out- put Yoke installation. A used Retainer Bolt could loosen during operation and may result in major vehicle com- ponent damage, severe injury or death. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 146: Installation
1. Inertia Brake Cover Cap Screws (x6) - 13 mm 2. Inertia Brake Cover 3. Inertia Brake Cover O-ring 4. Inertia Brake Housing 5. Inertia Brake Housing O-ring 6. Piston Pin 7. Return Spring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 147 Inertia Brake Cover. NOTICE: Ensure the Friction Discs are splined to the lower countershaft and Wear Guides are fully seated. 6. Install the Inertia Brake Cover onto the housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 148 9. Perform “Release Bearing and Clutch Release Yoke Installation” on page 167. 10. Perform “Transmission Installation” on page 211. Note: Complete all Service Routines or transmission performance will be degraded. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 150: Input Shaft Cover Installation
Special Instructions Special Tools None None Component Identification 1. Input Shaft Cover Cap Screws (x7) - 13 mm 2. Input Shaft Cover 3. Seal 4. O-ring 5. Input Shaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 151 2. Slide the Input Shaft Cover over the Input Shaft. Note: Align “TOP” at 12 o’clock. 4. Perform “Release Bearing and Clutch Release Yoke Installation” on page 167. 5. Perform “Transmission Installation” on page 211. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 152: Upper Countershaft Cover Installation
Installation | Upper Countershaft Cover Installation Upper Countershaft Cover Installation Special Instructions Special Tools None None Component Identification 1. Cap Screws (x6) - 13 mm 2. Upper Countershaft Cover 3. O-ring 4. Upper Countershaft 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 153 Installation” on page 167. 6. Perform “Transmission Installation” on page 211. Note: Complete all Service Routines or transmission performance will be degraded. 3. Install the Upper Countershaft Cover to the Clutch Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 154 2. MTM Cap Screws, Special (x2) - 15 mm 3. MTM Cap Screws (x14) - 13 mm 4. Mechatronic Transmission Module (MTM) 5. Main Housing 6. Output Speed Sensor 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 155 Main Housing and hand tighten with 2 MTM cap sensor fault codes set Active and the transmission will screws. not shift out of neutral. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 156 Installation | Mechatronic Transmission Module (MTM) Installation 8. Install the Confirm-Neutral Gauge (RR1086TR-2) into 9. Install the MTM Alignment Tool (RR1086TR-1) onto the slots of the synchronizer and sliding clutches. the main housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 157 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 158 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 159 5942) sets Active and the transmission will not shift out of neutral. 18. Slide O-ring over the MTM front alignment pin on the main housing until fully seated in the groove. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 160 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 161 24. Perform “Release Bearing and Clutch Release Yoke Installation” on page 167. 25. Perform “Transmission Installation” on page 211. Note: Complete all Service Routines or transmission performance will be degraded. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 162: Fluid Pressure Sensor (Fps) Installation
TRSM0950 Installation | Fluid Pressure Sensor (FPS) Installation Fluid Pressure Sensor (FPS) Installation Special Instructions Special Tools None None Component Identification 1. Fluid Pressure Sensor (x1) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 163 1. Inspect the Fluid Pressure Sensor (FPS) and O-ring for damage. If damaged, replace the FPS.; O-ring is ser- viced with sensor. 2. Install the Transmission FPS into the Main Housing and torque to 19-23 Nm (14-17 lb-ft). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 164: Output Speed Sensor Installation
Output Speed Sensor Installation Special Instructions Special Tools None None Component Identification 1. Output Speed Sensor Harness 2. Harness Retainers (x2) 3. Cap Screw - 10 mm 4. Output Speed Sensor Connector 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 165 4. Install the Output Speed Sensor 10 mm cap screw and torque to 8.8-10.4 Nm (6-8 lb-ft). 6. Secure the Output Speed Sensor Harness to the Har- ness Bracket with a tie strap. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 166 TRSM0950 Installation | Output Speed Sensor Installation 7. Connect the Output Speed Sensor Harness to the Con- nector on the Mechatronic Transmission Module (MTM) and close the latch. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 168: Linear Clutch Actuator (Lca) Installation
Linear Clutch Actuator (LCA) Installation Special Instructions Special Tools None • ServiceRanger Component Identification 1. Mechatronic Transmission Module (MTM) Housing 2. Linear Clutch Actuator (LCA) 3. LCA Cap Screws (x4) - T45 Torx 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 169: Release Bearing And Clutch Release Yoke
7. Allow air pressure to build to governor cut-off. 8. Connect ServiceRanger. 9. Go To “Service Routines”. 3. Insert the LCA into the MTM. 10. Select “Start” Clutch Calibration and follow on-screen prompts. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 170 Installation | Release Bearing and Clutch Release Yoke Installation Release Bearing and Clutch Release Yoke Installation Special Instructions Special Tools None None Component Identification 1. Release Bearing 2. Release Yoke 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 171 2. Install the lower Release Yoke socket over the lower pivot on the clutch housing and press until attached. 5. Perform “Transmission Installation” on page 211. Note: Complete all Service Routines or transmission performance will be degraded. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 172: Transmission Control Module (Tcm) Installation
1. Transmission Control Module (TCM) Cover - 10 or 13 mm Nuts 2. Transmission Control Module (TCM) 3. Mechatronic Transmission Module (MTM) 4. Transmission Control Module (TCM) Jackscrew - 7 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 173 8.8-10.4 Nm (78-92 lb-in) in a criss-cross pattern. Note: TCM Cover nuts are 10 or 13 mm. 2. Align the TCM to the 74-Way Harness Connector and TCM studs. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 174 TCM, go to Step 8. 8. Key on with engine off. Note: Vehicle display may indicate a flashing “F”, “CC”, or service transmission. 9. Connect ServiceRanger. 10. Go To “Configuration”. 11. Select “Identification”. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 176: Main Shaft And Countershaft Installation
25. Countershaft Flat Washers (x2) 8. Synchronizer Ring 17. Thrust Washer - Rear 26. Countershaft Snap Rings (x2) 9. Synchronizer Sliding Sleeve 18. Thrust Bearing - Rear 27. Input Shaft Snap Ring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 177 4. Lift and hold the Rail B Synchronizer Sliding Sleeve, install 3 rollers over the 3 springs and plungers and into the sliding sleeve groove. 2. Install 3 springs and plungers into Synchronizer hub. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 178 8. Install Thrust Washer - Front. Note: Align the 3 tabs on ring to the 3 openings on the hub at each spring and plunger. 9. Install Needle Bearing - Front. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 179 Note: Lower Countershaft has Inertia Brake Splines on the front and Oil Pump drive slot on the rear. 11. Install Bearing Race - Front. 12. Install Spherical Washer - Front with conical side down. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 180 Dropping Countershaft could result ment. in component damage and/or personal injury. Note: Paint marks are required for timing the Second- ary Drive Gear to the Countershafts. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 181 Main Hous- ing cannot be installed due to countershaft misalign- ment. Note: Paint marks are required for timing the Second- ary Drive Gear to the Countershafts. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 182 19. Install Primary Drive Gear with clutching teeth facing 22. Install Thrust Bearing - Rear. up onto Rail B Synchronizer. 20. Install Bearing Race - Rear. 21. Install Needle Bearing - Rear. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 183 Spring - Front. Washer - Rear in place during Main Shaft Assembly installation. Note: Transmission assembly lube holds Wave Spring - Rear in place during Main Shaft Assembly installa- tion. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 184 26. Slide and hold Rail C Sliding Clutch into Secondary Driven Gear. 28. Remove magnet from Main Shaft Key. NOTICE: Ensure to remove magnet or component damage may occur during assembly. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 185 Keep fingers clear of pinch point between trans- mission 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 186 37. Perform “Input Shaft Cover Installation” on page 147. 35. Perform “Lower Countershaft Cover and Inertia Brake Installation” on page 143. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 187 43. Perform “Mechatronic Transmission Module (MTM) Installation” on page 151. 44. Perform “Transmission Control Module (TCM) Installa- tion” on page 169. 45. Perform “Release Bearing and Clutch Release Yoke Installation” on page 167. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 188: Main Housing Installation
1. Main Housing External Cap Screws (x19) - 16 mm 2. Main Housing 3. Main Housing Internal Cap Screws (x6) - 16 mm 4. Rear Housing Alignment Pins (RR1090TR) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 189 3. Slide O-ring over the Clutch Housing Inertia Brake air passage alignment pin until fully seated in groove. 5. Install Lower Countershaft Pilot Tool (RR1071TR) onto Lower Countershaft above rear bearing race. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 190 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. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 191 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). 11. Remove 2 Rear Housing 90-degree Lifting Eyes and 15 mm cap screws from Main Housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 192 NOTICE: Use an appropriate lifting device to safely lift component. 16. Perform “Output Yoke Installation” on page 141. 17. Perform “Harness Bracket Installation” on page 203. 18. Perform “Output Speed Sensor Installation” on page 161. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 194: Bolt Pto Cover Installation
Special Tools None • Gasket Sealant (Loctite 5188) • Gasket Remover (Loctite SF 7631) Component Identification 1. 8-Bolt PTO Cover 2. PTO Cover Cap Screws (x8) - 18 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 195 NOTICE: Ensure there is nothing in the threaded bolt holes or the transmission may be damaged when cap screws are tightened. 5. Perform “Oil Fill Procedure” on page 213. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 196: Oil Pump Installation
Oil Pump Installation Special Instructions Special Tools None None Component Identification 1. Oil Pump Assembly Cap Screws (x18) - 13 mm 2. Oil Pump Assembly 3. O-ring 4. Oil Pump/Range Spacer 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 197 NOTICE: Ensure spacer tab is aligned to groove and sits flush with housing or component damage may occur during installation. 4. Press Oil Pump Assembly to ensure it sits flat on Main Housing sealing surface. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 198 8. Perform “Output Yoke Installation” on page 141. 9. Perform “Harness Bracket Installation” on page 203. 10. Perform “Output Speed Sensor Installation” on page 161. 11. Perform “Mechatronic Transmission Module (MTM) Installation” on page 151. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 200: Rear Housing Installation
1. Rear Housing Cap Screws (x21) - 16 mm 2. Rear Housing Threaded Cap Screws (x3) - 16 mm 3. 90-Degree Lifting Eyes (x2) 4. Rear Housing 5. Rear Housing Alignment Pins (x2) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 201 Note: Two cap screws are used to mount the harness bracket and the third is used by the OEM for additional NOTICE: Failure to install alignment pins results in attachment points. transmission component damage. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 202 16. Perform “Transmission Installation” on page 211. 17. Perform “Oil Fill Procedure” on page 213. 18. Key on with engine running. 19. Allow air pressure to build to governor cut-off. 20. Connect ServiceRanger. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 204 Installation | 4-Bolt PTO Cover Installation 4-Bolt PTO Cover Installation Special Instructions Special Tools None None Component Identification 1. O-ring 2. 4-Bolt PTO Cover 3. Cap Screws (x4) - 18 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 205 3. Insert a new 4-Bolt PTO Cover O-ring into groove until fully seated. 4. Install the 4-Bolt PTO Cover onto Rear Housing with 4 18 mm cap screws and torque to 69-81 Nm (51-60 lb-ft) in a criss-cross pattern. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 206: Harness Bracket Installation
TRSM0950 Installation | Harness Bracket Installation Harness Bracket Installation Special Instructions Special Tools None None Component Identification 1. Harness Bracket 2. Harness Bracket Cap Screws (x3) - 10 mm 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 207 3. Secure the Output Speed Sensor Harness to the Har- ness Bracket with a tie strap. 1. Install Harness Bracket. 2. Install 3 Harness Bracket 10 mm cap screws and torque to 8.8 - 10.4 Nm (6-8 lb-ft). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 208: Clutch Installation
1. Clutch Cover Cap Screws (x12) (M10 x 1.5 x 80mm, minimum class 10.9, flange type fasteners) 2. Clutch Cover 3. Driven Disc Assembly 4. Alignment Pins (x2) 5. Engine Flywheel 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 209 NOTICE: If any reading exceeds maximum runout, pre- mature clutch wear will occur. Refer to OEM engine manufacture guidelines for repair or replacement. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 210 3 and 9 o’clock. Note: Do not install the Alignment Pins into the center threaded hole of the 3-threaded hole groups. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 211 7. Install 6 remaining Clutch Cover cap screws finger tight. 9. Torque Clutch Cover cap screws 5 through 12 to 30 Nm (23 lb-ft) as shown in the torque sequence below. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 212 15. Perform “Input Shaft Pilot Bearing Wear Sleeve Disas- sembly/Assembly” on page 81. 12. Remove the Clutch Alignment Shaft (RR1087TR). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 213 Clutch Installation | Installation TRSM0950 16. Perform “Transmission Installation” on page 211. Note: Complete all Service Routines or transmission performance will be degraded. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 214: Transmission Installation
Special Instructions Special Tools None • Transmission Jack Adapter Plate (RR1067TR) • 2 cap screws and washers (M10 x 1.5 x 30 mm, minimum class 8.8) • ServiceRanger Component Identification 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 215 Note: Complete all Service Routines or transmission performance will be degraded. 8. Select “Start” Clutch Calibration and follow on-screen prompts. 9. Select “Start” Rail Calibration and follow on-screen prompts. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 216: Oil Fill Procedure
Special Tools None None. Component Identification 1. Oil Check Plug - 6 mm Hex 2. Oil Drain Plug - 6 mm Hex 3. Oil Fill Plug - 6 mm Hex 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 217 5. Install the Oil Check Plug and torque to 24.5-29.5 Nm (18-22 lb-ft). NOTICE: Do not over-torque the Oil Fill Plug or trans- mission damage may occur. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 218 NOTICE: If PTO-equipped, start the engine and run for 1 to 2 minutes to fill the PTO with oil, key off and repeat the Oil Fill Procedure. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 220: Oil Level Inspection Procedure
Special Tools None None Component Identification 1. Oil Check Plug - 6 mm Hex 2. Oil Drain Plug - 6 mm Hex 3. Oil Fill Plug - 6 mm Hex 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 221 “Oil Fill Procedure” on page 213. 7. Inspect the Oil Check Plug and O-ring for damage. If damaged, replace the Oil Check Plug; O-ring is ser- viced with plug. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 222: Manually Vent Linear Clutch Actuator (Lca)
LCA and Mechatronic Transmis- sion Module (MTM) housing when the cap screws are loosened. 4. Tighten the 4 LCA to MTM T45 cap screws and torque to 23-27 Nm (17-21 lb-ft). 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 224: Input Shaft Press (Rr1085Tr)
4 (2 inch 7/16 inch Grade 8 or 50.8 mm M12 Grade 10.9) cap screws, washers and nuts Component Identification 1. Input Shaft Assembly 2. Clutch Housing 3. Input Shaft Bearing 4. Input Shaft Snap Ring 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 225 5. Install and hand tighten 4 (2 inch 7/16 inch Grade 8 or Input Shaft. 50.8 mm M12 Grade 10.9) cap screws, washers and nuts to attach press to housing. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 226 11. Install and hand tighten 4 Main Housing to Clutch 9. Place and support Clutch Housing on a bench. Housing 16 mm cap screws in the inboard holes on each side of the press. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 227 CAUTION: Input Shaft Press weighs approximately 30 lbs. Keep fingers clear of pinch points between Input Shaft Press and other surfaces. Dropping Input Shaft Press could result in component damage and/or per- sonal injury. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 228 4. Rotate jack screw to press Input Shaft Bearing into Clutch Housing. NOTICE: Do not over press bearing into Clutch Hous- ing. Over pressing could result in component damage. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 229 13. Install and hand tighten 4 Main Housing to Clutch Housing 16 mm cap screws in the inboard holes on each side of the press. 11. Place Input Shaft Cup (RR1087TR-6) onto Input Shaft. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 230 Input Shaft Bearing. lbs. Keep fingers clear of pinch points between Input Shaft Press and other surfaces. Dropping Input Shaft Press could result in component damage and/or per- sonal injury. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 232: Lubrication Specifications
Maintenance and Lubricant Change Intervals Transmission inspections and lubricant change intervals are outlined below. Use only Eaton approved lubricant. For information, see TCMT0021 Eaton Lubrication Product Specification Man- ual. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 234: Oil Leak Inspection Process
Inspect repaired area to ensure oil leak has been eliminated. If the leak(s) still occurs, repeat steps or contact the Roadranger Call Center at 1-800-826-4357. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 236: Inspection Precautions
Check splines on all shafts for abnormal wear. If sliding clutch gears, companion flange, or clutch hub has wear marks in the spline sides, replace the specific shaft affected. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 237 • Check synchronizer contact surfaces on the syn- chronizer cups for wear. Washers • Check surfaces of all washers. Washers scored or reduced in thickness should be replaced. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 238: Torque Specifications
Fluid Pressure Sensor (FPS) - 24 26 - 30 Nm mm Hex (x1) (19-22 lb-ft) Clutch to flywheel cap screws - 15 53.5 - 67.7 Nm mm (x12) (40-50 lb-ft) 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 240: Handling, Inspection And Cleaning Of Parts
Any replacement part that is to be used to fix the transmission must first be cleaned with a solvent based cleaner to remove debris and dried with a lint free cloth before installation. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 242: Recycling Parts And Oil
Note: Never dispose of oil by putting it in the trash or pour- ing it on the ground, into sewers, or into streams or bodies of water. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 244: Roadranger Specialty Tools
Note: The input shaft is required to be pressed in and out of the clutch housing. Input Shaft Press (RR1085TR) can be purchased if the clutch housing does not properly fit the available press. 2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved...
Page 246: Change Log
Added Main Housing Disassembly/Assembly section Added Clutch Housing files Disassembly/Assembly section Added Input Shaft Disassembly/Assembly using Input Shaft Press (RR1085TR) section to the Appendix Removed table from Lubrication Specifications detailed information is in TCMT0021 Eaton Lubrication Product Specification Manual June 2018...
Page 248 For spec’ing or service assistance, call 1-800-826-HELP (4357) or visit www.eaton.com/roadranger. In Mexico, call 001-800-826-4357. Roadranger: Eaton and trusted partners providing the best products and services in the industry, ensuring more time on the road. Eaton Cummins Automated Transmission Technologies P.O.

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