Transmisión Rockewell 9 Marchas

7/25/2019 Transmisin Rockewell 9 Marchas

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NineSpeed

TenSpeedThirteenSpeedTransmissions

Maintenance Manual No. 26Revised 2-96

Automotive


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Silicone Gasket Materials

WARNINGWhen you apply some silicone gasket materials, small amounts of acid vapor are present. To preventpossible serious personal injury, make sure the work area is well-ventilated. If the silicone gasketmaterial gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a

doctor as soon as possible.

Loctite

WARNINGTake care when using Loctite to avoid serious personal injury. Follow the manufacturer's instructionsto prevent irritation to the eyes and skin. If Loctite gets into your eyes, flush them with water for 15minutes. Have your eyes checked by a doctor as soon as possible.

Cleaning Solvents

WARNINGIf you use solvents, hot solution tanks or alkaline solutions incorrectly, serious personal injury can

occur. To prevent serious personal injury, follow the instructions supplied by the manufacturer ofthese products. Do NOT use gasoline to clean parts. Gasoline can explode and cause seriouspersonal injury.

CAUTION

Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or waterand alkaline solutions will damage these parts. You can use isopropyl alcohol, kerosene or dieselfuel for this purpose.

If required, use a sharp knife to remove gasket material from parts. Take care not to damageground or polished surfaces.

Service NotesThis Maintenance Manual describes the correct service and repair procedures for the nine-speed, ten-speed andthirteen-speed Design Level One and Design Level Two manual transmissions.

You must follow your company safety procedures when you service or repair equipment. Be sure you understand all theprocedures and instructions before you begin work on the unit. Rockwell uses the following types of notes to givewarning of possible safety problems and to give information that will prevent damage to equipment:

WARNING

A warning indicates procedures that must be followed exactly. Personal injury can occur if the

procedure is not followed.

CAUTIONA caution indicates procedures that must be followed exactly. If the procedure is not followed,damage to equipment or components can occur. Personal injury can also occur in addition to damageor malfunctioning of equipment or components.

TORQUEThis symbol is used to indicate fasteners that must be tightened to a specific tourque value.

NOTE

A note indicates an operation, procedure or instruction that is important for correct service. A notecan also give information that will make service easier and quicker.

Some procedures require the use of special tools for safe and correct service. Failure to use these special tools when

required, can cause injury to service personnel or damage to vehicle components.
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Table of Contents

SUBJECT PAGESection 1 - General Information ................................................................................... 5

Description .................................................................................................................... 5

Identification.................................................................................................................. 6

Nine-Speed Manual Transmissions .............................................................................. 6

Ten-Speed Manual Transmissions ............................................................................... 6Thirteen-Speed Manual Transmissions ........................................................................ 6

Design Level 1 Manual Transmissions ......................................................................... 6

Design Level 2 Manual Transmissions ......................................................................... 8

Gear Timing .................................................................................................................. 9

Gasket Sealant ........................................................................................................... 12

Removing Gasket Sealant .......................................................................................... 12

Installing Gasket Sealant ............................................................................................ 12

Inspecting Used Parts ................................................................................................. 15

Repairing or Replacing Parts ...................................................................................... 19Cleaning Ground or Polished Parts............................................................................. 19

Cleaning Rough Parts ................................................................................................. 19

Drying the Cleaned Parts ............................................................................................ 19

Preventing Corrosion or Rust on Cleaned Parts ......................................................... 19

Section 2 - Lubrication and Maintenance .................................................................. 20

Transmission Oil Specifications .................................................................................. 20

Transmissions Oil Coolers .......................................................................................... 20

Scheduled Maintenance ............................................................................................. 21

Checking and Adjusting the Oil Level ......................................................................... 21Checking the Condition of the Breather Vent .............................................................. 22

Checking Fastener Torque ......................................................................................... 22

Inspecting the Transmission for Leaks and Damage .................................................. 22

Draining and Replacing the Transmission Oil ............................................................. 23

Adjusting Remote Shift Housing Linkage.................................................................... 24

Lubricating the Remote Shift Housing......................................................................... 24

Section 3 - In Vehicle Service ..................................................................................... 25

Removing the Shift Lever and Tower Assembly .........................................................25

Installing the Shift Lever and Tower Assembly ........................................................... 25

Removing the Slave Valve .......................................................................................... 27

Installing the Slave Valve ............................................................................................ 27

Removing the Air Filter and Regulator Assembly .......................................................28

Installing the Air Filter and Regulator Assembly ......................................................... 29

Removing the Output Yoke and Oil Seal .................................................................... 29

Installing the Oil Seal and Output Yoke ...................................................................... 30

Removing and Installing the Remote Control Assembly ............................................. 33
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Section 4 - Removing and Installing the Transmission........................................... 34

Removing the Transmission ....................................................................................... 34

Installing the Transmission ......................................................................................... 36

Section 5 - Overhauling the Shift Lever and Tower Assembly ................................ 41

Disassembling the Aluminum Tower Assembly ..........................................................41

Assembling the Aluminum Tower Assembly ............................................................... 43

Disassembling the Cast Iron Tower Assembly............................................................ 46

Assembling the Cast Iron Tower Assembly ................................................................ 47

Section 6 - Remote Control Assembly....................................................................... 48

Disassembling the Remote Control Assembly ............................................................ 48

Assembling the Remote Control Assembly ................................................................. 49

Section 7 - Removing and Installing the Top Cover Assembly ............................... 50

Removing the Top Cover Assembly............................................................................ 50Installing the Top Cover Assembly.............................................................................. 52

Section 8 - Overhauling the Top Cover Assembly.................................................... 54

Disassembling the Standard and Forward Position Top Cover Assembly ..................54

Assembling the Standard and Forward Position Top Cover Assembly .......................60

Disassembling the Standard and Forward Position X BarTop Cover Assembly................................................................................................ 66

Assembling the Standard and Forward Position X Bar Top Cover Assembly ..........72

Section 9 - Removing and Installing the Input Shaft ................................................ 79

Removing the Input Shaft ........................................................................................... 79

Installing the Input Shaft ............................................................................................. 81

Section 10 - Removing and Installing the Clutch Housing ......................................83Removing the Clutch Housing .................................................................................... 83

Installing the Clutch Housing ...................................................................................... 83

Section 11 - Removing and Installing the Auxiliary Case ........................................85

Removing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ................85

Installing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ..................90

Removing the Auxiliary Case-Thirteen-Speed Transmissions ....................................94Installing the Auxiliary Case-Thirteen-Speed Transmissions ......................................98

Removing the Auxiliary Drive Gear ........................................................................... 102

Installing the Auxiliary Drive Gear ............................................................................. 103

Section 12 - Overhauling the Main Case ................................................................. 104

Removing the Mainshaft ........................................................................................... 104

Removing the Input Shaft ......................................................................................... 110

Removing the Main Countershafts............................................................................ 113

Table of Contents (Continued)

SUBJECT PAGE


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Section 12 - Overhauling the Main Case(Continued)............................................. 104

Removing the Reverse Idler Gear Assembly ............................................................ 114

Removing the Oil Pump ............................................................................................ 115

Removing the Magnets ............................................................................................. 116

Removing the PTO Covers ....................................................................................... 116Installing the PTO Covers ......................................................................................... 117

Installing the Magnets ............................................................................................... 117

Installing the Oil Pump .............................................................................................. 118

Installing the Reverse Idler Gear Assemblies ........................................................... 118

Installing the Input Shaft ........................................................................................... 119

Installing the Main Countershafts.............................................................................. 123

Installing the Mainshaft ............................................................................................. 125

Section 13 - Overhauling the Auxiliary Drive Gear ................................................. 134

Disassembling the Auxiliary Drive Gear Assembly ................................................... 134

Assembling the Auxiliary Drive Gear Assembly ........................................................136

Section 14 - Overhauling the Mainshaft .................................................................. 137

Disassembling the Mainshaft .................................................................................... 137

Assembling the Mainshaft ......................................................................................... 139

Section 15 - Overhauling the Main Countershafts.................................................. 150

Disassembling the Main Countershaft ...................................................................... 150

Assembling the Main Countershaft ........................................................................... 152

Section 16 - Overhauling the Auxiliary Case .......................................................... 155

Disassembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions .......155

Assembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions............163

Disassembling the Auxiliary Case-Thirteen-Speed Transmissions...........................174

Assembling the Auxiliary Case-Thirteen-Speed Transmissions................................ 182

Section 17 - Main Countershaft End Play Adjustment ........................................... 193

Checking and Adjusting the End Play of the Main Countershafts ............................. 193

Section 18 - Auxiliary Countershaft End Play Adjustment .................................... 200

Checking and Adjusting the End Play of the Auxiliary Countershafts .......................200

Section 19 - Troubleshooting ................................................................................... 207General Information .................................................................................................. 207

Troubleshooting Other Systems ............................................................................... 208

Troubleshooting Leaks.............................................................................................. 209

Troubleshooting Vibrations ....................................................................................... 209

Troubleshooting Noises ............................................................................................ 210

Troubleshooting Operating Conditions...................................................................... 211


SUBJECT PAGE


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SUBJECT PAGE

Section 20 - Specifications ....................................................................................... 214

Transmissions Oil Capacities .................................................................................... 214

Transmission Oil Specifications ................................................................................ 214

Fastener Torque Locations-Nine-Speed and Ten-Speed Transmissions .................215

Fastener Torque Chart-Nine-Speed and Ten-Speed Transmissions........................218Fastener Torque Locations-Thirteen-Speed Transmissions .....................................220

Fastener Torque Chart-Thirteen-Speed Transmissions............................................ 223

Air Line Locations-Nine-Speed and Ten-Speed Transmissions................................225

Air Line Identification Chart-Nine-Speed and Ten-Speed Transmissions .................226

Air Line Locations-Thirteen-Speed Transmissions ................................................... 227

Air Line Identification Chart-Thirteen-Speed Transmissions .....................................228

Holding Cover Template ........................................................................................... 229

Special Tools ............................................................................................................ 230


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Section 1General Information

DescriptionSee Figure 11.

This publication describes the serviceprocedures for the following Rockwell

transmissions:

NineSpeed Transmissions. TenSpeed Transmissions. ThirteenSpeed Transmissions.

Two design levels are described in thispublication:

Design Level One. This applies totransmissions with serial numbersLB93001999 and below. Snap rings

are used to keep the tapered rollerbearings in the case.

Design Level Two. This applies totransmissions with serial numbersLB93002000 and above. Retainerplates are used to keep the taperedroller bearings in the case.

Figure 11

The main case, which includes the main-shaft, the main countershafts, the inputshaft, the reverse idler gear and the (op-tional) oil pump, are the same for all trans-

missions.

The auxiliary case is the same design fornine-speed and ten-speed transmissionswhile the auxiliary case for the thirteen-speed transmission is different. Thethirteen-speed transmission uses a differ-ent case, piston housing and output shaftassembly. The thirteenspeed transmis-sion also uses a splitter gear set in additionto a HI and LOrange gear set.

The input torque from the engine is distrib-uted by two countershafts and one main-shaft. An auxiliary case provides theLOandHIranges of operation.

Tapered roller bearings are used to sup-port the countershafts in the main trans-mission case and the auxiliary section.

NINE-SPEED TRANSMISSIONTEN-SPEED TRANSMISSION

THIRTEEN-SPEED TRANSMISSIONS


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An air shift system is used to select the LOor HI range of operation on all transmis-sions and the DIR and ODsplitter rangeof operation on thirteen-speed transmis-sions. For more information, see Mainte-nance Manual Number 26B, Nine SpeedManual Transmissions Air Shift Systems orMaintenance Manual 26D, Thirteen-Speed Transmissions Air Shift Systems.

Identification

An identification plate is installed on theside of the transmission. Use the informa-tion on the identification plate when order-ing parts. Figure 12.

See Figure 12for an explanation of themodel identification number and the identi-fication plate.

NineSpeed Manual

Transmissions

The transmission is identified by the num-ber 9 in the Speed portion of the modelnumber. Figure 12.

The transmission uses nine forward gears(five gears in the LOrange and four gearsin the HIrange) and two reverse gears.

The transmission may be either a Design

Level 1 or a Design Level 2. See theexplanation in this section.

TenSpeed ManualTransmissions


The transmission uses ten forward gears(five gears in the LOrange and five gearsin the HIrange) and two reverse gears.

The transmission is a Design Level 2.See the explanation in this section.

ThirteenSpeed ManualTransmissions


The transmission uses thirteen forwardgears (five gears in the LOrange andeight gears in the HIrange that are dividedbetween four DIRgears and four O/D

gears) and two reverse gears.

The transmission may be either a DesignLevel 1 or a Design Level 2.

The auxiliary case is different from the nine-speed and the ten-speed transmissions.

Design Level 1 ManualTransmissions

Design Level 1 Manual Transmissionsapply to transmissions with serial numbersbelow LB93002000.

The transmission is identified by the num-ber 1 in the Design Level portion of themodel number. Figure 12.


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RMX10-145A2S002

Rockwell TransmissionModel Number

R M X 2 S 00210-145 A

ROCKWELL

SPECIFICATION

RATIO

TYPE

A= Autom ated

E= Electric/Air

M=M anual

S= Engine

Synchro

Shift

W=Shift by

W ire

SPEED

Progressive

Forw ard

Speeds

x 10 =

N om inal

InputTorque

SHIFT PATTERN

N o letter=direct drivestandard H pattern

X=overdrive

standard H pattern

O=overdrive 9-speed

non-standard pattern

O R

overdrive 13-speed

standard H pattern

DESIGN LEVEL

1=Serial N um bersLB93001999 andB elow

2=Serial N um bersLB93002000 andAbove

SHIFT BAR

HOUSING

POSITION

F=Fow ardS=Standard

TransmissionSerial Number

O.E.M. TransmissionPart Number

CUST#

MODEL

SERIAL NO. & ASS'Y PLANT

RATIO DATE

Rockwell International

Manufacturing Date

These PlugsIndicate

Oil Pump

Figure 12


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Snap rings are used to retain the bearingcups for the main countershaft in the maincase and for the auxiliary countershafts in

the auxiliary case and the main case.Selective snap rings are used to adjust theend play in the main case and the auxiliarycase.

Design Level 2 ManualTransmissions

Design Level 2 Nine-Speed, Ten-speed

and Thirteen-Speed Manual Transmissionsapply to all transmissions with serial num-bers LB93002000 and above.

The transmission is identified by thenumber 2 in the Design Level portion ofthe model number. Figure 12.

Retainer plates are used to retain thebearing cups for the main countershaft inthe main case. The bearing cover and theselective washer are used to retain thecups for the auxiliary countershaft in theauxiliary case.

Selective shims are used to adjust the endplay in the main case. Selective washersare used to adjust the end play in theauxiliary case.


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Timing Marks in TransmissionCase

NOTE:To make sure the timing marks are inthe correct locations, count the numberof gear teeth, divide the total teethnumber by 2 and put the mark in thecorrect location.

1. Put timing marks on the main drivegear on the input shaft. Mark onetooth with paint. Mark a second toothopposite (180o) the first timing mark.Figure 15.

2. Use paint to put timing marks on twoteeth next to each other on each drivengear of the main countershafts. Makesure the marks are aligned with theslot for the key or the O stamping onthe countershaft. Figure 15.

3. During assembly, each of the twotiming marks on the main drive gear

must be between the two markedteeth on each countershaft drive gear.

Figure 16All the timing marks must be aligned ifthe transmission is to operate cor-rectly.

If the timing marks are not painted inthe correct position on the gears, onlyone set of marks will be aligned.

NOTE:

The main shaft and the auxiliary drive

gear must be installed when the align-ment marks in the transmission caseare checked.

4. To check the alignment of the timingmarks, rotate the input shaft. All thegears must rotate.

5. For complete service procedures, seeAssembling the Transmission Case inSection 12, Overhauling the MainCase.

Figure 14


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COUNTERSHAFT DRIVEN GEARMARK TWO TEETH OVER

THE SLOT FOR THE KEYOR THE "O" STAMPING

Figure 15

Figure 16

MAINDRIVE GEARMARK ONE TOOTH

ON EACH SIDE180APART

TIMINGMARK

TIMINGMARKS


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Figure 19

NOTE:APPLY SEALANTIN A 1/8 INCH(2MM) BEAD

BOLT HOLETRANSMISSION CASE

PUT THE PATTERN ON THE TRANSMISSION CASE PUT THE PATTERN ON THE TRANSMISSION CASE


TRANSMISSIONCASE

BOLTHOLE

BOTTOM COVER SIDE COVER

PUT BEADAROUND HOLE

FOUR HOLESSURROUNDEDBY SEALANT

BOLT HOLE

PUT THE PATTERN ON THE TRANSMISSION CASE

BEAD

BOLT HOLE

NOTE:APPLY SEALANTIN A 1/8 INCH(2MM) BEAD.

REAR COVER

TRANSMISSION CASE GASKET PATTERN AUXILIARY COVER GASKET PATTERN

CLUTCH HOUSING-TO-TRANSMISSIONCASE GASKET PATTERN

PTO COVERS-TO-TRANSMISSION CASEGASKET PATTERN

PUT THE PATTERN ON THE OUTPUT BEARING RETAINER

BOLT HOLE


OIL SLOT

BEAD TO BEKEPT OUTSIDEOF OIL SLOTS

OIL SLOT RETAINER

SHIFT BAR HOUSING-TO-TRANSMISSION

CASE GASKET PATTERN

OUTPUT BEARING RETAINER-TO-AUXILIARY

COVER GASKET PATTERN

INPUT BEARING RETAINER-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE INPUT BEARING RETAINER

RETAINER


OIL SLOT

BEAD TO BEKEPT OUTSIDEOF OIL SLOTS

BOLT HOLE

TRANSMISSION CASE

AUXILIARY COVER-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE AUXILIARY COVER

NOTE:DO NOT BLOCK OIL FEED HOLE


MAKE SURE THEPATTERN IS ON THETRANSMISSIONCASE AND NOTON THE RETAINER


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Figure 110

Figure 111

PISTONHOUSING

AUXILIARY

COUNTERSHAFTCOVER

NOTE:APPLY SEALANT IN A1/8 INCH (2MM) BEAD.

AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS-TO-AUXILIARY COVER GASKET PATTERN

(NINE-SPEED AND TEN-SPEED TRANSMISSION)

AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS-TO-AUXILIARY COVER GASKET PATTERN

(THIRTEEN-SPEED TRANSMISSION)

PISTONHOUSING

AUXILIARYCOUNTERSHAFTCOVER

NOTE:APPLY SEALANT IN A1/8 INCH (2MM) BEAD.

PUT THE PATTERN ON THE AUXILIARY COVER

SURROUND ALLHOLES WITH SEALANT

PUT THE PATTERN ON THE AUXILIARY COVER


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Inspecting the Parts

It is important to inspect all parts beforethe transmission is assembled. Check allparts for wear and replace damaged parts.Replacement of damaged parts now, willprevent failure of the assembly later.

Tapered Roller Bearing Cone

NOTE:The bearing cup and the bearing conemust be replaced as an assembly ex-cept when the cup is loose in the bore.If the cup is loose in the bore, install anoversize cup. In all other situations, do

not replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manufac-turer. For replacement part numbers,

see the chart in Figure 112.

Inspect the cup, the cone , the rollers andthe cage of all tapered roller bearings. Ifany of the following conditions exist, thecup and the cone must be replaced.

1. The outer surface of the large diameterend of the rollers is worn level with orbelow the center. Figure 113.

2. The radius at the large diameter end ofthe rollers is worn to a sharp edge.Figure 113.

Tapered Roller Bearing Cup and Cone Replacement Chart

NOTES: Use Part Number XCD2139DT.

Use Part Number XC11807DN.

Use Part Number XC1837DF.

BearingCup

and Cone Design

Component Location Transmission Level Part Number

Main Countershaft Front All 1 A-1228-W-1349

2 A-1228-T-1346

Rear All 1 A-1228-V-1348

2 A-1228-S-1345

Auxiliary Countershaft Front 9- and 10-Speed 1 A-1228-X-1350

2 A-1228-S-1345

13-Speed 1 A-1228-U-1373

2 A-1228-S-1345

Rear 9- and 10-Speed 1 A-1228-Y-1373

2 A-1228-U-1347 13-Speed 1 A-1228-Y-1351

2 A-1228-U-1347

Figure 112


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Figure 113

Figure 114

3. A visible roller groove is worn in theinner race surfaces of the cup or thecone. The groove can be seen at thesmall or large diameter end of bothparts. Figure 114.

Figure 115

4. Deep cracks or breaks in the surfaceof the cup, cone inner race or roller.Figure 115.

5. Bright wear marks on the outer surfaceof the roller cage. Figure 116.

6. Etching or pitting on rollers and on thesurfaces of the cup and cone innerrace that touch the rollers. Figure 116.

Figure 116

7. Spalling or flaking on the cup and coneinner race surfaces that touch therollers. Figure 117.

RECESSCENTER

SHARPEDGE

WORN

LEVEL


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Figure 117

Tapered Roller Bearing Cups

NOTE:The bearing cup and the bearing conemust be replaced as an assembly ex-cept when the cup is loose in the bore.If the cup is loose in the bore, install anoversize cup. In all other situations, donot replace the cup or the cone sepa-rately. Replace the cup and the cone ina matched set from the same manufac-

turer. For replacement part numbers,see the chart in Figure 112.

1. Normal cup wear is shown as aneven wear across the surface of thecup. Small indentations are accept-able. Figure 118.

Figure 118

2. Replace cups with small spalling orflaking marks or light bruising. Figure119.

Figure 119

3. Replace cups with large spalls anddeep indentations. Figure 120.

BRUISES

SMALLSPALL

NO SPALLS


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Figure 120

Ball BearingsInspect ball bearings for wear and dam-age. Make sure the bearings rotate in therace. Make sure the outer race is not wornor damaged. On bearings with grooves,make sure the grooves are not worn ordamaged. Replace any worn or damagedbearings.

GearsInspect the teeth of the gears for wear anddamage. Inspect the splines inside thegears for wear and damage. Inspect thegears for cracks or pits. Replace gearsthat are worn, damaged or cracked.

ShaftsInspect the splines and the grooves forwear and damage. Make sure the shaftsare not twisted. Make sure threads on the

end of the shafts are not worn or dam-aged. Replace any worn or damagedshafts.

O-Rings and Oil Seals

Inspect the O-rings and the oil seals forcuts and cracks. Make sure the parts are

not brittle or hard. Replace any worn,damaged or hard O-rings and oil seals.

Clutch CollarsInspect the teeth of the outside of theclutch collar for wear and damage. In-spect the splines inside the clutch collar forwear and damage. Replace any worn ordamaged clutch collars.

Case Housings

Inspect the case housings for cracks.Replace cracked housings.

Top CoverInspect the tips of the forks for wear anddamage. Make sure the forks are notbent. Make sure the shift rails are notworn or damaged. Inspect the balls andsprings for wear or damage. Replace anyworn or damaged parts.

Output YokesInspect the seal surface, the splines andthe end of the output yoke for wear anddamage. Do not sand or grind the sealsurface. Replace any worn or damagedparts.

LARGE SPALL


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injury, follow the instructions suppliedby the manufacturer. Do NOT use gaso-line to clean parts. Gasoline can ex-

plode.Use a cleaning solvent to clean ground orpolished parts and surfaces. Kerosene ordiesel fuel can be used for this purpose.DO NOT USE GASOLINE.

Do NOTclean ground or polished parts ina hot solution tank or with water, steam oralkaline solutions. These solutions willcause corrosion of the parts.

Cleaning the Rough Parts

Rough parts can be cleaned with theground or polished parts. Rough partsalso can be cleaned in hot solution tankswith a weak alkaline solution. Parts mustremain in the hot solution tanks until theyare completely cleaned and heated.

Drying the Cleaned Partsmust be dried immediately after cleaning.Dry parts with clean paper, rags, or com-pressed air.

Preventing Corrosion andRust on Cleaned Parts

Apply lubricant to cleaned and dried partsthat are not damaged and are to be imme-diately assembled.

If parts are to be stored, apply a specialmaterial that prevents corrosion and rust toall surfaces. Store the parts inside specialpaper or other material that preventscorrosion and rust.

Repairing or Replacing theParts

Replace worn or damaged parts. Thefollowing are some examples to check.

1. Replace any fastener if the corners ofthe head are worn.

2. Replace the washers if damaged.

3. Replace gaskets and oil seals at thetime of transmission repair.

4. Clean the parts and apply new gasketmaterial where required when thetransmission is assembled. SeeGasket Sealant in this section.

5. Remove nicks, mars and burrs fromparts having machined or groundsurfaces. Use a fine file, india stone orcrocus cloth for this purpose (exceptfor yokes).

6. Clean and repair the threads of fasten-ers and holes. Use a die or tap of thecorrect size or a fine file for this pur-

pose.

CAUTIONThreads must be clean and undamagedso that accurate adjustments and cor-rect torque values can be applied tofasteners and parts.

7. Use the correct type of Loctite orequivalent and tighten all fasteners tothe correct torque values. See theTorque Chart in Section 20, Specifica-tions.

Cleaning the Ground orPolished Parts

WARNINGIf you use cleaning solvents, hot solu-tion tanks or alkaline solutions incor-rectly, injury can occur. To prevent


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Section 2Lubrication and Maintenance

CAUTIONUse only the specified type of singleweight oils. Do not use multi-viscos-ity oils or EP (Extreme Pressure) gear

oils. Multi-viscosity oils and EP gearoils may damage components. The useof multi-viscosity or EP gear oils voidsthe warranty.

3. Check the oil level. The oil level mustbe even with the bottom of the hole ofthe fill plug.

If foam appears when the plug isremoved, air has not been removedfrom the oil. Install the plug and wait

for the air to dissipate.

If oil flows from the hole when the plugis loosened, the oil level is high. Letthe oil drain until the oil is at thespecified level.

If the oil level is below the bottom ofthe hole of the fill plug, add thespecified oil.

4. Install and tighten the fill plug to

35-50 lb-ft (48-67 N.m).5. Operate the vehicle for five minutes.

Check for correct operation.

Scheduled Maintenance

Every 10,000 Miles (16,000 km) of

Vehicle Operation. Check and adjust the oil level in the

transmission. Check the condition of the breather

vent. Check the torque of the fasteners. Inspect for leaks or damage on the

transmission. Service as necessary.

Every 50,000 Miles (80,000 km) ofVehicle Operation (Approved Pe-troleum Base and Heavy-DutyEngine Oils) Drain and replace the oil in the trans-

mission with approved petroleum baseand heavy-duty engine oils.

Every 250,000 Miles (400,000 km)of Vehicle Operation (ApprovedFull-Synthetic Oils) Drain and replace the oil in the trans-

mission with approved full-syntheticoils.

Checking and Adjusting

the Oil LevelSee Figure 22.

1. Make sure of the following beforechecking the oil level.

a. The oil is at room temperature

b. Wait ten minutes after the vehicle isparked before checking the level.

c. Make sure the vehicle is parked ona level surface.

2. Clean the area around the fill plug.Remove the fill plug from the side ofthe transmission.

Figure 22

FILLPLUG

DRAINPLUGS

OIL LEVEL MUSTBE EVEN WITH

BOTTOM OFFILL PLUG HOLE


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Inspecting theTransmission for Leaks

and DamageInspect the transmission for cracks, leaksand damage. Make sure the leaks aretransmission oil.

CAUTIONRepair all leaks. If leaks are not re-paired, the transmission will be dam-aged.

Inspect the following areas for leaks.

The output yoke and the oil seal in theoutput bearing retainer on the auxiliarycase.

The PTO covers on the main case. The auxiliary case to main case. The main case and the clutch housing. The clutch housing to flywheel hous-

ing. The auxiliary countershaft covers. The slave valve to the main case. The shift lever and tower assembly to

the top cover. The top cover to the main case. The fill and the drain plugs. The output bearing retainer to the

auxiliary case. The input bearing retainer to the main

case.

Speedometer bore or electronic speedpick-up in the output bearing retainer.

Figure 23

Checking the Torque ofthe Fasteners

Check the torque on the following. Seethe torque chart in Section 20, Specifica-tions. Clutch housing to engine flywheel. Top cover housing to main case. All electrical switches on the top cover

housing. Drain and fill plugs. PTO covers to main case. Auxiliary case to main case. Output bearing retainer to auxiliary

case. Piston housing cover to auxiliary

case. Auxiliary countershaft cover to

auxiliary case. Transmission to frame brackets. Output yoke to output shaft. Shift cover housing to top cover hous-

ing.

Checking the Condition ofthe Breather Vent

Make sure the breather vent is not dam-aged. Remove all dirt and oil from thescreen in the breather vent. Figure 23.


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Draining and Replacing

the Transmission Oil

NOTE:Drain the oil when the transmission ishot.

1. Make sure the vehicle is parked on alevel surface. Put a large containerunder the transmission. Put a screenon top of the container.

NOTE:Rockwell recommends replacing themagnetic drain plug each time the oil is

changed. Use the correct part. Pipeplugs will leak if used as a drain plug.

The magnetic drain plug can be reusedif, after cleaning, the plug has a mini-mum pick-up capacity of 1.5 pounds(0.7 kilograms) of low carbon steel.

2. Remove the drain plugs from thebottom of the transmission. Drain anddiscard the oil.

Inspect the O-rings on the drain plugs.Replace worn or damaged O-rings.

Inspect the screen on top of the con-tainer for metal particles and damagedparticles. Service the transmission asnecessary.

3. If the transmission is disassembled orreplaced and an oil cooler is used,remove the cooler. Remove anddiscard the oil from the cooler and the

oil lines. Install the oil cooler and thelines. Tighten the fittings to the speci-fied torque of the manufacturer of thevehicle.

4. Install and tighten the drain plug to 35-50 lb-ft (48-67 N.m).

5. Clean the area by the fill plug. Re-move the fill plug from the side of the

transmission.

CAUTIONUse only the specified type of singleweight oils. Do not use multi-viscos-ity oils or EP (Extreme Pressure) gearoils. Multi-viscosity oils and EP gearoils may damage components. The useof multi-viscosity or EP gear oils voidsthe warranty.

6. Add the specified transmission oilthrough the hole for the fill plug.

Add the oil until the oil level is evenwith the bottom of the hole of the fillplug. Figure 24.

7. Install and tighten the fill plug to 35-50lb-ft (48-67 N.m).

8. Operate the vehicle for five minutes.Check for correct operation.

Figure 24

FILLPLUG

DRAINPLUGS

OIL LEVEL MUSTBE EVEN WITH

BOTTOM OFFILL PLUG HOLE


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Section 3In-Vehicle Service

WARNINGTo prevent serious eye injury, alwayswear safe eye protection when doingmaintenance or service.

Removing the Shift Leverand Tower Assembly1. Shift the transmission into the NEU-

TRALposition. Remove the air fromthe air supply system.

2. Disconnect the air lines from the shiftknob at the slave valve.

3. Remove the capscrews and the wash-ers that fasten the shift tower housingto the top cover housing.

NOTE:Do not lose any detent springs or ballswhen the shift tower housing is re-moved. If any springs or balls comeout, install the parts in the correct bore.Install the ball before the spring isinstalled.

4. Remove the shift tower housing andlever assembly and the gasket fromthe top cover housing. Discard thegasket Figure 31.

5. Remove any gasket material betweenthe shift lever housing and the topcover housing.

Figure 32

Installing the Shift Leverand Tower Assembly1. Make sure the transmission is in the

NEUTRALposition. Figure 32.

NEUTRALPOSITION

Figure 31SHIFT LEVER

AND TOWER ASSEMBLY


28/236Page 26


CAUTIONThe aluminum housing uses a gasketthat is different from the gasket on thecast iron housing. Use the correct

gasket. If the wrong gasket is used, thearea between the shift tower housingand the top cover housing will leak.

2. Install a new gasket for the shift towerhousing on the top cover housing.

3. Put the shift tower housing in positionon the top cover housing. Make surethe bottom of the lower shift lever iscorrectly installed between the forksand the sleeves in the top cover hous-

ing. Figure 31.

4. Install the mounting capscrews andwashers on the shift tower housing.Tighten the capscrews to 35-45 lb-ft(48-61 N.m) in the sequence shown inFigure 33.

5. Install the cover (if used) around theshift tower housing.

6. Operate the vehicle. Make sure thetransmission operates correctly in allgears.

Figure 33

TORQUE SEQUENCE


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Removing the Air Filterand Regulator Assembly

See Figure 37.

Figure 36

7. Connect the air lines to the slavevalve. Figure 36.

a. Connect the BLACK1/8 or 5/32inch outer diameter air line to thepilot port fitting (stamped letter 'P'on the valve).

b. Connect the RED1/8 or 5/32 inchouter diameter air line to the pilotsupply port fitting (stamped letters'PS'on the valve).

c. Connect the RED1/4 or 5/16 inchouter diameter air line to the supplyfitting (stamped letter 'S').

d. Connect the BLACK1/4 or 5/16inch outer diameter air line to theLOrange fitting (stamped letter'L').

e. Connect the BLUE1/4 or 5/16 inchouter diameter air line to the HI

range fitting (stamped letter 'H').

8. Operate the vehicle. Check the airshift system for correct operation.

Figure 37

1. Remove the air from the air supplysystem.

2. Disconnect and mark the air lines onthe filter and regulator assembly.

3. Remove the mounting capscrews andthe washers from the filter and regula-tor assembly. Remove the filter andregulator assembly.

4. On thirteen-speed transmissions,remove the O-ring from between thefilter and regulator assembly and thepiston housing cover. Figure 38.

RED AIR LINE-TO SUPPLY PORT

('PS')

RED AIR LINE-TO SUPPLY

('S')

BLUE AIR LINE-TO HI RANGE

('H)

BLACK AIRLINE-TO

LO RANGE ('L')

BLACK AIR

LINE-TOPILOT PORT ('P')

FILTER ANDREGULATORASSEMBLYSUPPLY

PORT

DELIVERYPORT


31/236Page 29


Figure 38

Removing the OutputYoke and the Oil Seal

NOTE:Before replacing the oil seal, make sureof the following:

1. The oil seal leaks. The lip of the oilseal is packed with grease. Under

normal conditions, the area be-tween the lip of the oil seal and theyoke is wet. To check if the sealleaks, clean the area around theseal (Make sure the oil is at thespecified level.). If drops of oilappear, the seal must be replaced.If the area between the lip of theseal and the yoke is wet, do notreplace the oil seal.

2. The correct oil is in the transmis-sion. If the wrong oil is used, theoil seal will be damaged and leak.See Transmission Oil Specifica-tions in Section 20.

3. The yoke is not worn or damaged.If the yoke is worn or damaged,replace the yoke. Do not repairyokes.

Figure 39

Installing the Air Filter andRegulator Assembly

See Figure 37.

1. On thirteen-speed transmissions,lubricate the O-ring with a siliconlubricant such as Dow Corning #111Silicone Grease or equivalent. Put the

O-ring for the filter and regulator as-sembly in the port in the piston hous-ing cover. Figure 37.

1. Put the filter and regulator assemblyon the top of the range cylinder.

2. Install the mounting capscrews andwashers. Tighten the capscrews to85-115 lb-in (10-12 N.m).

3. Connect the REDair line to the DELIV-

ERYport on the filter and regulatorassembly. Connect the air line fromthe air supply system to the SUPPLYport on the slave valve (stamped letterSon the valve. Figure 39.

4. Operate the vehicle. Check the airshift system for correct operation.

O-RING

FILTER ANDREGULATORASSEMBLY

FILTER ANDREGULATORASSEMBLY

SUPPLYPORT

DELIVERYPORT


32/236Page 30


4. Use the correct tool and the correctprocedure to install the seal. UseSeal Driver Tool, Rockwell PartNumber 3256-Z-1014 or Kent-Moore

Part Number J-39161 to install theseal. Do not remove the outputbearing retainer to install the seal.If the correct tool and/or the correctprocedure is not used, the seal willleak.

WARNING

Do not work under a vehicle supportedonly by jacks. Jacks can slip or fall overand cause serious personal injury.

Support the vehicle with safety stands.Block the wheels to prevent the vehiclefrom moving.

1. Put the transmission in NEUTRAL.Make sure the parking brake isapplied.

2. Disconnect the driveshaft from theoutput yoke of the transmission.

3. Put a holding tool, such as Kent-Moore

Tool, J-3453, Flange/Yoke HoldingBar, or equivalent, on the yoke.

4. Put a 2-3/4 inch socket on the nut thatfastens the yoke to the output shaft.Remove and discard the nut.Figure 310.

5. Remove the yoke from the outputshaft. Remove the speedometer tonering or drive gear from the yoke. Re-place the yoke if worn or damaged.

6. Use a slide hammer and puller, suchas Snap-On Light Duty Puller Set,CG2400B, or equivalent, to remove theseal from the retainer. Discard theseal. Figure 311.

Installing the Oil Seal and

the Output Yoke

1. Inspect the bore for the seal in theoutput bearing retainer and the seal

journal on the output yoke for wear ordamage. Replace the retainer if wornor damaged.

2. Lubricate the outer surface of theoutput bearing retainer where the sealis installed with the oil that is used inthe transmission.

Figure 311

OIL SEAL

PULLER

HOLDINGTOOL

YOKE

Figure 310


33/236Page 31


CAUTIONHold the seal only on the outer diame-ter. Do not touch the inner diameter ofthe seal. Touching contaminates the

inner diameter of the seal and causes aleak between the shaft and the seal.

3. Install the oil seal in the output bearingretainer.

CAUTIONUse only the specified seal driver tool.If a different driver tool is used, the sealwill not be installed at the correct depthand will leak.

4. Use seal driver tool, Rockwell PartNumber 3256-Z-1014 or Kent-MoorePart Number J-39161, to install theseal. Clean and inspect the tool.Replace the tool if the area thattouches the seal is worn or damaged.Figure 312.

5. Clean the seal driver tool. Put the oilseal on the seal driver tool so that thespring is away from the tool. Makesure the seal is flat against the surface

of the tool. Figure 313.

6. Drive the seal into the retainer until theflange on the tool touches the retainer.Make sure there are no gaps betweenthe tool and the retainer.

CAUTIONUse a cleaning solvent to clean theyoke. Do not use a crocus cloth topolish the journal of the yoke. If acrocus cloth is used, the seal will leak.

7. Clean the yoke with a cleaning solvent.Lubricate the journal and splines in theyoke with the oil that is used in thetransmission.

CAUTIONMake sure the speedometer drive gearor tone ring is correctly installed or theoutput shaft seal may be damagedwhen the yoke is installed.

8. Install the speedometer drive gear ortone ring on the yoke.

Figure 312

SEALDRIVERTOOL

On 115 and 125 Series transmission,use the sleeve inside the seal drivertool.

On 135, 145 and 155 Series transmis-sions, remove the sleeve from theinside of the seal driver tool.

Figure 313SPRING


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35/236Page 33


To adjust the distance, loosen the jamnuts and move the rod to the correctdistance. Tighten the jam nuts to 35-50 lb-ft (47-67 N.m).

8. Adjust the linkage according to theprocedure of the manufacturer of thevehicle.

9. Operate the vehicle and check forcorrect operation.

Removing and Installingthe Remote Control

Assembly

NOTE:See the recommended procedure fromthe manufacturer of the vehicle. Thefollowing is a general procedure toremove and install the remote controlassembly.

1. Raise the cab according to the proce-dure of the manufacturer of the ve-hicle.

2. Measure the length of the adjustingrod from the centerline of each ballsocket as shown in Figures315 and 316. Mark the location ofthe adjusting rod and the ball sockets.

3. Disconnect the linkage to the remotecontrol assembly.

4. Remove the capscrews that fasten theremote control housing to the top coverhousing. Remove the housing. Re-move and discard the gasket. Removeany gasket material between theremote control housing and the topcover housing.

5. Install a new gasket on the transmis-sion.

6. Put the remote control housing inposition. Install and tighten the cap-screws to 35-45 lb-ft (47-61 N.m).

7. Connect the linkage to the outer shiftlever of the remote housing. Installand tighten the nut to 12-18 lb-ft (17-24 N.m).

8. Adjust the length of the adjusting rodto the distance measured in step 2 orto the distance specified by the manu-facturer of the vehicle. Figures 315and 316.

Figure 315

Figure 316

ONE-PIECEADJUSTING

ROD

ADJUST TOSPECIFICATIONS

OF VEHICLEMANUFACTURER

ADJUST TOSPECIFICATIONS

OF VEHICLEMANUFACTURER

TWO-PIECEADJUSTING

ROD


36/236Page 34

Section 4Removing and Installing the Transmission

Removing the

Transmission

See the recommended procedure from themanufacturer of the vehicle to remove thetransmission. Some vehicles require thatthe engine is supported when the trans-mission is removed. The following is a

general procedure to remove the transmis-sion.

1. Remove the air from the air supplysystem.

2. Put a large container under the trans-mission. Remove both drain plugs(and if necessary, the cooler lines).Drain and discard the oil. Figure 4-1.

Figure 4-1

WARNINGTo prevent serious eye injury, alwayswear safe eye protection when doing

maintenance or service.

3. Remove the shift lever from the trans-mission. If necessary, remove the shifttower assembly from the transmission.

4. Put marks on the yoke or the flange ofthe driveshaft and the output shaft ofthe transmission. The marks on thedriveshaft and the output shaft makesure the driveshaft is correctly rein-

stalled.

5. Remove the driveshaft.

6. Disconnect all the electrical connec-tions (if used) for the back-up lampswitches, the neutral safety switch andthe temperature indicator.

7. Disconnect and mark all the air linesfrom the transmission.

8. Disconnect the speedometer connec-tions from the output bearing retainer.

9. If used, remove the spring from theclutch lever on the transmission. Markand disconnect the clutch linkage fromthe clutch housing on the transmission.

10. If a hydraulic system is used on theclutch, disconnect the push rod andthe spring from the release fork. Re-move the hydraulic cylinder from thebracket on the transmission. Usewires to support the cylinder on theframe.

WARNINGMake sure the transmission is securelysupported on the overhead hoist or the

jack. If the transmission is not securelysupported, the transmission may falland cause serious personal injury ordamage.

11. Support the transmission with an overhead hoist or with a transmission jack.Make sure the transmission is securelysupported.

12. Remove the fasteners that attach thetransmission to the brackets on theframe.

OIL LEVEL MUST BE EVENWITH BOTTOM OF FILLPLUG HOLE

DRAINPLUG

FILLPLUG


37/236Page 35

Section 4Removing and Installating the Transmission

CAUTIONMake sure the transmission does nothang by the input shaft. The clutchassembly and the pilot bearing will be

damaged if the transmission is sup-ported by the input shaft.

10. Remove the bolts and the washers thatattach the clutch housing to the en-gine. Pull the transmission straight outfrom the flywheel housing. Removethe transmission from the vehicle.Figure 4-2.

11. If used, remove the clutch brake as-sembly from the input shaft of the

transmission. Inspect transmissioninput bearing retainer surface forexcessive wear which can affect theclutch adjustment. Figure 4-3.

Figure 4-3

Figure 4-2

TRANSMISSION-PULL

TRANSMISSIONSTRAIGHT OUT

INPUT SHAFT-MAKE SURE

TRANSMISSIONIS NEVER

SUPPORTEDBY INPUT SHAFT

CLUTCHBRAKE


38/236Page 36


Installing the

Transmission

See the recommended procedure from themanufacturer of the vehicle to install thetransmission. The following is a generalprocedure to install the transmission.

1. Inspect the clutch housing for wearand damage. Replace worn anddamaged housings.

2. Inspect the cross shaft bores in thehousing. Make sure plugs are in thebores that are not used. If the boresare not plugged, dirt and contaminantsgo into the clutch housing and damagethe clutch. Figure 4-4.

Figure 4-4

Figure 4-5

3. Make sure an inspection cover isinstalled on the bottom of the clutchhousing. If an inspection cover is notused, dirt and contaminants go into theclutch housing and damage the clutch.Figure 4-5.

Figure 4-6

4. Inspect the input bearing retainer onthe transmission. Check the areawhere the clutch brake touches theretainer. Replace worn or damagedretainers.

5. Measure the distance from the top ofthe splines on the input shaft to the topof the bearing retainer as shown inFigure 4-6. If the distance is more

than 8.72 inches (221.48 mm), theinput bearing retainer is worn and mustbe replaced.

MAKE SURETHE UNUSEDBORES AREPLUGGED

IF DIMENSION 'A' ISMORE THAN

8.72 INCHES (221.48 mm),REPLACE THE INPUTBEARING RETAINER

INSPECTION COVER


39/236


40/236Page 38


supported by the clutch or the discs.The clutch or the discs are damagedwhen the transmission is not correctlyinstalled.

15. Install the transmission according tothe following procedure. Figure 4-10.

a. Put the transmission so that theinput shaft is aligned with the pilotbearing.

b. Move the input shaft into the clutchhousing. Make sure the two tips ofthe release fork are installed be-tween the release bearing assem-bly and the clutch cover.

c. If necessary, rotate the output shaftof the transmission to align thesplines on the input shaft with theteeth in the hubs of the clutchdiscs.

12. Put the transmission in gear.

WARNINGMake sure the transmission is securely

supported on the overhead hoist orjack. If the transmission is not securelysupported, the transmission may falland cause serious personal injury ordamage.

13. Put the transmission on a transmissionjack or an overhead hoist.

14. If installed, remove the inspectioncover from the clutch housing.

CAUTIONBe careful when installing the inputshaft of the transmission in the hubs ofthe disc. If the transmission is forcedor jammed, the clutch discs or theclutch housing will be damaged. Also,do not let the transmission hang or be

Figure 4-10

SEE VIEW A VIEW A

INPUT SHAFTMUST BEALIGNED

WITH PILOTBEARING

TIPS OF RELEASE FORKMUST BE INSTALLEDBETWEEN RELEASE

BEARING AND CLUTCH


41/236Page 39

Section 4Removing and Installating the Transmission

Install and tighten the fasteners ac-cording to the specifications and theprocedure of the manufacturer of thevehicle.

24. Connect the shift lever assembly to thetransmission. If removed, install theshift tower assembly on the transmis-sion.

25. Lubricate the clutch housing, the crossshaft bushings and the release bearinghousing. See the procedure of themanufacturer of the vehicle.

26. Adjust the clutch and/or the linkage.See the procedure of the manufac-turer of the vehicle

CAUTIONMake sure the inspection cover on theclutch housing is used. If an inspec-tion cover is not used, dirt and con-taminants get into the clutch housingand damage the clutch.

27. Install the inspection cover. Install andtighten the capscrews. Tighten the

capscrews to the specified torque ofthe manufacturer of the vehicle.

CAUTIONUse the specified oil. Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. The wrong oil will damagethe transmission.

28. Clean the area by the fill plug. Re-move the fill plug from the transmis-

sion. Add the specified oil until the oillevel is even with the bottom of the

d. Push the transmission against theflywheel housing.

16. Install the capscrews that fasten theclutch housing on the transmission to

the flywheel housing. Tighten thecapscrews to the specified torque andthe sequence specified by the manu-facturer of the vehicle.

17. Align the transmission with the brack-ets on the frame. Install the fastenersthat hold the transmission on thebrackets. Tighten the fasteners to thetorque specified by the manufacturerof the vehicle.

18. Remove the transmission jack or liftingdevice from the transmission.

19. If a hydraulic assist system is used forthe clutch, install the slave cylinder inthe bracket on the transmission. Con-nect the push rod to the release leveron the transmission. Connect thespring to the release lever.

20. Connect the clutch linkage to therelease lever on the transmission.Connect the spring to the releaselever.

21. Connect the air lines to the transmis-sion.

22. Connect the electrical connectors tothe transmission.

23. Connect the driveshaft to the outputyoke on the transmission. Make surethe alignment marks on the output

yoke and the driveshaft that weremade during removal are aligned.


42/236Page 40


Figure 4-11hole of the fill plug. Figure 4-11.

See Transmission Oil Capacities andTransmission Oil Specifications inSection 20, Specifications.

Install and tighten the fill plug to 35-50lb-ft (48-67 N.m).

29. Operate the vehicle. Check for correctoperation.

OIL LEVEL MUST BE EVENWITH BOTTOM OF FILL

PLUG HOLE

FILLPLUG

DRAINPLUG


43/236


44/236Page 42

Section 5Overhauling the Shift Lever and Tower Assembly

NOTE:If an aluminum shift tower assembly isreplaced, replace the entire assemblywith a cast iron shift tower assembly.

Make sure the gasket between the shifttower housing and the top cover hous-ing is replaced. A different gasket isused on the aluminum than on the castiron housing.

1. Remove the shift lever and towerassembly as described in Section 3,InVehicle Service.

2. If necessary, separate the upper shiftlever from the lower shift lever. See

the following.

a. If clips are used,remove one clip.Remove the clip and pin assemblyfrom the lever. Remove the bush-ings. Figure 52.

b. If a bolt and nut is used,removethe nut and the bolt.

c. Remove the upper shift lever fromthe lower shift lever. Figure 52.

Figure 52

Figure 53

4. Put the assembly in a vise with brassjaws. Make sure the inside of thehousing is away from you.

5. Remove the snap ring that fastens theupper retainer plate and the lever inthe housing. Figure 53.

6. Remove the set screws from the sideof the housing. Remove the lowerretainer from the housing. Figure 54.

Figure 54

NUT

BUSHINGPIN

CLIP

BOLT

SNAPRING

SETSCREW

HOUSING

3. Remove the clamps that fasten theboot to the housing. Remove the bootfrom the housing and the lower shiftlever.


45/236


46/236Page 44


3. Install the lower retainer plate in thehousing. Make sure the tabs of theretainer are in the slots in the housing.

4. Install the lever so that the slots in thelever are installed over the pins. Fig-ure 58.

5. Install the upper retainer plate over thelever and in the housing. Make surethe tabs on the plate are installed inthe slots in the housing. On somehousings, make sure the pins in theplate are aligned with the slots in theball on the lever. Figure 58.

Figure 59

Figure 510

SNAPRING

HOUSING

SETSCREW

Figure 58

6. Install the snap ring that fastens theupper retainer plate and the lever inthe housing. Figure 59.

7. Install and tighten the set screw thatfastens the upper retainer plate in thehousing. Figure 510.

LEVER

UPPERRETAINER

8. Install the boot on the housing. Makesure the lip on the boot is installed inthe groove in the housing. Install theclamps or cable ties that fasten theboot to the lower lever and the hous-ing. Figure 511.


47/236Page 45


NUT

BUSHINGPIN

CLIP

BOLT

Figure 511

9. If removed, connect the upper shiftlever assembly to the lower lever. Seethe following: Figure 512.

a. Install the upper shift lever assem-bly on the lower lever. Make surethe bores for the retainers arealigned.

Figure 512

b. If clips are used, install a bushing ineach side. Install a clip on one endof the pin. Install the pin in thebores. Install the clip on the otherend of the pin.

c. If a bolt and nut is used, install thebolt in the bores. Install and tightenthe nut to 8-12 lb-ft (11-16 N.m).

BOOT


48/236


49/236


50/236


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52/236Page 50

Section 7Removing and Installing the Top Cover Assembly

WARNINGTo prevent serious eye injury, alwayswear safe eye protection when doing

maintenance or service.

Removing the Top CoverAssembly

NOTE:Four different top cover assemblies areavailable. See Figure 71.

Standard position top cover with astandard shift pattern.

Standard position top cover with anx shift pattern.

Forward position top cover with astandard shift pattern.

Figure 71

Forward position top cover with anX shift pattern.

Standard position top covers have thedetent balls and springs under the shiftlever housing.

Forward position covers have the de-tent springs and balls under a platebehind the shift lever housing.

Top covers with an X shift patternhave a stud and a nut that fastens therocking lever assembly to the topcover.

1. Shift the transmission into the NEU-

TRALposition.

2. Remove the transmission (if neces-sary) and the shift lever and towerassembly as described in Section 3,InVehicle Service.

STANDARD POSTIONTOP COVER

STANDARD SHIFT PATTERN

STANDARD POSTIONTOP COVER

"X" SHIFT PATTERN

FORWARD POSTIONTOP COVER

"X" SHIFT PATTERN

FORWARD POSITIONTOP COVER

STANDARD SHIFT PATTERN

INDICATES"X" BAR


53/236Page 51

Section 7Removing and Installating the Top Cover Assembly

NOTE:If a heavy-duty detent spring is used,the spring (different color) is in thebore on the slave valve side of the

transmission.

3. Remove the three detent springs fromthe top cover from the holes in the topcover. Figure 72.

4. Use a magnet to remove a detent ballfrom the each of the three holes.Figure 72.

5. Remove the mounting capscrews andwashers from the top cover.

CAUTIONUse a rubber mallet or dead blowhammer to separate the top cover fromthe transmission case. Do not use prybars or screwdrivers to separate thecover from the case. Pry bars or screw-drivers may damage the cover and casemounting surfaces. If the cover is stilldifficult to remove, remove the slavevalve and the interlock pin from the

main case.6. Remove the top cover from the trans-

mission case. Figure 73.

7. Use a scraper to remove the sealantmaterial from the top cover and thetransmission case.

Figure 72

Figure 73

DETENTSPRING

HEAVY-DUTYSPRINGLOCATION(IF USED)

DETENTBALL

TOPCOVER


54/236Page 52

Section 7Removing and Installing the Top Cover Assembly

Installing the Top Cover

Assembly1. Inspect the tips of the forks. If the tips

of the forks are worn or damaged,replace the forks.

Inspect the shift sleeves. If thesleeves are worn or damaged, replacethe sleeves.

To replace the fork or the sleeve, seeSection 8, Overhauling the TopCover.

2. Inspect the set screws, if the set

screws are loose, see the following:a. Clean the threads of the set

screws. Make sure all dirt isremoved from the threads.

NOTE:See the specifications of the sealantmanufacturer for the cure time.

b. Apply Loctite #242 (Rockwell PartNumber (2297-V-5430) or

equivalent to the threads of thecapscrews

c. Tighten the capscrews to thetorque in the Torque SpecificationsChart.

3. Inspect the lockwire. If the lockwire ismissing or damaged, see the following:

a. Install the new lockwire.

b. Bend the wire towards the

capscrew.

c. Twist the wire at least oncebetween the parts. On the 1-2sleeve and fork assembly, the wirecan be wrapped around the shaft.

4. Make sure the transmission is in theNEUTRALposition.

5. Use Loctite Master Gasket Sealant,#5699 (Rockwell Part Number

2297-A-7021) and a sealant dispenser,to put a new 1/8 inch (2 mm) sealantpattern for the top cover on the case.See Gasket Sealant in Section 1.Figure 74.

Figure 74

TRANSMISSION CASE

FOUR HOLESSURROUNDEDBY SEALANT

NOTE:If the top cover is difficult to install,remove the slave valve and the inter-lock pin from the main case.

6. Install the top cover. Make sure thecover is in the NEUTRALposition.Make sure the forks of the coverengage the collars in the transmissioncase. Figure 75.


55/236Page 53

Section 7Removing and Installating the Top Cover Assembly

Figure 76

HEAVY-DUTYSPRINGLOCATION(IF USED)

DETENTBALL

DETENTSPRING

Figure 75TOP

COVER

7. Install the mounting capscrews andwashers for the top cover. Tighten thecapscrews to 25-35 lb-ft (34-47 N.m).

8. Install a detent ball in each of the threeholes in the top cover. Figure 76.

NOTE:Replace the detent springs as a set.

Use the yellow spring (Rockwell partnumber 2258-D-1278) in all the holes.

NOTE:If a heavy-duty detent spring is used,install the spring (different color) in thebore on the slave valve side of thetransmission.

9. Install a spring on top of each detentball in the holes in the top cover.Figure 76.


56/236Page 54

Section 8 Standard PatternOverhauling the Top Cover Assembly Top Cover

SPRING

Disassembling the Standard and Forward PositionTop Cover AssemblySee Figures 81 and 82.

Figure 81REVERSE

SWITCHPLUG

BREATHERVENT

BALL

LONG PIN

NEUTRAL SWITCHPLUG

SHORT PIN

FORWARDPOSITION HOUSING

STANDARDPOSITIONHOUSING

(FOR FORWARD

POSITIONHOUSINGSEE BOX)

OILSCOOP

OILSCOOP

GASKET

COVER

PLATE

REVERSESWITCHPLUG


57/236Page 55

Standard Pattern Section 8Top Cover Overhauling the Top Cover Assembly

Figure 82

NOTE:The standard position top cover andthe forward position top cover use

different housings. The forward posi-tion housing uses a plate and a gasketinstalled over the detent balls andsprings.

1. Remove the top cover from the trans-mission case as described in thissection. Make sure the top cover is inthe NEUTRALposition. Figure 83.

WARNINGTo prevent serious eye injury, al-ways wear safe eye protection whendoing maintenance or service.

Figure 83 SLEEVES INNEUTRALPOSITION

LOCKWIRE INSTALLATION NOTES:1. Trim excess wire to 1/4 inch (6mm).

2. Bend the wire towards the capscrew.

3. Twist the wire at least once between parts.

4. On the 1-2 sleeve, the wire can bewrapped around the shaft.

5. Make sure the wire does not interfere withthe movement of the rail.

CLIP

BALL SPRING LOW REVERSEFORK

SPRINGPLUNGER

1-2 SLEEVE

3-4 SLEEVE

NEUTRALCHECK SHAFT

3-4 SLEEVE

3-4 FORKLOCKWIRE

SETSCREW

1-2FORK

1-2 SHAFT BALL

LOW

REVERSESHAFT

PIN

BALL


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3-4 SHIFTSHAFT

Figure 87 3-4 SHIFTSLEEVE

9. On Design Level 1, nine-speedtransmissions,if necessary, disas-semble the 3-4 shift sleeve. Removethe clip that fastens the 3-4 plunger inthe housing. Remove the plunger.Figure 88.

Figure 8-8 PLUNGER ANDSPRING

CLIP

10. Remove the interlock ball from thebottom of the top bore of the first set ofbores at the rear of the housing. Fig-ure 89.

Figure 89

BALL

11. Remove the 1-2 shift shaft, the 1-2shift fork and the 1-2 shift sleeve fromthe housing. Remove the pin interlockfrom the end of the 1-2 shift shaft.Figure 810.

Figure 810 1-2 SHIFTSLEEVE

1-2SHIFTFORK

PIN

12. Remove the interlock ball from thebottom of the middle bore in the firstset of bores in the housing. Figure811.

3-4 SHIFTFORK

1-2 SHIFTSHAFT


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Figure 811

13. Remove the neutral check shaft fromthe top cover. Figure 812.

BALL

Figure 812NEUTRALCHECKSHAFT

NOTE:On standard position top covers, one ortwo reverse switches may be used. On

forward position top covers, one re-verse switch is used.

14. Remove the reverse switch(es) orplugs from the top of the housing.Remove the long pin(s) from eachbore. Figure 813.

Figure 813REVERSE

SWITCH BORES LONG PIN

BREATHERVENT

15. Remove the low-reverse shift shaft.Remove the low-reverse shift sleeveand fork assembly. Figure 814.

Figure 814

16. If necessary, disassemble the low-

reverse sleeve and fork assembly.Remove the clip that fastens theplunger in the housing. Remove theplunger and the spring. Remove thespring and the ball from the bore nextto the plunger bore. Figure 815.

LOW-REVERSESHIFT SHAFT

LOW-REVERSEFORK AND

SLEEVE


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Assembling the Standard

and Forward Position Top

Cover AssemblySee Figures 81 and 82.

NOTE:The standard position and the forwardposition top covers use different hous-ing. The forward housing also uses aplate and a gasket installed over thedetent balls and springs.

1. Lubricate all the parts of the top cover

with the oil that is used in the transmis-sion.

2. Do the following to the set screws thatfasten the shift sleeves and/or forks tothe shift shafts and the capscrews forthe oil scoops.

a. Clean the threads of the fasten-ers with Loctite Safety Solvent#755 (Rockwell part number2297-P-6412) or equivalent.

Make sure all dirt is removedfrom the threads.

NOTE:See the specifications of the sealantmanufacturer for the "cure" time.

b. Apply Loctite #242 (Rockwellpart number 2297-V-5430) orequivalent to the threads of thefasteners.

3. Install the top cover in a vise withbrass jaws. Make sure the low-re-verse bore holes are toward the bot-tom of the vise.

4. Install the short pin in the bore for theneutral safety switch. Install the switchor plug and tighten to 35-50 lb-ft (48-67 N.m). Figure 818.

5. Install the breather vent in the topcover. Tighten to 15-20 lb-ft (21-27N.m). Figure 818.

NOTE:On standard position top covers, one ortwo reverse switches may be used. Onforward position top covers, one re-verse switch is used.

6. Install the larger pin(s) in the bore(s)for the reverse switch. Install theswitches or plugs and tighten to 35-50lb-ft (48-67 N.m). Figure 818.

Figure 818

7. If disassembled, install the plungerassembly in the low-reverse shift 7fork.See the following. Figure 819.

a. Put the fork in a vise with brassjaws.

b. Install the spring and the ball in thebore next to the plunger.

c. Install the plunger and the spring inthe bore of the fork.

d. Install the snap ring that holds theassembly in the fork.

LARGE PINS(REVERSE SWITCH)

SHORT PIN (NEUTRAL SAFETY SWITCH)


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Figure 819

8. Assemble the low-reverse shift shaftassembly. See the following proce-dure.

NOTE:The low-reverse shaft is the shortest ofthe three shafts.

a. Put the low-reverse shift shaft inthe bottom bore of the housing.Make sure the boss on the end of

the shaft is toward the rear of thehousing. Make sure the detentgrooves in the rail are aligned withthe detent ball holes in the housing.Figure 820.

b. Put the low-reverse shift fork as-sembly in the top cover so that theplunger of the fork is toward you.Make sure the bore of the fork andsleeve assembly is aligned with the

bore in the housing. Figure 820.c. Push the shift shaft through the

low-reverse sleeve and fork assem-bly.

d. Push the shaft through the assem-bly until the holes in the fork andshaft are aligned.

Figure 820

Figure 821

CAUTIONAfter the setscrews with the Loctitesealant (see step 2) are tightened to thespecified torque, do not loosen ortighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the setscrews may loosen during operation.

e. Install the set screw with the Loc-

tite sealant (see step 2) thatfasten the fork in position on theshaft. Tighten the set screw to 35-45 lb-ft (47-54 N.m). Figure 821.

CLIP

PLUNGERAND

SPRING

LOW-REVERSE

SHAFT

LOW-REVERSE

FORK

SET SCREW


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c. Put the 1-2 shift sleeve in thehousing. Make sure the bore of thesleeve is aligned with the bore inthe housing. Make sure the

threaded hole in the sleeve istoward the rear of the housing.Figure 824.

d. Push the shift shaft through the 1-2shift sleeve. Figure 824.

e. Put the 1-2 shift fork in the housing.Make sure bend on the fork isinstalled toward the middle set ofshift rail bores in the top coverhousing. Make sure the bore of the

fork is aligned with the bore in thehousing. Figure825.

f. Push the shift shaft through the 1-2fork. Figure 825.

Figure 825

g. Push the shaft through the assem-

bly until the holes in the fork andthe sleeve are aligned with theholes in the shaft.

CAUTIONAfter the set screws with the Loctitesealant (see step 2) are tightened to thespecified torque, do not loosen or

tighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the cap-screws may loosen during operation.

h. Install the set screw with the Loc-tite sealant (see step 2) thatfasten the fork and the sleeve inposition on the shaft. Tighten theset screw to 35-45 lb-ft (47-54N.m).

i. Install the lock wire in the holes inthe set screws.

12. Put the interlock ball in the bottom ofthe top bore of the first set of bores atthe rear of the housing. Figure 826.

Figure 826

13. Make sure the low-reverse sleeve andthe 1-2 sleeve are in the NEUTRALposition. The slots in the sleeve mustbe aligned. Figure 827.

1-2FORK

BALL


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Figure 827 NOTE:On R-ratio transmissions, the bill ofmaterial refers to the 3-4 shift fork asthe O/D (Overdrive) shift fork and the

3-4 shift sleeve as the O/D shift sleeve.

15. Assemble the 3-4 shift rail assembly.See the following procedure.

NOTE:The 3-4 shift shaft has a slot on oneside

NOTE:Move the 1-2 shift shaft assembly so

that the interlock ball is completelyinstalled in the bore. Move the 1-2shaft assembly so that the 3-4 shaft canbe installed.

a. Put the 3-4 shift shaft in the topbore of the housing. Make sure theinterlock slot on the end of the railis toward the rear of the housing.Make sure the detent grooves inthe shaft are aligned with the de-

tent ball holes in the housing.Figure 829.

Figure 829

14. If removed, install the plunger assem-bly in the 3-4 shift sleeve. Put thesleeve in a vise with brass jaws. In-stall the spring (if used) and theplunger in the sleeve. Install the snapring that holds the assembly in thefork. Figure 828.

Figure 828

3-4SLEEVE

3-4SHAFT

SLEEVES INNEUTRALPOSITION

CLIP

PLUNGER ANDSPRING


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b. Put the 3-4 shift sleeve in thehousing. Make sure the bore of thefork and sleeve assembly is alignedwith the bore in the housing. Make

sure the slot pin in the 3-4 sleeve isaligned with the hole in the 1-2sleeve. Figure 830.

Figure 830

c. Push the shift shaft through the 3-4shift sleeve.

e. Put the 3-4 shift fork in the housing.

Make sure the bend on the fork isinstalled toward the last set ofbores in the housing. Make surethe bore of the fork is aligned withthe bore in the housing. Figure 8-29.

f. Push the shift shaft through the 3-4fork.

g. Push the shaft through the assem-bly until the holes in the fork andthe sleeve are aligned with the

holes in the shaft.

CAUTIONAfter the set screws with the Loctitesealant (see step 2) are tightened to thespecified torque, do not loosen or

tighten. If loosened or tightened, theset screws must be removed, cleanedand new sealant applied or the setscrews may loosen during operation.

h. Install the set screws with theLoctite sealant (see step 2) thatfastens the 3-4 fork and the sleeveto the rail. Tighten the set screw to35-45 lb-ft (47-54 N.m).

i. Install the lock wire in the cap-

screws, the sleeve and the fork.

15. If removed, install the large oil scoopon the housing. Install and tighten thecapscrews with the Loctite sealant(see step 2) to 10-13 lb-ft (13-17 N.m).Figure 831.

16. If removed, install the small scoop onthe housing. Install and tighten thecapscrews with the Loctite sealant(see step 2) to 10-13 lb-ft (13-17 N.m).

Figure 831.

Figure 831

3-4FORK

OILSCOOPS


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Section 8 X BarOverhauling the Top Cover Assembly Top Cover

Disassembling the Standard and the Forward PositionX Bar Top Cover Assembly

See Figures 832 and 833.

Figure 832

BREATHERVENT

REVERSESWITCH

PLUG

BALL

SPRING

BALL

REVERSESWITCH

PLUG

LONG PIN

FORWARD POSITIONHOUSING

STANDARDPOSITION HOUSING

(FOR FORWARDPOSITION HOUSING

SEE BOX)

OILSCOOP

SPACERPLATE

ROCKINGLEVER

GUIDEPIN

NEUTRAL SWITCHPLUG

SHORTPIN

OILSCOOP

COVERPLATE

GASKET


69/236Page 67

X Bar Section 8Top Cover Overhauling the Top Cover Assembly

Figure 833

NOTE:The standard position X bar top coverassembly and the forward position X

top cover assembly use different hous-ings. The forward housing also uses aplate and a gasket installed over thedetent balls and springs.

1. Remove the top cover assembly asdescribed in this section. Make surethe top cover assembly is in the NEU-TRALposition. Figure 834.

WARNINGTo prevent serious eye injury, al-ways wear safe eye protection whendoing maintenance or service.

Figure 834NEUTRALPOSITION

LOCKWIRE INSTALLATION NOTES:1. Trim excess wire to 1/4 inch (6mm).

2. Bend the wire towards the capscrew.

3. Twist the wire at least once between parts.

4. On the 1-2 sleeve, the wire can bewrapped around the shaft.

5. Make sure the wire does not interfere withthe movement of the rail.

LOW-REVERSESHAFT

CLIP

BALL

PLUNGER

SPRING

LOW-REVERSEFORK

1-2 SLEEVE

3-4 SLEEVE

NEUTRALCHECKSHAFT

3-4 SHAFT

3-4 FORK3-4SHIFT

SLEEVESHAFT

3-4X-BAR

SLEEVE

LOCKWIRE

SETSCREW

1-2FORK

1-2SHAFT

PINBALL

BALL


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2. On forward top covers, remove thecapscrews that fasten the detentspring cover plate (if installed) to thetop cover assembly. Remove the plate

and the gasket.

NOTE:If a heavy-duty detent spring is used,the spring (different color) in the boreon the slave valve side of the transmis-sion.

3. If installed, remove the three detentsprings and balls from the top of thehousing. Figure 835.

Figure 835

SPRINGBALL

NOTE:On standard position top cover assem-blies, two reverse switches may beused. On forward position housings,one reverse switch is used.

4. Remove the reverse switches or plugsfrom the housing. Remove the longpins from each bore. Figure 836.

Figure 836

5. If necessary, remove the breather fromthe top of the cover. Figure 837.

6. Remove the neutral safety switch orplug. Remove the short pin from thebore. Figure 837.

Figure 837

CAUTIONDo not damage the machined surface ofthe case. If the surface is damaged, thecase will leak.

7. Put the top cover assembly on thebench so that the forks are toward youor in a vice with brass protectors onthe jaws of the vise.

NEUTRAL SAFETYSWITCH BORE

REVERSESWITCH BORES

LONG PIN

SHORTPIN


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Figure 842

13. Remove the interlock pin from the endof the 1-2 shift shaft. Figure 843.

BALL

Figure 843

PIN

14. Remove the set screws and removethe 1-2 shift shaft, the 1-2 shift forkand the 1-2 shift sleeve from thehousing. Figure 844.

Figure 844

1-2 SHIFTFORK

1-2 SHIFTSLEEVE 1-2 SHIFT

SHAFT

15. Remove the interlock ball from thebottom of the middle bore in the firstset of bores in the rear of the housing.Figure 845.

Figure 845

BALL


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X Bar Section 8Top Cover Overhauling the Top Cover A

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