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ProDemand

2010 Volvo VT - Series - VT-830

Repair: MACK - mDRIVE & VOLVO - I-SHIFT - SERVICE

IDENTIFICATION
NOTE: There are references to both mDRIVE as well as I-Shift transmissions in this article due to the fact they are used in Volvo and Mack trucks. This article covers
BOTH the MACK mDrive and The Volvo I-shift transmissions which are almost identical.

Identify type of transmission from tag embossed on top of clutch housing. Back of range housing also bears an identification tag. Use nomenclature table to identify
transmission version.

TRANSMISSION NOMENCLATURE REFERENCE

Type D12AD, D12AO & D12AO23

TmD Transmission mDRIVE
12 Number of forward gears
A Automatic
Nomenclature
D Direct drive
O Overdrive
23 Torque Capacity 2300 Ft. Lbs. (3100 N.m)
Fig 1: Right Side View
G00512695
View Full-Screen
Fig 2: View From Rear
G00512651
View Full-Screen
Fig 3: View Of Front
G00512659
View Full-Screen
Fig 4: Left Side View
G00512703
View Full-Screen
Fig 5: View Of Top
G00512699
View Full-Screen
Fig 6: View Of Main Connectors
G00512683
View Full-Screen
Fig 7: Solenoid Locations (Overdrive Unit)
G00510382
View Full-Screen
Fig 8: Solenoid Locations (DirectDrive Unit)
G00510381
View Full-Screen

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT

Recommended tool for diagnostic work is manufacturer diagnostic tool.

Communication for control modules on information link is established according to SAE J1587 standard. Following valuable information are included in Fault Codes
generated by control modules.

• MID (Message Identification Description): Identifies control module.

• PID (Parameter Identification Description): Identifies a parameter value.
• PPID (Proprietary Parameter Identification Description): This is a unique identification of a parameter value.
• SID (Subsystem Identification Description): Identifies component.
• PSID Proprietary Subsystem Identification Description: This is unique identification of a component.
• FMI Failure Mode Identifier: Identifies fault types.

FMI TABLE

FMI Display Text SAE Text

0 Value is too high Valid data but exceeding normal range
1 Value is too low Valid data but lower than normal operating range
2 Data is incorrect Incorrect/erratic/intermittent data
3 Electrical fault Voltage is shorted high or exceeding normal range
4 Electrical fault Voltage is lower than normal range or shorted low
5 Electrical fault Circuit is open or current is lower than normal range
6 Electrical fault Circuit is grounded or current is exceeding normal range
7 Mechanical fault Improper response from mechanical system
8 Electrical or mechanical fault Frequency, pulse width or period is abnormal
9 Communication related error Update rate is not normal
10 Electrical or mechanical fault Abnormal rate of change
11 Fault cannot be identified Unidentifiable failure mode
12 Fault in component Component or intelligent device defective
13 Calibration is incorrect Out of calibration
14 Fault cannot be identified Special instructions
15 Fault cannot be identified SAE Data Formal Subcommittee reserves for future assignment

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 Control Module, Fault Tracing > PID
MID CONTROL MODULE (PID) REFERENCE

MID 130 PID 31 Range Cylinder, Position

MID 130 PID 32 Split Cylinder, Position
MID 130 PID 33 Clutch Cylinder, Position
MID 130 PID 36 Clutch Wear, Status
MID 130 PID 37 Air Pressure, Transmission
MID 130 PID 65 Brake Switch
MID 130 PID 158 Control Module, Battery Voltage
MID 130 PID 160 Main Shaft, Rotation Speed
MID 130 PID 161 Input Shaft, Rotation Speed
MID 130 PID 177 Oil Temperature, Transmission

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 Control Module, Fault Tracing > PPID
MID CONTROL MODULE (PPID) REFERENCE

MID 130 PPID 10 Gear Selector Cylinder 1, Position

MID 130 PPID 11 Gear Selector Cylinder 2, Position
MID 130 PPID 50 Clutch, Pre-Load
MID 130 PPID 51 Clutch Disc, Pull Position
MID 130 PPID 54 ECM +5 Volts Output
MID 130 PPID 55 ECM, Temperature
MID 130 PPID 140 Inclination Angle

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 Control Module, Fault Tracing > PSID
MID CONTROL MODULE (PSID) REFERENCE

MID 130 PSID 1 PWM Valve, Quick Engagement

MID 130 PSID 2 PWM Valve, Slow Engagement
MID 130 PSID 3 PWM Valve, Quick Disconnection
MID 130 PSID 4 PWM Valve, Slow Disconnection
MID 130 PSID 5 Ground, Quick PWM Valves
MID 130 PSID 6 Ground, Slow PWM Valves
MID 130 PSID 12 Solenoid Valve, Gear Selector Cylinder 1, Inner
MID 130 PSID 13 Solenoid Valve, Gear Selector Cylinder 1, Outer
MID 130 PSID 14 Solenoid Valve, Gear Selector Cylinder 2, Inner
MID 130 PSID 15 Solenoid Valve, Gear Selector Cylinder 2, Outer
MID 130 PSID 20 Solenoid Valve, Power Take-Off (PTO) 1
MID 130 PSID 21 Solenoid Valve, PTO 2
MID 130 PSID 22 Solenoid Valve, Brake, Counter Shaft
MID 130 PSID 23 Split Engagement System
MID 130 PSID 24 Range Engagement System
MID 130 PSID 25 Gears 1/R Engagement System
MID 130 PSID 26 gears 2/3 Engagement System
MID 130 PSID 27 Clutch System
MID 130 PSID 28 Transmission Brake
MID 130 PSID 200 Communication Interference, Data Link, ECM
MID 130 PSID 201 Communication Interference, Data Link, Vehicle ECU
MID 130 PSID 204 Communication Interference, Data Link, Brake Control Module
MID 130 PSID 207 Communication Interference, Data Link, Gear Selector Control Module
MID 130 PSID 210 J1939 Data Link Interruption, Lighting ECM
MID 130 PSID 211 J1939 Data Link Interruption, Adaptive Cruise Control ECM
MID 130 PSID 232 Powertrain Can
MID 130 PSID 254 DIEE Signal

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 Control Module, Fault Tracing > SID
MID CONTROL MODULE (SID) REFERENCE

MID 130 SID 35 Solenoid Valve, High Range

MID 130 SID 36 Solenoid Valve, Low Range
MID 130 SID 37 Solenoid Valve, High Split
MID 130 SID 38 Solenoid Valve, Low Split
MID 130 SID 231 SAE J1939 Data Link
MID 130 SID 240 Program Memory
MID 130 SID 250 SAE J1587 Data Link
MID 130 SID 253 Calibration Memory EEPROM

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 31 Range Cylinder Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Voltage exceeding normal range, ASIC status indicates short circuit Slow changes in gear.
FMI 3 N/A
or shorted to high source to U-BATT Yellow light is transmitted.
Circuit is open or current is lower Yellow light is transmitted.
FMI 5 ASIC status indicates open circuit N/A
than normal range Slow changes in gear.
Circuit is grounded or current is ASIC status indicates short circuit Yellow light is transmitted.
FMI 6 N/A
exceeding normal range to ground Slow changes in gear.
Yellow light is transmitted.
Incorrect checksum in NVRAM
FMI 13 Calibration value is not in range Inhibited cranking N/A
or sensor is not calibrated.
Engine fails to start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 32 Split Cylinder Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Voltage exceeding normal range, ASIC status indicates short circuit Slow changes in gear.
FMI 3 N/A
or shorted to high source to U-BATT Yellow light is transmitted.
Circuit is open or current is lower Yellow light is transmitted.
FMI 5 ASIC status indicates open circuit N/A
than normal range Slow changes in gear.
Circuit is grounded or current is ASIC status indicates short circuit Yellow light is transmitted.
FMI 6 N/A
exceeding normal range to ground Slow changes in gear.
Yellow light is transmitted.
Incorrect checksum in NVRAM
FMI 13 Calibration value is not in range Inhibited cranking. N/A
or sensor is not calibrated.
Engine will not start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 33 Clutch Cylinder Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE
Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Sensor signal (SEPoC) indicates Yellow light is transmitted.
difference between clutch Clutch performance is slow.
Incorrect, erratic, or intermittent
FMI 2 positions and inverted sensor At slow and at slow speed, N/A
data
signal (SEPoCINV) is to large and shifting is not smooth.
both signals are in range Slow changes in gear.
Yellow light is transmitted.
Sensor signal indicates shorted
Clutch performance is slow.
Voltage exceeding normal range, UBATT or sensor supply if at
FMI 3 At slow and at slow speed, N/A
or shorted to high source least one of sensor signals is
shifting is not smooth.
above normal range
Slow changes in gear.
There is open circuit in any of
sensor signals if: one of sensor
Yellow light is transmitted.
signals is in range and other
Clutch performance is slow.
Circuit is open or current is lower sensor signal is below range.
FMI 5 At slow and at slow speed, N/A
than normal range There is open circuit on ground if
shifting is not smooth.
both sensor signals are in range
Slow changes in gear.
and sum of sensor signals is above
a specific value.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
One of following indicates both
sensor signals are below normal:
Sensor ASIC status indicates Yellow light is transmitted.
sensor internal fault. Clutch performance is slow.
FMI 12 Component or device defective Shorted ground on any of sensor At slow and at slow speed, N/A
signals. shifting is not smooth.
Circuit is open on supply. Slow changes in gear.
Short circuit between 2 sensor
signals.
Yellow light is transmitted.
Incorrect checksum in NVRAM
FMI 13 Calibration value is not in range Inhibited cranking. N/A
or sensor is not calibrated.
Engine will not start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 36 Clutch Wear Status
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Valid data but exceeding normal Clutch wear exceeding or equal to If code is active for a long time,
FMI 0 N/A
operational range "Service Due Position" clutch may completely wear out
resulting in failure.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 37 Transmission Air Pressure
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Sensor signal is within range.
Valid data but exceeding normal Yellow light is transmitted
FMI 0 More than 145 Psi. (10.0 bar) N/A
operational range Clutch performance is slow
pressure.
Yellow light is transmitted.
Sensor signal is within range. Compressed air, transmission
Valid data but lower than
FMI 1 Less than 72.5 Psi. (5.0 bar) symbol sent. N/A
operational range
pressure. No gear changes.
Clutch performance is slow.
Voltage is shorted high or Sensor signal exceeding normal
FMI 3 Yellow light is transmitted N/A
exceeding normal range range
Circuit is open or current is lower Sensor signal lower than normal
FMI 5 Yellow light is transmitted N/A
than normal range range

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 65 Brake Switch
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
White light is transmitted along
Gear is shifted to neutral or
with pop up message.
FMI 14 Special Instructions "FOLD" position without N/A
Selected gear (remain neutral) is
applying service brake
not engaged by transmission.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 158 Battery Voltage Control Module
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Valid data but exceeding normal 12 Volt System: More than 19
FMI 0 Yellow light is transmitted N/A
operational range Volts voltage
12 Volt System: Less than 9
Valid data but lower than Yellow light is transmitted.
FMI 1 Volts and engine is running for 5 N/A
operational range Low transmission performance.
s

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 160 Rotation Speed Main Shaft
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Sensor signal within normal
range.
Main shaft speed differs from both
countershaft speed and vehicle
speed provided by Vehicle ECU.
This fault will activate only when
following conditions are present
for a time of 2.0.
More than 300 RPM input shaft
speed; computed from main shaft
speed sensor (SESM).
A gear (not neutral) engaged in
transmission.
More than 300 RPM input shaft
speed, computed from counter Yellow light is transmitted.
Valid data but lower than
FMI 1 shaft speed sensor (SESC). Slow changes in gear. N/A
operational range
More than 50 RPM variation of Changes in gear is not smooth.
input shaft speed value computed
from main shaft speed sensor
(SESM) and counter shaft speed
sensor (SESC).
More than 30 RPM variation of
input shaft speed computed from
main shaft speed sensor (SESM)
and vehicle speed provided by
Vehicle ECU.
Less than 30 RPM variation of
input shaft speed computed from
counter shaft speed sensor (SESC)
and vehicle speed provided by
Vehicle ECU.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 2 Incorrect, erratic, or intermittent Wrong direction indicated by Yellow light is transmitted N/A
data sensor. Slow changes in gear
This fault is activated only when
following conditions is present for
a time of 2, 0.
Clutch is engaged and input shaft
speed computed from countershaft
speed sensor (SECS) is more than
300 RPM.
Clutch position is more engaged
than slip point and engine speed,
nearly 600 RPM is provided by
ECM and input shaft speed
 computed from countershaft speed
sensor (SECS) is more than 600
RPM.
A forward gear is engaged in
transmission and reverse
movement indicated by mainshaft
speed sensor (SESM).
A reverse gear is engaged and
forward movement indicated by
mainshaft speed sensor (SESM).
No other active fault related to
main shaft speed (SEMS) on
sensor.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition: Possible Symptoms Possible Cause
Yellow light is transmitted Slow
Voltage is shorted high or Signal or supply voltage
FMI 3 changes in gear Changes in gear is N/A
exceeding normal range exceeding normal range
not smooth
Yellow light is transmitted Slow
Voltage is lower than normal Signal or supply voltage lower
FMI 4 changes in gear Changes in gear is N/A
range or shorted low than normal range
not smooth
Signal voltage is lower than Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 normal range. Slow changes in gear. N/A
than normal range
Supply voltage within range. Changes in gear is not smooth.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 161 Input Shaft, Rotation Speed
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Sensor signal is within range.
Counter shaft speed not identical
to main shaft speed (SESM) and
vehicle speed supplied by Vehicle
ECU during rotation of
countershaft.
This fault is activated if following
conditions are present for 2.
Gear (not neutral) engaged in
transmission.
More than 300 RPM input shaft
Yellow light is transmitted.
speed - computed from main shaft
Slow changes in gear.
speed sensor (SESM).
No use of transmission brake up-
More than 300 RPM input shaft
shifts.
speed - computed from counter
Improper functioning of
Valid data but lower than shaft speed sensor (SESC).
FMI 1 engagement point. N/A
operational range More than 50 RPM variation of
Starting gear will only engage
input shaft speed computed from
with vehicle standstill or with
counter shaft speed sensor (SESC)
vehicle speed high enough to
and main shaft speed sensor
synchronize transmission with
(SESM).
engine.
More than 50 RPM variation of
input shaft speed computed from
counter shaft speed sensor (SESC)
and vehicle speed supplied by
Vehicle ECU differ more than 30
RPM.
Less than 30 RPM variation of
input shaft speed computed from
main shaft speed sensor (SESM)
and vehicle speed supplied by
Vehicle ECU.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 4 Voltage is lower than normal Sensor signal lower than normal Yellow light is transmitted. N/A
range or shorted low range Slow changes in gear.
No use of transmission brake up-
shifts.
Improper functioning of
engagement point.
Starting gear will only engage
with vehicle standstill or with
vehicle speed high enough to
 synchronize transmission with
engine.
Yellow light is transmitted.
Slow changes in gear.
No use of transmission brake up-
shifts.
Improper functioning of
Circuit is open or current is lower Sensor signal exceeding normal
FMI 5 engagement point. N/A
than normal range range
Starting gear will only engage
with vehicle standstill or with
vehicle speed high enough to
synchronize transmission with
engine.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PID 177 Transmission Oil Temperature
NOTE: FMI 0 has 3 levels of severity, low, medium and high. All times are reset when key is switched off.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
In range sensor signal Yellow light is transmitted.
Valid data but exceeding normal
FMI 0 (Low) More than 212°F (100°C) during Flashing of symbol for high N/A
operational range
18000 s transmission oil temperature.
In range sensor signal Yellow light is transmitted.
Valid data but exceeding normal
FMI 0 (Medium) More than 248°F (120°C) during Flashing of symbol for high N/A
operational range
600 transmission oil temperature.
In range sensor signal Illumination of Red stop light.
Valid data but exceeding normal
FMI 0 (High) More than 284°F (140°C) during Flashing of symbol for high N/A
operational range
30 transmission oil temperature.
Voltage is lower than normal Sensor signal lower than normal
FMI 4 Yellow light is transmitted. N/A
range or shorted low range
Circuit is open or current is lower Sensor signal exceeding normal
FMI 5 Yellow light is transmitted. N/A
than normal range range

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 10 Gear Selector Cylinder 1 Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Voltage is shorted high or ASIC status indicates short circuit Yellow light is transmitted.
FMI 3 N/A
exceeding normal range to U-BATT Slow changes in gear.
Circuit is open or current is lower Yellow light is transmitted.
FMI 5 ASIC status indicates open circuit N/A
than normal range Slow changes in gear.
Circuit is grounded or current is ASIC status indicates short circuit Yellow light is transmitted.
FMI 6 N/A
exceeding normal range to ground Slow changes in gear.
Yellow light is transmitted.
Incorrect checksum in NVRAM.
FMI 13 Calibration value is not in range Inhibited cranking. N/A
Not calibrated sensor.
Engine will not start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 11 Gear Selector Cylinder 2 Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Voltage is shorted high or ASIC status indicates short circuit Yellow light is transmitted.
FMI 3 N/A
exceeding normal range to U-BATT Slow changes in gear.
Circuit is open or current is lower Yellow light is transmitted.
FMI 5 ASIC status indicates open circuit N/A
than normal range Slow changes in gear.
Circuit is grounded or current is ASIC status indicates short circuit Yellow light is transmitted.
FMI 6 N/A
exceeding normal range to ground Slow changes in gear.
Yellow light is transmitted.
Incorrect checksum in NVRAM
FMI 13 Calibration value is not in range Inhibited cranking.
Not calibrated sensor N/A
Engine will not start.
FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 50 Clutch Pre-Load
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
More than 200 KJ stored energy
Yellow light is transmitted.
Valid data but exceeding normal calculated
FMI 0 Overheated clutch. N/A
operational range Energy calculation is time based
Clutch slowly engaged.
for VTNA and physical for others
More than 8.0 s clutch slip with Yellow light is transmitted.
Active Cutch protection
FMI 11 less than 0.8 m (e.g. hill holding Unnecessary clutch slip. N/A
(unidentifiable error)
event) vehicle movement Clutch engaged slowly.
Try to start in high range in White light transmitted.
FMI 14 Special instructions N/A
manual position Can not start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 51 Clutch Disc Pull Position
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Incorrect checksum in NVRAM Yellow light is transmitted
FMI 13 Calibration value is not in range N/A
Slip point not calibrated Vehicle can not be run

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 54 ECM +5 Volts Output
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Clutch performance is slow.
Valid data but exceeding normal
FMI 0 Voltage exceeding normal range Shifting at start and at slow speed N/A
operational range
is not smooth.
Slow changes in gear.
Yellow light is transmitted.
Clutch performance is slow.
Valid data but lower than Voltage is lower than normal
FMI 1 Shifting at start and at slow speed N/A
operational range range
is not even.
Slow changes in gear.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 55 ECM Temperature
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Valid data but exceeding normal
FMI 0 More than 257°F (125°C) temp Yellow light is transmitted N/A
operational range

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PPID 140 Inclination Angle
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 2 N/A
 Incorrect, erratic, or intermittent Sensor signal exceeding or lower Yellow light is transmitted.
data than normal range. Incorrect start gear.
Vehicle not running for a specific Low gear selection performance.
time. Low downhill and uphill gear
change performance.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 1 PWM Valve Quick Engagement
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
High-side drive is shorted to Yellow light is transmitted.
Voltage is shorted high or U-BATT. Error in clutch performance.
FMI 3 N/A
exceeding normal range No active fault code for short Clutch performance is slow.
circuit to U-BATT on VAF. Slow changes in gear.
Yellow light is transmitted.
Circuit is open or current is lower Error in clutch performance.
FMI 5 Circuit is open in high-side drive N/A
than normal range Clutch performance is slow.
Slow changes in gear.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Error in clutch performance.
FMI 6 N/A
exceeding normal range side drive Clutch performance is slow.
Slow changes in gear.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 2 PWM Valve Slow Engagement
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
High-side drive is short circuit to Yellow light is transmitted.
Voltage is shorted high or U-BATT. Error in clutch performance.
FMI 3 N/A
exceeding normal range No active fault code for short Shifting at start and at slow speed
circuit to U-BATT on VAS. is not even.
Yellow light is transmitted
Circuit is open or current is lower Error in clutch performance.
FMI 5 Circuit is open in high-side drive N/A
than normal range Shifting at start and at slow speed
is not even.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Error in clutch performance.
FMI 6 N/A
exceeding normal range side drive Shifting at start and at slow speed
is not even.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 3 PWM Valve Quick Disconnection
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or No active fault code for short Error in clutch performance.
FMI 3 N/A
exceeding normal range circuit to U-BATT on VAF Clutch performance is slow.
Slow changes in gear.
Yellow light is transmitted.
Circuit is open or current is lower Error in clutch performance.
FMI 5 Circuit is open in high-side drive N/A
than normal range Clutch performance is slow.
Slow changes in gear.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Error in clutch performance.
FMI 6 N/A
exceeding normal range side drive Clutch performance is slow.
Slow changes in gear.
FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 4 PWM Valve Slow Disconnection
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Short circuit to U-BATT in high- Yellow light is transmitted.
Voltage is shorted high or side drive. Error in clutch performance.
FMI 3 N/A
exceeding normal range No active fault code for short Shifting at start and at slow speed
circuit to U-BATT on VAS. is not even.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive. Error in clutch performance. N/A
than normal range
Clutch performance is slow.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Error in clutch performance. N/A
exceeding normal range side drive.
Clutch performance is slow.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 5 Ground Quick PWM Valves
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in low Error in clutch performance.
FMI 3 N/A
exceeding normal range side drive Clutch performance is slow
Slow changes in gear.
Short circuit to ground in low
Yellow light is transmitted.
side drive.
Circuit is grounded or current is Error in clutch performance.
FMI 6 No active fault code related to N/A
exceeding normal range Clutch performance is slow.
shorted ground on VAFE or
Slow changes in gear.
VAFD.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 6 Ground Slow PWM Valves
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted
Voltage is shorted high or Short circuit to U-BATT in low Error in clutch performance
FMI 3 N/A
exceeding normal range side drive Shifting at start and at slow speed
is not even
Short circuit to ground in low
Yellow light is transmitted.
side drive.
Circuit is grounded or current is Error in clutch performance.
FMI 6 No active fault code for short N/A
exceeding normal range Shifting at start and at slow speed
circuit to ground on VASE or
is not even.
VASD.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 12 Solenoid Valve, Gear Selector Cylinder 1, Inner
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Valve activated. N/A
exceeding normal range side drive
Wrong gear selection.
Yellow light is transmitted Valve
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive will not activate Wrong gear N/A
than normal range
selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate. N/A
exceeding normal range side drive
Wrong gear selection.
FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 13 Solenoid Valve, Gear Selector Cylinder 1, Outer
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Valve activated. N/A
exceeding normal range side drive
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
Wrong gear selection.
Yellow light is transmitted
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate Wrong N/A
exceeding normal range side drive
gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 14 Solenoid Valve, Gear Selector Cylinder 2, Inner
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Valve activated. N/A
exceeding normal range side drive
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
Wrong gear selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate. N/A
exceeding normal range side drive
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 15 Solenoid Valve, Gear Selector Cylinder 2, Outer
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Valve will not activate. N/A
exceeding normal range side drive
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
Wrong gear selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate. N/A
exceeding normal range side drive
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 20 Solenoid Valve Power Take-Off 1
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high Valve activated.
FMI 3 N/A
exceeding normal range side drive PTO will not deactivate.
Changes in gear is not smooth.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
PTO not functioning.
FMI 6 N/A
 Circuit is grounded or current is Short circuit to ground in high- Yellow light is transmitted.
exceeding normal range side drive Valve will not activate.
PTO not functioning.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 21 Solenoid Valve Power Take-Off 2
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high Valve activated.
FMI 3 N/A
exceeding normal range side drive PTO will not deactivate.
Changes in gear is not smooth.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
PTO not functioning.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate. N/A
exceeding normal range side drive
PTO not functioning.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 22 Solenoid Valve, Brake, Counter Shaft
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Illumination of Red stop light.
Valve and brake activated.
Voltage is shorted high or Short circuit to U-BATT in high Driving vehicle will damage
FMI 3 N/A
exceeding normal range side drive transmission.
Removal of drive shaft needed to
move vehicle.
Yellow light is transmitted.
Circuit is open or current is lower
FMI 5 Circuit is open in high-side drive Valve will not activate. N/A
than normal range
Slow changes in gear.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high-
FMI 6 Valve will not activate. N/A
exceeding normal range side drive
Slow changes in gear.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 23 Split Engagement System
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Unintentional disengagement of Low split jumps out. Yellow light is transmitted.
FMI 0 N/A
indirect split Inactive split cylinder valves. Loss of torque.
Direct split disengages High split jumps out. Yellow light is transmitted.
FMI 1 N/A
unintentionally Inactive split cylinder valves. Loss of torque.
Split cylinder position leaves
Neutral split disengages
FMI 2 neutral position. Yellow light is transmitted N/A
unintentionally
Inactive split cylinder valves.
Blocked engagement of neutral Failure to engage neutral split Yellow light is transmitted.
FMI 7 N/A
split gear Eco roll not available.
Yellow light is transmitted.
Blocked engagement of indirect Failure to engage indirect split Loss of torque.
FMI 11 N/A
split gear Wrong gear selection.
Slow changes in gear.
Yellow light is transmitted.
Loss of torque.
FMI 12 Blocked engagement of direct split Failure to engage direct split gear N/A
Wrong gear selection.
Slow changes in gear.
FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 24 Range Engagement System
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Range cylinder leaves low range
Low range disengaged Yellow light is transmitted.
FMI 0 position. N/A
unintentionally Loss of torque.
Inactive range cylinder valves.
Range cylinder leaves high range
High range disengaged Yellow light is transmitted Loss
FMI 1 position. N/A
unintentionally of torque
Inactive range cylinder valves.
Yellow light is transmitted.
FMI 11 Blocked engagement of low range Failure to engage low range Loss of torque. N/A
Wrong gear selection.
Yellow light is transmitted.
FMI 12 Blocked engagement of high range Failure to engage high range gear Loss of torque. N/A
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 25 Gears 1/R Engagement System
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Brass lugs.
Clutch teeth, engaging sleeve.
Control housing detent assembly.
Cylinder stroke.
First gear disengages 1/R cylinder leaves 1st position. Yellow light is transmitted.
FMI 0 Gear wheel.
unintentionally Inactive 1st cylinder valves. Loss of torque.
Main shaft hub.
Piston rod.
Transmission Control Module
(TCM).
Brass lugs.
Clutch teeth, engaging sleeve.
Control housing detent assembly.
Cylinder stroke.
Reverse gear disengages 1/R gear leaves reverse position. Yellow light is transmitted.
FMI 1 Gear wheel.
unintentionally Inactive 1/R cylinder valves. Loss of torque.
Main shaft hub.
Piston rod.
Transmission Control Module
(TCM).
Brass lugs.
Control housing detent assembly.
1/R cylinder leaves neutral Yellow light is transmitted.
Cylinder stroke.
FMI 2 Neutral disengages unintentionally position. Loss of torque.
Piston rod.
Inactive 1/R cylinder valves. Slow changes in gear.
Transmission Control Module
(TCM).
Brass lugs.
Control housing detent assembly.
Engaging sleeve.
1/R cylinder cannot reach neutral Yellow light is transmitted.
FMI 7 Blocked engagement of neutral Piston rod.
position when requested Slow changes in gear.
Seals, solenoid valve.
Transmission Control Module
(TCM).
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Brass lugs.
Yellow light is transmitted. Control housing detent assembly.
1st gear can not engage.
Loss of torque. Gear and engagement Clutch
No active fault code on SEPo1R.
Wrong gear selection. teeth.
No active fault code for low air
FMI 11 Blocked engagement of first gear System will not select 1st gears Gear wheel.
pressure.
for a while after 5 successful Piston rod.
No active fault code on any of 1st
gearshifts a NEW attempt to use Seals, solenoid valve.
and reverse gear cylinder valves.
1st gear may be made. Transmission Control Module
(TCM).
FMI 12 Blocked engagement of reverse Failure to engage reverse gear Yellow light is transmitted. Brass lugs
gear R gear will not engage, but Control housing detent assembly.
system will attempt it as long as Gear and engagement Clutch
gear lever is in reverse position. teeth.
Gear wheel.
Piston rod.
 Seals, solenoid valve.
Transmission Control Module
(TCM).

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 26 Gears 2/3 Engagement System
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Brass lugs.
Clutch teeth engaging sleeve.
Control housing detent assembly.
2/3 gear leaves 2nd position - as
Cylinder stroke.
Second gear disengages indicated by 2/3 cylinder Yellow light is transmitted.
FMI 0 Gear wheel.
unintentionally position. Loss of torque.
Main shaft hub.
Inactive cylinder valves.
Piston rod.
Transmission Control Module
(TCM).
Brass lugs
Clutch teeth engaging sleeve.
Control housing detent assembly.
Third gear disengages 2/3 cylinder leaves 3rd position. Yellow light is transmitted. Cylinder stroke.
FMI 1
unintentionally Inactive 3rd cylinder valves. Loss of torque. Gear wheel.
Main shaft hub.
Piston rod.
TCM.
Brass lugs.
Split cylinder position leaves Control housing detent assembly.
FMI 2 Gear engages unintentionally neutral position. Yellow light is transmitted. Cylinder stroke.
Inactive split cylinder valves. Piston rod.
TCM.
Brass lugs.
Control housing detent assembly.
2/3 gear cylinder will not obtain Yellow light is transmitted. Engaging sleeve.
FMI 7 Blocked engagement of neutral
neutral position when requested Slow changes in gear. Piston rod.
Seals, solenoid valve.
TCM.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Brass lugs.
Yellow light is transmitted.
Control housing detent assembly.
Loss of torque.
Gear and engagement Clutch
Wrong gear selection.
Blocked engagement of second teeth.
FMI 11 Failure to engage 2nd gear System will not select 2nd gear
gear Gear wheel.
for a while after 5 successful
Piston rod.
gearshifts a NEW attempt to use
Seals, solenoid valve.
2nd gear may be made.
TCM.
Yellow light is transmitted. Brass lugs.
Loss of torque Control housing detent assembly.
Wrong gear selection. Gear and engagement clutch teeth.
FMI 12 Blocked engagement of third gear Failure to engage 3rd gear System will not select 3rd gear for Gear wheel.
a while after 5 successful Piston rod.
gearshifts a NEW attempt to use Seals, solenoid valve.
3rd gear may be made. TCM.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 27 Clutch System
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Clutch disengages without
command.
No active fault code on SEPoC.
No active fault code for low air Yellow light is transmitted.
FMI 0 Clutch disengages unintentionally pressure. Slow changes in gear. Clutch valve assembly.
No active fault code on any of Clutch performance is slow.
clutch cylinder valves.
PCB temperature exceeds a preset
limit.
FMI 1 Unintentional engagement of Clutch engages without Yellow light is transmitted. Clutch cylinder.
clutch command. Slow changes in gear. Clutch valve assembly.
No active fault code on SEPoC. Error in clutch performance. Clutch cylinder air hose.
No active fault code related to Clutch cylinder air connection.
low air pressure.
No active fault code on any of
clutch cylinder valves.
PCB temperature exceeds a
specific limit.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Improper clutch
disengagement/engagement when
commanded.
No active fault code on SEPoC. Clutch.
Clutch mechanical system Yellow light is transmitted. Clutch cylinder.
Out of adjustment or not
FMI 7 malfunctions. No active fault code Slow changes in gear. Clutch cylinder air hose.
responding mechanical system
for low air pressure. Unreliable clutch performance. Clutch valve assembly.
No active fault code on any of clutch Clutch valve assembly air supply.
cylinder valves.
More than 50°F (10°C) PCB
temperature.
Low system air pressure.
Failure to reach set point for clutch Yellow light is transmitted.
These component(s) are leaking
position using normal actuator Rough start.
air: clutch cylinder clutch valve
FMI 8 Clutch system control, limit for using actuator Rough shifting.
assembly clutch cylinder air hose
valves exceeded, clutch position is Slow shifting.
clutch cylinder air connection
beyond tolerance at disengaged Slow clutch engagement at start.
position.
Yellow light is transmitted.
Clutch.
Too much torque transferred (by Vehicle tends to creep on flat
FMI 11 Clutch drag Warped flywheel.
clutch) in disengaged position. ground at idle.
Transmission input shaft.
Excessive wear on clutch.
Yellow light is transmitted.
Failure for clutch to transfer a
FMI 12 Unintentional clutch slip Reduction of engine torque to Clutch
specific torque without slipping
prevent clutch from slipping.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Illumination of Red stop light.
Failure to disengage clutch.
Engine shut down.
FMI 14 Clutch system Failure to disengage clutch N/A
Failure to shift gears.
Failure to engage neutral gear
position.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 28 Transmission Brake
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Out of adjustment or not Transmission braking failure with
FMI 7 Slow changes in gear at N/A
responding mechanical system valve activated
stationary.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 200 Communication Interference, Data Link, Engine Control Module
(ECM)
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 9 Update rate is not normal ECM messages via SAE J1939 Yellow light is transmitted. N/A
data link missing If no CAN 2 data link exists,
automatic gear selection enters
backup mode with gear changes
only at certain vehicle speeds.
If no CAN 2 data link exists and if
engine does not receive TCM
 messages, gear changes will be
slow.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 201 Communication Interference, Data Link, Vehicle ECU
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
If pedal position is not
determined, automatic gear
selection enters backup mode with
gear changes only at certain
Faulty accelerator pedal position
Not Normal frequency, pulse vehicle speeds.
FMI 8 or brake pedal switch - indicated N/A
width, or period Shifting at start and at slow speed
by Vehicle ECU signal
is not even.
If service brake is not determined,
automatic gear selection enters
backup mode with gear changes
only at certain vehicle speeds.
Yellow light is transmitted.
Automatic gear selection enters
ECM messages over SAE J1939 backup mode with gear changes
FMI 9 Update rate not normal N/A
data link missing) only at certain vehicle speeds.
Harsh shifting at start and at slow
speed.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 204 Communication Interference, Data Link, Brake Control Module
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause

Frequency, pulse width, or period Incorrect wheel speeds from Yellow light is transmitted.
FMI 8 N/A
not normal Brake ECM (MID 136) may Slow changes in gear.
cause this fault.
Missing Brake ECM (MID 136) Yellow light is transmitted.
FMI 9 Update rate not normal
message may cause this fault Slow changes in gear. N/A

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 207 Communication Interference, Data Link, Gear Selector Control
Module
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Missing GSCM (MID 223) Poor response on manual gear
FMI 9 Update not normal N/A
message may cause this fault changes and poor response upon
pressing gear lever buttons.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 210 J1939 Data Link Interruption Lighting ECM
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 9 Update rate not normal Missing LCM (MID 216) Yellow light is transmitted. N/A
message may cause this FMI Incorrect start gear.
Possibly automatic gear selection
performance degrades a certain time
 after start.
Possibly automatic gear selection
performance degrades a certain time
after a trailer has been
connected/disconnected.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 211 J1939 Data Link Interruption Adaptive Cruise Control ECM
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Missing ACC (MID 219) Yellow light is transmitted.
FMI 9 Update rate is not normal message Malfunctioning retarder ACC N/A
ACC is installed function.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 232 Powertrain Can
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Incorrect, erratic, or intermittent
CAN 2 data link communication Yellow light is transmitted.
FMI 2 N/A
data failure Slow gear shifts.
ECM messages over SAE J1939 Yellow light is transmitted.
FMI 9 Update rate is not normal N/A
data link missing Slow gear shifts.
NOTE: Vehicles that have CAN 2 data link exists between engine and TCM use this fault code.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 PSID 254 DIEE Signal
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted
Inhibited cranking Engine will not
Voltage is shorted high or
FMI 3 High voltage at DIEE terminal start Except for programming of N/A
exceeding normal range
MSW, all communication with
control module disabled

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 35 Solenoid Valve High Range
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high Valve activated.
FMI 3 N/A
exceeding normal range side drive Missing low range gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower Valve will not activate.
FMI 5 Circuit is open in high-side drive N/A
than normal range Missing high range gears.
Wrong gear selection.
Yellow light is transmitted Valve
Circuit is grounded or current is Short circuit to ground in high- will not activate Missing range
FMI 6 N/A
exceeding normal range side drive gears.
Wrong gear selection.
FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 36 Solenoid Valve Low Range
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Voltage is shorted high or Short circuit to U-BATT in high Valve activated.
FMI 3 N/A
exceeding normal range side drive Missing high range gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower Valve will not activate.
FMI 5 Circuit is open in high-side drive N/A
than normal range Missing low range gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Valve will not activate.
FMI 6 N/A
exceeding normal range side drive Missing range gears.
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 37 Solenoid Valve High Split
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Valve activated.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Missing indirect and neutral split N/A
exceeding normal range side drive
gears.
Wrong gear selection.
Yellow light is transmitted Valve
Circuit is open or current is lower will not activate.
FMI 5 Circuit is open in high-side drive N/A
than normal range Missing splitter gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Valve will not activate.
FMI 6 N/A
exceeding normal range side drive Missing splitter gears.
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 38 Solenoid Valve Low Split
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Valve activated.
Voltage is shorted high or Short circuit to U-BATT in high
FMI 3 Missing direct and neutral split N/A
exceeding normal range side drive
gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is open or current is lower Valve will not activate.
FMI 5 Circuit is open in high-side drive N/A
than normal range Missing splitter gears.
Wrong gear selection.
Yellow light is transmitted.
Circuit is grounded or current is Short circuit to ground in high- Valve will not activate.
FMI 6 N/A
exceeding normal range side drive Missing splitter gears.
Wrong gear selection.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 231 SAE J1939 Data Link
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 2 Incorrect, erratic, or intermittent CAN 2 data link communication Yellow light is transmitted. N/A
data failure Slow gear shifts.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 240 Program Memory
NOTE: Boot program only sets this fault code during power-up. Boot program does not save any fault codes.
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Incorrect, erratic, or intermittent Data is incorrect in program
FMI 2 Inhibited cranking. N/A
data memory
Engine will not start.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 250 SAE J1587 Data Link
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Failure to receive signal from Slow gear shifts.
FMI 9 Update rate is not normal MID 128 PID 190, PID 85, PPID Failure to view fault codes. N/A
212 within 30s Not possible to run on-vehicle
tests.

FAULT CODE INDEX > MID 130 TRANSMISSION CONTROL UNIT > MID
130 SID 253 Calibration Memory EEPROM
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Error in flash checksum data set.
FMI 13 Calibration value is not in range Inhibited cranking. N/A
Missing program code.
Engine will not start.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT
Recommended tool for diagnostic work is manufacturer diagnostic tool.

Communication for control modules on information link is established according to SAE J1587 standard. Following valuable information are included in Fault Codes
generated by control modules.

• MID (Message Identification Description): Identifies control module.

• PID (Parameter Identification Description): Identifies a parameter (value).
• PPID (Proprietary Parameter Identification Description): This is a unique identification of a parameter (value).
• SID (Subsystem Identification Description): Identifies component.
• PSID Proprietary Subsystem Identification Description: This is unique identification of a component.
• FMI Failure Mode Identifier: Identifies fault types.

FMI TABLE

FMI Display Text SAE Text

0 Value is too high Valid data but exceeding normal range
1 Value is too low Data is valid, but below normal range
2 Data is incorrect Incorrect/erratic/intermittent data
3 Electrical problem Voltage is shorted high or exceeding normal range
4 Electrical problem Voltage is lower than normal range or shorted low
5 Electrical problem Circuit is open or current is lower than normal range
6 Electrical problem Circuit is grounded or current is exceeding normal range
7 Mechanical problem Improper response from mechanical system
8 Electrical or mechanical problem Frequency, pulse width or period is abnormal
9 Communication related error Update rate is not normal
10 Electrical or mechanical problem Abnormal rate of change
11 Fault cannot be identified Unidentifiable failure mode
12 Fault in component Component or intelligent device defective
13 Calibration is incorrect Out of calibration
14 Fault cannot be identified Special instructions
SAE Data Formal Subcommittee reserves for future
15 Fault cannot be identified
assignment

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 130 SID 231 SAE J1939 Data Link
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Gear lever commands slower
(J1587).
No memorization during 1.5
Incorrect, erratic, or intermittent CAN 2 data link communication seconds of direction change
FMI 2 N/A
data failure requests with vehicle driving.
Manual mode is disabled
temporary.
Downhill help is disabled.
Return to drive is disabled.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 Control Module Fault Tracing > PSID
MID CONTROL MODULE (PSID) REFERENCE

MID 223 PSID 9 Gear Selector, Position

MID 223 PSID 36 Relay Power Supply
MID 223 PSID 42 Signals, Key
MID 223 PSID 200 Communication Interference, Data Link, ECM
MID 223 PSID 201 Communication Interference, Data Link, Vehicle ECU
MID 223 PSID 205 Communication Interference, Data Link, TCM
MID 223 PSID 214 No Data From BBM

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 Control Module Fault Tracing > SID
MID CONTROL MODULE (SID) REFERENCE

MID 130 SID 231 SAE J1939 Data Link

MID 223 SID 240 Program Memory
MID 223 SID 250 SAE J1587 Data Link
MID 223 SID 253 Calibration Memory EEPROM
MID 223 SID 254 Hardware Fault

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 9 Gear Selector Position
GEAR SELECTOR POSITION REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Signals from sensor DO NOT Some or all stalk actions
FMI 12 Component or device defective N/A
correspond with valid value malfunction.
Failure to select gear.
FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 36 Relay Power Supply
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Fault displayed after ignition
Improper response from OFF.
FMI 7 Relay will not release N/A
mechanical system Battery discharge possible when
vehicle is not used, if main circuit
breaker is not opened.
FMI 12 Component or device defective 0 voltage at terminal 1 Failure to drive vehicle N/A

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 42 Signals Key
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Transmission supplied and Opt
driver fully functional until main
circuit breaker is opened.
Discrepancy between hard-wired
Incorrect, erratic, or intermittent Battery discharge possible when
FMI 2 ignition signal and that indicated N/A
data vehicle not used, if main circuit
signal on network
breaker not opened.
Transmission not supplied and
vehicle immobilized after main
circuit breaker has been cycled.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 200 Communication Interference, Data Link, Engine Control
Module (ECM)
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
ECM messages over SAE J1939 Yellow light is transmitted.
FMI 9 Update rate is not normal N/A
data link missing) Downhill help is disabled.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 201 Communication Interference, Data Link, Vehicle ECU
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Downhill help is disabled.
Message missing on SAE J1939 Return to drive is disabled.
FMI 9 Update rate is not normal data link from following control Yellow light is transmitted. N/A
module: Vehicle ECU Temporary manual mode is
disabled.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 205 Communication Interference, Data Link, Transmission
Control Module
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 9 Update rate is not normal Transmission Control module Yellow light is transmitted. N/A
(TCM) message over SAE J1939 No memorization during 1.5
data link missing: seconds of direction change
requests when vehicle is driving.
Temporary manual mode is
disabled.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 PSID 214 No Data From BBM
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
FMI 9 Update rate is not normal Bodybuilder message over SAE Yellow light is transmitted N/A
J1939 data link missing

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 SID 240 Program Memory
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted
GSCM: No function except
Incorrect, erratic, or intermittent Data error in program memory
FMI 2 supply relay N/A
data Not programmed control module
Failure to move out of neutral
position

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 SID 250 SAE J1587 Data Link
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
A control module being
FMI 9 Update rate is not normal SAE J1587 data link malfunctions Yellow light is transmitted
programmed

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 SID 253 Calibration Memory EEPROM
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted.
Incorrect, erratic, or intermittent
FMI 2 Main software error Use of default values of Control module not programmed
data
parameters.

FAULT CODE INDEX > MID 223 GEAR SELECTOR CONTROL UNIT >
MID 223 SID 254 Hardware Fault
FAULT CONDITION & POSSIBLE SYMPTOMS REFERENCE

Fault Type FMI Description Fault Condition Possible Symptoms Possible Cause
Yellow light is transmitted. Gear selector control module
FMI 12 Component or device defective Control module internal fault
Failure to drive vehicle. (GSCM)
SPECIAL TOOLS
SPECIAL TOOLS

Tool No. Tool Name

- Premium Tech Tool & software
J44773 Air Line Release Tool
OCT 5018 Clutch Handler
85108826 Transmission Line Tool (15 mm)
88800005 Hollow Drift
88800006 Retainer
88800015 Puller
88800033 Brace
88800034 Puller
88800035 Puller
88800174 Mandrel
88800195 Coupler
9986485 Overhaul Stand
9988185 Snap Ring Pliers
9989876 Dial Indicator Gauge
9990015 Coupler
9990024 Centering Dift
9990027 Socket Wrench
9990028 Fixture
9990029 Retainer
9990030 Puller
9990031 Anchorage
9990084 Adapter
9990120 Mandrel
9990266 Rivet Bracket
9991801 Handle
9991821 Bearing Extractor
9992000 Drift Handle
9992003 Mandrel
9992215 Mandrel
9992241 Press
9992337 Lever
9992500 Hollow Drift
9992564 Installation Tool
9992613 Standard Handle 25x350
9992619 Spindle
9992621 Mandrel
9992631 Driving Plate
9992653 Mandrel
9992671 Hydraulic Cylinder
9992911 Hollow Drift
9994731 Yoke
9996041 Spindle
9996042 Sleeve
9996081 Mandrel
9996154 Sleeve
9996156 Mandrel
9996176 Mandrel
9996222 Hydraulic Pump, Air Operated
9996239 Lifting Chain
9996291 Hollow Drift
9996315 Spindle
9996361 Hollow Drift
9996413 Mandrel
9996454 Extension
9996479 Lifting Eye
9996480 Socket AF 75
9996483 Screw
9996498 Pin
9996499 Arm
9996500 Yoke
9996600 Hydraulic Cylinder 10 Tonnes
9996601 Yoke
9996602 Puller Arm Pins
9996603 Rod End
9996635 Arm
9996725 Hollow Drift
9996788 Seal Driver
9996857 Clutch Removal Fixture
9996876 Guide
9996889 Mandrel
9996896 Retainer
9996901 Mandrel
9996904 Hollow Drift
9996905 Fixture
9996910 Fixture
9996913 Puller
9996917 Screw
9996924 Washer
9996925 Adapter
9998051 Press Tool
9998215 Puller
9998219 Puller
9998393 Hollow Drift
9998401 Ring
9998542 Puller
9998570 Counterhold
9998575 Seal Installer
9998597 Companion Flange Removal Tool
88800174 Seal Installer
9998588 Mandrel
9998597 Puller
9999696 Magnetic Stand
9999737 Intermediate Flange

DESCRIPTION & OPERATION > GENERAL

Twelve forward speeds and up to 4 reverse speeds are standard to all mDRIVE/I-Shift based on programming. mDRIVE/I-Shift Transmissions are single countershaft,
automated mechanical transmissions. This includes splitter section, main section with 3 forward and one reverse gear, and range gear section.

Synchronizers are used in splitter and range gears meanwhile a countershaft brake is used in main section. Countershaft brake can mesh gears and equalize shaft speeds as
necessary. Torque converter is eliminated by a clutch system which is a single disc automated system. A clutch pedal is not necessary for mDRIVE/I-Shift which is a "two
pedal" transmission.

With assistance from compressed air and electrical solenoids, mDRIVE/I-Shift performs following tasks which are timed and controlled by TCM:

• Shifting.
• Clutch control.
• Countershaft brake.

Vehicle must have a dedicated air tank for supplying air to these components. A supply line feeds transmission and then air is distributed to other components internally.
There are air control solenoids in transmission control housing contains and in clutch control valve assembly.

Several mDRIVE/I-Shift versions models are available to support power ranges of engines as well as offering different gear arrangements.

OPERATION REFERENCE

Application TmD12AO TmD12AO23 TmD12AD

Operation Two Pedal Two Pedal Two Pedal
Forward Speeds 12 12 12
Engines Available MP7/MP8 (D11/D13) MP10/D16 MP7/MP8 (D11/D13)
Overall Ratio 15.04:1 15.04:1 14.94:1
Top Ratio Overdrive 0.78:1 Overdrive 0.78:1 Direct 1.00:1
Weight Lbs. (kg) 614 (279) 627 (285) 614 (279)

DESCRIPTION & OPERATION > CLUTCH

A dry clutch and single disc are on all vehicles with mDRIVE/I-Shift. Depending on engine, it will vary which pressure plate is used. The 16L engines use a self adjusting
pressure plate. It is necessary to cage self adjusting pressure plate before removal. Adjusters can not be reset if caged incorrectly. MP7/D11 and MP8/D13 will use a non
adjusting pressure plate. All pressure plates and clutch are replaced in matching sets.

mDrive is completely automated by clutch cylinder mounted behind pressure plate. mDrive automation has features that include:

• Clutch protection active warning.

• High clutch load warning.

In these cases transmission control module (TCM) will display a warning light in Co-Pilot. If warnings are ignored clutch will engage slowly to protect itself. Clutch will
disengage if accelerator pedal is released.
DESCRIPTION & OPERATION > CLUTCH CONTROL VALVE
Mounted on exterior of clutch housing, clutch control valve controls compressed air supply to clutch cylinder so engagement and disengagement of clutch can be
controlled. There are 4 solenoid valves in control valve. For engagement task; 2 engagement valves, one slow and one fast are included. Two disengagement valves, one
slow and one fast are also included for disengagement. In order to obtain desired engagement or disengagement speed, valves can be used alone or together as necessary. A
serviceable filter integral into control valve filters air supply so contaminants cannot reach clutch cylinder.

Fig 1: I-Shift Clutch Control Valve

View Full-Screen

DESCRIPTION & OPERATION > CLUTCH CYLINDER

This is a fully automated component, located inside clutch housing, encircling input shaft and installed to actuate clutch. Clutch actuation is accomplished by using
compressed air (for moving cylinder) as needed. Clutch control valve regulates pressurized air.

A release bearing is integrated in Clutch cylinder. In event that mDRIVE/I-Shift is unintentionally left in gear and parking brake has been applied, TCM will automatically
shift to neutral after 4 minutes. This is system's strategy to protect release bearing and crank shaft thrust bearing from wear and damage.

There is a position sensor on exterior of clutch cylinder to monitor clutch position and clutch engagement point. This sensor also aids in clutch wear calculation. Monitoring
clutch requires following two clutch position reference values.

1. X1 Value - A base line value set anytime a NEW clutch is installed. This is done by performing Clutch Engagement Point Calibration using scan tool.
2. X2 Value - A value representing current position of clutch.
Fig 1: I-Shift Clutch Cylinder
 View Full-Screen

DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER

ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Component List
COMPONENT DESCRIPTION

MID Component Description

A14 ECM (engine control module)
SA 0/MID128/ECM B04 Sensor, crankshaft position (CKP)
Y39 Solenoid valve, EB (engine brake)
MID130/TCM A13 TCM (transmission control module)
A109 GSCM (gear selector control module)
MID223/GSCM
S171 Gear selector
A17 Vehicle ECU (vehicle electronic control unit)
S59 Position switch, brake pedal
B25 Sensor, accelerator pedal (with Maccelerator)
B12 Sensor, output shaft speed (road speed)
MID144/Vehicle ECU
S43 Pressure switch, parking brake
S28 Switch, power takeoff
S25 Switch, cruise control
S24 Switch, engine brake
A3 Instrument cluster
MID140/Central Instrument Cluster
S08/S09 Switch, differential lock/wheel lock
A12 ABS control unit (anti-lock brake system control module)
MID136/ABS
B13-20 Sensor, wheel speed
DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER
ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Communication With Engine Control Module (ECM), SA 0/MID 128
Signals/information:

• Engine signals: Torque monitoring and engine speed (RPM).

DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER

ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Communication With Gear Selector Control Module (GSCM), Mid 223
Signals/information:

• Gear selector input.

DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER

ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Communication With Vehicle ECU, MID 144
Signals/information:

• AP position, including Maccelerator.

• Brake pedal status.
• Cruise control.
• Engine brake switch.
• Grade Gripper.
• Parking brake status.
• PTO control.

DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER

ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Communication With Instrument Cluster MID 140
Signals/information:

• Information on gear selector display.

• Warnings on Co-Pilot display.
• On board DTCs for TCM and GSCM.

DESCRIPTION & OPERATION > COMMUNICATION WITH OTHER

ELECTRONIC CONTROL UNITS (ECUS) > Components (Signal Summary) >
Communication With Anti-Lock Brake System (ABS) Control Module MID 136
Signals/information:

• Information from wheel speed sensor.

• ABS status information.
• Traction control status information.
• Enhanced stability technology (VEST) information.
• Grade Gripper.
DESCRIPTION & OPERATION > CONTROL HOUSING ASSEMBLY
Control housing assembly is comprised of:

• TCM.
• Shift solenoids.
• Countershaft brake solenoid.
• Gear position sensors.
• Oil temperature sensor.
• Shaft speed sensors.
• Shift forks and their shift cylinders.

When gear selector selects a gear, in conjunction with engine ECM, these components work to reduce engine torque to a comfort level, before control housing transitions
transmission to neutral and then to selected gear.

Supply of pressurized air to cylinders, that is critical for change of gears, is controlled by solenoid. Control housing controls countershaft brake solenoid, which controls
pressure of air moving to brake assembly. This air pressure control is critical for synchronizing shaft speeds to mesh main gears. Once transmission has shifted to neutral,
ECM starts adjusting engine speed (RPM) so selected gear can be accommodated after shift takes place.

Control housing cover contains 2 electrical sockets and also contains TCM:

1. Vehicle communication.
2. Clutch cylinder.
Fig 1: I-Shift Vehicle Communication & Clutch Cylinder Electrical Socket

View Full-Screen

There are 9 solenoid valves in control housing cover. See Figure & Figure. These valves control path of pressurized air:

• Solenoid valve 2nd gear.

• LR. Solenoid valve, low range.
• Solenoid valve 3rd gear.
• HR. Solenoid valve, high range
• B. Solenoid valve, brake.
• LS. Solenoid valve, low split.
• R. Solenoid valve, reverse.
• HS. Solenoid valve, high split.
• Solenoid valve 1st gear.

Overdrive Transmissions:

• Solenoid valve 2nd gear.

• LR. Solenoid valve, low range.
• Solenoid valve 3rd gear.
• HR. Solenoid valve, high range.
• B. Solenoid valve, brake.
 • HS. Solenoid valve, high split.
• R. Solenoid valve, reverse.
• LS. Solenoid valve, low split.
• Solenoid valve 1st gear.

Direct Drive Transmission.

Locations of 4 parallel cylinders and one of cylinder position sensors:

1. Split cylinder.
2. 1/R cylinder.
3. 2/3 cylinder.
4. Range cylinder.
5. Split cylinder position sensor.

Locations of other 3 cylinder position sensors and speed sensors:

1. Range cylinder position sensor.

2. Countershaft speed sensor.
3. Main shaft speed sensor.
4. 2nd/3rd gear cylinder position sensor.
5. 1st/reverse cylinder position sensor.

Locations of other 3 shift forks:

1. 1st-Reverse gear shift fork.

2. 2nd-3rd gear shift fork.
3. Splitter gear shift fork.

DESCRIPTION & OPERATION > COUNTERSHAFT BRAKE

Counter shaft brake is integrated into clutch housing, at front of countershaft. Purpose of this brake is to stop moving components in transmission when starting gear is
selected. This eliminates transmission wear and noise. This brake aids in synchronizing shaft speeds during gear shifting for fast shifting. See Figure.

Solenoid in control housing activates this brake by controlling pressurized air flow to brakes integrated pneumatic cylinder which applies pressure to friction and steel disc
plates.

DESCRIPTION & OPERATION > CO-PILOT/DASH DISPLAY

Current operating information regarding mDRIVE/I-Shift transmission is displayed. Remember Transmission information is always displayed in a portion of Dash Display.

Co-Pilot/Dash Displays:

1. Mileage.
2. Time.
3. Available Gears Down.
4. Ambient Air Temp (AAT).
5. Current Gear.
6. Available Gears Up.
7. Driving Mode (P) (performance mode.)

DESCRIPTION & OPERATION > ELECTRICAL SYSTEM > Sensors &

Electrical Connections
1. General wiring harness routing. See Fig 1.
2. Clutch control valve.
3. Speed sensor.
4. Wiring harness connector to clutch control valve.
5. Vehicle communication.
Fig 1: Identifying General Wiring Harness Routing
 View Full-Screen

DESCRIPTION & OPERATION > FEATURE DESCRIPTION & FUNCTION

• Automatic Gear Shifting in Drive Mode.

This is an automated default mode, applicable in most driving situations. When enabled, this mode will take maximum advantage of other mDRIVE/I-Shift features.
This includes Engine Braking, EconoRoll, Maccelerator, Performance Mode or Economy Mode. Selection for starting gear is made based on engine power rating,
load and slope of road. Start gear is normally 1 or 2 with a trailer connected, 4 when bob-tailing. Depending on mode selection made, transmission carries out all gear
changes in order to optimize performance and fuel economy.

• Manual Shifting in Drive and Manual Mode.

In this mode, using up/down arrows on premium gear selector key pad, driver can select gears. Number of available up/down gears using arrows are indicated in Co-
Pilot display.

• Manual Selection of Starting Gear.

In "Manual mode" starting gears can be selected within 1-6 without trailer and 1-3 with a trailer connected. In "Drive Mode" selection for starting gear is made based
on engine power rating and slope of road. Selected gear is adjustable by up to 2 gears above calculated unless it exceeds "Highest available start gear", which is a
customer programmable parameter ranging between 1-6. Default value of this parameter is 6.

• Idle Governor Driving Mode.

This mode is used while driving in congested traffic where constant depressing or releasing of AP is not needed. TCM engages clutch completely. ECM controls
engine speed using engine idle governor. Regardless of engine load, idle governor adjusts torque in order to maintain idle speed and constant vehicle speed. There is
no wear and overheating risk of clutch because clutch stayed fully engaged. Idle-drive mode is enabled by increasing vehicle speed to a desired gear and then
releasing pedal fully. Lower idle-driver speed is selected either by depressing down-arrow on gear lever or by slightly applying service brake. Transmission will shift
to a lower gear in both of conditions.

• Economy Mode.

When ignition is placed in ON position, transmission is in this mode. Co-Pilot display exhibits "E" as driving mode. In order to optimize fuel economy, transmission
will select shift points and engine parameters automatically. It is encouraged to use economy mode as primary driving mode under normal conditions.

• Performance Mode.

If operated in this mode, Co-Pilot display exhibits "P". In order to optimize grade ability, transmission strategy changes. When TCM determines that Performance
Mode is no longer necessary, it returns to Economy Mode.

• MackCelerator.

To activate this feature, depress AP completely toward floor so MackCelerator switch is depressed. AP assembly houses MackCelerator switch. In order to maximize
vehicle acceleration, system changes gear selection strategy thereby resulting in instant gear downshift. Because of available engine power, TCM may not downshift
in some situations. Upon lifting AP, MackCelerator deactivates causing MackCelerator switch to release.

• Dynamometer Mode.

This mode serves as component of all vehicles software as long as vehicle is running on a dynamometer. If front wheels are not moving at same speed as rear wheels,
mDRIVE/I-Shift transmission will not up shift. This is vital to when on a dynamometer, to put gear selector in D position and to depress AP completely to floor. This
 enables vehicle to hold existing gear for 10 second so dynamometer mode can be engaged and transmission can begin shifting during this period. Driver can
disengage dynamometer mode by releasing AP. When running in Dynamometer Mode, Co-Pilot display exhibits "E".

• Standard Power Takeoff (PTO) Features.

All mDRIVE/I-Shift transmission has basic PTO Function which is always available. Basic function includes predefined splitter positions. Operator can set software
parameters that define which splitter gear to engage when transmission PTO 1/2 are engaged.

• Enhanced PTO Features.

With this feature, PTO features can be activated by setting software parameters. See following list for features. Activation of these functions require a bodybuilders
module (BBM) be installed in vehicle.

1. Gear Selection adaptation to RPM limits. Operator can set software parameters that limits RPMs when engine or transmission PTOs are engaged. Note that this
feature will adapt gear selection strategy to these speed limitations.
2. Auto Neutral. This feature enables transmission to See neutral and back into gear based on an external input (e.g. parking brake status), irrespective of gear
lever position.
3. Reverse Inhibit. Due to this function, reverse gear can be blocked even if gear lever is shifted to reverse.
4. Split Box Engagement. Software supports use of a splitter box for running high capacity PTOs. When BBM engages split box, direct gear engages.

DESCRIPTION & OPERATION > GEAR RATIO

Gear ratios for TmD12AD, TmD12AO, and TmD12AO23:

GEAR RATIO REFERENCE

Gear Selection 12 Geared TmD12AD 12 Geared TmD12AO & TmD12AO23

1st 14.94:1 11.73:1
2nd 11.73:1 9.21:1
3rd 9.04:1 7.09:1
4th 7.09:1 5.57:1
5th 5.54:1 4.35:1
6th 4.35:1 3.41:1
7th 3.44:1 2.70:1
8th 2.70:1 2.12:1
9th 2.08:1 1.63:1
10th 1.63:1 1.28:1
11th 1.27:1 1.00:1
12th 1.00:1 0.78:1
Reverse gear R1 17.48:1 13.73:1
Reverse gear R2 13.73:1 10.78:1
Reverse gear R3 4.02:1 3.16:1
Reverse gear R4 3.16:1 2.48:1

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features
NOTE: Optional features are available in I-shift transmission. For more information about standard and optional features, consult truck dealer.

Improved I-Shift transmission feature packages can add additional benefits. Features that can be upgraded are described below.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Gear Selector
• Vehicles equipped with this manufacturer I-shift have two gear selectors:
◦ Driver's seat gear selector - Gear selector is connected to driver's seat and can be folded to provide more space while entering cabin. Basic and Premium are
two available seat installed selector configurations. Selector is Vehicle's program package level dependent.
◦ Dash installed gear selector - This selector performs similar functions as Premium seat installed selector.
• Gear positions such as R (Reverse), N (Neutral), D (Drive), and M (Manual) are available on both selectors. Drive position implies automatic gear shift and no driver
input is required. Any of below operations can be performed by driver when Manual position is selected:
◦ Shifting gears using buttons (+, -).
◦ Locking and holding current operating gear until selector is placed in Drive position.
• If manual position is engaged at a stop with basic selector, vehicle will start in first and hold that gear.
• Both gear selectors have E/P button that offers economy and performance options. If I-Shift is left in gear (with parking brake applied), TCM will automatically
shifts to neutral as ignition switch is turned OFF. This prevents transmission from being stuck in gear due to drive line "torque up".
• Gear Selector Electronic Control Module (GSECM), in dashboard, receives signals from selector. GSECM interprets these signals into communication information,
which is then transferred to TCM.
 • To move gear lever from N position, depress gear selector lock. DO NOT press gear selector lock while performing following operations:
◦ Shifting gear lever from R to N position.
◦ Moving gear lever back and forth between D and M positions.
◦ Moving lever from D to N position.
• In Premium gear selector, operator can manually select operating gear in both driving modes (automatic and manual) using manual gear selection buttons. Same
buttons can be used to select vehicle start gear and idle driving gear as well.
• E/P button is available in premium gear selector. When vehicle starts, transmission is in Economy mode. To activate Performance Mode , press E/P button.
NOTE: Performance mode cannot be engaged with disabled E/P parameter.
• Press Fold button on top of lever to fold gear lever from N to horizontal position. No need to press button while returning lever to vertical position.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > D Position
• To maintain desired vehicle speed for current driving conditions, transmission will automatically upshift and downshift (as required).
• Driver cannot manually select a different gear due to Basic gear selector.
• Current operating gear is displayed along with up and down arrows (indicating number of available manual upshift/downshift) on each side of gear display when
Premium gear selector lever is in D position.
• Manual gear selection buttons can be used by operator to upshift or downshift (as indicated by arrows). In order to maintain desired vehicle speed for current driving
conditions, transmission will automatically upshift and downshift. As driving condition changes, number of available manual upshifts and downshifts also change.
• To skip gear shift more than one gear at a time (by maximum of three), press manual gear selection buttons multiple times.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > M Position
• Current gear is displayed along with up and down arrows when Premium gear selector lever is in M position. Operator will have to use manual gear selection buttons
to upshift/downshift manually, as transmission will not change gears automatically. As driving condition changes, number of available manual upshifts and
downshifts also change.
• Transmission automatically engages proper gear once engine RPM drops to less than allowable speed. When driving on a downhill with steep slope, use M-position
to control engine RPM, in desired gear.
CAUTION: DO NOT start vehicle in too high gear, otherwise clutch may be damaged.
• DID indicates lower gear message along with Information light and an audible warning if vehicle requires lower transmission gear to start (in Premium gear selector
mode).
• To select a low gear, use manual gear selection button or move gear lever to D position on gear selector. Keep using button to shift to lower start gear, until message
and lights go OFF.
• For stationary vehicle with Basic selector mode, vehicle start gear changes to first if gear lever shifts from D to M position.
CAUTION: Engine may be damaged due to over-revving when transmission is locked in a gear.
• Move gear lever from D to M position to lock transmission in current gear. Use this function for all 12 forward gears. Move lever to D position to return to automated
program.

NOTE: Fuel economy reduces if vehicle is operated in M position for long time.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > R Position
• Current gear (along with up and down arrows) is displayed when Premium selector lever is in R position. Operator will have to upshift/downshift manually by using
manual gear selection buttons as transmission does not change gears automatically.
• If vehicle is equipped with four reverse gears, vehicle must be stationary to shift between R2 and R3.
NOTE: Only VHD vehicles have R3 and R4 reverse gears.
• When vehicle is moving with Basic gear selector and gear lever is shifted from D or R to M position, transmission will remain in current gear until lever returns to D,
R or N.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Engine Idle Governor Driving Mode
• Maneuvering vehicle at lower speed can be allowed by selecting Engine Idle Governor driving mode. Following functions are performed by this feature:
◦ Operates engine at idle when operator adjusts vehicle speed by selecting a gear.
◦ Keeps clutch closed to avoid slipping or overheating.
◦ Maintains idle speed and constant vehicle speed by adjusting torque (although variation of engine load may occur).
• If necessary, shift transmission down one gear by tapping service brake.
• When driving in slow traffic, use manual gear selector button to upshift/downshift once start gear is fully engaged (with premium gear selector). Engine will adjust
torque to fit next gear once higher gear is selected using gear selection button. Thus, pressing accelerator pedal to increase speed is not needed. Press brake pedal so
that clutch will bring vehicle to rest by disengaging transmission.
NOTE: In idle drive, use +/- button to adjust speed up to 6th gear.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Economy & Performance Modes (Only With Premium
& Dash Installed Gear Selectors)
• Transmission defaults to Economy mode when engine is started. DID indicates 'E' (Economy mode) in driving mode. Fuel economy is improved by automatic
selection of shift points and engine parameters by transmission. Economy mode is preferred in normal driving conditions.
• In Performance mode, DID indicates P/P+ as driving mode. Performance mode is similar to Economy mode in terms of vehicle acceleration from a standstill.
• Instead of providing faster acceleration, Performance mode offers higher speed and less skip shifting, thus providing larger engine torque margin and improving
driving in tough conditions.
• Vocational, construction and heavy hauler vehicles have Performance Plus (P+) mode instead of P mode. P+ mode offers improved gear shifting and standard
features.
NOTE: P+ mode is not offered with Comprehensive and Gentle packages. Once operator switches to P mode in Gentle/Comprehensive package, normal P mode
activates instead of P+ mode. Operation of vehicle in P+ mode is allowed by Performance software package.

Modification of P mode to meet particular operating conditions is allowed by following customer-requested options:

◦ Full operator control.

◦ No operator control.
◦ Auto return to E mode (under particular operating conditions).
• Kick-Down function can also be disabled by a customer-requested option.
• Performance Bonus software package can be used to enable P mode.

NOTE: Fuel economy reduces if vehicle is operated in P mode for long time.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Kick-Down
• Accelerator pedals with and without kick-down switch are available. Few software packages have Kick-Down function which can be enabled/disabled (as required).
• Performance Bonus software package can be used to enable Kick-Down feature. Always ensure D position of gear selector before enabling Kick-Down.
• Press accelerator pedal down to floor to request Kick-down, and lift pedal to cancel this feature. Transmission downshifts when vehicle acceleration is optimized
after request for Kick Down is made.
• If vehicle will accelerate faster in current gear, transmission will not downshift, thus maximum acceleration is ensured without downshifting.

NOTE: Fuel economy reduces if vehicle is operated with engaged Kick Down for long time.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Eco-Roll (Optional Feature)
• Eco-Roll automatically disengages driveline when vehicle speed can be maintained without engine, and thus reduces fuel consumption.
• Engine speed is temporarily reduced to idle when Eco-Roll is active.
• Use this feature while in cruise control mode or normal driving conditions with accelerator pedal.
• Optional dash-mounted switch can be used to temporarily enable/disable Eco-Roll. Feature will also be re-enabled by ignition OFF-ON cycle.
NOTE: Eco-Roll feature is available at 7th or higher gears, while 12th being default gear.
• Eco-Roll can only be enabled in brake stalk position A (vehicles without dash-mounted switch). Move brake stalk to 0, 1, 2 or 3 position to disable and link Eco-Roll
to E+ driving mode.
• Eco-Roll activates automatically (when enabled) when following conditions exist:
◦ Vehicle not moving on a downhill or uphill with steep slope.
◦ Economy mode is ON.
◦ Shift lever is in D and I-VEB stalk switch is in A position.
◦ Optional switch not used to disable Eco-Roll.
◦ Service brake and accelerator pedal are released
◦ Transmission is operating in 7th or higher gear.
◦ Brake cruise set speed exceeds cruise set-speed by more than 3 mph (5 km/h).
◦ Vehicle speed below 78 mph (125 km/h).
◦ Inactive VEST and ABS
• DID indicates Eco-Roll and E+ as driving mode when Eco-Roll is available. Current gear (7-12) changes to N in DID when Eco-Roll is active.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Engine Brake Performance Mode
NOTE: Temporary interruption of braking torque is observed when transmission is shifting gears with active engine brake, causing vehicle speed to increase momentarily
(on downhill). Temporary loss of engine braking is similar to that observed in conventional manual transmission, when downshifting.

• I-Shift transmissions offer enhanced engine brake (I-VEB) and can be activated after engine attains normal working temperature. Status bar in DID indicates current
brake position. 6-position engine brake control has a switch on end to set and change speed for brake cruise and engine brake activation during coasting.
• Condition of brake blending occurs when service brake is automatically assisted by engine brake (when in A-position).
• 1/3, 2/3 and 3/3 of braking torque is available from engine in position 1, 2 and 3. In order to maximize available braking torque, engine speed is kept on a higher
level, in B-position.
• Brake cruise speed can be adjusted when cruise control mode is ON and brake control lever is in A-position. DID indicates value for set speed and brake cruise
speed. Performance is optimized when transmission interacts with engine brake.
• Gear with highest level of braking is selected by transmission when Engine Brake Performance Mode is active. Move and hold brake control to B position for at least
one second to enable Engine Brake Performance Mode. Once mode is activated, DID indicates B in driving mode.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Hill Start Assist (Optional Feature)
• While starting vehicle on a steep slope, Hill Start Assist provides anti-roll back assistance. Pressure in brake chambers is maintained by brake system for appropriate
time interval even after releasing service brake pedal. Driver thus gets more time to move foot from brake to accelerator pedal.
WARNING: Use Hill Start Assist to temporarily hold vehicle on a grade. To hold vehicle for long time, apply vehicle brake (independent of Hill Start Assist).
Failure to do so may cause personal injury or death due to loss of vehicle control.
• Turn ignition ON to enable Hill Start Assist, and press dash-mounted switch to temporarily disable this feature (indicated by blinking of Hill Start Assist telltale in
instrument cluster). This feature is re-enabled when switch is again pressed or when vehicle attains more than 12 mph (20 km/h) of speed.
• Feature is also re-enabled by ignition OFF-ON. Illumination of Hill Start Assist telltale indicates fault in feature. Repair fault to access feature again.
• Hill Start Assist activates automatically (when enabled), but only under following conditions:
◦ Zero vehicle speed.
◦ Vehicle on more than 2% incline/decline.
◦ Shift lever in R-position on decline or in D-position on incline.
◦ Service brake applied, and ABS operating properly.
◦ No ABS activity in preceding stops.
• Once service brake pedal is released, apply brakes for 3 seconds approx. or until accelerator pedal is pressed (whichever occurs first).
• Instrument cluster pop-up message is displayed when feature is active.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Transmission Power Take-Off (PTO)
• Pre-defined splitter positions are present on basic PTO functions. It is possible to adjust parameters that define which splitter gear (low or high) to engage when PTO
1 and 2 are engaged. PTO1 will occur first if two or more PTOs are used simultaneously.
• When gear lever is in N position with Premium gear selector, operator can select split gear (while using PTO) using manual gear selection buttons.

NOTE: Engage PTO in lower speeds by driving at speeds up to 6 mph (10 km/h).
NOTE: Shifting of gears does not occur when PTO is engaged.

DESCRIPTION & OPERATION > I-SHIFT GEAR SELECTOR > I-Shift

Transmission Features > Limp Home Mode
NOTE: Use Limp Home Mode only to get a vehicle to a safe or secure location. DO NOT use this feature for driving any distance.

• "Limp Home Mode" (indicated as L in DID) can be activated when major sensor failure or internal damage in transmission has occurred.
• "Limp Home Mode" offers only 1, 3 and 5 forward gears with premium selector and only first gear with basic selector. Reverse gear 1 is also available regardless of
selector.
• Gears can only be shifted if vehicle is at rest. Turn OFF ignition to deactivate "Limp Home Mode". Feature can be activated as follows:
◦ On seat installed gear selectors: To activate "Limp Home Mode", press and hold L button on gear selector while moving lever to position D.
◦ On dash installed gear selectors (Premium only): Press N button, then press and hold D Button (Automatic) and M button (Manual) to activate feature.

DESCRIPTION & OPERATION > LIMP MODE

NOTE: Use this mode only for shifting vehicle to a safer spot, when no other means to move vehicle is available.

If mDRIVE/I-Shift transmission with Fleet gear selector, has a mechanical problem, activate Limp Mode using one of these methods:

• Fleet Gear Selector: Simultaneously depress brake pedal and hold Neutral (N) and asterisk (*) buttons. To change gears, press Manual (M) or Reverse (R) buttons.
• Premium Gear Selector: Simultaneously depress brake pedal and hold Neutral (N) and Plus (+) buttons. Pressing Manual (M) or Reverse (R) buttons will change
modes or gears to permit vehicle to move. Use Plus (+) button to select gears (D1), (D3) and (D5). A gear cannot be adjusted once it has been selected in Limp Mode
when vehicle is moving.
Move vehicle by releasing brake pedal. To deactivate Limp Mode, turn ignition OFF.

DESCRIPTION & OPERATION > LUBRICATION SYSTEM

CAUTION: DO NOT reuse drained out mDRIVE/I-Shift oil. Replace oil as well as oil filter. Reusing old oil can damage transmission components.

Lubrication is provided to transmission by combination of pressure from an oil pump and splashing. Oil delivered to main shaft not only lubricates but also cools these
components: range gears, input shaft and main shaft bearings. Countershaft brake and output shaft bearings also receive lubrication. There are 2 overflow valves on
lubrication system: one to ensure transmission lubrication when filter is blocked and other to prevent very high pressure in system, e.g. during cold start. These valves
contain compression spring and valve peg.

Overflow valve ensuring sufficient lubrication for transmission.

Overflow valve to prevent excessive oil pressure.

DESCRIPTION & OPERATION > MACKCELLERATOR (MACK ONLY)

Two versions of accelerator pedals are available: with and without MackCellerator switch. On Premium shifter, MackCellerator function is standard while it is optional on
Fleet shifter. Enabling of MackCellerator requires gear selector be in D mode.

To enable MackCellerator, press accelerator pedal down completely to floor. Lifting accelerator pedal will cancel this function. When requested, MackCellerator allows
transmission to optimize vehicle acceleration, resulting in a downshift. However, transmission will not downshift if it determines vehicle speed can gallop faster by
remaining in current gear. This is how system ensures maximum acceleration without downshifting.

NOTE: DO NOT allow MackCellerator to remain engaged for extended periods, this will degrade fuel economy.

MackCellerator Switch:

1. 100% Throttle.
2. MackCellerator.

DESCRIPTION & OPERATION > MACK POWERLEASH+ ENGINE

BRAKE
NOTE: Braking torque will be interrupted momentarily when PowerLeash+ Engine Brake is active and transmission is shifting gears. This action increases vehicle speed
temporarily if driving downhill. Same momentary loss of engine braking will experience when downshifting conventional manual transmission.

All mDRIVE transmissions have PowerLeash+ engine brake. Engine brake can be activated when engine has obtained normal working temperature.

PowerLeash Active Co-Pilot Display Screen.

Following dash mounted switches are used to activate PowerLeash+ Engine Brake:

Control Switch: Note that left most switch is PowerLeash+ ON-OFF or control switch. If engine brake icon is depressed, switch will illuminate and PowerLeash+ engine
brake functions will activate. Once PowerLeash+ activates, Co-Pilot is displayed on PowerLeash Speed + screen.

NOTE: If control switch is in OFF position, PowerLeash+ will not function.

NOTE: There is an exception provided that a Bendix Active Cruise Control and Collision Warning system are equipped on vehicle. If so, Bendix system assumes all
fueling and braking control when in active cruise control mode.

Mode Switch: Type of desired engine brake operation is selected using PowerLeash+ Mode switch. See following for individual switch functions:

• Latch Mode: When LATCH is pressed, LATCH mode will activate. If operating in this mode, applying zero pedal will cause activation of engine brake. For this
mode to become operational, cruise control must be disabled. Normally this mode activates brake whenever throttle pedal is released. PowerLeash+ setting is
automatically set at 100%.
• Auto Mode: This is normal mode and can be used regardless vehicle has cruise control or not. It is encouraged to use this mode for PowerLeash+. With cruise control
engaged, Cruise 'n Brake feature will activate. If cruise control is not engaged, activation of engine brake is switch's SET, setting dependent.

PowerLeash+ is in Auto mode if Mode switch is in center position. In Auto mode, vehicle's downhill speed can be controlled comfortably. Control to vehicle speed is
accomplished without necessitating driver's manual input to adjust braking effort or application of service brakes.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > MID 130
Transmission Control Module (TCM) & MID 223 Gear Selector ECU (GSECU)
 • Use this information while diagnosing transmission faults. Type, description, symptoms and possible causes for fault codes associated with MID 130 and MID 223
are discussed in article. .
• Description of sensors associated with MID 130 and MID 223 are also discussed in this article.
• Use Scan Tool to perform diagnostics.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > MID 130
Transmission Control Module (TCM)
• Over SAE J1939/J1587 data links, TCM sends and receives messages to/from Gear Selector ECU (GSECU) and other control units in vehicle.
• TCM is mounted on upper portion of control housing. Depending on type of software being installed, functionality of TCM may vary.
• TCM consists of:
◦ SAE J1587 and J1939 data links
◦ CAN 2 data link
◦ Powerdrivers
◦ Inclination Sensor
◦ Temperature Sensor
◦ Controlling Solenoid Valves.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > Transmission
Control Module (TCM) Sensors > Clutch Position Sensor
Sensor is installed inside bell housing, at side of clutch cylinder assembly.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > Transmission
Control Module (TCM) Sensors > Main Shaft Speed Sensor(s)
• Speed sensors are installed in transmission, on lower portion of control housing and they measure speed of main shaft and countershaft.
• A hall element, an integral component of main shaft sensor, allows measurement of rotation speed and rotation direction of shaft.
• Countershaft speed sensor is an inductive sensor, which senses speed of countershaft and computes speed of every gear in transmission.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > Transmission
Control Module (TCM) Sensors > Output Shaft Speed Sensor
Mounting location of sensor is outside of rear transmission housing.

DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > Transmission
Control Module (TCM) Sensors > Transmission Control Housing Sensors
• Mounted in lower portion of transmission control housing, following four position sensors measure position of specific air cylinder within control housing.
• Transmission Control Housing Sensors are inductive sensors that change their characteristic based on position of metal pin that follows movements of air cylinders.
1. Range Cylinder Position Sensor.
2. Split Cylinder Position Sensor.
3. 1st/Reverse Cylinder Position Sensor.
4. 2nd/3rd Gear Cylinder Position Sensor
DESCRIPTION & OPERATION > MID 130 (TCM) & MID 223 (GSECU)
DESIGN & FUNCTION (CHU, CXU, GU, TD - MDRIVE) > MID 223 Sensors >
Gear Selector Electronic Control Unit (GSECU)
• GSECU communicates with gear selector via eight wires. These wirings are required while decoding a switch matrix (inside GSECU).
• Gear selector lever houses various switches: some are normal and some are hall-effect switches.
• Mounting location of GSECU is lower center of dash, see rear of Vehicle ECU.

DESCRIPTION & OPERATION > OIL COOLER

Radiator lower tank houses oil cooler, which is of a liquid to liquid design. Oil cooler is fed with oil and heat from oil is transferred to cooler, and then back to
transmission.

DESCRIPTION & OPERATION > OIL FILTER

Cartridge style filter is installed in filter housing connected to outside of main housing. Cover contains filter support tube to prevent filter collapsing. There are inlet and
outlet ports for oil cooler lines on top portion of housing.

Fig 1: Identifying Transmission Oil Filter

View Full-Screen

DESCRIPTION & OPERATION > OIL LEVEL

Oil is drained through plug placed at bottom and/or plug on right side of transmission.

NOTE: There are 2 oil drain plugs.

Oil fill plug is installed on right side. Oil level can be seen through sight glass.

1. Drain plug at bottom of transmission.

2. Drain plug on right side of transmission.
3. Sight glass.
4. Fill plug and level.

Sight glass for oil level inspection. See Figure.

DESCRIPTION & OPERATION > OIL PUMP

This eccentric pump is driven off reverse gear. Cartridge style filter is mounted on pressure side of pump to filter oil.

DESCRIPTION & OPERATION > PNEUMATIC SYSTEM > Compressed Air

Connections
Compressed air is required for following functions:

• Shifting.
• Clutch disengagement.
• Countershaft brake engagement.

Solenoid valves control compressed air. Air supply for transmission is provided by air tank. Supply line feeds air to transmission to left side of control housing. Air
compressor pressurizes tank mounted on engine. Check valve prevents loss of air pressure when main air system has leakage.

Compressed air connection between control housing and clutch control valve.

Compressed air connection between tank and control housing.

Air connection between control housing and countershaft brake. Air connection from clutch control valve to clutch cylinder hose.

DESCRIPTION & OPERATION > TRANSMISSION OIL TYPE/QUALITY

CAUTION: Add only recommended synthetic transmission oil in I-Shift transmission otherwise transmission components may be damaged.
NOTE: DO NOT reuse drained I-Shift synthetic oil. Use NEW oil and filter when changing transmission oil.

• Castrol Syntrans SAE 75W-85 synthetic oil is factory filled in I-Shift transmissions.
• I-Shift Transmissions (85111057 or 85111058) use Exxon Mobil 97307 spec synthetic oil. This oil is fully compatible with Castrol Syntrans 75W-85 oil and provides
regular oil drain interval.
• "D" Design Level I-Shift transmissions use Castrol Syntrans SAE 75W-85 synthetic oil (85121104) for extended oil drain intervals.

DESCRIPTION & OPERATION > PROGRAMMING & FEATURES > MACK

mDRIVE Grade Gripper
WARNING: Grade Gripper can hold vehicle temporarily on grade during vehicle launch. In order to hold vehicle on a grade for an extended period, vehicle brake must be
applied, independent of Grade Gripper; otherwise loss of vehicle control may occur which can cause personal injury or death.

If enabled, this optional feature will provide anti-rollback assistance to driver during vehicle launch on a hill. To enable this feature; apply vehicle brakes; when in forward
gear and starting on an incline, or in reverse gear when starting on a decline. Activation of feature requires all of following conditions:

• Ignition in RUN position and there is engine speed (RPM).

• 0 MPH (0 km/h) vehicle speed.
• Gripper disable switch not selected.
• Vehicle in a forward gear on an incline equal to or more than 2%, or in a reverse gear on a decline equal to or more than 2%.
• Service brake set.
• No relevant SAE J1939 data link communications fault.
• Downgraded mode nor enabled.

Function in a downgraded mode:

• If an existing fault or expecting information from control modules missing such as TCM and ABS.
 • If braking with active ABS, automatic traction control (ATC) or electronic stability program (ESP) is detected.

When service brake pedal is released, system will activate. System then maintains brake chamber pressure for up to 3 seconds or until positive torque exists in drive line.

"Grade Gripper Active" will appear on Co-Pilot display as long as feature is active.

When vehicle starts up, Grade Gripper defaults to ON position. A dash-mounted momentary switch can deactivate feature temporary however feature will re-enable when
vehicle begins another drive cycle. At this moment momentary switch is depressed again or vehicle exceeds 12 MPH (20 km/h).

During temporarily disable period, Grade Gripper telltale in instrument cluster will blink to alert driver. This telltale illuminates solidly when system is permanently
disabled.

mDrive Grade Gripper operates with assistance from following components: Grade Gripper momentary switch, Solenoids to ABS, Vehicle ECU.

Two control modules support operation of this feature by providing input to Vehicle ECU: TCM and ABS Control Module.

DESCRIPTION & OPERATION > PROGRAMMING & FEATURES >

Feature Packages
There are several optional program packages which offer flexibility to tailor truck regarding specific applications or operator wishes. Depending on type of program
package software being installed in TCM, different characteristics or features are accessible on Transmission. This also depends on which features are active within
package. Operator can also deactivate some features within a given package to further tailor system if desired.

A list of available hardware and software packages for mDRIVE/I-Shift Transmission is given below.

mDRIVE & Or I-SHIFT TRANSMISSION SOFTWARE PACKAGES

Premium Selector (Australia

Model Feature Fleet Gear Selector Premium Gear Selector
Only)
Dash Mounted Gear Selector Fleet Premium Premium
MackCellerator Pedal Optional Standard Standard
PowerLeash+ Standard Standard Standard
Hardware Features
Grade Gripper Optional Standard Not Available
Dash Mounted Gear Selector Dash Mounted Gear Selector Dash Mounted Gear Selector
Shifter Mount and Type
Keypad Keypad Keypad
Manual Gear Selection N/A Included Included
Performance-Economy Mode N/A Included Included
Software Features Low Speed Modulation Control Included Included Included
Basic Auto-Neutral Control Included Included Included
Basic PTO Controls Included Included Included
Basic Shift Standard Standard Standard
Maxi-Shift N/A N/A Optional
Shift Software
EZ Shift Optional Optional N/A
Heavy Duty Shift N/A N/A Optional

DESCRIPTION & OPERATION > PROGRAMMING & FEATURES > Shifter

Software
There are 4 transmission shift software options available for mDRIVE/I-Shift transmission.

STATUS DESCRIPTION

Software Status Description

Basic Shift Standard Intelligent Shifter Package.
With this package, shift between gears is slower and smoother. Typically used for cattle haul or other
EZ-Shift Optional (1) applications where smooth shifting is vital.
Aggressive shifting for higher Gross Combination Weights (GCWs), frequent grades or heavy duty or off
Maxi-Shift Optional (2) road operations are offered.
Most aggressive shifting between gears are provided by this package. Typically used for extremely high
Heavy Duty Shift Optional (2) Combined Gross Vehicle Weight (CGVW) operations; more than 150, 000 Lbs. (68000 Kg)
(1) N/A on MTA vehicles
(2) N/A on US10 and MTI vehicles

DESCRIPTION & OPERATION > PROGRAMMING & FEATURES >

Replacing Program Package
Anytime replacing a program package, update Vehicle Data Administration (VDA), before it can be downloaded into vehicle by entering appropriate Conversion Kit No.
into dealer service tool. For more details see, VCADS PRO Conversion Kit and Accessory Kit Numbers. Once conversion has completed, reprogram TCM (MID 130).

DESCRIPTION & OPERATION > RANGE GEAR

Range gears synchronization is placed at exterior of ring gear, reducing unit's length. Wider synchronization area means shorter selection time. Wide planetary gears give
strength and helical gears result in a quiet operation of planetary gear.

DESCRIPTION & OPERATION > SYNCHRONIZATION

Transmission housing contains non-synchronized main gears. Countershaft brake is used to equalize shaft speeds and mesh gears. For more details see, Countershaft
Brake .

Both Split gear and Range gear are synchronized.

DESCRIPTION & OPERATION > TRANSMISSION CONSTRUCTION

Transmission can be studied under 3 main sections:

• Clutch housing: This section serves as transmission housing front wall.

• Main housing: Comprised of main shaft, counter shaft, reverse shaft and selector assembly. This assembly is installed into transmission control housing.
• Range housing: Comprised of range planetary gear assembly and output shaft.

Internal parts of transmission includes:

• Input shaft.
• Main shaft.
• Range gear with selector unit.
• Countershaft.
• Oil pump with reverse shaft.
• Control housing with selector unit.
• Power takeoff (PTO) drive shaft, if equipped.

Main shaft houses trailing wheel for reverse gear, main gears and range sections sun gear. Range section contains planetary gears integrated with output shaft. Countershaft
features fixed gears.

DESCRIPTION & OPERATION > VENTILATION

By providing improved internal case venting, case ventilation extends oil life and maintenance intervals.

• Plug vent.
• Vent holes.

ADJUSTING > MAIN SHAFT & COUNTERSHAFT > Transmission Removed

WARNING: Ensure parking brakes are applied, transmission is in neutral, and wheels are blocked prior start any task, or personal injury or death could occur.

Tools required: Screw (9996917), Dial Indicator Gauge (9989876), Retainer (9990029), Screw (9996483), Magnetic Stand (9999696). See Special Tools .

1. Remove rear transmission housing from transmission first by removing its reconnectors. Remove reconnectors from rear cover around main shaft then remove cover.
2. Install a NEW shim ring on main shaft. Use a shim 0.035 In. (0.9 mm) thinner than original shim.
3. Install main shaft rear cover and secure with its reconnectors. Torque reconnectors to specifications using a diagonal pattern.
4. Install countershaft cover along with a NEW shim. Secure cover by tightening reconnectors in a diagonal pattern to specifications . NEW shim must be 0.035 in. (0.9
mm) thinner than original shim.
5. Lock gears using Special Holder Tool (9990029) for clutch sleeves. Assemble Special Screws (9996917), (9996483) into end of main shaft and into end of
countershaft.
6. Turn main shaft 20 turns. Verify following conditions while movement of main shaft and countershaft are being measured in following steps:
1. Gear 2 LS engages.
2. Countershaft brake disengages.
3. Splitter gear clutch ring is in rear position with overdrive.
4. Splitter gear clutch ring is in front position without overdrive.
 7. Install Dial Gauge (9989876) to Magnetic Stand (9999696) . Position place stand on countershaft cover. Position tip of dial gauge so it contacts end of main shaft.
Set gauge dial to zero and mark measurement point on main shaft.
8. To read and record end play measurement at marked position on main shaft, do as follows: turn transmission to horizontal operating position, lift measuring probe
and rotate main shaft 20 turns.
9. Turn transmission back to vertical servicing position then remove main shaft rear cover. Install another ring shim 0.004- 0.008 In. (0.1-0.2 mm) thicker than
measured end play with existing shim. This is required to obtain a preload of 0.004- 0.008 In. (0.1- 0.2 mm).
10. Apply oil to sealing ring. Install main shaft rear cover and secure by tightening connector in a diagonal pattern to specifications .
11. Turn main shaft 20 turns.
12. With Dial Gauge (9989876) and Magnetic Stand (9999696) placed on countershaft cover, position tip of dial gauge so it contacts special screw in end of
countershaft. Set gauge dial to zero and mark measurement point.
13. To read and record dial gauge measurement at marked measurement point as follows: shift transmission to horizontal operating position, lift measuring probe, and
rotate countershaft 20 turns.
14. Shift transmission to vertical servicing position. Remove countershaft cover. Install another ring shim 0.004- 0.008 In. (0.1- 0.2 mm) thicker than measured end play
with existing countershaft shim. This is required to obtain a preload of 0.004- 0.008 In. (0.1- 0.2 mm).
15. Install countershaft cover and secure by tightening reconnectors in a diagonal pattern to specifications .
16. Remove 2 Special Screws (9996917), (9996483) connected to ends of main shaft and countershaft.
17. Position rear transmission housing onto transmission and secure by tightening reconnectors.

REMOVAL & INSTALLATION > BRASS PIN SELECTOR FORK > Removal
1. Install control housing with selector forks facing up.
2. Exercise caution and drill out brasspin rivet heads on splitter, 1/R and 2/3rd selector forks. Carefully break them off selector fork.
NOTE: To protect control housing from shavings during drilling cover using paper.

REMOVAL & INSTALLATION > BRASS PIN SELECTOR FORK >

Installation
1. Assemble NEW smaller brasspins to 1/R and 2/3rd selector forks. Using riveting bracket, rivet them.

Assemble larger brasspins to splitter selector fork and rivet them.

NOTE: Ensure brasspins are not tight and can move slightly after riveting.
It is essential to rivet pins to prevent falling out of selector forks during installation of control housing to transmission.
2. Using Riveting Bracket (9990266) , press out tubular pins for support bosses on 1/R and 2/3rd selector forks.
3. Install NEW supporting bosses by pressing in tubular pin with polygrip pliers. Calibrate transmission after installation of control housing.

Use scan tool to perform 40105-4 Gearbox calibration.

REMOVAL & INSTALLATION > CLUTCH (11L, 13L)

WARNING: Obtain correct service article, tools and experience prior to working with vehicle. Ignoring to any of these requirements could damage components and also
cause dangerous situations.
CAUTION: Prior to disconnecting or connecting any electronic components, place vehicle ignition switch in OFF position. Damage to electronic components will result in
if circuits are not de-energized.

Tools required: Transmission Line (15 mm) (85108826), Centering Dift (9990024), Cab Lifting Hook, F-Truck (9996857), Bearing Extractor (9991821), Installation
(9992564), Handle (9991801), Pilot Shaft (9996896), OTC 5018. See Special Tools .

REMOVAL & INSTALLATION > CLUTCH (11L, 13L) > Removal

1. Set parking brake.
WARNING: BATTERIES: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery
explosion. DO NOT disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures
2. Disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system. Lift vehicle and support with jack stands.
NOTE: Ensure vehicle is lifted enough so transmission and jack can be easily moved underneath frame rails.
4. Disconnect oil cooler hoses from filter housing using Transmission Line (15 mm) (85108826) . Remove drive shaft.
NOTE: Remove universal joint caps and intermediate bearing to support bracket reconnectors.
NOTE: Ensure position of connectors on bracket are marked to aid installation of intermediate bearing in original position. Move shaft aside.
5. At rear of transmission disconnect air hose supply.
6. Unscrew Straight Raufoss fitting from 90 degree fitting in cover.
7. Remove wiring harness to transmission tie straps.
8. Disconnect Wiring harness at control housing, speed sensor, and 2 chassis connectors. Move harness aside.
9. Remove cab engine cover (if required for access to upper fasteners).
10. Bolts that secure transmission and engine are on bottom and sides of clutch housing.
 NOTE: At this point DO NOT remove top 4 bolts that secure transmission to engine.
11. Install transmission tightly to jack.
12. Remove battery cables-to-brackets fasteners, which are on top of clutch housing, and top 4 fasteners that secure transmission to engine.
13. Using care, pull back transmission enough that input shaft is off pressure plate. Lower transmission to pull it off under vehicle.
NOTE: While lowering transmission, inspect around it to ensure nothing is dragging or hanging.
14. Install clutch Centering Dift (9990024) . Loosen pressure plate reconnectors a few turns at a time in a diagonal pattern and remove them.
15. Loosen reconnectors on alignment studs. DO NOT remove reconnectors from alignment studs.
16. Install Lifting Tool (9996857) , Retainer/Adapter (9996896) to Clutch Jack (OTC 5018) .
17. Install lifting hook on lifting tool between diaphragm spring and casing. Adjust lifting tool and retainer to pressure plate.
NOTE: Modify lifting tool as necessary by grinding or cutting off corner.
18. Remove alignment studs connector, and pressure plate connector.
19. Remove Centering Dift (9990024) and clutch disc.
20. Inspect and ensure flywheel is clean, oil-free and Okay. If necessary, clean flywheel. Inspect condition of following components and replace if necessary: flywheel,
clutch cylinder, release bearing, and clutch position sensor.
NOTE: Resurface flywheel, if there is insignificant amount of wear or damage.
21. Remove pilot bearing (use Bearing Extractor (9991821) ) and make note of exact position before removal, for installation.

REMOVAL & INSTALLATION > CLUTCH (11L, 13L) > Installation

1. Install (press in using Drift 9992564 and Handle 9991801 ) NEW pilot bearing.
NOTE: Ensure pilot bearing is pressed in and is tight.
2. Pressure plate is installed on fixture in original orientation (observed during removal of old unit)
CAUTION: Ensure clutch disc is installed in correct direction or improper operation and component damage will occur.
3. Using line up shaft (9990024) install NEW clutch disc.
NOTE: Install clutch disc with that side facing toward flywheel. Clutch disc hub is stamped on flywheel side.
NOTE: Clutch pressure plate side contains a Yellow sticker. Install clutch disc with that side facing toward pressure plate.
4. Install NEW pressure plate. Install 2 reconnectors loosely on alignment studs.
5. Remove lifting tool and jack.
6. Install pressure plate bolts by tightening to specifications .
NOTE: Ensure they are tightened in a diagonal pattern a few turns at a time so pressure plate is not exposed to undue force.
7. Remove clutch line up shaft.
8. When clutch and pressure plate have installed, verify that all 4 form springs have snapped out.
9. Do as follows to simplify installation of transmission. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install service plug by tightening to specifications .
NOTE: If this step is skipped, there will be installation interference. It will be installed under clutch cylinder spring pressure to result in failure to slide forward into
place against engine mating surface.
10. Using caution and an assistant, install transmission and align it to engine. Loosely install 2 upper and lower reconnectors that secure transmission to engine.
NOTE: Align clutch splines by turning input shaft.
11. Install remaining bolts that secure transmission to engine by tightening to specifications . Remove transmission jack.
NOTE: It is encouraged to install bolts on top of clutch housing first for easy access to holes. With transmission jack removed, install all bolts.
12. Connect battery cables using their mounting connectors and install engine cab cover, if removed.
13. With electrical harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
14. Install NEW wiring harness to transmission tie straps.
15. At back of transmission connect air supply hose. Install straight Raufoss fitting into 90 degree fitting in cover. Connect oil cooler hoses to filter housing.
16. Install: drive shaft, universal joint caps and intermediate Bearing To Support bracket bolts. Torque bolts to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
17. Remove supporting jack stands. Lower vehicle.
18. With air system pressurized, perform leak inspection.
19. Connect all removed cables to negative battery terminals.
20. Inspect transmission oil level and fill approved oil if necessary.
21. When transmission has installed, using scan tool perform a clutch engagement point calibration.

REMOVAL & INSTALLATION > CLUTCH (16L)

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.
NOTE: Engine employs twin mass flywheel which may exhibit some torsional movement while working on clutch and its components. This torsional movement is normal,
and is not indication of damage or improper installation.

Tools required: Transmission Line (15 mm) (85108826), Centering Dift (9990024), Cab Lifting Hook, F-Truck (9996857), Bearing Extractor (9991821), Installation
(9992564), Handle (9991801), Pilot Shaft (9996896), OTC 5018. See Special Tools .

REMOVAL & INSTALLATION > CLUTCH (16L) > Removal

1. Set vehicle parking brake. Put shift lever in neutral.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system. Lift vehicle so it is supported with jack stands.
NOTE: Ensure vehicle is lifted enough so transmission on jack can be easily moved underneath frame rails.
4. Disconnect oil cooler hoses from oil filter housing using Transmission Line (15 mm) (85108826) .
5. Disconnect drive shaft. If equipped, universal joint caps and bolts hold intermediate bearing to support bracket.
NOTE: On some vehicles, intermediate bearing is secured to support bracket by bolts and universal joint caps.
 NOTE: Chock exact position of bolts on bracket to aid installation of intermediate bearing in original position. Move drive shaft aside.
6. At back of transmission remove Straight Raufoss fitting from 90 degree fitting in cover and air supply hose.
7. Remove wiring harness to transmission tie straps.
8. Disconnect wiring harness at these location: control housing, speed sensor, and 2 chassis connectors. Move harness aside.
9. Remove engine cab cover if necessary.
10. Remove bolts that secure transmission to engine on bottom and sides of clutch housing.
NOTE: At this point DO NOT Top 4 transmission to engine bolts.

Prior to removal of next item, place transmission jack beneath transmission and secure transmission to it.

11. On top of clutch housing, remove Battery cables to brackets bolts.

12. On top transmission to engine, remove 4 bolts.
13. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is hanging or dragging.
14. Install special clutch line up shaft tool Centering Dift (9990024) . Loosen stop bolt to cage pressure plate adjusting system, but DO NOT remove stop bolt
completely.
15. Loosen pressure plate bolts a few turns at a time in a diagonal pattern and remove them. Loosen nuts on alignment studs, but DO NOT remove stop bolt completely.
16. Install clutch lifting fixture (9996857) , retainer and adapter to Clutch Jack (OTC 5018) .
17. Install lifting hook on clutch lifting fixture between diaphragm spring and casing. Adjust clutch lifting fixture and retainer to pressure plate.
NOTE: Modify clutch lifting fixture as necessary by grinding or cutting off corner.
18. Remove alignment studs nuts. Remove pressure plate.
NOTE: Prior to removal, observe position of pressure plate to aid installation of NEW unit in same position.
19. Remove clutch disc. Remove clutch line up shaft tool.
20. Inspect and ensure flywheel is clean, oil-free and okay. If necessary, clean flywheel.
21. Inspect condition of following components and replace if necessary: flywheel, clutch cylinder, release bearing, and clutch position sensor.
22. Remove pilot bearing with an impact extractor. See Bearing Extractor (9991821)

REMOVAL & INSTALLATION > CLUTCH (16L) > Installation

1. Install a replacement pilot bearing with a pilot bearing drift (9992564) and use drift handle (9991801) .
2. Install clutch disc with clutch line up shaft tool Centering Dift (9990024) .
CAUTION: Ensure clutch disc is installed in correct direction, or improper operation and component damage will occur.
NOTE: Clutch disc hub is printed on flywheel side. Install clutch disc with that side facing toward flywheel.
NOTE: Clutch pressure plate side contains a Yellow sticker. Install clutch disc with that side facing toward pressure plate.
3. Install replacement pressure plate on clutch lifting fixture.
NOTE: Ensure NEW pressure plate is installed on clutch lifting fixture in original orientation.
4. Install pressure plate on transmission and install nuts loosely on 2 studs.
5. Remove clutch lifting fixture and jack.
CAUTION: Ensure bolt is tightened as instructed or component damage may occur.
6. Tighten pressure plate bolts in a diagonal pattern and torque to specifications .
7. Remove clutch line up shaft tool Centering Dift (9990024) and verify that all 4 form springs have snapped out after clutch and pressure plate are installed.
8. Ensure NEW pressure plate adjusting system is not caged. If caged, tighten stop bolt.
9. Do as follows to simplify installation of transmission. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install plug by tightening to specifications .
NOTE: If this step is skipped, there will be installation interference. It will be installed under clutch cylinder spring pressure to result in failure to freely slide forward
into place against engine mating surface.
10. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower bolts securing transmission to engine loosely.
NOTE: Align clutch splines by turning input shaft.
11. Install remaining bolts securing transmission to engine by tightening to specifications . Remove jack.
NOTE: It is encouraged to install bolts on top of clutch housing first for easy access to holes. With transmission jack removed, install remaining bolts.
12. Install battery cables using their mounting bolts. Install cab engine cover, if necessary.
13. With electrical harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
14. Install NEW wiring harness to transmission tie straps.
15. Reconnect air supply hose at rear of transmission and thread straight Raufoss fitting into 90 degree fitting in cover.
16. Reconnect oil cooler hoses to oil filter housing and drive shaft to rear of transmission.
NOTE: Install Universal Joint Caps & Intermediate Bearing To Support Bracket Bolts if necessary Torque them to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
17. Remove supporting jack stands. Lower vehicle.
18. With air system pressurized, perform leak inspection.
19. Connect all removed cables to negative battery terminals.
20. Inspect transmission oil level and fill approved oil if necessary.
21. Using Tech tool, perform a clutch engagement point calibration. Erase any fault codes.

REMOVAL & INSTALLATION > CLUTCH CONTROL VALVE FILTER

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

REMOVAL & INSTALLATION > CLUTCH CONTROL VALVE FILTER >

Removal
 1. Drain air tank to remove all air from system.
WARNING: NEVER remove drain plug completely, clutch valve unit holds pressurized air. To relieve air pressure, leave it slightly cracked. If removed completely
when under pressure, plug may become a dangerous projectile that can cause serious personal injury.
2. Relieve air system by removing service plug on top of clutch valve. See Figure.
3. Remove bolts from clutch valve.
Fig 1: Locating Clutch Position Sensor Wiring Harness Connector

View Full-Screen
4. Disconnect clutch position sensor wiring harness connector. To access filter, turn rotate valve around. Ensure clutch valve and transmission assembly sealing surfaces
are cleaned.
5. Remove cover plate screw, rubber seal, and filter on back of clutch valve.
NOTE: Observe placement of gasket and filter before removal.

REMOVAL & INSTALLATION > CLUTCH CONTROL VALVE FILTER >

Installation
1. Install a NEW filter and rubber seal.
NOTE: Ensure filter is installed with ridge facing out away from valve.
2. On back of clutch valve install cover plate and secure with a NEW screw.
3. Reconnect clutch position sensor wiring harness connector to clutch valve. See Figure. Install bolts securing clutch valve and torque to specifications . See Figure.
4. Install clutch valve service plug and torque to specifications .
5. With air system pressurized, perform leak inspection.

REMOVAL & INSTALLATION > CLUTCH CYLINDER

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > CLUTCH CYLINDER > Removal

1. Set parking brake.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system.
4. Lift vehicle and support with jack stands.
NOTE: Ensure vehicle is lifted enough so transmission and jack can be easily moved underneath frame rails.
 5. Use Transmission Line (15 mm) (85108826) tool to remove Oil cooler hoses from filter housing.
6. Remove drive shaft.
NOTE: Remove universal joint caps and intermediate Bearing-To-Support bracket reconnectors if necessary.
NOTE: Ensure position of reconnectors on bracket is marked to aid installation of intermediate bearing in original position. Move shaft aside.
7. Remove air hose from back of transmission.
8. Loosen Straight Raufoss fitting from 90 degree fitting in cover.
9. Remove wiring harness to transmission tie straps.
10. Disconnect speed sensor, and 2 chassis connectors at wiring harness on control housing.
NOTE: Move harness aside.
11. Remove cab engine cover if necessary.
12. Remove reconnectors that secure transmission to engine on bottom and sides of clutch housing.
NOTE: DO NOT remove top reconnectors securing transmission to engine.
13. Secure jack to transmission.
14. Remove battery reconnectors on top of clutch housing.
15. Remove top reconnectors that secure transmission to engine.
16. Remove transmission. Pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to ensure
nothing dragging or hanging.
WARNING: NEVER remove drain plug completely, clutch valve unit holds high pressure air. To relieve air pressure, leave it slightly cracked to prevent serious
personal injury.
17. Drain all air from system by removing service plug. See Figure.
18. Remove tie straps for wiring harness and air hose to clutch cylinder. See Figure.
19. Remove clutch valve reconnectors.
20. Disconnect clutch position sensor wiring harness connector. See Figure. Then move clutch valve aside. See Figure.
21. Remove clip that reconnects air hose in clutch cylinder.
22. Disconnect air hose from clutch cylinder.
23. Remove clutch cylinder and bolts.

REMOVAL & INSTALLATION > CLUTCH CYLINDER > Installation

1. Clean hose connections and inspect them. Replace damaged component. Replace all "O" rings.
NOTE: NEW clutch cylinder does not provide hose fitting; reuse hose fitting.
2. Remove fasteners, then remove air hose fittings. Place fittings on NEW cylinder and torque to specifications .
NOTE: Always use NEW "O" rings.
3. Install NEW clutch cylinder and torque to specifications . See Figure.
4. With air hose connected to clutch cylinder, install locking clip. Inspect if clutch valve assembly sealing surface is clean.
5. On back of clutch valve remove cover plate connector. Then remove rubber seal and filter.
NOTE: Observe position of gasket and filter before removal.
6. Install a NEW filter and rubber seal.
NOTE: Ensure filter is installed with ridge facing out away from valve.
7. Position cover plate on back of clutch valve and secure by installing a NEW connector. See Figure.
8. Connect clutch position sensor wiring harness connector to clutch valve. See Figure. See Figure.
9. Install clutch valve mounting fasteners and torque to specifications .
10. Use NEW tie straps to secure wiring harness and air hose.
11. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With piston held in, install plug by tightening to
specifications .
NOTE: If this step is skipped, there will be installation interference. Transmission will be installed under clutch cylinder spring pressure to result in failure to freely
slide forward into place against engine mating surface.
12. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower reconnectors that secure transmission to engine loosely.
NOTE: Align clutch splines by turning input shaft.
13. Install remaining reconnectors securing transmission to engine by tightening to specifications . Remove jack.
NOTE: Install reconnectors on top of clutch housing first for easy access. With jack removed, install remaining reconnectors.
14. Install battery cables using their mounting reconnectors. Install cab engine cover if necessary.
15. With electrical harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
16. Install NEW wiring harness to transmission tie straps.
17. Reconnect air supply hose at rear of transmission. Install straight Raufoss fitting into 90 degree fitting in cover and reconnect oil cooler hoses to filter housing.
18. Install drive shaft, universal joint caps and intermediate Bearing To Support bracket fasteners, if equipped. Torque to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket properly.
19. Remove jack stands and lower vehicle.
20. With air system pressurized, perform leak inspection.
21. Connect all removed cables to negative battery terminals.
22. Inspect transmission oil level and add approved oil if necessary.
23. When transmission has installed, using scan tool, perform a clutch engagement point calibration.

REMOVAL & INSTALLATION > CLUTCH CYLINDER SUPPLY HOSE

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .
REMOVAL & INSTALLATION > CLUTCH CYLINDER SUPPLY HOSE >
Removal
1. Set parking brake.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system. Lift vehicle and support with jack stands.
NOTE: Ensure vehicle is lifted high enough so transmission and jack can be easily moved underneath frame rails.
4. Disconnect oil cooler hoses using Transmission Line (15 mm) (85108826) from oil filter housing.
5. Remove drive shaft.
6. Remove universal joint caps and intermediate bearing bracket bolts.
NOTE: Ensure position of bolts on bracket is marked to aid installation of intermediate bearing in original position. Move shaft aside.
7. At rear of transmission disconnect air supply hose.
8. Unscrew straight Raufoss fitting at a 90 degree fitting in cover.
9. Remove wiring harness to transmission tie straps.
10. Disconnect wiring harness at these locations: 2 chassis connectors, control housing, and speed sensor. Move harness aside.
11. Remove cab engine cover if necessary.
12. Remove bolts that secure transmission to engine on bottom and sides of clutch housing.
NOTE: At this point DO NOT remove top bolts securing transmission and engine.
13. Place and secure transmission to jack stand.
14. Remove battery cables bracket bolts on top of clutch housing.
15. Then remove 4 transmission to engine bolts.
16. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is dragging or hanging.
WARNING: NEVER remove drain plug completely, clutch valve unit holds high pressure air. To relieve air pressure, leave it slightly cracked. If removed
completely when under pressure, plug may become a dangerous projectile that can cause serious personal injury.
17. All air from system. Remove service plug on top of clutch valve. See Figure.
18. Remote bolts securing clutch valve.
19. Disconnect clutch position sensor wiring harness connector. See Figure. Move clutch valve aside. See Figure.
20. Remove air hose to clutch cylinder and straps reconnecting wiring harness. See Figure.
21. Remove clip that reconnects air hose in clutch cylinder.
22. Remove air hose from clutch cylinder by pushing out through side of transmission clutch housing. See Figure.

REMOVAL & INSTALLATION > CLUTCH CYLINDER SUPPLY HOSE >

Installation
1. Reconnect NEW hose by pushing it through clutch housing and connect to clutch cylinder. Then install locking clip. See Figure.
2. Install NEW tie straps to secure wiring harness to air hose.
3. Inspect if clutch valve sealing surface is clean. Replace if needed. See Figure.
4. Reconnect clutch position sensor wiring harness connector to clutch valve and install bolts securing clutch valve. See Figure. Torque clutch valve mounting fasteners
to specifications .
5. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With piston held in, install plug using torque specifications. .
NOTE: If this step is skipped, transmission will be installed under clutch cylinder spring pressure. This will result in failure to freely slide forward into place against
engine for a good mating surface contact.
6. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower bolts securing transmission to engine loosely.
NOTE: Align clutch splines by turning input shaft.
7. Install remaining bolts securing transmission to engine by tightening to specifications . Remove jack.
NOTE: Install bolts on top of clutch housing first. With jack removed, install remaining bolts.
8. Install battery cables using their mounting bolts. Install cab engine cover.
9. With wiring harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
10. Install NEW wiring harness to transmission tie straps.
11. Connect air supply hose at rear of transmission by threading straight Raufoss fitting into 90 degree fitting in cover.
12. Reconnect oil cooler hoses to filter housing.
13. Install drive shaft.
14. Install universal joint caps and intermediate bearing that hold bracket bolts if necessary Torque to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
15. Remove jack stands and lower vehicle.
16. With air system pressurized, perform leak inspection.
17. Connect all removed cables to negative battery terminals.
18. Inspect transmission oil level and add approved oil if necessary.

REMOVAL & INSTALLATION > CLUTCH POSITION SENSOR

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > CLUTCH POSITION SENSOR > Removal

 1. Set parking brake. Place transmission in neutral gear. Remove battery box cover.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Release all air pressure in system at air tanks.
4. Lift vehicle and use jack stands.
NOTE: Ensure vehicle is lifted enough so transmission and jack can be easily moved underneath frame rails.
5. Disconnect oil cooler hoses from filter housing using Transmission Line (15 mm) (85108826) tool.
6. Drive shaft and intermediate bearing that support bracket fasteners if necessary.
NOTE: Ensure position of fasteners on bracket is marked. This will ensure exact position of intermediate bearing for installation. Move shaft aside.
7. At rear of transmission disconnect air supply hose.
8. Unscrew straight Raufoss fitting from 90 degree fitting in cover.
9. Disconnect wiring harness at these locations: control housing, speed sensor, and 2 chassis connectors.
NOTE: Leave harness connected to transmission and move it out of way.
10. Remove cab engine cover if necessary.
11. Remove fasteners that secure transmission to engine that run along bottom and sides of clutch housing.
NOTE: DO NOT remove top connectors securing transmission to engine at this point.
NOTE: Prior to removal of next item, position transmission jack in place and secure transmission to it.
12. Remove battery cables to brackets connectors on top of clutch housing.
13. Remove 4 connectors on top transmission to engine mount.
14. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is dragging or hanging.
15. With caution tie straps reconnecting wiring harness and air hose to clutch cylinder.
16. Disconnect clutch cylinder position sensor wiring connector from clutch control valve.
17. Remove fasteners on clutch position sensor.
18. Remove clutch position sensor.

REMOVAL & INSTALLATION > CLUTCH POSITION SENSOR >

Installation
1. Install NEW clutch position sensor and fasteners. Torque reconnectors to specifications .
2. Reconnect clutch cylinder position sensor wiring harness connector to clutch control valve. Use NEW tie straps to secure wiring harness and air hoses.
3. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. Hold piston in and install plug by tightening to
specifications .
NOTE: If this step is skipped, during installation transmission will be installed under clutch cylinder spring pressure to result in failure to freely slide forward into
place against engine mating surface.
4. With help of assistant, loosely install 2 upper and lower fasteners to transmission to engine to hold transmission in place. Then align clutch splines by turning input
shaft.
5. Install all fasteners for transmission to engine by tightening to specifications .
NOTE: It is encouraged to install reconnectors on top of clutch housing first for easy access to holes. With transmission jack removed, install remaining reconnectors.
6. Install battery cables using their mounting reconnectors. Install engine cab cover.
7. With wiring harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
8. Install NEW wiring harness to transmission tie straps.
9. At back of transmission connect air supply hose. Install straight Raufoss fitting into 90 degree fitting in cover and reconnect transmission oil cooler hoses to filter
housing.
10. Install drive shaft, universal joint cap retaining straps, Reconnect connectors that secure intermediate Bearing-To- Support bracket if necessary Torque reconnectors
to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket.
11. Remove jack stands and lower vehicle.
12. With air system pressurized, perform leak inspection.
13. Connect all negative cables to battery terminals that were disconnected and place battery box cover.
14. Inspect transmission oil level and add approved oil if necessary.
15. When transmission has installed, using scan tool, perform a clutch engagement point calibration.

REMOVAL & INSTALLATION > CLUTCH VALVE ASSEMBLY

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

REMOVAL & INSTALLATION > CLUTCH VALVE ASSEMBLY > Removal

1. Drain air tank to remove all air from system. See Figure.
2. At control housing disconnect clutch valve wiring harness.
WARNING: NEVER remove drain plug completely, clutch valve unit holds pressurized air. To relieve air pressure, leave it slightly cracked. If removed completely
when under pressure, plug may become a dangerous projectile that can cause serious personal injury.
3. To Ensure that no air is in system, remove plug on top of clutch valve. See Figure.
4. Remove tie strap on air supply line going to transmission case.
5. Remove Raufoss fitting. Remove clutch valve mounting reconnectors to disconnect air supply line for clutch valve. See Figure.
6. Cut tie strap that reconnects clutch valve wiring harness, disconnect clutch position sensor on wiring harness, and then remove clutch valve.
REMOVAL & INSTALLATION > CLUTCH VALVE ASSEMBLY >
Installation
1. Inspect if clutch valve sealing surface is clean and closely inspect NEW valve and verify gasket is installed correctly. See Figure.
2. On NEW clutch valve, connect clutch position sensor to wiring harness. Install clutch valve fasteners by tightening to specifications .
3. Thread Raufoss fitting into valve to connect air supply line to clutch valve and reconnect clutch valve wiring harness connector to control housing. See Figure.
4. Install NEW air supply line to clutch valve wiring harness tie straps.
5. With air system pressurized, perform leak inspection.

REMOVAL & INSTALLATION > COMPANION FLANGE

WARNING: Ensure parking brakes are applied, transmission is in neutral, and wheels are blocked prior start any task, or personal injury or death could occur.

Tools required: Counterhold (9998570), Adapter (9990084), Spindle (9992619), Mandrel (9992653), Hydraulic Cylinder (9992671), Puller (9998597), Hydraulic Pump,
Air Operated (9996222), Seal Installer (88800174), Spindle (9996315), Mandrel (9996901), Adapter (9996925). See Special Tools .

REMOVAL & INSTALLATION > COMPANION FLANGE > Removal

1. Set parking brake. Position shift lever in neutral.
2. Thoroughly clean area around companion flange.
3. Remove universal joint caps then disconnect yoke from front of drive shaft. Move shaft aside.
4. Remove universal joint yoke from companion flange.
5. Remove companion flange nut. Once removed, use counterhold tool (9998570) to remove it.
6. Do as follows to assemble companion flange removal tools.
1. Install Puller (9998597) to companion flange.
2. Assemble Spindle (9992619) and (Mandrel (9992653) together and assemble Hydraulic Cylinder (9992671) and Adapter (9990084) together.
3. Completely thread Spindle (9992619) into Hydraulic Cylinder (9992671) .
4. Thread Adapter (9990084) into Puller (9998597) .
5. Adjust Spindle (9992619) inward so it makes contact with output shaft.
7. Remove companion flange.
NOTE: For hydraulic pressure install Hydraulic Pump, Air Operated (9996222) . Anytime replacing/removing companion flange, also replace output shaft seal.
8. Remove output shaft seal using an appropriate extracting tool.

REMOVAL & INSTALLATION > COMPANION FLANGE > Installation

1. Thoroughly clean seal mating surface in tail housing.
2. Install output shaft seal after greasing NEW seal lip. Use Seal Installer (88800174) .
3. Replace V-ring. Ensure V-ring lays against stop on companion flange during installation.
NOTE: Ensure mating surfaces of companion flange have no obvious damage.
CAUTION: Neither treat companion flange with heat nor hit with a hammer; ensure only approved special tools are used for installation. Otherwise component
damage will occur.
CAUTION: Complete installation of companion flange prior to installation of retaining nut. If not pressed it on completely, accelerated damage to output shaft
bearing or range oil pipe may occur.
4. First Ensure installation tools are put together. Then press companion flange on output shaft.
1. With companion flange positioned on output shaft, thread Adapter (9996925) into end of output shaft.
2. Install Mandrel (9996901) onto Spindle (9996315) and Thread Spindle (9996315) into Adapter (9996925) until it bottoms.
3. Slide Hydraulic Cylinder (9992671) onto Spindle (9996315) and install nut on end of assembly.
5. Install a NEW companion flange nut "O" ring.
6. Using as assistant, install companion flange nut using counterhold tool (9998570) by tightening to specifications .
NOTE: Ensure tool is removed after completion of installation of nut.
7. With companion flange nut locked in place, peen it in both recesses on companion flange using a hammer and a punch.
NOTE: Punch must have a rounded tip; ensure it is pushed in to bottom. Use care to prevent cracks on surface.
8. Position Universal Joint Yoke on companion flange and secure by tightening bolts to specifications .
9. With drive shaft in its yoke, install universal joint caps and secure by tightening bolts to specifications .

REMOVAL & INSTALLATION > COMPANION FLANGE

WARNING: Working without sufficient training, correct service information or tools may cause serious personal injury or death.
WARNING: Prior to starting procedure apply parking brakes, set transmission to neutral and block wheels to prevent any unexpected vehicle movement as it can lead to
serious injury and/or death.
Fig 1: Identifying Companion Flange
 View
Full-Screen

REMOVAL & INSTALLATION > COMPANION FLANGE > Removal

NOTE: Information may change without notice. Illustrations are meant for reference and so may vary from actual vehicle version. However, this article is developed with
main components as accurately as possible.

Ensure only experienced personnel perform this procedure. Obtain training if necessary.

WARNING: Working around vehicle without sufficient training, correct service article and proper tools can cause serious personal injury or death.
WARNING: Prior to working always apply parking brakes, set transmission to neutral and block wheels to prevent unexpected vehicle movement as it can lead to serious
injury or death.
 1. Set parking brake.
2. Ensure transmission around companion flange is clean.
3. Disconnect front of drive shaft from yoke and put aside after removing universal joint caps.
4. From companion flange, remove universal joint joke and then remove flange nut.
NOTE: Connect Counterhold Tool (9998570) before removal of flange nut, then remove tool when nut is removed.
5. Assemble removal tools of companion flange as follows:
1. Connect Flange (9998597) to companion flange then assemble Puller (9992619) and Drift (9992653) together. Thread Hydraulic Ram (9992671) and Adapter
(9990084) together.
2. Thread Puller (9992619) completely into Hydraulic Ram (9992671) and Adapter (9990084) into Flange (9998597).
3. Adjust Puller (9992619) inward until it makes contact with shaft.
6. Pull companion flange off.
NOTE: Hydraulic pressure is provided when Air Coupler (9996222) is connected.
NOTE: Output shaft seal must be replaced if companion flange is removed/replaced.
7. Remove output shaft seal with proper extracting tool.
8. Seal mating surface (in transmission tail housing) must be cleaned.

REMOVAL & INSTALLATION > COMPANION FLANGE > Installation

1. Apply grease to NEW seal lip and install output shaft seal using Seal Installer (88800174).
2. Replace companion flange V-ring, which should be placed against stop on flange.
NOTE: For any obvious damage, inspect mating surfaces of companion flange.
CAUTION: Use only permitted tools or else it may lead to component damage. Always prevent heating of companion flange.
CAUTION: Prior to installation or tightening of retaining nut, install companion flange completely or output shaft bearing or range oil pipe will damage.

Press companion flange on output shaft after assembling installation tools

1. Place companion flange on output shaft and thread Assembly Tool (9996925) into shaft end.
2. Position Tappet (9996901) over Flange (9996315) and thread into Assembly Tool (9996925) until it touches surface.
3. Slide tool Hydraulic Ram (9992671) onto Flange and install mounting nut on end of assemble.
3. Install NEW companion flange nut "O" ring and tighten flange nut to 332 ± 37 Ft. Lbs. (450 ± 50 N.m) using Counterhold Tool (9998570).
NOTE: Use counterhold tool during installation and tightening of companion flange nut. Remove it when done.
NOTE: Install companion flange nut and tighten, use assistance if needed.
4. Secure companion flange nut in position, peen nut in both recesses on flange by applying a punch.
NOTE: There must be a rounded tip in punch, push in right to bottom. NO crack should occur.
5. On companion flange, install universal joint yoke and torque mounting bolts to 140 ± 11 Ft. Lbs. (190 ± 15 N.m).
6. Place drive shaft back into its yoke. Install universal joint caps and torque mounting bolts to 122 ± 7 Ft. Lbs. (166 ± 10 N.m).

REMOVAL & INSTALLATION > CONTROL HOUSING

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

REMOVAL & INSTALLATION > CONTROL HOUSING > Removal

1. Perform Gear Activation, and Control Housing using scan tool for removal and installation. Ensure to follow instructions for scan tool.
NOTE: On overdrive transmissions, ensure transmission is positioned as follows:
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: On direct drive transmissions, ensure transmission are positioned as follows:
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: You may perform this operation with transmission removed from vehicle if necessary.
NOTE: If scan tool failed to activate necessary gears for removal of control housing, activate gears manually. Do as instructed in this procedure after transmission
removal.
NOTE: If required to fully engage gears within transmission, move vehicle forward or backward.
2. Set parking brake.
3. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
4. Drain air tank to remove all air from system.
5. Lift vehicle and use jack stands.
NOTE: Ensure vehicle is lifted enough so transmission and jack can be easily moved underneath frame rails.
6. Disconnect oil cooler hoses using Transmission Line (15 mm) (85108826) tool, from filter housing.
7. Remove drive shaft. Remove universal joint caps and intermediate Bearing To Support bracket fasteners if necessary.
NOTE: Ensure position of fasteners on bracket is marked to aid installation of intermediate bearing in original position. Move shaft aside.
8. At rear of transmission disconnect air supply hose.
9. Unscrew straight Raufoss fitting from 90 degree fitting in cover.
10. Remove wiring harness to transmission tie straps.
11. Disconnect wiring harness at these locations: control housing, speed sensor, and 2 chassis connectors. Then move harnesses aside.
12. Remove cab engine cover if access is needed to upper connectors.
13. Remove fasteners that secure transmission to engine on bottom and sides of clutch housing.
NOTE: DO NOT remove top fasteners securing transmission to engine at this point.
NOTE: Prior to removal of following item, place transmission jack and secure it.
14. Remove battery cables to brackets fasteners on top of clutch housing.
15. Remove connectors that secure top transmission to engine.
16. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is tangled or hanging from it. See Figure.
17. At control housing remove clutch valve wiring connector.
18. At upper control housing fitting disconnect clutch control valve air supply tube.
19. Remove straight Raufoss fitting from 90 degree fitting in cover.
20. Remove control housing and upper cover fasteners.
NOTE: These steps are for only if: if manually doing a Gear Activation, replacing control housing with no NEW cover, and control housing removal or installation.
21. Always do a manual procedure on control housing removal and installation, and gear activation.
NOTE: Continue to step 25 if scan tool could activate correct gears for control housing removal. If it did not continue with next steps.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
1. Lift top edge of upper cover and angle it down against clutch housing. Disconnect electrical connection and remove top cover.
NOTE: Never put tension or weight to wiring harness or connector.
2. Overdrive Transmission:
1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. High Split.
7. Reverse Gear.
8. Low Split.
3. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a over drive transmission are listed below. For positions on a direct drive unit, see step 22.
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged.
NOTE: In order to mesh gears, turn output shaft while range section is being engaged.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to
engage. DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
22. Direct Drive Transmission:
1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. Low Split.
7. Reverse Gear.
8. High Split.
23. Use compressed air to bore holes to put transmission gears in correct position for control housing removal.
24. This list indicates necessary gear positions for direct drive transmissions. If transmission has overdrive go to step 21.
1. High Split.
2. High Range.
3. 2nd/3rd-Neutral Position.
4. 1st/Reverse-Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged.
NOTE: In order to mesh gears, turn output shaft while range section is being engaged.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to
engage. DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
25. If scan tool succeed in gear activation, carefully separate control housing from locating pins with a pry bar. Remove control housing.
NOTE: If failed to remove control housing from transmission upon application of gentle upward pressure, see steps C or 22 prior to re-attempt removal.
NOTE: DO NOT damage transmission tooth wheel during removal.

REMOVAL & INSTALLATION > CONTROL HOUSING > Installation

1. Ensure sealing surface of control housing is clean and install a NEW gasket on control housing.
1. HR - High Range.
2. S - split.
3. 2/3 - 2nd/3rd Gear In Neutral.
4. R - Reverse Gear.
2. Inspect followings to verify position:
1. Split engaging ring: in its rearmost.
2. 2nd/3rd engaging ring: in neutral or middle.
3. Reverse gear engaging ring: in its rearmost.
3. Be sure that split engaging ring is in farthest rear position, 2nd/3rd engaging ring must be in neutral or middle position, reverse gear engaging ring must be in its
farthest rear position, and that range fear is in high range.
4. Ensure range gear is in high range.
NOTE: NEW control housing forks must correspond to position of engaging rings. If not, use hand and position them carefully.
 5. Inspect if range servo piston is positioned out 1 In. (25.4 mm) to correctly mate with main housing.
6. Using care lower control housing so tooth wheel is protected from damage. Split fork must end up in correct position in engaging ring.
7. Install NEW solenoid valve seals, "O" ring on countershaft brake and a NEW upper cover gasket.
NOTE: Ensure this and next 2 steps are only performed if control housing was replaced without a NEW upper cover. If control housing is being replaced with a
NEW upper cover, continue with step 10.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
8. With NEW upper cover in place, connect wiring harness. Lower upper cover into place.
NOTE: Never put pressure or weight to wiring harness or connector.
9. Install reconnectors that secure upper cover using torque specifications .
10. Install reconnectors that secure control housing by tightening in a diagonal pattern to specifications .
11. Reconnect clutch control valve air supply tube to fitting of upper control housing. Thread straight Raufoss fitting into 90 degree fitting in cover. See Figure.
12. Reconnect control housing to clutch valve wiring harness connector.
13. When control housing has been installed, perform Transmission Calibration using scan tool and recommended instructions for transmission and removal.
NOTE: If calibration fails, inspect if shift fork position sensor values are correct. If they are incorrect, possibly shift forks are incorrectly installed to engaging rings
and this hinders correct transmission shifting. Remove control housing to inspect shift fork installation and position of engaging ring. Re-install control housing
starting from Step 1.
14. Do as follows to simplify installation of transmission: remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install plug by tightening to specifications .
NOTE: If this step is skipped, there will be installation interference. Transmission will be installed under clutch cylinder spring pressure to result in failure to freely
slide forward into place against engine mating surface.
15. Using caution and an assistant, install transmission and align it to engine. Loosely install 2 upper and lower fasteners that secure transmission to engine.
NOTE: Align clutch splines by turning input shaft.
16. Install remaining reconnectors That Secure Transmission To Engine by tightening to specifications . Remove jack.
NOTE: It is encouraged to install reconnectors on top of clutch housing first for easy access to holes. With jack removed, install remaining reconnectors.
17. Install battery cables using their mounting reconnectors.
18. Install cab engine cover.
19. With electrical harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
20. Install NEW wiring harness to transmission tie straps.
21. Reconnect air supply hose at rear of transmission. Install straight Raufoss fitting into 90 degree fitting in cover. Reconnect transmission oil cooler hoses to filter
housing.
22. Install: drive shaft, universal joint caps and fasteners that secure intermediate Bearing To Support bracket if necessary Tighten caps and reconnectors to
specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
23. Remove jack stands. Lower vehicle.
24. With air system pressurized, perform leak inspection.
25. Connect all removed cables to negative battery terminals.
26. Inspect transmission oil level and add approved oil if necessary.
27. When transmission has installed, using scan tool, perform a clutch engagement point calibration.

REMOVAL & INSTALLATION > CONTROL HOUSING PRESSURE

SENSOR (mDrive)
WARNING: Obtain correct service article, tools, and experience prior to working with vehicle. Ignorance to any of these requirements could damage components or cause
dangerous situations.
NOTE: Figures are for reference and may vary from actual vehicle version.

Ensure only experienced personnel perform this procedure. Obtain training if necessary.

CAUTION: Handle electrical components with care as these components are fragile (including wiring harness inside transmission control housing) and can be easily
damaged.

Proper Electro Static Discharge (ESD) procedures:

• Keep component in protective package until it is time to install.

• Prevent electrostatic charge build-up in body by briefly holding a known good ground prior to handling component. Repeat this procedure often after sitting down
from a standing position, sliding across a seat, or walking a short distance.
• DO NOT touch electrical terminals of component unless written in diagnostic procedure.
• Ground package to a known ground on vehicle before removing component.
• Ensure to connect ground lead first if multimeter is used.

REMOVAL & INSTALLATION > CONTROL HOUSING PRESSURE

SENSOR (mDrive) > Removal
1. Remove vehicle transmission
2. Remove mounting bolts from control housing and from upper cover. Next, carefully lift upper cover top edge while angling down against clutch housing. Remove
top cover after disconnecting electrical connection.
NOTE: It is discouraged to apply tension or weight on connector or wiring harness.
Fig 1: Identifying Control Housing & Upper Cover
 View Full-Screen
3. With care, release solenoid valve connectors while avoiding damage of ribbon.
Fig 2: Locating Solenoid Valve Connectors
 View Full-Screen
4. With a 2.5 mm Allen wrench, fully seated, remove and dispose of screw rivets holding cover in place.
CAUTION: After removal of cover, DO NOT touch printed circuit board as electronics could be damaged by Electro Static Discharge (ESD) or static electricity.
CAUTION: Handle electrical components with care as these components are fragile (including wiring harness inside transmission control housing) and can damage.
5. Gently lift cover. Then disconnect both ribbon clips and release ribbon from guide pin, then remove cover. See Fig 2.
NOTE: Observe direction clips are facing and when replacing install in the same manner.
6. Remove and dispose of pressure sensor screw rivets.
Fig 3: Locating & Measuring Pressure Sensor

View Full-Screen
7. Gently disconnect pressure sensor connector without making contact with circuit board; then remove sensor and "O" ring. See Fig 3.

REMOVAL & INSTALLATION > CONTROL HOUSING PRESSURE

SENSOR (mDrive) > Installation
1. Place NEW "O" ring onto NEW pressure sensor and gently attach connector to circuit board.
2. Install sensor and tighten NEW self-tapping screws until 0.004 - 0.008 In. (0.1 - 0.2 mm) clearance is attained between sensor and screw heads. Once clearance is
reached, tighten screws an additional (180°) half turn.
 3. Place cover onto circuit board before top cover is secured into position. Gently lift top cover to install solenoid ribbon onto guide pin; seat top cover and position
clips correctly.
NOTE: Note that clips are facing different directions.
4. Secure top cover with NEW self-tapping screw rivets and tighten to specification .
5. Remove old gasket from upper cover and position NEW solenoid valve seals, counter shaft brake "O" ring, and NEW upper cover gasket. See Figure.
6. Install control housing cover and connect electrical contacts. DO NOT damage ribbon.
7. Install and tighten NEW screws in upper cover to specification .
8. Install and tighten control housing screws to specification .
9. Install vehicle transmission.

REMOVAL & INSTALLATION > ELECTRONIC CONTROL UNIT (ECU)

GEAR SELECTOR
WARNING: Ensure parking brakes are applied, transmission is in neutral, and wheels are blocked prior start any task, or personal injury or death could occur.

REMOVAL & INSTALLATION > ELECTRONIC CONTROL UNIT (ECU)

GEAR SELECTOR > Removal
1. Set parking brake.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Remove instrument cluster panel to dash reconnectors. Using care move instrument cluster panel aside.
4. Remove tie straps that hold gear selector ECU in place.
5. At end of defective gear selector ECU, disconnect wiring harness from connector.
6. Remove ECU from dash.

REMOVAL & INSTALLATION > ELECTRONIC CONTROL UNIT (ECU)

GEAR SELECTOR > Installation
1. Install gear selector ECU in dash. Connect wiring harness.
2. Install NEW tie straps on gear selector ECU to hold in place.
3. Install instrument cluster panel onto vehicle dash and secure by tightening reconnectors.
4. Connect all removed cables to negative battery terminals.
5. Erase all DTCs and configure TCM with its software. Perform clutch engagement point calibration. Inspect gear selector ECU functionality.

REMOVAL & INSTALLATION > GEAR SELECTOR

NOTE: Information may change without notice. Illustrations are meant for reference and hence may vary from actual vehicle version. However, this article is developed
with main components as accurately as possible.
WARNING: Seek proper training from your supervisor prior to performing this procedure to prevent personal injury or damage.
CAUTION: To avoid electronic components from damage, always switch ignition OFF prior to disconnecting or connecting any electronic components, else electronic
components may be damaged permanently.

REMOVAL & INSTALLATION > GEAR SELECTOR > Removal

1. Set parking brake.
WARNING: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery explosions. DO NOT
disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures.
2. Remove all cables from ground (negative) battery terminals.
3. With parking brake knobs removed, remove fasteners securing gauge panel D to dash. Pull panel a little away from dash without disconnecting switch wires.
4. Remove radio mounting box-to-dash fasteners and pull box a little away from dash.
5. Disconnect wiring harness connector from gear selector by pulling gear selector harness connector tab down, and remove fasteners and brackets.
6. Remove radio mounting box gear selector.
NOTE: Lower bracket is smaller than upper bracket.

REMOVAL & INSTALLATION > GEAR SELECTOR > Installation

 1. Install radio mounting box gear selector and tighten brackets and fasteners to specification.
2. Connect wiring harness connector.
NOTE: Lower bracket is smaller than upper bracket.
3. On dash, first install radio mounting box and then install gauge panel D. Tighten fasteners to specification after each installation.
4. Install parking brake knobs.
5. Connect all cables (removed earlier) to ground (negative) battery terminals.
6. Turn ON engine and inspect for correct operation of gear selector.

REMOVAL & INSTALLATION > GEAR SELECTOR CONTROL UNIT

(AT2512C, ATO2512C, AT2812C, ATO3112C)
NOTE: Information may change without notice. Figures are meant for reference and may vary from actual vehicle. However, this article is developed with main
components as accurately as possible.

Ensure only experienced personnel perform this procedure. Obtain training if necessary.

WARNING: Working around vehicle without sufficient training, correct service article and proper tools can cause serious personal injury or death.
CAUTION: Prior to connecting or disconnecting any electronic component, always switch OFF ignition. Failure to do so may result permanent damage to components.

REMOVAL & INSTALLATION > GEAR SELECTOR CONTROL UNIT

(AT2512C, ATO2512C, AT2812C, ATO3112C) > Removal
WARNING: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery explosions. DO NOT
disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures.

1. Remove batteries negative cable to disconnect vehicle power.

2. Remove Fuse Relay Center (FRC) cover mounting screws
NOTE: Opening cup holder allows screw access.
3. Remove FRC cover and cover panel.
NOTE: Cup holder closed.
4. Disconnect wiring connector for Gear Selector Electronic Control Unit (GSECU). Remove GSECU after removing two mounting screws.
Fig 1: Locating Gear Selector Electronic Control Unit Wiring Connector
 View Full-Screen

REMOVAL & INSTALLATION > GEAR SELECTOR CONTROL UNIT

(AT2512C, ATO2512C, AT2812C, ATO3112C) > Installation
1. Install NEW GSECU and its mounting screws, and connect wiring connector.
2. Install cover panel, FRC cover and its mounting screws.
3. Connect negative cable of batteries. This will restore vehicle power.
4. Use PC tool to configure NEW GECU.

REMOVAL & INSTALLATION > GEAR SELECTOR WIRING HARNESS

(I-SHIFT TRANSMISSION)
WARNING: Without sufficient training, proper service literature and tools, never try to repair or service this vehicle as it can make vehicle unsafe and cause serious
personal injury or death.
CAUTION: Before disconnecting or connecting any electronic components, turn OFF vehicle ignition and de-energize circuits to avoid damage to electronic components.

1. Disconnect wiring harness connectors located at selector and at seat's back.

2. Remove harness from seat by cutting two tie straps securing harness to seat frame.
3. Shift the two harness retaining clips to NEW harness.
NOTE: Before removing clips, note their position on old harness so they can be installed in same position.
4. Install NEW harness on seat frame and keep tie straps loose on frame. This will allow for adjustment of harness slack.
5. Install wiring harness connectors at selector and at back of seat.
6. Wiring harness adjustment is made to enable enough slack for seat movement. Tighten harness tie straps.

REMOVAL & INSTALLATION > INPUT SHAFT SEALING RING

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Hollow Drift (88800005), Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > INPUT SHAFT SEALING RING > Removal
WARNING: Sufficient training is necessary before performing this procedure to prevent personal injury or death.
WARNING: Ensure air pressure has been released prior to beginning any task on air system component. Failure to follow this instruction may result in separation of
component, causing serious personal injury.

1. Apply parking brake.

2. Move shift lever to neutral.
WARNING: BATTERIES: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery
explosions. DO NOT disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures.
3. Disconnect all battery cables from negative (ground) terminals.
WARNING: HEAVY COMPONENTS: Properly support and use suitable lifting devices when removing heavy components. Failure to use appropriate lifting and
supporting devices can result in personal injury or death.
4. Drain air system, and use jack to raise and support vehicle.
NOTE: Vehicle must be raised to height enough for transmission and jack to clear vehicle when removed.
5. From transmission oil filter housing, disconnect oil cooler hoses using Transmission Oil Cooler Lines Disconnect Tool (85108826) .
6. Remove drive shaft from transmission (rear).
NOTE: Intermediate bearing (which supports bracket) is held by universal joint caps and bolts.
NOTE: Position of bolts on bracket must be noted in order to ensure reinstallation of intermediate bearing in correct position. Drive shaft must be positioned out of
way.
7. Unscrew straight Raufoss fitting from 90 degree fitting (present in cover) to disconnect air supply hose from transmission rear.
8. Cut wiring harness-to-transmission tie straps.
9. Disconnect wiring harness from control housing.
10. Disconnect speed sensor and two chassis connectors.
NOTE: Harness should be placed out of way.
11. Remove cab engine cover to access top bell housing bolts.
12. Remove mounting bolts that connect transmission to engine along bottom and sides of clutch housing.
NOTE: Top four transmission-to-engine mounting bolts must not be removed at this time.
13. Secure transmission by placing transmission jack under transmission.
14. Remove battery cables-to-brackets bolts on top of clutch housing.
15. Remove top four mounting bolts that connect transmission to engine.
16. Keep pulling transmission until input shaft clears pressure plate. Now lower and pull transmission out of vehicle.
NOTE: Transmission must be pulled from beneath vehicle.
NOTE: While lowering transmission, ensure there is no wiring or air hoses hung on it.
WARNING: Air under high pressure is present in clutch valve unit. Service plug can become a projectile if removed entirely. Leave drain plug slightly cracked so
that air pressure can be released slowly. Once air pressure is released, remove plug. Failure to follow this instruction may cause serious personal injury.
17. Service plug is located on top of clutch valve unit. Remove plug so that no air is left inside system. See Figure.
18. Use care to remove tie straps for wiring harness, and air hose to clutch cylinder. Remove clutch valve mounting bolts.
19. Disconnect clutch position sensor wiring harness connector. Keep clutch valve aside. See Figure.
20. Disconnect air hose from clutch cylinder by removing clip.
21. Remove clutch cylinder by removing mounting bolts.
22. Remove input shaft sealing ring using suitable seal removal tool.

REMOVAL & INSTALLATION > INPUT SHAFT SEALING RING >

Installation
1. Perform necessary cleaning and inspection of surface where sealing ring contacts transmission.
2. Coat sealing lip of replacement sealing ring with NEW transmission oil. Now install replacement sealing ring using Seal Installer (88800005) .
3. Clean supply hose connections and inspect for damaged parts. Replace "O" rings of supply hose. Replace components if damage is detected.
4. Install and tighten clutch cylinder on input shaft with mounting bolts to specification.
5. Connect air hose and install locking clip.
 6. Inspect for clean sealing surface on clutch valve assembly. Replace clutch valve seal (if required). See Figure.
7. Now connect wiring harness connector (for clutch position sensor) to clutch valve. See Figure.
8. Install and tighten clutch valve with mounting bolts to specifications .
9. Secure wiring harness and air hose in position using NEW tie straps.
10. From clutch control valve assembly, remove service plug and push piston all way into clutch cylinder to aid transmission installation. While holding piston, install
and tighten plug to specification.
NOTE: If this step is not performed, transmission cannot freely slide forward into place against engine mating surface.
11. Carefully install and align transmission to engine. Hold transmission in position by loosely installing upper and lower transmission-to-engine mounting bolts (two in
number).
NOTE: Installation may require an assistant.
NOTE: To align clutch splines, rotate input shaft.
12. Install and tighten remaining mounting bolts to specification. Remove transmission jack.
NOTE: To obtain easy access, first tighten mounting bolts on clutch housing (top). Then remove transmission jack to install other mounting bolts.
13. Place battery cables in brackets and install mounting bolts.
14. Install cab engine cover (if removed earlier).
15. With wiring harness positioned, connect control housing, speed sensor, and chassis connectors.
16. Secure wiring harness to transmission using NEW tie straps.
17. Thread straight Raufoss fitting into 90 degree fitting in cover to connect air supply hose.
18. Connect oil cooler hoses.
19. Install drive shaft.
20. Install and tighten intermediate bearing-to-support bracket universal joint caps and bolts to specifications .
NOTE: Ensure to center rubber insulator properly in U-bracket.
21. Lower vehicle by removing supporting jacks, and connect all battery cables to negative (ground) terminals.
22. Inspect for leaks by pressurizing air system.
23. Inspect for adequate level of transmission oil, add suitable oil if required.

REMOVAL & INSTALLATION > OUTPUT SHAFT SEALING RING >

Removal
WARNING: Sufficient training is necessary before performing this procedure to prevent personal injury or death.
WARNING: Apply parking brake, place transmission in neutral/park and block wheels prior to performing diagnostic or service procedures.

1. With parking brake applied, clean transmission around companion flange.

2. Remove or disconnect following:
1. Universal joint caps.
2. Front of drive shaft from yoke and place aside.
3. Universal joint yoke from companion flange.
4. Flange nut.
NOTE: Connect Counter Hold Tool (9998570) and remove tool after removing flange nut.
3. Assemble removal tools for companion flange.
1. Connect Tool (9998597) to companion flange, and assemble Tools (9992619) and (9992653) together.
2. Thread Tools (9992671) and (9990084) together.
3. Thread Tool (9992619) into Tool (9992671) , and Tool (9990084) into Tool (9998597) .
4. Perform inward adjustment of Tool (9992619) until tool makes contact with output shaft.
4. Remove companion flange.
NOTE: To provide hydraulic pressure, connect Tool (9996222) .
5. Remove output shaft seal using proper extracting tool.

REMOVAL & INSTALLATION > OUTPUT SHAFT SEALING RING >

Installation
1. Clean seal mating surface in transmission tail housing, and use grease to lubricate NEW seal lip.
2. Install seal for output shaft.
3. Use Seal Installer Tool (9998575) .
4. Perform replacement of "V" ring on companion flange.
NOTE: Ensure that "V" ring lies against companion flange stop.
NOTE: Inspect for visible damage on companion flange mating surfaces
CAUTION: DO NOT heat companion flange or hit with hammer. In order to avoid flange damage, perform installation by using suitable tools.
CAUTION: Prior to installing or tightening retaining nut, install companion flange completely. Damage to output shaft bearing or range oil pipe may be caused due
to inadequate pressing of flange.
5. Perform assembly of installation tools, and press flange on output shaft.
1. Place flange on shaft.
2. Thread Tool (9996925) into output shaft end. Now, place Tool (9996901) into (9996315) .
3. Thread Tool (9996315) all way into (9996925) .
4. Slide Tool (9992671) on (9996315) .
5. Install mounting nut on assemble end.
6. Install NEW "O" ring for flange nut. Install and tighten nut to 406 ± 37 Ft. Lbs. (550 ± 50 N.m) .
NOTE: Connect Counter Hold Tool (9998570) and remove tool after installing flange nut.
NOTE: Installation and tightening of nut may require an assistant.
7. Lock flange nut in position. Peen nut in both recesses on companion flange using punch.
NOTE: Use punch with rounded tip and push all way down. Inspect for cracks.
8. Install and tighten universal joint yoke on companion flange with mounting bolts. Tighten to 140 ± 11 Ft. Lbs. (190 ± 15 N.m) .
 9. Position drive shaft. Install and tighten universal joint caps with mounting bolts to 122 ± 7 Ft. Lbs. (166 ± 10 N.m) .

REMOVAL & INSTALLATION > OIL FILTER HOUSING

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > OIL FILTER HOUSING > Removal

1. Drain transmission oil into an appropriate container by removing drain plug. Install plug using torque specification.
2. Remove oil drain plug and catch drain out oil into an appropriate container.
NOTE: In order to stop oil dripping, ensure plug is reinstalled after draining housing.
3. Disconnect transmission oil cooler hoses using Transmission Line (15 mm) (85108826) . Remove reconnectors, oil filter housing and gasket.

REMOVAL & INSTALLATION > OIL FILTER HOUSING > Installation

1. Install a NEW gasket ensure sealing surface is clean.
2. Move oil cooler adapter to NEW filter housing and install. Tighten retainer to specifications .
NOTE: Ensure both of oil cooler "O" rings are replaced.
3. Using fasteners, install NEW Oil Filter Housing. Torque fasteners to specifications .
NOTE: Install these items initially to position housing in place: housing, gasket and 2 of center reconnectors.
NOTE: Start torque-tightening from center reconnectors and work outward.
4. Connect oil cooler hoses. Add approved transmission oil into transmission.

REMOVAL & INSTALLATION > OIL FILTER HOUSING GASKET

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > OIL FILTER HOUSING GASKET >

Removal
1. Drain transmission oil and oil filter into an appropriate container by removing drain plugs. Install plug using Torque Specifications .
2. Disconnect transmission oil cooler hoses using Transmission Line (15 mm) (85108826) . Remove reconnectors, oil filter housing and gasket.
3. Install a NEW oil filter housing gasket and ensure sealing surface is clean.

REMOVAL & INSTALLATION > OIL FILTER HOUSING GASKET >

Installation
1. Using fasteners, install oil filter housing. Torque fasteners to specifications . Start torque-tightening from center reconnectors and work outward.
NOTE: Install these items initially to position housing in place: housing, gasket and 2 of center fasteners.
2. Connect transmission oil cooler hoses. Add approved transmission oil into transmission.

REMOVAL & INSTALLATION > POWER TAKE-OFF

WARNING: Sufficient training is necessary before performing this procedure to prevent personal injury or death.
WARNING: Ensure air pressure has been released prior to beginning any task on air system component. Failure to follow this instruction may result in separation of
component, causing serious personal injury.
WARNING: Apply parking brake, place transmission in neutral/park and block wheels prior to performing diagnostic or service procedures.
REMOVAL & INSTALLATION > POWER TAKE-OFF > Installation
WARNING: HEAVY COMPONENTS: Properly support and use suitable lifting devices when removing heavy components. Failure to use appropriate lifting and
supporting devices can result in personal injury or death.

1. Lift rear portion of vehicle and support.

NOTE: Reduce fluid loss from transmission by lifting rear portion of vehicle until rear of transmission is raised to 3-3.5 in (76-89 mm).
2. Drain air system and air supply tank of I-Shift transmission.
NOTE: Pressure protection safety valve present on this tank will not allow air drainage with other air systems.
3. From transmission range housing, remove PTO mounting surface block off plate.
NOTE: Collect lost transmission fluid by placing a drain pan.
4. Assemble following: PTO drive shaft, bearing, thrust washer and snap rings.
NOTE: Always strike inner race of bearing while assembling. Use a brass drift to strike. Striking must be done evenly around bearing circumference.
5. Apply adequate amount of grease on PTO drive shaft bearing and install shaft assembly in transmission.
NOTE: Use of synthetic based grease (1077790 or equivalent) is recommended.
NOTE: Use a plastic/rubber faced hammer to gently tap shaft after placing shaft in transmission (if needed).
NOTE: If snap ring on outer bearing makes contact with mating groove on transmission, bearing is seated.
6. Apply adequate amount of lubricant on PTO drive shaft pilot bearing and install bearing.
NOTE: Use of synthetic based grease (1077790 or equivalent) is recommended.
7. Coat PTO mounting surface with bead of silicone sealant.
NOTE: DO NOT use gaskets or "O" rings to seal PTO mating surfaces, use only silicone sealant.
NOTE: Prior to coating PTO mating surface with silicone seal, clean surfaces thoroughly.
8. Install air line bracket on PTO mounting bolt (left upper). Install and tighten PTO with mounting bolt to 63 ± 11 Ft. Lbs. (85 ± 15 N.m) .
9. From transmission oil filter housing (back side), remove PTO oil supply line plug.
10. Install and tighten oil feed line fitting into port on transmission oil filter housing (back side) to 15 Ft. Lbs. (20 N.m) .
NOTE: Seal fitting with copper gasket.
11. Connect and tighten PTO oil feed line to oil port to 11 Ft. Lbs. (15 N.m) .
12. Wiring connectors for PTO solenoid are connected to transmission wiring harness (on top of transmission). Make harness free by cutting straps (if required).
NOTE: Connectors have printed indications of PTO1 and PTO2 at wiring tags.
NOTE: Wiring numbers for PTO1 are NA11A1 and NA20A1.
NOTE: Wiring numbers for PTO2 are NA16A1 and NA17A1.
13. Install one pipe plug and two quick connect air fittings into PTO solenoid.
NOTE: Air line of 3/8 In. will fit in supply line while 1/4 In. will fit in outlet fitting.
14. Install and tighten PTO solenoid to bracket with bolts to 80 In. Lbs. (9 N.m) .
15. Remove top left range housing mounting bolts (two in number).
16. Install and tighten bracket with range housing bolts to 81 Ft. Lbs. (110 N.m) . Now connect PTO1 wiring to solenoid.
NOTE: Connectors have printed indications of PTO1 and PTO2 at wiring tags.
NOTE: Wiring numbers for PTO1 are NA11A1 and NA20A1.
NOTE: Wiring numbers for PTO2 are NA16A1 and NA17A1.
17. Install a 90° air line quick connect fitting into PTO and 1/4 In. air line from solenoid to PTO.
NOTE: 1/4 In. air line is suitable for fitting.
NOTE: Secure line using tie straps and keep away from moving parts.
18. With plug removed from air line port (3/8 In.) (on left inner frame rail pressure protection manifold), install solenoids.
19. Install air supply line (3/8 In.) to manifold and connect to solenoid.
NOTE: Secure line using tie straps and keep away from moving components.
20. Follow below steps to install fittings in Air Tank (20958620).
NOTE: This tank is meant to provide air to transmission only and will replace original I-Shift transmission air tank.
1. Install Automatic Air Vent Valve (20760379) along with "O" ring.
2. Install Pressure Protection Safety Valve (3186824).
3. Install air line quick connect (1/2 In. air tank supply line) and Manual Air Fill Valve (8397496) along with Nipple (8078126).
4. Install pipe plug and air line quick connect.
5. Install pipe plug, and drain valve and Cable Assembly (20703654) having 45° elbow nipple.
21. Few vehicles have intermediate cross member while others have service cross member. Install tank to crossmember (whichever present) and tighten mounting bolts
to adequate torque: 63 Ft. Lbs (85 N.m) .
22. Relocate air drain valve cable bracket, and mount bracket on appropriate NEW position on vehicle left side with existing frame bolts. Tighten bolts to 63 Ft. Lbs (85
N.m)
23. Connect valve cable to bracket, and remove air lines from I-Shift air tank.
NOTE: Use NEW lines in replacement tank. Discard all old lines.
NOTE: NEW lines should be connected to same position from where old lines were disconnected. Note position of lines before removing.
24. With original equipment, I-Shift air tank removed, install NEW 1/2 In. air tank supply and air tank outlet line.
NOTE: Depending on vehicle equipment, it is necessary to remove components to gain access to fasteners.
NOTE: Use tie straps to secure lines, route these lines away from moving parts.
25. Pressurize tank and inspect if leaks are present. If no leakage is found, pressurize rest of air system
NOTE: Drain air tank and repair leak if leakage is detected. Re-test until leaks are fully repaired.
26. Lower vehicle by removing supports.
27. Using NEW approved oil (Castrol Syntrans, ExxonMobil 97307 Spec oils, or a synthetic oil meeting 97307 Spec fluid), fill transmission.
NOTE: Keep on filling oil until fluid level is between minimum and maximum of sight glass.
NOTE: Use of NEW oil is strongly recommended. Never use old oil from I-Shift transmission when filling.
NOTE: Installation process might cause fluid loss up to 1-2.1 quarts (1-2 liters).
28. With FRC cover removed from cab, install fuse (5 amp) in FRC fuse slot F40.
Fig 1: Identifying Fuse Relays
 View Full-Screen
29. Install ISO relay in FRC relay location R7, and install FRC cover.
30. Remove dash switch blank on dash board from either position 3 or 5. PTO switch connector may be found in cab wiring harness.
31. Locate position 3 or 5 (whichever available) and install PTO switch on suitable position.
32. Flash TCM with suitable software for a single PTO using Scan Tool.
NOTE: Suitable software does not depend upon outputs on PTO, it depends upon number of solenoids used to actuate PTO (single or dual solenoids).
33. Use Scan Tool to perform "Transmission and Clutch Calibration" after flashing TCM with software.
34. Perform PTO Parameter Programming .
NOTE: Changing Vehicle ECU default parameter from engine1 to transmission1 (for PTO position mounting) is strongly recommended.
35. Inspect transmission fluid level by running vehicle. To maintain fluid level between sight glass minimum and maximum, top off transmission.
NOTE: PTO uses transmission fluid for lubrication purpose. After being run initially, PTO retains .75 liters (.8 qts.), of transmission fluid. Thus, after installing NEW
PTO, always top off transmission fluid.

REMOVAL & INSTALLATION > RANGE/SPLIT/GEAR SELECTOR

POSITION SENSOR
WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > RANGE/SPLIT/GEAR SELECTOR

POSITION SENSOR > Removal
1. Perform Gear Activation, Control Housing, for Removal and Installation using tech tool.
NOTE: On overdrive transmissions, ensure transmission is positioned as follows:
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: On direct drive transmissions, ensure transmission are positioned as follows:
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: You may perform this operation with transmission removed from vehicle if necessary.
NOTE: If tech tool failed to activate necessary gears for removal of control housing, activate gears manually. Do as instructed in this procedure after transmission
removal.
NOTE: If required to fully engage gears within transmission, move vehicle forward or backward.
2. Set parking brake.
3. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
4. Drain air tank to remove all air from system.
5. Lift vehicle and use jack stands.
6. Disconnect oil cooler hoses from filter housing using Transmission Line (15 mm) (85108826) tool.
7. Remove drive shaft.
NOTE: Remove universal joint caps and intermediate bearing to support bracket reconnectors if necessary.
 NOTE: Ensure reconnectors on bracket is marked in same position as before to aid installation of intermediate bearing in original position. Move shaft aside.
8. Remove Straight Raufoss fitting from 90 degree fitting in cover.
9. Remove wiring harness to transmission tie straps.
10. Disconnect these connectors: control housing, speed sensor, and 2 chassis connectors from wiring harness. Move harness aside.
11. Remove cab engine cover.
12. Remove fasteners on sides and bottom clutch housing that secure transmission to engine.
NOTE: At this time DO NOT remove top fasteners securing transmission to engine.
13. Use transmission jack to secure it.
14. Disconnect Battery cables to brackets fasteners on top of clutch housing.
15. Remove top reconnectors that secure transmission to engine.
16. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is hanging or dragging. See Figure.
17. Disconnect clutch valve wiring connector at control housing.
18. Remove Straight Raufoss fitting from 90 degree fitting in cover.
19. Remove connectors form control housing.
20. Perform Gear Activation, Control Housing manually for Removal and Replacement.
NOTE: These next steps are only if Tech tool was not able to activate proper gears for removal. If Tech tool was successful go to step 28.
21. Remove 6 upper cover fasteners.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
22. Lift top edge of upper cover and angle it down against clutch housing. Disconnect electrical connection and remove top cover. Use care while doing this step to avoid
damage.
NOTE: Never put tension or weight to wiring harness or connector.
23. Overdrive Transmission:
1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. High Split.
7. Reverse Gear.
8. Low Split.
24. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a over drive transmission are listed below. For positions on a direct drive unit, see step 26.
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged.
NOTE: In order to mesh gears, turn output shaft while range section is being engage.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to engage.
DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
25. Direct Drive Transmission:
1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. Low Split.
7. Reverse Gear.
8. High Split.
26. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a direct drive transmission are listed below. For positions on an overdrive unit, see step 24.
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged.
NOTE: In order to mesh gears, turn output shaft while range section is being engage.
NOTE: Position that gear set to neutral prior to attempting to engage reverse if 2nd or 3rd gear is engaged.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of two gears to engage.
DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
CAUTION: Ensure gentle and uniform pressure is applied to lift control housing from transmission. DO NOT use excessive force as this can damage components.
27. Use care to separate control housing from locating pins using a pry bar.
28. Remove control housing.
NOTE: If failed to remove control housing from transmission upon application of gentle upward pressure, see steps 24 or 26 prior to re-attempt removal.
NOTE: DO NOT damage transmission tooth wheel during removal.
29. Disconnect position sensor wiring harness connector and remove fasteners.
1. Disconnect cylinder position sensor.
1. Range Cylinder Position Sensor.
2. 2nd/3rd Gear Cylinder Position Sensor.
3. 1st/Reverse Gear Cylinder Position Sensor.
30. Remove sensor. Remove retaining ring.
REMOVAL & INSTALLATION > RANGE/SPLIT/GEAR SELECTOR
POSITION SENSOR > Installation
1. Using retaining ring, install NEW position sensor.
2. Install sensor reconnectors using Torque Specifications .
3. Reconnect position sensor wiring harness.
4. Ensure control housing sealing surface is clean.
5. Install a NEW control housing gasket.
1. HR - High Range.
2. S - Split.
3. 2/3 - 2nd/3rd Gear In Neutral.
4. R - Reverse Gear.
6. Inspect followings to verify position:
1. Split engaging ring: in its rearmost.
2. 2nd/3rd engaging ring: in neutral position or middle position.
3. Reverse gear engaging ring: in its rearmost position.
7. Ensure range gear is in high range.
NOTE: NEW control housing forks must correspond to position of engaging rings. If not, use hand and position them carefully.
8. To install correctly with main housing inspect if range servo piston is positioned out 1 In. (25.4 mm).
9. Using care lower control housing so tooth wheel is protected from damage. Split fork must end up in correct position in engaging ring.
10. Install these items: NEW solenoid valve seals, "O" ring for countershaft brake, and a NEW upper cover gasket.
NOTE: Ensure this and next 2 steps are only performed if Gear Activation, Control Housing was performed manually for removal and replacement. If no manual
activation was done, continue with step 13.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
11. With NEW upper cover in place, connect wiring harness and place upper cover into place.
NOTE: Never put tension or weight to wiring harness or connector.
12. Install 6 fasteners that secure upper cover and tighten to specifications .
13. Install fasteners that secure control housing and tighten to specifications .
14. Thread straight Raufoss fitting into 90 degree fitting in cover. See Figure.
15. Reconnect control housing to clutch valve wiring harness connector.
16. When control housing has been installed, perform Transmission Calibration with transmission removed.
NOTE: If calibration does not work, inspect if shift fork position sensor values are in range. If they are incorrect, possibly shift forks are incorrectly installed to
engaging rings and this hinders correct transmission shifting. Remove control housing to inspect shift fork installation and position of engaging ring. Re-install
control housing starting from Step 4.
17. Do as follows to simplify installation of transmission remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install plug by tightening to specifications .
NOTE: If this step is skipped, there will be installation interference. Transmission will be under clutch cylinder spring pressure. This will prevent it from freely
sliding forward into place against engine mating surface.
18. Using caution and an assistant, install transmission and align it to engine. Loosely install 2 upper and lower reconnectors that secure transmission to engine.
NOTE: Align clutch splines by turning input shaft.
19. Install upper fasteners first then reconnect lower that secure transmission to engine. Tighten to specifications and remove jack..
20. Install battery cables using their mounting fasteners.
21. Install cab engine cover.
22. With electrical harness in place, re-install these items: control housing, speed sensor, and 2 chassis connectors.
23. Install NEW wiring harness to transmission tie straps.
24. Thread straight Raufoss fitting into 90 degree fitting in cover. Connect oil cooler hoses to oil filter housing.
25. Install: drive shaft, universal joint caps and fasteners that secure intermediate Bearing To Support bracket if necessary Tighten to specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
26. Remove jack stands. Lower vehicle.
27. With air system pressurized, perform leak inspection.
28. Connect all removed cables to negative battery terminals.
29. Inspect transmission oil level and add approved oil if necessary.
30. Operate engine. Perform leak test and good operation. After shutdown, inspect and refill fluids as required.

REMOVAL & INSTALLATION > REAR OUTPUT SHAFT SEAL

WARNING: Ensure parking brakes are applied, transmission is in neutral, and wheels are blocked prior start any task, or personal injury or death could occur.

Tools required: Counterhold (9998570), Adapter (9990084), Spindle (9992619), Mandrel (9992653), Hydraulic Cylinder (9992671), Puller (9998597), Hydraulic Pump,
Air Operated (9996222), Seal Installer (88800174), Spindle (9996315), Mandrel (9996901), Adapter (9996925). See Special Tools .

REMOVAL & INSTALLATION > REAR OUTPUT SHAFT SEAL > Removal
1. Set parking brake. Position shift lever in neutral.
2. Thoroughly clean area around companion flange.
3. Remove universal joint caps then disconnect front of drive shaft from yoke. Move shaft aside.
4. Remove universal joint yoke from companion flange. Remove companion flange nut using special tool Counterhold (9998570) . Dispose of nut "O" ring. After
removal of nut, remove tool.
5. Do as follows to assemble companion flange removal tools:
1. Install Puller (9998597) to companion flange.
2. Assemble Spindle (9992619) and Mandrel (9992653) together and assemble Hydraulic Cylinder (9992671) and Adapter (9990084) together.
3. Thread Spindle (9992619) into Hydraulic Cylinder (9992671) .
 4. Thread Adapter (9990084) into Puller (9998597) .
5. Adjust Spindle (9992619) inward so it makes contact with output shaft.
6. Remove companion flange by pulling off using assembled removal tools. Dispose of V-ring.
NOTE: Install Hydraulic Pump, Air Operated (9996222) to provide hydraulic pressure for removal of flange.

Tools required: Adapter (9990084), Spindle (9992619), Mandrel (9992653), Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated (9996222), Puller
(9998597). See Special Tools .

7. Remove damaged output shaft sealing ring using an appropriate extraction tool.

REMOVAL & INSTALLATION > REAR OUTPUT SHAFT SEAL >

Installation
1. In transmission tail housing thoroughly clean output shaft sealing ring mating surface.
2. Lubricate outer component of output shaft sealing ring. Install output shaft sealing ring into transmission tail housing with special tool Seal Installer (88800174) .
3. Install a NEW V-ring onto companion flange.
NOTE: Ensure V-ring lays against stop on companion flange.
NOTE: Ensure mating surfaces of companion flange have no obvious damage.
CAUTION: Neither treat companion flange with heat nor hit with a hammer; ensure only approved special tools are used for installation. Otherwise component
damage will occur.
CAUTION: Complete installation of companion flange prior to installation of retaining nut. If not pressed it on completely, accelerated damage to output shaft
bearing or range oil pipe may occur.
4. Do as follows and install companion flange:
1. With companion flange positioned on output shaft, thread Adapter (9996925) into end of output shaft.
2. Install Mandrel (9996901) onto Spindle (9996315) and thread Spindle (9996315) into Adapter (9996925) until it bottoms.
3. Slide Hydraulic Cylinder (9992671) onto Spindle (9996315) and install nut on end of assembly.

Tools required: Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated (9996222), Spindle (9996315), Mandrel (9996901), Adapter (9996925). See Special
Tools .

5. Install a NEW companion flange nut "O" ring.

6. Using as assistant, install companion flange nut using special Counterhold (9998570) tool by tightening to Torque Specifications .
NOTE: Ensure tool is removed after completion of installation of nut.
7. With companion flange nut locked in place, peen it in both recesses on companion flange using a punch.
NOTE: Punch must have a rounded tip to ensure it is pushed in to bottom. Use care to prevent cracks on surface.
8. Position universal joint yoke on companion flange and secure by tightening bolts to Torque Specifications .
9. With drive shaft in its yoke, install universal joint caps and secure by tightening bolts to Torque Specifications .

REMOVAL & INSTALLATION > SPEED SENSOR & CABLE HARNESS

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > SPEED SENSOR & CABLE HARNESS >
Removal
1. Perform Gear Activation, Control Housing using scan tool for Removal and Installation.
NOTE: On overdrive transmissions, ensure transmission is positioned as follows:
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: On direct drive transmissions, ensure transmission are positioned as follows:
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: You may perform this operation with transmission off vehicle if necessary.
NOTE: If scan tool failed to activate necessary gears for removal of control housing, activate gears manually. Do as instructed in this procedure after transmission
removal.
NOTE: If required to fully engage gears within transmission, move vehicle forward or backward.
2. Set parking brake. Position shift lever in neutral.
3. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
WARNING: BATTERIES: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery
explosion. DO NOT disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures
4. Drain air tank to remove all air from system.
 5. Lift vehicle and support with jack stands.
6. Disconnect oil cooler hoses from filter housing using Transmission Line (15 mm) (85108826) tool.
7. Remove drive shaft.
NOTE: Remove universal joint caps and intermediate bearing to support bracket bolts if necessary
NOTE: Ensure position of bolts on bracket is marked to aid installation of intermediate bearing in original position. Move shaft aside.
8. Unscrew Straight Raufoss fitting from 90 degree fitting in cover.
9. Remove air supply hose at rear of transmission.
10. Remove wiring harness to transmission tie straps.
11. Disconnect wiring harness at these locations: control housing, speed sensor, and 2 chassis connectors. Move harness aside.
12. Remove cab engine cover.
13. Bolts that secure transmission and engine along bottom and sides of clutch housing.
NOTE: At this time DO NOT remove top bolts securing transmission and engine.
NOTE: Prior to removal, secure transmission to jack.
14. On top of clutch housing remove battery cables to brackets bolts.
15. Remove top 4 transmission to engine bolts. With caution pull transmission back until input shaft is off pressure plate, then lower transmission and pull off. While
lowering transmission periodically Inspect around it to assure nothing is dragging or hanging, such as wiring or hoses. See Figure.
16. At control housing disconnect clutch valve wiring connector.
17. At upper control housing fitting disconnect clutch control valve air supply tube. It maybe necessary to loosen fittings and remove with air line connected.
18. Remove control housing and six upper mounting bolts.
19. Lift top edge of upper cover and angle it down against clutch housing. Disconnect electrical connection and remove top cover. Use care while doing this step to avoid
damage.
NOTE: Never put tension or weight to wiring harness or connector.
20. Ensure manual activation of gear is performed only if scan tool failed to activate gears for control housing.

Overdrive Transmission:

1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. High Split.
7. Reverse Gear.
8. Low Split.
21. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a over drive transmission are listed below. For positions on a direct drive unit, see step 23.
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged and turn output shaft while range section is being engage.
NOTE: It is necessary to position gear in neutral prior to attempting to engage reverse gear.
NOTE: To engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to engage. DO NOT
turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
22. Drive Transmission:
1. High Range.
2. 3rd Gear.
3. Low Range.
4. 2nd Gear.
5. 1st Gear.
6. Low Split.
7. Reverse Gear.
8. High Split.
23. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a direct drive transmission are listed below. For positions on an overdrive unit, see step 21.
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged and turn output shaft while range section is being engage.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to engage.
DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
CAUTION: Ensure gentle and uniform pressure is applied to lift control housing from transmission. DO NOT use excessive force as this can damage components.
Use guide pins for this operation, otherwise component damage may void warranty.
24. If tool succeed in gear activation, carefully remove control housing from locating pins with a pry bar.
NOTE: If failed to remove control housing from transmission upon application of gentle upward pressure, see steps 21 or 23 prior to re-attempt removal.
NOTE: DO NOT damage transmission tooth wheel during removal.
25. Disconnect all position sensor wiring harness connectors.
NOTE: Observe wiring harness routing prior to disconnecting wiring harness.
26. Remove main shaft. Remove countershaft speed sensors.
27. Remove wiring harness to attachment plate tie straps.
28. Remove wiring harness by removing harness to housing screw.
NOTE: Ensure direction of wiring harness is observed before disassembly. There are 2 ways of installing harness; if installed backward, harness will not connect to
all of sensors.
REMOVAL & INSTALLATION > SPEED SENSOR & CABLE HARNESS >
Installation
1. Apply approved grease to "O" ring and on wiring harness.
2. Install NEW wiring harness.
NOTE: Ensure wiring harness is installed in original direction. There are 2 ways of installing wiring harness; if installed backward, harness will not connect to all of
sensors and route harness away from split cylinder.
3. Connect all position sensor wiring harness connectors.
NOTE: Ensure electrical cable lies inside lug on range cylinder.
4. Using reconnectors, Install main shaft & countershaft speed sensors. Torque reconnectors to specifications .
5. Install NEW wiring harness to attachment plate tie straps.
6. Install a NEW control housing gasket and ensure sealing surface is clean.
1. HR - High Range.
2. S - Split.
3. 2/3 - 2nd/3rd Gear In Neutral.
4. R - Reverse Gear.
7. Inspect followings to verify position:
1. Split engaging ring: in its rearmost.
2. 2nd/3rd engaging ring: in neutral position or middle position.
3. Reverse gear engaging ring in its rearmost position.
8. Ensure range gear is in high range.
NOTE: Control housing forks must correspond to position of engaging rings. If not, use hand and position them carefully.
9. To correctly mate with main housing, inspect if range servo piston is positioned out 1 In. (25.4 mm).
10. Using care lower control housing with guide pins (9996876) , so tooth wheel is protected from damage. Split fork must end up in correct position in engaging ring.
11. Install NEW an "O" ring for countershaft brake, solenoid valve seals, and a NEW upper cover gasket.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
12. With NEW upper cover in place, connect wiring harness. Lower upper cover into place.
NOTE: Never put tension or weight to wiring harness or connector.
13. Install all 6 fasteners that secure upper cover using a diagonal pattern and Torque Specifications .
14. Connect clutch control valve air supply tube to upper control housing fitting, and wiring harness connector to control housing. See Figure.
15. When control housing has been installed, perform Transmission Calibration using scan tool with transmission removed.
NOTE: If calibration fails, inspect if shift fork position sensor values are in correct positions. If they are incorrect, possibly shift forks are incorrectly installed to
engaging rings and this hinders correct transmission shifting. Remove control housing to inspect shift fork installation and position of engaging ring. Re-install
control housing starting from Step 7.
16. Do as follows to simplify installation of transmission: remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install plug by tightening to specification .
NOTE: If this step is skipped, there will be installation interference. Transmission will be under clutch cylinder spring pressure and will not freely slide forward into
place against engine mating surface.
17. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower bolts securing transmission to engine loosely.
NOTE: Align clutch splines by turning input shaft.
18. Install remaining bolts securing transmission to engine by tightening to specifications and remove transmission jack. See.
NOTE: It is encouraged to install bolts on top of clutch housing first for easy access holes. With transmission jack removed, install remaining bolts.
19. Install battery cables using their mounting bolts. Install cab engine cover.
20. With wiring harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
21. Install NEW wiring harness to transmission tie straps.
22. Reconnect air supply hose at rear of transmission by threading Straight Raufoss fitting into 90 degree fitting in cover. Reconnect transmission oil cooler hoses to
filter housing.
23. Install drive shaft, universal joint caps and bolts that secure intermediate bearing to support bracket and tighten to Torque Specifications . Ensure rubber insulator is
centered in U-bracket correctly.
24. Remove jack stands. Lower vehicle.
25. With air system pressurized, perform leak inspection.
26. Connect all removed cables to negative battery terminals.
27. Inspect transmission oil level and add approved oil if necessary.

REMOVAL & INSTALLATION > TRANSMISSION

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > TRANSMISSION > Removal

1. Set parking brake. Position shift lever in neutral.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system.
4. Lift vehicle and support with jack stands.
5. Remove oil cooler hoses from filter housing using Transmission Line (15 mm) (85108826) tool.
NOTE: If lower fuel crossover lines are present, close fuel line valves to prevent leakage from fuel tanks.
6. Remove brackets and disconnect lower crossover fuel lines. Move brackets and lines aside.
7. Remove drive shaft and universal joint caps and intermediate Bearing To Support bracket bolts if necessary.
NOTE: Chock position of bolts on bracket. This will ensure bolts are replaced in same place for installation. Move shaft aside.
8. Unscrew Straight Raufoss fitting from 90 degree fitting in cove and remove air supply hose at rear of transmission.
 9. Remove wiring harness to transmission tie straps.
10. Disconnect wiring harness at these locations: control housing, speed sensor, and 2 chassis connectors. Move harness aside.
11. Remove engine cab cover.
12. Remove bolts that secure transmission and engine on bottom and sides of clutch housing.
NOTE: At this point DO NOT remove top bolts securing transmission and engine.
NOTE: Prior to removal of following item, position transmission jack and secure transmission to it.
13. Battery cables to brackets bolts on top of clutch housing.
14. Remove 4 bolts on top of transmission to engine.
15. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is hanging or dragging.
16. Shift drive shaft yoke to NEW transmission and secure by tightening reconnectors to Torque Specifications .
WARNING: HEAVY COMPONENTS: Properly support and use suitable lifting devices when removing heavy components. Ensure lifting devices can support
component comfortably and are Okay. Ensure hooks are correctly positioned. If required, use a spreader bar. Ensure lifting hooks are not side loaded. Failure to use
appropriate lifting and supporting devices and also ignorance to safety instructions can result in personal injury or death.
17. Remove old transmission from jack.

REMOVAL & INSTALLATION > TRANSMISSION > Disassembly

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.

1. Thoroughly clean exterior of transmission.

NOTE: Ensure nipples and valves remain plugged during high pressure cleaning.
2. Do procedure 40091-3 Transmission Activation, Control Housing with VCADS 9 Vehicle Computer-Aided Diagnostic System program installed for Removal and
Installation:
NOTE: On overdrive transmissions, ensure transmission is positioned as follows before removing control housing:
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: On direct drive transmissions, ensure transmission are positioned as follows before removing control housing:
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.

If VCADS program failed to activate necessary gears for housing removal, continue with step 9. If succeeded, continue with next step.

NOTE: If VCADS failed to activate necessary gears for removal of housing, move control housing manually to position so it can be lifted off transmission.
3. Inspect if:
1. Splitter gear is in its rear position.
2. 2nd and 3rd in neutral and 1st/reverse in rear position and set to high range.
4. Remove reconnectors that secure control housing and 6 reconnectors that secure upper cover.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
5. Lift top edge of upper cover and angle it down against clutch housing. Disconnect electrical connection and remove cover. Use care while doing this step to avoid
damage.
NOTE: Never put tension or weight to wiring harness or connector.
6. Install 4 reconnectors correctly. DO NOT damage control housing while tightening reconnectors. This is required to assure control housing does not move and
damage pulse wheel on main shaft.
7. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a over drive transmission are listed below. For positions on a direct drive unit, see step 8.
1. Low Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged. Then turn output shaft while range section is being engage.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to engage.
DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged.
8. In order to position transmission gears in place for control housing removal, apply compressed air to appropriate bore holes.
NOTE: Required gear positions for a direct drive transmission are listed below. For positions on an overdrive unit, see step 7.
1. High Split.
2. High Range.
3. 2nd/3rd - Neutral Position.
4. 1st/Reverse - Reverse Position.
NOTE: In order to mesh gears, turn input shaft while splitter section is being engaged and turn output shaft while range section is being engage.
NOTE: In event that 2nd or 3rd gear is engaged, position that gear set to neutral prior to attempting to engage reverse.
NOTE: Attempt to engage neutral for 2nd/3rd gear set by applying air pressure gradually to bore holes. Applying too much air will cause one of 2 gears to engage.
DO NOT turn shaft when attempting to position this gear set.
NOTE: In order to mesh gears turn output or input shaft while reverse is being engaged. See Figure.
9. Disconnect clutch valve wiring harness connector. Disconnect clutch valve air supply line using J44773 Air Line Release Tool . Remove reconnectors that secure
valve. See Figure.
10. Disconnect clutch position sensor wiring harness connector. See Figure. Cut tie strap that reconnects wiring harness. Now remove valve assembly.
11. Position spacer flange onto fixing plate. Using arm, install fixing plate to transmission.
12. Install transmission onto overhaul stand with an appropriate lifting device. Use Overhaul Stand (9986485), Anchorage (9990031), Fixture (9996905), Intermediate
Flange (9999737)Special Tools
13. Remove transmission oil drain plug and drain fluid into an appropriate container. Install drain plug by tightening to Torque Specifications .
 WARNING: HOT FLUIDS: Avoid burns from hot fluids by allowing components to cool and observe appropriate safety precautions when relieving pressurized
systems containing hot fluids. When working on cooling systems, release cooling system pressure by slowly loosening radiator cap.
14. Drain transmission oil into a suitable container by removing oil filter oil drain plug. Install oil filter drain plug by tightening to Torque Specifications .
15. Remove oil filter cover. Remove guide sleeve.
16. Remove reconnectors, oil filter housing, and gasket.
CAUTION: Ensure gentle and uniform pressure is applied to lift control housing from transmission. DO NOT use excessive force as this can damage components.
17. Remove control housing to transmission case reconnectors. Carefully separate control housing from locating pins using a pry bar. Remove control housing.
NOTE: If failed to remove control housing from transmission upon application of gentle upward pressure, see step 7 or 8 prior to re-attempt removal.
NOTE: DO NOT damage transmission tooth wheel during removal. Use Level (9992337) .
18. If a retarder is present in transmission, go to 19 and 21. If not, See step 22.
19. Remove retarder temperature sensor from heat exchanger and connector from plate.
20. Remove tie straps that reconnect retarder wiring harness.
21. Remove heat exchanger to retarder cooler reconnectors.
22. Rotate transmission until output shaft flange is facing up.
23. Install Counterhold (9998570) tool onto output shaft flange. Remove nut and "O" ring form flange.
24. Remove companion flange. Use Adapter (9990084), Spindle (9992619), Hydraulic Cylinder (9992671), Mandrel (9996156), Hydraulic Pump, Air Operated
(9996222), Puller (9998597) .
25. Remove plug, spring, and blocking body for range function.
NOTE: Drag blocking body out using a magnet if necessary.
26. If a retarder is equipped, do steps 27 and 28. If retarder is not equipped, See step 29.
27. Remove retarder to range housing reconnectors.
28. Exercise caution and lift retarder off transmission.
29. Remove range housing reconnectors.
NOTE: If a retarder is equipped, ensure reconnectors are removed from retarder socket.
30. Install lifting eye in output shaft and adapter. Use Lifting Eye (9996479), Adapter (9996925) .
31. Using Press (9998051) tool, disconnect main housing and range housing.
32. Using care, lift range housing away.
NOTE: Range cylinder piston rod must not jam in transmission housing, or damage to shaft may occur.
33. Using special tool Socket Wrench (9990027) , remove oil distributor pipe.
34. Remove: snap ring securing high range synchronizer, and both halves of washer.
35. Install both puller halves onto high range synchronizer hub. Along with hydraulic cylinder, spindle, and drift, install one half of Puller (9998542) onto puller rings.
Use Puller (88800015), Puller (9998542), Hydraulic Cylinder (9992671), Mandrel (9996889), Puller (9998542) .
NOTE: Split in puller rings must be at 90 degree to split in puller.
36. Install other half of puller and hydraulic pump.
37. Press off high range synchronizer. Use Hydraulic Pump, Air Operated (9996222) .
38. Remove reconnectors that secure reversing shaft center. Remove rear cover and adjustment washer for countershaft.
39. Assemble puller and spindle to reversing shaft. Assemble hollow drift, hydraulic cylinder, and hydraulic pump to spindle. Use Spindle (9996315), Screw (9996917),
Mandrel (9990120), Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated (9996222) .
40. Remove reversing shaft and oil pump with reverse gear pinion. Then remove main shaft rear cover and overdrive gear oil pipe.
41. Remove main shaft adjustment shim. Turn transmission until input shaft faces up. See Figure.
42. Disconnect air hose from clutch cylinder. Remove clip that reconnect air hose in clutch cylinder, reconnectors, and then clutch cylinder.
43. Remove countershaft brake air supply tube and air hose on clutch cylinder.
44. Remove countershaft brake cover and reconnectors.
45. Remove Brake plates, 2 friction plates and 3 steel plates.
46. Remove countershaft brake cover gasket and Countershaft brake piston and spring.
47. Remove clutch housing to transmission reconnectors and clutch housing.
48. Remove air supply tube nipple for countershaft brake pipe and countershaft sleeve.
49. Remove magnet between clutch housing and lower component of base housing. If necessary clean magnet.
NOTE: Assemble lifting tool using lifting arms and spacer ring from Special (Fixture (9990028) Lifting Arm Kit (Retainer (88800006), fixture plate, and chain.
NOTE: After removal, clean magnet.
50. Install assemble lifting tool onto shaft assembly. Use Retainer (88800006), Fixture (9990028), Lifting Chain (9996239), Fixture (9996910) .
51. Arrange a wooden fixture to receive shaft package.
NOTE: In order to avoid gear teeth damage, DO NOT place main shaft on a workbench or similar surface. Perform all work with main shaft vertically positioned.
52. Using care, remove shaft assembly and put it in wooden fixture. Remove lifting tool from shaft assembly.
53. Remove countershaft outer race from clutch housing. It is encouraged to use a puller, yoke, cylinder, pump, and spindle. Use Brace (88800033), Puller (88800035),
Hydraulic Cylinder (9992671), Spindle (9996041), Hydraulic Pump, Air Operated (9996222) .
NOTE: Unless bearing replacement is needed, DO NOT remove outer race.
54. Remove input shaft outer race from clutch housing. Ensure a puller, yoke, cylinder, pump, and spindle are used. Use Brace (88800033), Puller (88800035), Hydraulic
Cylinder (9992671), Spindle (9996041), Hydraulic Pump, Air Operated (9996222) .
NOTE: Unless bearing replacement is needed, DO NOT remove outer race.
55. Remove countershaft rear bearing outer race from transmission housing using Drift Handle (9992000) and Mandrel (9992215) .
NOTE: Unless bearing replacement is needed, DO NOT remove outer race.
56. Remove main shaft rear bearing outer race from transmission housing using Standard Handle 25x350 (9992613) and Mandrel (9996176) a drift and handle.
NOTE: Unless bearing replacement is needed, DO NOT remove outer race.
57. Remove overflow valve and oil screen.

REMOVAL & INSTALLATION > TRANSMISSION > Assembly

1. Thoroughly clean all components and replace if necessary. Inspect condition of bearings, shafts, gears, and synchronizers.
NOTE: Ensure NEW bearings and bearing races are taken from same box.
2. Apply transmission oil to all components prior to installation.
3. Drive main shaft rear bearing outer race into housing enough that outer race is nearly 0.2 In. (5 mm) above bottom of housing. Use same technique for countershaft
outer race.

If not already removed, tap outer races out so they are nearly 0.2 In. (5 mm) above bottom of housing. This step is critical for accurate measurements of shaft
assembly.

4. Rotate transmission over 1/2 turn. Install oil screen and overflow valve using Torque Specifications .
 5. Assemble shaft assembly. Install lifting tool to shaft assembly tightly. Apply lubrication to all bearings so correct clearance can be obtained. Use Retainer
(88800006), Fixture (9990028), Lifting Chain (9996239), Fixture (9996910) .
6. Lift shaft assembly into transmission housing and remove fixture and 3 lifting arms from shafts with care.
7. Install air pipe nipple for countershaft brake.
8. If installing countershaft outer race in clutch housing, press it in until it bottoms in clutch housing. Ensure a cylinder, drift, hollow drift, and spindle are being used.
Mandrel (9992003), Spindle (9996041), Sleeve (9996042), Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated (9996222) .
9. If installing input shaft outer race in clutch housing, press it in until it bottoms in clutch housing. Ensure a cylinder, drift, pump, hollow drift, and spindle are used.
Use Hydraulic Cylinder (9992671), Spindle (9996041), Sleeve (9996042), Mandrel (9996081), Ring (9998401) .
10. Coat main housing's mating surfaces to clutch housing with high-temperature liquid gasket an install magnet.
11. Install clutch housing on base housing. Ensure guide dowels enter their holes in clutch housing. Secure housing by tightening reconnectors to Torque Specifications .
12. With Lever (9992337) , remove seal for input shaft.
13. Press in seal with Hollow Drift (88800005) .
NOTE: Put an approved grease in space between seal lips to 1/3. DO NOT lubricate felt ring. Prior to installation, lubricate sealing ring mating face to input shaft.
14. Rotate transmission 1/2 turn. During measurement of main shaft and countershaft, 2 LS gear must be engaged. Install Screw (9996917) on to main shaft.
15. Install Screw (9996483) on countershaft.

Without overdrive: splitter gear clutch ring in its forward position.

With overdrive: splitter gear coupling cone in its rearmost position.

NOTE: DO NOT install countershaft brake and oil pump.

16. Lock gears with Retainer (9990029) for clutch sleeves. Install Bolts - Screw (9996917) and Screw (9996483) .
17. Rotate shaft 20 turns.
18. Install Dial Indicator Gauge (9989876) onto Magnetic Stand (9999696) . Ensure measuring tip touches sun-wheel. Set dial indicator to "0" and mark measuring
point.
19. Turn transmission 1/2 turn. With measurement tip raised, turn shaft 20 turns. Read clearance value from marked measurement point.
20. Rotate transmission half a turn, then rotate shaft 20 turns.
21. Rotate dial indicator to countershaft. Ensure measuring point touches countershaft. Set dial indicator to "0" and mark measuring point. Rotate transmission half a
turn.
22. With tip of dial gauge raised, turn countershaft for minimum 20 turns. Inspect clearance value from marked measurement point.
NOTE: If measurement of axial play has been taken, it is vital to adjust mainshaft and countershaft to prevent incorrect preloading.
23. If there was no axial play, preloading for shafts is correct.
24. Remove these items in order: Dial Indicator (9989878), Magnetic Stand (Magnetic Stand (9999696), Bolt (Screw (9996917), Bolt (Screw (9996483) and
countershaft cover.
25. Install oil pump correctly using a NEW gasket. Using a plastic mallet, beat reversing shaft into transmission housing. Install screws into reversing gear correctly
using Torque Specifications .
NOTE: Bevel for rotation lock must be in correct position.
26. Install countershaft cover and secure by tightening reconnectors to Torque Specifications .
27. Install overdrive oil pipe, if it applies.
28. For high range press in synchronizer. Use Coupler 9990015, Hydraulic Cylinder (9992671), Mandrel (9996081), Spindle (9996315), Puller (9998542) .
29. Install both washer halves, and high range snap ring.
30. Remove Forks Retainer (9990029) that secure clutch sleeves.
31. Install pre-lubricated NEW "O" rings onto oil distribution piping. Install oil distribution piping using Socket Wrench (9990027) and tighten to Torque
Specifications .
32. Coat main transmission housing mating surface with an approved high-temperature liquid gasket.
33. Assemble adapter and lifting eye into range section output shaft. Install range housing over main housing.

Align piston rod & planet wheel lower if necessary. Install reconnectors to torque specification, See Torque Specifications .

NOTE: It is vital to insert Guide Pins (9996876) into transmission housing to simplify assembly process. Also use Lifting Eye (9996479), Guide (9996876), Adapter
(9996925) .
34. If a retarder is equipped, perform steps 35 and 40. If not equipped, proceed with step 41.
35. Coat a NEW "O" ring with silicon grease then install retarder. Insert guide bolts into holes and lower retarder into position. Using hand, install nuts in order A, B, C
and D. Torque nuts to Torque Specifications .
NOTE: Once retarder has been tightened, some clearance must exist between retarder and range housing.
36. Rotate transmission quarter a turn.
37. Install NEW "O" rings on heat exchanger and range housing and grease "O" rings.
38. Raise heat exchanger enough that narrow components are fitted into their respective holes. Secure by installing reconnectors. Using upper rear screws, pull in heat
exchanger, See Torque Specifications .
39. Install retarder temperature sensor.
40. Install tie straps that reconnect retarder wiring harness.
41. Assemble blocking body, spring, and plug for range function. Using a NEW gasket and a NEW oil filter, install oil filter housing. Secure housing by installing
reconnectors to Torque Specifications .
42. Rotate transmission quarter a turn.
43. Install a NEW gasket between countershaft brake cover and clutch housing. Assemble friction and steel plates. Start and finish with steel plates. Ensure 2 friction
plates and 3 steel plates are installed alternately.
NOTE: Ensure last steel plate is positioned inside brake cover and it is installed with cover.
NOTE: Apply clean transmission oil to plates.
44. Install sleeve using a NEW "O" ring, spring, and piston. Install countershaft brake cover over discs and torque reconnectors to Torque Specifications .
45. Install air supply tube to countershaft brake cover. Install fittings using Torque Specifications .
NOTE: Prior to installation, clean air tube threads. See Figure.
46. Install clutch air hose and cylinder, and torque clip to Torque Specifications .
47. Rotate transmission quarter a turn.
48. Assemble Magnetic Stand (9999696) and Dial Indicator Gauge (9989876) on Retainer (9990029) holder. Inspect gear wheel runout. Ensure dial gauge tip is.08 In.
(2 mm) below teeth. Runout should be not more than.016 In. (0.4 mm).
49. Install a NEW control housing gasket on a clean surface.
1. HR - High Range.
2. S - Split.
3. 2/3 - 2nd/3rd Gear in Neutral.
4. R - Reverse Gear.
50. Inspect followings to verify position:
1. Split engaging ring: in its rearmost.
2. 2nd/3rd engaging ring: in neutral or middle.
 3. Reverse gear engaging ring: in its rearmost.
51. Verify that range gear is in high range.
NOTE: Control housing forks must correspond to position of engaging rings. If not, use hand and position them carefully.
52. To correctly reconnect with main housing Inspect if range servo piston is positioned out 1 In. (25.4 mm).
53. Using care lower control housing so tooth wheel is protected from damage. Split fork must end up in correct position in engaging ring.
54. Install these items in order: NEW solenoid valve seals, an "O" ring for countershaft brake, and a NEW upper cover gasket.
NOTE: Ensure this and next 2 steps are only performed if Gear Activation, removal or replacement of Control Housing was performed manually. If no need for
manual activation, continue with step 57.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
55. With NEW upper cover in place, connect wiring harness. Lower upper cover into place.
NOTE: Never put tension or weight to wiring harness or connector.
56. Install 6 reconnectors that secure upper cover using Torque Specifications .
57. Install reconnectors that secure control housing to Torque Specifications .
58. When installation of control housing is done, perform Transmission Calibration using scan tool and recommended instructions with transmission removed.
NOTE: If calibration fails, inspect if shift fork position sensor values are correct. If they are incorrect, possibly shift forks are incorrectly installed to engaging rings
and this hinders correct transmission shifting. Remove control housing to inspect shift fork installation and position of engaging ring. Re-install control housing
starting from Step 49.
59. Remove transmission from overhaul stand then remove fixture.
60. Inspect and replace clutch valve seal if it is defective. See Figure.
61. Reconnect clutch position sensor wiring harness connector to clutch valve and torque to specification, See Torque Specifications . See Figure.
62. Reconnect clutch control valve air supply tube to upper control housing fitting and valve wiring connector to control housing. See Figure.

REMOVAL & INSTALLATION > TRANSMISSION > Installation

1. Position NEW transmission and secure it to jack.
2. Do as follows to simplify installation of transmission: remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With
piston held in, install plug by tightening to specification. See Torque Specifications .
NOTE: If this step is skipped, there will be installation interference. It will be installed under clutch cylinder spring pressure to result in failure to freely slide forward
into place against engine mating surface.
3. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower bolts securing transmission to engine loosely.
NOTE: Align clutch splines by turning input shaft.
4. Install remaining bolts securing transmission to engine by tightening to specification. Remove transmission jack. See Torque Specifications .
NOTE: It is encouraged to install bolts on top of clutch housing first for easy access. With transmission jack removed, install remaining bolts.
5. Install battery cables using mounting bolts. Install cab engine cover.
6. With wiring harness in place, re-install these items; control housing, speed sensor, and 2 chassis connectors.
7. Install NEW wiring harness to transmission tie straps.
8. At rear of transmission reconnect air supply hose by threading straight Raufoss fitting into 90 degree fitting in cover. Reconnect oil cooler hoses to filter housing.
9. Install universal joint caps, drive shaft, and intermediate Bearing To Support bracket bolts if necessary Tighten to Torque Specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
10. Reconnect lower crossover fuel lines to install brackets. Open lower crossover fuel line valves to fuel tanks.
11. Remove supporting jack stands. Lower vehicle.
12. With air system pressurized, perform leak inspection.
13. Connect all removed cables to negative battery terminals.
14. Fill transmission oil into transmission.
15. When transmission has installed, configure NEW TCM with its software tool. After TCM has been flashed with its software, perform a clutch engagement position
calibration. Use scan tool to do this task.

REMOVAL & INSTALLATION > TRANSMISSION ECU

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Transmission Line (15 mm) (85108826). See Special Tools .

REMOVAL & INSTALLATION > TRANSMISSION ECU > Removal

1. Set parking brake. Position shift lever in neutral.
2. In order to prevent electrical shock and component damage, disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system.
4. Lift vehicle and support with jack stands.
5. Disconnect oil cooler hoses from oil filter housing using Transmission Line (15 mm) (85108826) tool.
6. Remove drive shaft, universal joint caps, and intermediate bearing to support bracket bolts if necessary
NOTE: Ensure to chock exact position of bolts to ensure same location for installation.
7. Disconnect straight Raufoss fitting from 90 degree fitting in cover and air supply at rear of transmission.
8. Remove wiring harness to transmission tie straps.
9. Remove electrical harness at these locations: control housing, speed sensor, and 2 chassis connectors and move harness aside.
10. Remove cab engine cover if needed.
11. Remove bolts that secure transmission to engine on bottom and sides of clutch housing.
NOTE: At this point DO NOT remove top bolts securing transmission and engine.
NOTE: Position jack and secure transmission to it.
12. Battery cables to brackets bolts on top of clutch housing and remove top 4 transmission to engine bolts.
 13. To remove transmission, pull it back until input shaft is off pressure plate, then lower transmission and pull off. While lowering transmission, inspect around it to
ensure nothing is dragging or hanging. See Figure.
14. Disconnect clutch valve wiring connector at control housing.
15. Disconnect Straight Raufoss fitting from 90 degree fitting in cover and clutch control valve air supply tube at upper control housing fitting.
16. Remove control housing and all 6 upper cover bolts.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
17. Lift top edge of upper cover and angle it down against clutch housing. Disconnect electrical connection and remove top cover. Use care while doing this step to avoid
damage.
NOTE: Never put tension or weight to wiring harness or connector.

REMOVAL & INSTALLATION > TRANSMISSION ECU > Installation

1. Install NEW upper cover gasket, an "O" ring for countershaft brake, and solenoid valve seals.
CAUTION: Exercise caution while working with electrical components. They are delicate and may damage due to improper handling.
2. With NEW upper cover in positioned, connect electric harness and install upper cover.
NOTE: Never put tension or weight to wiring harness or connector.
3. Install 6 upper cover bolts using torque specification. See Torque Specifications .
4. Position bolts securing control housing and tighten them in a diagonal pattern to Torque Specifications .
5. Install straight Raufoss fitting into 90 degree fitting and connect clutch control valve air supply tube to upper control housing fitting. See Figure.
6. Reconnect clutch valve wiring connector to control housing.
7. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With piston held in, install plug and tighten to Torque
Specifications . If this step is skipped, there will be installation interference. It will be installed under clutch cylinder spring pressure to result in failure to freely slide
forward into place against engine mating surface.
8. Using caution and an assistant, install transmission and align it to engine. Install 2 upper and lower bolts securing transmission to engine loosely. Align clutch splines
by turning input shaft.
9. Install remaining bolts that secure transmission and engine using specification. Remove transmission jack. See Torque Specifications .
NOTE: It is encouraged to install bolts on top of clutch housing first for easy access. With transmission jack removed, install remaining bolts.
10. Install battery cables using their mounting bolts.
11. Install cab engine cover.
12. With electrical harness in place, re-install these items: control housing, speed sensor, and 2 chassis connectors.
13. Install NEW wiring harness to transmission tie straps.
14. Thread straight Raufoss fitting into 90 degree fitting in cover and reconnect air supply hose at rear of transmission.
15. Reconnect oil cooler hoses to filter housing.
16. Install drive shaft, universal joint caps and intermediate Bearing To Support bracket bolts if necessary
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
17. Remove supporting jack stands. Lower vehicle.
18. With air system pressurized, perform leak inspection.
19. Connect all removed cables to negative battery terminals.
20. Inspect transmission oil level and add approved oil if necessary.
21. When transmission has installed, configure TCM with its software. Once TCM has flashed with its software, perform a transmission and clutch, pulling position,
calibration. Use scan tool to do these tasks.

REMOVAL & INSTALLATION > TRANSMISSION OIL COOLER (LEU,

MRU)
NOTE: Information may change without notice. Illustrations are meant for reference and hence may vary from actual vehicle version. However, this article is developed
with main components as accurately as possible.
WARNING: Seek proper training from your supervisor prior to performing this procedure to prevent personal injury or damage.

REMOVAL & INSTALLATION > TRANSMISSION OIL COOLER (LEU,

MRU) > Removal
1. With vehicle parked on a level surface, block front wheels, set parking brake and put transmission in neutral, then remove battery box covers.
WARNING: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery explosions. DO NOT
disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures.
2. Disconnect all cables from negative (ground) battery terminals.
3. Drain coolant by connecting Coolant Extractor (85112740) to drain fitting at radiator bottom.
NOTE: Alterative draining method: Connect Coolant Drain Hose (9996049) to radiator drain fitting and drain coolant into a suitable container.
4. Remove skid plate fasteners after placing appropriate lifting device under skid plate, then remove skid plate.
5. At transmission cooler, remove front brake valves-to-bracket fasteners. Disconnect wiring harness from each valve and place them aside. Mark position of wiring
harnesses for reinstallation.
6. Disconnect transmission oil cooler coolant hoses and drain any coolant (remaining in system) into a proper vessel. Mark position of coolant hoses for reinstallation.
7. Disconnect oil cooler transmission lines and mark their position. Position a suitable container to drain transmission oil and plug lines to avoid contamination and fluid
loss.
8. Remove transmission oil cooler fasteners.
9. Remove transmission oil cooler and bracket with care.
REMOVAL & INSTALLATION > TRANSMISSION OIL COOLER (LEU,
MRU) > Installation
1. If applicable, use NEW sealing rings to transfer fittings to replacement oil cooler from damaged oil cooler.
2. Install replacement oil cooler and bracket onto vehicle and position fasteners, but do not tighten.
3. Line up transmission oil cooler fittings and hose connections with transmission oil lines and coolant hoses. Tighten mounting fasteners of oil cooler to 63 ± 11 Ft.
Lbs. (85 ± 15 N.m) .
4. Unplug transmission oil lines and connect it to oil cooler by taking reference from mark apply during removal and tighten fittings to secure.
5. Follow marks applied during removal and connect coolant hoses to transmission oil cooler, secure with hose clamps.
6. Install front brake valves onto transmission oil cooler bracket and tighten fasteners to 35 ± 6 Ft. Lbs. (48 ± 8 N.m) . Follow mark applied earlier and connect wiring
harnesses to valves.
7. Install skid plate onto vehicle with a lifting device and secure with fasteners. Remove lifting device after installation.
8. Use Coolant Extractor (85112740) to fill cooling system with suitable coolant.
9. Connect cables (released earlier) to positive and ground (negative) battery terminals and install battery box cover(s).
10. Inspect fluid levels and refill if required.
11. With engine ON, inspect for leaks and correct operation.

OVERHAUL > BRAKE COUNTERSHAFT

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

1. Set parking brake. Position shift lever in neutral.

2. Disconnect all cables from negative battery terminals.
3. Drain air tank to remove all air from system.
4. Lift vehicle and support with jack stands.
5. Drain transmission oil by removing drain plug. Install plug and torque to specifications .
6. Remove oil cooler hoses from oil filter housing using Transmission Line (Transmission Line (15 mm) (85108826) .
7. Remove drive shaft.
NOTE: Remove universal joint caps and intermediate bearing to support bracket reconnectors if necessary.
NOTE: Ensure position of reconnectors on bracket is marked to aid installation of intermediate bearing in original position. Move shaft aside.
8. Remove Straight Raufoss fitting from 90 degree fitting in cover and wiring harness to transmission tie straps
9. Disconnect wiring harness at these locations: control housing, speed sensor, and 2 chassis connectors. Move harness aside.
10. Remove engine cab cover.
11. Remove reconnectors that secure transmission to engine on bottom and sides of clutch housing.
NOTE: At this point DO NOT remove top reconnectors securing transmission to engine.
12. Prior to removal of following item, position transmission jack and secure it.
13. On top of clutch housing remove battery cables to brackets reconnectors.
14. Remove top 4 reconnectors that secure transmission to engine and pull it back until input shaft is off pressure plate. Then lower transmission and remove from
vehicle. While lowering transmission, inspect around it to ensure nothing is hanging or dragging.
WARNING: NEVER remove drain plug completely, clutch valve unit holds high pressure air. To relieve air pressure, leave it slightly cracked. If removed
completely when under pressure, plug may become a dangerous projectile that can cause serious personal injury.
15. Remove all air from system by removing service plug at top of clutch valve. See Figure.
16. Remove wiring harness tie straps.
17. Remove air supply hose to clutch cylinder and reconnectors on clutch cylinder. See Figure. See Figure.
18. Disconnect clutch position sensor wiring harness connector. Move clutch valve aside. See Figure.
19. Remove clip that reconnects air hose in clutch cylinder.
20. Disconnect clutch cylinder air hose, reconnectors, and clutch cylinder.
21. Remove air supply tube P-clamp connector.
22. Disconnect air supply tube from countershaft brake cover. With upper fitting loosened, disconnect lower fitting. Position tube correctly first by turning it to side then
gently tightening upper fitting.
23. Remove reconnectors and countershaft brake cover.
24. Remove brake plates, 2 friction plates and 3 steel plates.
25. Remove countershaft brake cover gasket, piston, spring, and sleeve.
NOTE: DO NOT reuse old sleeve "O" ring.
26. Inspect friction and steel plates contact surface.
NOTE: Replace friction plates, if worn and steel plates, if tarnished Blue or damaged.
27. Thoroughly clean and inspect all reusable components.
NOTE: DO NOT clean friction plates.
WARNING: Ensure cylinder points piston side down toward a workbench. Relieve air pressure from air system prior to start any service on air system, otherwise
there is threat of severe injury from violent separation.
CAUTION: Ensure cylinder is placed on a clean soft surface to avoid damaging piston.
28. In order to remove piston and seals, gently apply compressed air into cylinder inlet.
29. Replace piston seals. Install NEW seals with lips facing away from each other.
NOTE: Lubricate seals with clean transmission oil.
CAUTION: Be careful while inserting piston and DO NOT damage seals.
30. With piston inserted into cylinder, press it carefully into place.
31. Assemble friction plate and steel plates; start and finish with steel plates. Ensure 2 friction plates and 3 steel plates are installed alternately.
NOTE: Ensure last steel plate is positioned inside brake cover and it is installed with cover.
NOTE: Apply NEW transmission oil to plates.
32. Using a NEW "O" ring, spring, and piston, install sleeve.
NOTE: Apply clean transmission oil to sleeve.
33. Install countershaft brake cover and a NEW cover gasket over discs and reconnectors. See Torque Specifications .
34. Install countershaft brake cover connecting air supply tube. Install fittings and tighten to specifications .
NOTE: Prior to installation, clean air tube threads.
35. Install air supply tube p-clamp reconnectors using and tighten to specifications .
36. Thoroughly clean and inspect condition of supply hose connections. DO NOT reuse hose "O" rings. If damaged, replace hose or connections.
 37. Using reconnectors, install clutch cylinder. Torque reconnectors to specification, See Torque Specifications .
38. With air hose connected to clutch cylinder, reconnect locking clip.
39. Ensure clutch valve sealing surface is clean. Inspect and replace clutch valve seal if damage is observed. See Figure.
40. Reconnect sensor wiring harness connector to clutch valve. See Figure.
41. Install clutch valve reconnectors by tightening to specifications
42. Install NEW wiring harness and air hose tie straps.
43. Remove service plug on clutch control valve assembly and completely push piston into clutch cylinder. With piston held in, install plug and tighten to specifications .
NOTE: If this step is skipped, there will be installation interference. It will be installed under clutch cylinder spring pressure and will not freely slide forward into
place against engine mating surface.
44. Using caution and an assistant, install transmission and align it to engine. Loosely install 2 upper and lower reconnectors that secure transmission to engine.
NOTE: Align clutch splines by turning input shaft.
45. Install remaining reconnectors that secure transmission to engine by tightening to specifications then remove jack.
NOTE: It is encouraged to install reconnectors on top of clutch housing first for easy access to holes. With transmission jack removed, install remaining reconnectors.
46. Using reconnectors, connect battery cables to brackets on top of clutch housing. Install cab engine cover.
47. With wiring harness in place, re-install control housing, speed sensor, and 2 chassis connectors.
48. Install NEW wiring harness to transmission tie straps.
49. Install straight Raufoss fitting into 90 degree fitting in cover. Reconnect oil cooler hoses to oil filter housing.
50. Install: drive shaft, universal joint caps and intermediate Bearing To Support bracket reconnectors. Torque reconnectors to Specifications .
NOTE: Ensure rubber insulator is centered in U-bracket correctly.
51. Replace transmission oil filter and remove jack stands. Lower vehicle.
52. With air system pressurized, perform leak inspection.
53. Connect all removed cables to negative battery terminals.
54. Inspect oil level and fill approved oil as necessary.
55. Operate engine. Perform leak test and operativeness. After shutdown, inspect and refill fluids as required.

OVERHAUL > BRAKE, INTERMEDIATE SHAFT

WARNING: Without adequate training, proper service literature and tools, never try to repair or service vehicle as it can make vehicle unsafe and lead to severe personal
injury or death.
WARNING: Ensure air pressure is released correctly prior to starting any work on any part of air system, otherwise component may separate violently, resulting in serious
personal injury.

1. Set parking brake.

WARNING: BATTERIES: Disconnect negative battery cable first when disconnecting batteries to avoid electrical shock and sparks that could cause battery
explosions. DO NOT disconnect batteries with engine running. Disconnecting batteries with engine running can cause electrical component failures.
2. Remove all negative battery cables.
3. Drain air system.
4. Lift vehicle, then use jack stands to support it.
5. Drain transmission oil by removing transmission drain plug. Install and tighten plug to specification 26±4 Ft. Lbs. (35±5 N.m)
6. Disconnect filter housing's transmission oil cooler hoses using Disconnect Tool 85108826.
7. Remove drive shaft.
NOTE: If universal joint caps and bolts which secure intermediate bearing to support bracket are present, then remove them.
NOTE: In order to install intermediate bearing exactly in same place as before, mark position of bolts on bracket.
8. With air supply hose at transmission's rear part disconnected, remove tie straps which secure wiring harness to transmission.
9. Disconnect electrical harness at control housing, speed sensor, and two chassis connectors.
NOTE: Put harness aside.
10. Remove cab engine cover and then transmission-to-engine mounting bolts along bottom and sides of clutch housing.
NOTE: Top four transmission-to-engine mounting bolts should not be removed at this time.
11. Secure transmission to suitably positioned transmission jack.
12. Remove bolts which secure battery cables to brackets on clutch housing's top part, then remove top four transmission-to-engine mounting bolts.
13. Pull transmission back carefully, until input shaft clears pressure plate, then lower transmission and pull it out from below vehicle.
NOTE: Periodically inspect around transmission while lowering it to ensure nothing (like wiring or air hoses) is caught or hung up on it.
WARNING: Clutch Valve Unit contains high air pressure. Loosen drain plug slightly so air pressure can be released slowly.

Remove service plug from top of clutch valve and ensure system is air-free.

Fig 1: Identifying Clutch Valve Service Plug

 View Full-Screen
14. Remove wiring harness tie straps, and remove air supply hose to clutch cylinder, and then clutch valve mounting bolts.
Fig 2: Identifying Clutch Valve Mounting Bolts
 View Full-Screen
15. Disconnect wiring of clutch position sensor (located behind clutch valve) and keep sensor out of way.
Fig 3: Identifying Clutch Valve Position Sensor
 View Full-Screen
16. Remove clip that holds air hose in clutch cylinder, then disconnect hose from cylinder. Remove mounting bolts and clutch cylinder.
Fig 4: Identifying Clutch Cylinder Components
 View Full-Screen
17. Remove air supply tube P-clamp bolts and disconnect air supply tube from intermediate shaft brake cover.
NOTE: Loosen upper fitting of tubes and disconnect lower fitting. Move tube to side and tighten upper fitting. This will keep tube in position.
18. Remove intermediate shaft brake cover, brake plates, two friction plates and three steel plates.
Fig 5: Identifying Intermediate Shaft Brake Cover Mounting Bolts
 View Full-Screen
19. Remove intermediate shaft brake cover gasket, piston, spring and sleeve.
NOTE: Replace "O" ring from sleeve.
20. Inspect friction and steel plates contact surfaces.
NOTE: Replace friction plates which are totally or partially worn out and steel plates which are tarnished Blue or damaged.
21. Clean all parts to be reused and inspect them.
NOTE: DO NOT clean friction plates.
22. Remove piston and seals with gradual application of compressed air into cylinder inlet.
WARNING: Cylinder MUST pointed piston side down toward a workbench during disassembly. Otherwise components can separate violently, which can result in
serious personal injury.
CAUTION: To avoid piston damage, place cylinder on a clean soft surface like shop towels.
WARNING: COMPRESSED AIR: Avoid personal injury from flying debris when using compressed air, wear appropriate protective clothing such as appropriate eye
protection.
23. Remove old piston seals and then install NEW seals. Install NEW seals with lips facing away from each other.
NOTE: Use clean transmission oil to coat seals.
24. Insert piston into cylinder, then press it smoothly into position.
CAUTION: Be careful while inserting piston to avoid seal damage.
25. Install steel plates and friction plates. Start and end with steel plates. During installation, install two friction plates and three steel plates.
NOTE: For ease of assembly, position last steel plate inside brake cover, then install it with cover.
NOTE: Use clean transmission oil to lubricate plates.
 26. Install sleeve with its NEW "O" ring, spring and piston.
NOTE: Use clean transmission oil to coat sleeve.
27. Install intermediate shaft brake cover and a NEW cover gasket over discs and tighten mounting bolts to specification 33±4 Ft. Lbs. (45±5 N.m). See Fig 5
28. Connect air supply tube to intermediate shaft brake cover and tighten fittings to specification 18±3 Ft. Lbs. (25±4 N.m).
NOTE: Before connecting, clean threads for air tube.
29. Install bolt securing air supply tube P-clamp and tighten to specification 15±2 Ft. Lbs. (20±2 N.m)
30. Clean supply hose connections and then inspect them. Replace "O" rings of hose. Replace damaged component if hose or connections are damaged.
31. Install clutch cylinder, then install and tighten mounting bolts to specification 33±4 Ft. Lbs. (45±5 N.m). See Fig 4
32. Once air hose is connected to clutch cylinder, install locking clip.
33. Inspect if sealing surface on clutch valve is clean. Inspect clutch valve seal and replace it, if needed. Connect clutch position sensor wiring to clutch valve.
34. Install clutch valve mounting bolts and tighten it to specification 15±2 Ft. Lbs. (20±3 N.m). See Fig 2
35. Use NEW tie straps to secure wiring harness and air hose in correct position.
36. Remove clutch control valve assembly's service plug, then push piston all way into clutch cylinder. This will simplify transmission installation. Hold piston in, then
install and tighten plug to specification 5±1 Ft. Lbs. (7±2 N.m). See Fig 1
NOTE: Not performing this step will obstruct installation. Installation of transmission will be against clutch cylinder spring pressure and transmission will not slide
forward into position against engine mating surface.
37. Install and align transmission to engine. Install two upper and two lower transmission-to-engine mounting bolts (loosely).
NOTE: Align clutch splines by rotating input shaft.
38. Install and tighten remaining transmission-to-engine mounting bolts to specification 68±6 Ft. Lbs. (92±8 N.m), then remove transmission jack.
NOTE: Install and tighten mounting bolts on clutch housing top part first to aid access. With transmission jack removed, install remaining mounting bolts.
39. Install battery cables and their mounting bolts.
40. Install cab engine cover.
41. Place electrical harness, then reconnect control housing, speed sensor, and two chassis connectors.
42. Secure wiring harness to transmission by installing NEW tie straps.
43. Connect air supply hose at rear of transmission, and transmission oil cooler hoses to filter housing.
44. Install drive shaft, universal joint caps and intermediate bearing-to-support bracket bolts (if equipped). Tighten all fasteners to specification
NOTE: Install Universal Joint Caps and intermediate bearing-to-support bracket bolts (if equipped).
NOTE: Place rubber insulator centered in U-bracket.
45. Lower vehicle by removing supporting Jack Stands.
46. Pressurize air system and inspect for leakage.
47. Connect all negative battery cables.
48. Use approved transmission oil to fill transmission.

OVERHAUL > CONTROL HOUSING > Removed

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Mandrel (9998588). See Special Tools .

OVERHAUL > CONTROL HOUSING > Control Housing Overview

• A. Position Sensor for Range Cylinder.
• B. Countershaft Speed Sensor.
• C. Main Shaft Speed Sensor.
• D. Position Sensor, 2nd and 3rd Cylinder.
• E. Position Sensor 1st and Reverse Cylinder.
• F. Position Sensor Split Cylinder.
• R. Range Cylinder.
• 2/3. 2/3 Cylinder.
• 1/R. 1/R Cylinder.
• S. Split Cylinder.

OVERHAUL > CONTROL HOUSING > Disassembly

1. Using scan tool, read X1 value or inspect label for X1 value.

Scan tool is needed when replacing upper cover. Disconnect all position sensor wiring harness connectors.

2. Remove main shaft and countershaft speed sensors. Remove fasteners securing wiring harness attachment plate.
3. Turn control housing until it lies on selector forks. Remove all reconnectors that secure upper cover. Then turn control housing until its split fork side is against
bench.
4. With cover upper edge loosened, fold it down towards bench carefully. Remove electrical connector; DO NOT damage electrical cabling.
5. Remove these items: seals for solenoid valves, "O" ring for countershaft brake and cover gasket.
6. Remove fasteners and then wiring harness. Use care to avoid component damage.
7. Turn control housing until selector forks are facing upward.
8. Remove locking keys for these cylinders: 2nd/3rd cylinder, 1/R cylinder and split cylinder. Remove all 4 position sensors. Keys are spring-loaded. All of sensors are
similar.
WARNING: SPRINGS UNDER PRESSURE: Carefully follow disassembly and assembly procedures and safety precautions when working on components having
springs under pressure. Sudden release of spring pressure can cause severe personal injury or death if proper procedures and safety precautions are not followed.
Always wear appropriate protective clothing.
 9. At rear of split cylinder remove piston and sealing ring. Remove 1/R cylinder front cover. Remove selector fork with covers and position.
NOTE: 2nd/3rd selector fork needs to be in neutral position. This will allow inhibitor pin for 1st/R and 2nd/3rd cylinders not to lock front cover in place.
10. Remove piston from front of 1st/R cylinder. With both covers for 2nd/3rd cylinder loosened, remove selector fork with cover and piston.
11. Remove rear cover and piston from back of 2nd/3rd cylinder.
12. Remove range cylinder cover. Pull out and remove piston. DO NOT damage piston rod seal.
NOTE: Ensure bushing and seal in rear end plate of range cylinder remain connected, they cannot be replaced separately.
13. With both covers for split cylinder loosened, pull out selector fork with cover and piston. Then remove rear cover.
14. Thoroughly clean housing and inspect all internal components to replace if defective.
NOTE: Damage to any of seals or bushings requires replacement of whole cover because these components cannot be replaced individually.
NOTE: Apply clean air through air passages between cylinders and solenoid valves. All passages must be dry and clean.

Lubricate all piston surfaces, piston sliding surfaces and sealing rings prior to installation.

OVERHAUL > CONTROL HOUSING > Assembly

1. Assemble NEW sealing rings and support strips to range piston. Grease sliding surfaces and sealing rings. Note that sliding surfaces are lips of sealing ring.
2. Install piston into range cylinder carefully. Using a NEW "O" ring, install cover and secure by installing reconnectors to specifications .
3. Press out spring pin for 2nd/3rd selector fork. Ensure drift and sleeve is being used as a counterhold. Using care tap out spring pin from selector fork to remove
selector fork using Mandrel (9998588) . Remove cover and piston from piston rod.
NOTE: Spring and pin for position sensor.
4. Use a NEW piston and "O" ring into cover, then install cover onto piston rod. Assemble position sensor pins and springs to selector fork.
5. Install selector fork 2nd/3rd onto piston rod. Install piston rod by pressing to bottom of fork. Using a drift and a sleeve, press in spring pin.
NOTE: Ensure spring pin opening is facing cover and lengthwise in relation to piston rod.
6. Assemble selector fork 2nd/3rd with cover and piston into 2nd/3rd cylinder. Using a NEW "O" ring, install piston and rear cover. Secure them by installing fasteners
to specifications .
7. Install: a NEW "O" ring to rear split cover, piston into cylinder using a NEW piston seal, rear cover using fasteners. Torque fasteners to specifications .
8. Using a drift and a sleeve as a counterhold, press out spring pin for 1st/R selector fork.

Tapping spring pin out of selector fork, remove fork carefully.

9. Remove cover and piston from rod.

10. Install a NEW piston on rod. Install a NEW "O" ring on cover.
11. Assemble 1st/R selector fork on piston rod. Using a drift with a sleeve, carefully press in spring pin.
NOTE: Ensure spring pin opening is facing cover and lengthwise in relation to rod.
12. Install a NEW "O" ring to front cover. Install a NEW piston to front of cylinder for 1st/R cylinder.
13. Install a NEW "O" ring into front cover of 1st/R cylinder. Install locking pin into cover.

Install cover and tighten fasteners to specifications .

14. Place 2nd/3rd selector fork in neutral position and press in locking pin against 2nd/3rd selector fork so that it engages in groove for neutral.
15. Install selector fork with piston and cover into 1st/R cylinder. Install fasteners to specifications .
16. Remove spring pin out from split selector fork using drift and sleeve as a counterhold.

Remove selector fork by tapping spring pin out from selector.

17. Remove cover and replace all sealing rings with NEW rings on pistons.
18. Install cover onto piston rod. Then install selector fork and press in spring pin using a drift and a sleeve with caution.
NOTE: Ensure spring pin opening is facing cover and parallel with rod.
19. Assemble selector fork with piston and cover into split cylinder. Install selector fork stop and fasteners securing cover & stop to specifications .
20. Install locking keys for these cylinders: 2nd/3rd, 1st/R and split.
21. Install all position sensors and secure by installing fasteners to specifications .
22. Grease wiring harness "O" ring.
23. Turn control housing until front edge lies on bench. Install wiring harness.
NOTE: Notice wiring harness direction.
24. Install these items: NEW seals to solenoid valves, a NEW countershaft brake "O" ring and a cover NEW gasket.
25. Connect wiring harness for cover.
NOTE: DO NOT damage wiring harness. Ensure control housing front edge is against bench prior to installation of cover.
26. Install cover and turn control housing until it lies on selector forks. Install 6 NEW cover fasteners and tighten to specifications .
27. Turn control housing until upper cover is against bench. Install wiring harness attachment plate then connect wiring harness to position sensors ensuring it is routed
inside lug on range cylinder.
28. Install speed sensors using fasteners and tighten to specifications .
29. Using scan tool, perform a functional test Gear test, removed transmission.
WARNING: Perform test with control housing onto upper cover. Stay clear from control housing during test to prevent bodily injury.
NOTE: Perform calibration, when control housing has been assembled into transmission. If cover has been changed, enter X1 value into TCM.

OVERHAUL > COUNTERSHAFT > Disassembly

Tools required: Mandrel (9996156), Hydraulic Pump, Air Operated (9996222), Hollow Drift (9996291), Hollow Drift (9996361), Mandrel (9996413), Extension
(9996454), Hydraulic Cylinder 10 Tonnes (9996600), Yoke (9996601), 9996602, Rod End (9996603), Arm (9996635), Mandrel (9996901), Hollow Drift (9996904), Puller
(9996913), Puller (9998219). See Special Tools .

1. Ensure main shaft is positioned vertically prior to starting any work.

CAUTION: DO NOT place main shaft horizontally; this can cause damage to gears.
2. Remove retaining ring from front bearing. Remove front then rear. Use Hydraulic Pump, Air Operated (9996222), Mandrel (9996413), Hydraulic Cylinder 10 Ton
(9996600), Rod End (9996603), Puller (9996913), Mandrel (9996156), Extension (9996454), Yoke (9996601), 9996602, Arm (9996635), Puller (9998219) .
 3. Remove gear sprockets individually.
CAUTION: Use care not to drop off countershaft or gear sprockets.

OVERHAUL > COUNTERSHAFT > Assembly

1. Thoroughly clean and inspect all components. Apply approved transmission oil to all needle bearings, ball bearings and gears during reassembly.
2. Install 2nd gear sprocket, using gear press force to specifications . Use Hollow Drift (9996904) tool.
CAUTION: Improper gear sprocket seating will result if applying less than minimum specification. Using more than maximum will damage gear sprocket or
countershaft.
3. Install high primary HP gear sprocket using specified gear press force to specifications . Use Hollow Drift (9996904) tool.
CAUTION: Improper HP gear sprocket seating will result if applying less than minimum specification. Using more than maximum will damage HP gear sprocket or
countershaft.
4. Install low primary LP gear sprocket using specified LP Gear Press Force. See specifications . Use Hollow Drift (9996904) and Mandrel (9996901) tools.
CAUTION: Improper LP gear sprocket seating will result if applying less than minimum specification. Using more than maximum will damage LP gear sprocket or
countershaft.
5. Install front bearing using specified bearing press force. See specifications . Use Hollow Drift (9996904) and Hollow Drift (9996361) tools.
CAUTION: Using more than maximum specified force will damage bearing or countershaft.
6. Install rear bearing using specified bearing press force. See specifications . Use Hollow Drift (9996904) and Hollow Drift (9996291) tools.
CAUTION: Using more than maximum specified force will damage bearing or countershaft.

OVERHAUL > MAIN SHAFT > Disassembly

Tools required: Puller (9990030), Hollow Drift (9992500), Spindle (9992619), Mandrel (9992621), Hydraulic Cylinder (9992671), Hollow Drift (9992911), Yoke
(9994731), Sleeve (9996154), Hydraulic Pump, Air Operated (9996222), Extension (9996454), Socket AF 75 (9996480), Pin (9996498), Arm (9996499), Yoke (9996500),
Hydraulic Cylinder 10 Tonnes (9996600), Rod End (9996603), Arm (9996635), Hollow Drift (9996725), Hollow Drift (9996904), Puller (9998215), Hollow Drift
(9998393), Puller (9998542). See Special Tools .

1. Vertically position main shaft prior to starting any work.

CAUTION: DO NOT place main shaft horizontally; this can cause damage to gears.
2. Remove splitter synchronizing ring, synchronizing cone, and support bearing. Use Yoke (9994731), Hydraulic Pump, Air Operated (9996222), Extension (9996454),
Hydraulic Cylinder 10 Ton (9996600), Rod End (9996603), Arm (9996635), Puller (9998215) .
3. If there is clearance between bearing and puller, inserting 0.39x0.83x0.047 In. (10x21x1.2 mm) long 5 pieces of brass between them.
4. Using a soft faced mallet, remove connector. Hit raised portion of socket where a ratchet would be connected to loosen connector.
NOTE: If failed to loosen connector with soft faced mallet do as follows. Mount shaft in a press then using vertical down pressure, grasp shaft in place and loosen it
using a socket and leverbar.

Tools required: Socket AF 75 (9996480). See Special Tools .

5. Remove 3rd gear sprocket, spacer ring, engaging sleeve, and 2nd gear sprocket hub. Use Spindle (9992619), Hydraulic Cylinder (9992671), Hydraulic Pump, Air
Operated (9996222), Puller (9998542), Puller (9990030), Spindle (9992619) .
6. Remove 1st gear sprocket, tooth wheel, 2nd gear sprocket bearing race, and needle bearing. Use Spindle (9992619), Hydraulic Cylinder (9992671), Hydraulic Pump,
Air Operated (9996222), Pin (9996498), Arm (9996499), Yoke (9996500) .
CAUTION: There must be some gap between sprocket and arms to prevent damage to sprocket.
7. Remove engaging ring. Correctly position shaft in Puller (9990030) , by turning over.
8. Remove reverse gear sprocket, bearing and spacing sleeve with piston rings, reverse gear sprocket needle bearing. Use Puller (9990030), Mandrel (9992621),
Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated (9996222), Extension (9996454), Pin (9996498), Arm (9996499), Yoke (9996500) .
9. Using a sleeve mandrel to hold bearing, remove spacing sleeve. Use Hollow Drift (9992911) .

OVERHAUL > MAIN SHAFT > Assembly

1. Thoroughly clean and inspect all components. Apply approved transmission oil to all needle bearings, ball bearings and gears during reassembly.
2. Install main shaft in press with sun gear facing up, reverse gear sprocket needle bearing, and reverse gear sprocket with engaging teeth turned down.
3. Press on rear bearing using bearing press force to specifications . Use Hollow Drift (9996725) .
4. Using care press on spacing sleeve with piston rings.
CAUTION: To prevent potential damage to piston ring groove, do pressing on spacing sleeve only with inner chamfer of sleeve using correct tool.
5. Turning shaft over, install engaging sleeve for 1st/reverse.
6. With engaging sleeve teeth turned downward, install needle bearing and 1st gear sprocket.
7. With flange facing downwards, install toothed wheel so it is routed through main shaft lubrication channel using specified press force, See specifications .
8. Install 2nd gear sprocket needle bearing race.
9. With teeth for engaging sleeve facing upward, install needle bearing and then install 2nd gear sprocket.
10. Press on hub for 2nd gear sprocket using specified press force to specifications .
11. Install 3rd gear sprocket engaging sleeve. Using specified press force, press on 3rd gear sprocket rear bearing to specifications .
NOTE: Bearing is a matched set, including spacer and gear and hence serviced as a unit.
12. Install spacer ring. With larger coupling teeth for splitter turned up and rounded teeth turned down, install 3rd gear sprocket.
13. Using specified bearing press force, press on front bearing for 3rd gear sprocket to specifications .
NOTE: Bearing, spacing sleeve and gear come as a set and hence must replace as a single unit.
14. Install connector & socket wrench using Torque Specifications .
NOTE: Using vertical down pressure, vertically mount shaft in a press tightly to simplify torquing connector to Torque Specifications .
15. With shaft held tight, lock connector in place using punching tab.
NOTE: A punch with a rounded point must be used. Ensure it does not crack tab.
 16. Press on support bearing.
17. Install splitter synchronizing ring. Install synchronizing cone.

OVERHAUL > RANGE GEAR > Disassembly

WARNING: Relieve air pressure from air system prior to start any service on air system, otherwise there is threat of severe injury from violent separation.

Tools required: Snap Ring Pliers (9988185), Adapter (9990084), Press (9992241), Spindle (9992619), 9992631, Hydraulic Cylinder (9992671), 9994078, Mandrel
(9996081), Mandrel (9996156), Hydraulic Pump, Air Operated (9996222), Spindle (9996315), Lifting Eye (9996479), 9996788, Mandrel (9996901), Adapter (9996925),
Puller (9998542), Counterhold (9998570), Seal Installer (88800174), Puller (9998597), Socket Wrench (9990027), Coupler (88800195), Puller (8880015), Mandrel
(88800174), Screw (9996917). See Special Tools .

1. Inspect condition of brass dowels, Replace if damaged or worn using Lifting Eye (Lifting Eye (9996479) and Adapter (9996925) .
2. Remove emergency steering servo pump and sealing ring using Special (9994078) .
3. Remove toothed pole wheel and vehicle speed sensor (VSS) from housing.
4. Remove snap ring using Snap Ring Pliers (Snap Ring Pliers (9988185) to aid removal.
5. Remove range gear bolt then range gear.
NOTE: Planetary gear must have freedom of movement and must not drop off. Negligence may cause component damage.
6. Remove planetary gear from press and press out output shaft bearing.
7. Output shaft bearing - press out to remove. Use Press (9992241) tool.
NOTE: If a retarder is equipped, perform steps 8 and 9; if not equipped, continue with step 10.
8. Remove retarder drive snap ring.
9. Remove retarder gear drive by pressing it out. Use Hydraulic Cylinder Hydraulic Cylinder (9992671), Hydraulic Pump, Air Operated Hydraulic Pump, Air Operated
(9996222), Puller (9998542), Coupler (88800195) .
10. Remove selector fork. Replace brass dowels if needed.
11. Inspect and ensure markings on synchronizing ring align with a chamfered and tooth on ring gear.
12. Remove these items from ring gear: low range engaging ring, synchronizer ring and ring spring.
13. Inspect planetary gear and replace gear if wear exceeds 0.05 in. (1.3 mm).
14. Remove oil return pipe, snap ring, and washer. Use Socket Wrench (9990027) .

OVERHAUL > RANGE GEAR > Assembly

1. Install puller rings. Install one half of puller on rings along with these items: hydraulic cylinder, spindle and drift. Use Puller (88800015), Puller (9998542),
Hydraulic Cylinder Hydraulic Cylinder (9992671), Mandrel (Mandrel (9996889) .
NOTE: Ensure angle of divide in puller rings to divide in puller is 90 degree.
2. Install other half then install hydraulic pump. Then remove high range engaging ring. Use Puller (9998542), Hydraulic Pump, Air Operated Hydraulic Pump, Air
Operated (9996222) .
3. Thoroughly clean and inspect condition of all components.
NOTE: DO NOT clean synchronizing rings.
4. Inspect these components for wear surfaces: high range engaging ring, low range engaging ring synchronizing ring and ring gear.

Inspect rings and engaging teeth for blueing and wear. Replace if necessary.

WARNING: When making orders for one of these items: high range engaging ring, low range engaging ring or synchronizing ring and it comes in a kit with all 3
components. Replacement of all 3 is necessary.
5. Press in a NEW high range engaging ring.
6. Install: washer, locking ring, and oil return pipe. Use Socket Wrench (9990027) .
7. Remove old sealant from range housing.
8. Apply transmission fluid to sliding surfaces and "O" rings during installation. Carbon fiber lining on synchronizing ring needs lubrication.
9. If a retarder is equipped, do step 10. If not equipped, continue with step 11.
10. Press on retarder gear drive then install drive gear snap ring. Use Driving Plate (9992631), Puller (9998542), Coupler (88800195) .

Tools required: See.

11. Press NEW bearing in range housing. Use Seal Driver (9996788) .
12. Install bearing snap ring using Snap Ring Pliers (9988185) . Use thickest available snap ring. Clearance must be not more than 0.004 in. (0.1 mm). Measure play
using a feeler gauge.
13. Install planetary gear in press then lift on range housing. On output shaft press on bearing in range housing. Use Press (9992241) and Washer (9996924) .

Tools required: See.

Install pole wheel and vehicle speed sensor. Torque to specifications .

14. Put seal on Mandrel (88800174) and install it on range gear housing.
NOTE: Put a low temperature grease into space between sealing lips to 1/3 full.
15. Install synchronizing ring, ring spring and ring gear.
NOTE: Correct alignment of markings on synchronizing ring with a chamfered tooth on ring gear is important.
16. Assemble engaging ring and selector fork on ring gear. Install package in range housing and secure by tightening bolts diagonally to specifications .
NOTE: Ensure self-tapping screws are used on holes if a NEW range housing has been installed. Original screws or NEW self-tapping screws must be used.
17. Install emergency steering servo pump, if applicable. Install Lifting Eye (9996479) and Adapter (9996925) .
SPECIFICATIONS > PRESS FORCES
NOTE: Ensure press forces are applied to cleaned components only.
PRESS FORCES

Application Min (Ton) Max (Ton)

Input shaft
Bearing, inner race - 5
Main shaft
Bearing, inner race - 5
Hub, 2nd high primary 2.5 20
Tooth wheel 1 5
Coupling ring, high range 5 25
Countershaft
Gear, high primary 21 40
Gear, low primary 21 40
Bearing, inner race - 5
2nd gear 17 40
Output shaft
Companion flange 1 12
Bearings - 8
Main housing
Reverse gear 0.5 5
Outer rings - 2

SPECIFICATIONS > SHAFT BEARING PRELOAD

SHAFT BEARING PRELOAD

Application In. (mm)

Main shaft 0.004-0.008 (0.10-0.20)
Countershaft 0.004-0.008 (0.10-0.20)

SPECIFICATIONS > SHAFT BEARING PRELOAD > Axial Clearance

AXIAL CLEARANCE

Application In. (mm)

Locking ring, input shaft max 0.004 (0.05)
Locking ring, countershaft max 0.004 (0.10)
Locking ring, output shaft max 0.004 (0.10)
Planet wheel, range 0.02-0.051 (0.50-1.30)

SPECIFICATIONS > SHAFT BEARING PRELOAD > Runout

RUNOUT

Application In. (mm)

Tooth wheel max 0.016 (0.4)

SPECIFICATIONS > SHAFT BEARING PRELOAD > Radial Clearance

RADIAL CLEARANCE

Application In. (mm)

Output Shaft (as measured at companion flange.) max. 0.040 (1)

SPECIFICATIONS > SYSTEM PRESSURE

SYSTEM PRESSURE
Application Psi. (Bar)
System air pressure, at control housing 95-145 (6.5 - 10)

SPECIFICATIONS > DIRECT DRIVE (11L, 13L)

Transmission technology means to have right ratio for right speed at right time. This is the most advanced and fuel efficient - automated manual transmission on road today.

Functionality of features programmable per customer preference:

1.
1. Available with auto return to Economy.
2. Available with Performance Bonus Reward.
3. Available in Economy mode only.
4. Available with Performance Bonus Reward.
5. Not available with Different functions are included under P+ mode that adapts gearshifts and gear selection to poor or hilly driving conditions.

AT2612D SPECIFICATIONS

Application Specification
AT2612D 2-pedal Automated Manual Transmission with Direct Drive
Designed to be Mated D11, D13
Number of Forward Speeds 12
Ratios, Forward Gears
1 14.94:1
2 11.73:1
3 9.04:1
4 7.09:1
5 5.54:1
6 4.35:1
7 3.44:1
8 2.70:1
9 2.08:1
10 1.63:1
11 1.27:1
12 1.00:1
Overall Ratio 14.94:1
Ratios, Reverse Gears
R1 17.48:1
R2 13.73:1
R3 4.02:1
R4 3.16:1
Maximum input Torque, Ft. Lbs. (N.m) 1920 (2600)
Maximum Gross Combination Weight, Lbs. (Tons) 110, 000 (50) - Higher with application approval
Dry weight, Lbs. (Kg.) 597 (271)
Clutch Volvo 17 In. Single Plate Organic with Single Mass Flywheel
Oil Capacity, Qts (L) 16 (15)
Oil Drain Interval, Mi. (Km.) 500, 000 (800, 000) On-Highway, Less Than Equal to 80k GCW
R - Reverse, N - Neutral,
Gear Selector Positions
D - Drive, M - Manual
E - Economy, P - Performance,
Driving Modes B - Maximum Braking,
L - Limp Home
Transmission Mounted
Power Take-Offs Available Clutch Dependent Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
Engine Mounted
Clutch Independent Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
AT2612D FEATURE & BENEFITS

Feature Benefit
High Intelligence Level - (Continuously monitors numerous parameters to determine
Fuel save and better performance
most optimum operation over next seconds and selects ratios properly)
Eco-Roll allows engine drop to idle speed on slight downhill grades unless driver
When enabled to save fuel, lowers parasitic consumption by up to 30 HP
disables Eco-Roll
Integrated with I-VEB through Engine Brake Control Stalk Outstanding, predictable performance ("Downhill Cruise")
Slow driving is possible with Idle Governor Driving Mode (e.g., stalled traffic or
Provides driver comfort and excellent low speed operation with extended clutch life
backing) without cycling clutch
Optimum acceleration is provided by Programmable Kick-Down switch Truck performance gets maximum driver input
Provides "Dual Personality" transmission with optimized shift points for fuel
There are programmable Economy and Performance modes
economy or performance
Driver receive additional information from Informative Driver Display Driving experience is more content that generates better driver retention
Optional Performance Plus (P+) mode includes functions adapting gearshifts to off-
Adjustable for vocational and heavy haul applications
road conditions and provide additional torque if starting from a standstill
Pumped lubrication rather than splash lubrication Provides lubrication where required, even at low speeds for longer life
2 shifters and multiple software feature packages available Enables custom-tailoring to wants and needs of customer
Upgradeability throughout displacement ratings of engine Enables re-programming to any engine rating for maximum resale value
Easy for driver to fully master vehicle speed under any low speed condition (e.g.,
Ultra smooth clutch and launch control
when backing up to a trailer or a loading dock)
FEATURE PACKAGES

Family 1 Family 2
Features Fuel Economy Performance Comprehensive Gentle-Shift
Ergonomic seat mounted shifter X X X X
Basic Shifter type without manual
X
controls
Premium Shifter type with manual
X X X
controls
Manual gear shifting in Drive mode X X X
Manual gear shifting in Manual
Hold only X X X
mode
Manual selection of start gear X X X
Idle Governor driving mode X X X X
Manual selection of idle driving
X X X
gears
Economy mode X X X X
Performance/Performance Plus (P+)
XA, D XA XA
mode
Kick-Down XB XB XB XB
Eco-Roll XC XC XC
Engine Brake Performance mode X X X X
Auto Neutral when parking brake
X X X X
applied
Auto Neutral at key-off if gear
X X X X
engaged
Hill Start Assist Optional Optional Optional Optional
STD PTO features X X X X
Enhanced PTO features Optional Optional Optional Optional
Feature upgradeability Unlimited within family and between families with gear shifter change
Engine Torque upgradeability. Unlimited by clutch, transmission and prop shaft.

SPECIFICATIONS > OVERDRIVE (11L & 13L)

Functionality of features programmable per customer preference:

1. Available with auto return to Economy.

2. Available with Performance Bonus Reward.
3. Not available with Different functions are included under P+ mode that adapts gearshifts and gear selection to poor or hilly driving conditions.
4. Available in Economy mode only.
5. Available with Performance Bonus Reward.

ATO2612D SPECIFICATIONS

Application Specification
Designed to be Mated to D11, D13
Number of Forward Speeds Twelve
Ratios, Forward Gears
1 11.73:1
2 9.21:1
3 7.09:1
4 5.57:1
5 4.35:1
6 3.41:1
7 2.70:1
8 2.12:1
9 1.63:1
10 1.28:1
11 1.00:1
12 0.78:1
Overall Ratio 15.04:1
Ratios, Reverse Gears
R1 13.73:1
R2 10.78:1
R3 3.16:1
R4 2.48:1
Maximum input Torque, Ft. Lbs. (N.m) 1920 (2600)
Maximum Gross Combination Weight, Lbs. (Tons) 125, 000 (56) - Higher with application approval
Dry weight, Lbs. (Kg.) 597 (271)
Clutch Volvo 17 In. Single Plate Organic with Single Mass Flywheel
Oil Capacity, Qts (L) 16 (15)
Oil Drain Interval, Mi. (Km.) 500, 000 (800, 000) On-Highway, Less Than = 80k GCW
Gear Selector Positions R - Reverse, N - Neutral,
D - Drive, M - Manual
Driving Modes E - Economy, P - Performance,
B - Maximum Braking,
L - Limp Home
Power Take-Offs Available Clutch Dependent Transmission Mounted
Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
Clutch Independent Engine Mounted
Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
ATO2612D FEATURES & BENEFITS

Feature Benefit
High Intelligence Level - (Continuously monitors numerous parameters to determine Fuel save and better performance
most optimum operation over next seconds and selects ratios properly)
Eco-Roll allows engine drop to idle speed on slight downhill grades unless driver When enabled to save fuel, lowers parasitic consumption by up to 30 HP
disables Eco-Roll
Integrated with I-VEB through Engine Brake Control Stalk Outstanding, predictable performance ("Downhill Cruise")
Slow driving is possible with Idle Governor Driving Mode (e.g., stalled traffic or Provides driver comfort and excellent low speed operation with extended clutch life
backing) without cycling clutch
Optimum acceleration is provided by Programmable Kick-Down switch Truck performance gets maximum driver input
There are Programmable Economy and Performance modes Offers a "Dual Personality" transmission with optimized shift points for fuel
economy or performance
Driver receive additional information from Informative Driver Display Driving experience is more content that generates better driver retention
Adjustable for vocational and heavy haul applications Optional Performance Plus (P+) mode includes functions adapting gearshifts to off-
road conditions and provide additional torque if starting from a standstill
Pumped lubrication rather than splash lubrication Provides lubrication where required, even at low speeds for longer life
2 shifters and multiple software feature packages available Enables custom-tailoring to wants and needs of customer
Upgradeability throughout displacement ratings of engine Enables re-programming to any engine rating for maximum resale value
Ultra smooth clutch and launch control Easy for driver to fully master vehicle speed under any low speed condition (e.g.,
when backing up to a trailer or a loading dock)
I-SHIFT FEATURE PACKAGES

Family 1 Family 2
Features Fuel Economy Performance Comprehensive Gentle-Shift
Ergonomic seat mounted shifter X X X X
Basic Shifter type without manual X
controls
Premium Shifter type with manual X X X
controls
Manual gear shifting in Drive mode X X X
Manual gear shifting in Manual Hold only X X X
mode
Manual selection of start gear X X X
Idle Governor driving mode X X X X
Manual selection of idle driving X X X
gears
Economy mode X X X X
Performance/Performance Plus (P+) XA, D XA XA
mode
Kick-Down XB XB XB XB
Eco-Roll XC XC XC
Engine Brake Performance mode X X X X
Auto Neutral when parking brake X X X X
applied
Auto Neutral at key-off if gear X X X X
engaged
Hill Start Assist Optional Optional Optional Optional
STD PTO features X X X X
Enhanced PTO features Optional Optional Optional Optional
Feature upgradeability Unlimited within family and between families with gear shifter change
Engine Torque upgradeability Unlimited by clutch, transmission and prop shaft

SPECIFICATIONS > OVERDRIVE (16L)

Transmission technology means to have right ratio for right speed at right time. This is the most advanced and fuel efficient - automated manual transmission on road today.

Functionality of features programmable per customer preference:

1. Available with auto return to Economy.

2. Available with Performance Bonus Reward.
 3. Available in Economy mode only.
4. Available with Performance Bonus Reward.
5. Not available with Different functions are included under P+ mode that adapts gearshifts and gear selection to poor or hilly driving conditions.

ATO3112D SPECIFICATIONS

Application Specification
Designed to be Mated Volvo D16
Number of Forward Speeds Twelve
Ratios, Forward Gears
1 11.73:1
2 9.21:1
3 7.09:1
4 5.57:1
5 4.35:1
6 3.41:1
7 2.70:1
8 2.12:1
9 1.63:1
10 1.28:1
11 1.00:1
12 0.78:1
Overall Ratio 15.04:1
Ratios, Reverse Gears
R1 13.73:1
R2 10.78:1
R3 3.16:1
R4 2.48:1
Maximum input Torque, Ft. Lbs. (N.m) 2350 (3180)
Maximum Gross Combination Weight, Lbs. (Tons) 143, 000 (65) - Higher with application approval
Dry weight, Lbs. (Kg.) 597 (271)
Clutch Volvo 17 In. Single Plate Organic with Single Mass Flywheel
Oil Capacity, Qts (L) 16 (15)
Oil Drain Interval, Mi. (Km.) 500, 000 (800, 000) On-Highway, Less Than = 80k GCW
R - Reverse, N - Neutral,
Gear Selector Positions
D - Drive, M - Manual
E - Economy, P - Performance,
Driving Modes B - Maximum Braking,
L - Limp Home
Transmission Mounted
Power Take-Offs Available Clutch Dependent Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
Engine Mounted
Clutch Independent Shaft (SAE 13-1400),
Pump (Parker/DIN 5462)
ATO3112D FEATURES & BENEFITS

Feature Benefit
High Intelligence Level - (Continuously monitors numerous parameters to determine
Fuel save and better performance
most optimum operation over next seconds and selects ratios properly)
Eco-Roll allows engine drop to idle speed on slight downhill grades unless driver
When enabled to save fuel, lowers parasitic consumption by up to 30 HP
disables Eco-Roll
Integrated with I-VEB through Engine Brake Control Stalk Outstanding, predictable performance ("Downhill Cruise")
Slow driving is possible with Idle Governor Driving Mode (e.g., stalled traffic or
Provides driver comfort and excellent low speed operation with extended clutch life
backing) without cycling clutch
Optimum acceleration is provided by Programmable Kick-Down switch Truck performance gets maximum driver input
Offers a "Dual Personality" transmission with optimized shift points for fuel
There are Programmable Economy and Performance modes
economy or performance
Driver receive additional information from Informative Driver Display Driving experience is more content that generates better driver retention
Optional Performance Plus (P+) mode includes functions adapting gearshifts to off-
Adjustable for vocational and heavy haul applications
road conditions and provide additional torque if starting from a standstill
Pumped lubrication rather than splash lubrication Provides lubrication where required, even at low speeds for longer life
2 shifters and multiple software feature packages available Enables custom-tailoring to wants and needs of customer
Upgradeability throughout displacement ratings of engine Enables re-programming to any engine rating for maximum resale value
Easy for driver to fully master vehicle speed under any low speed condition (e.g.,
Ultra smooth clutch and launch control
when backing up to a trailer or a loading dock)
I-SHIFT FEATURE PACKAGES

Family 1 Family 2
Features Fuel Economy Performance Comprehensive Gentle-Shift
Ergonomic seat mounted shifter X X X X
Basic Shifter type without manual
X
controls
Premium Shifter type with manual
X X X
controls
Manual gear shifting in Drive mode X X X
Hold only X X X
Manual gear shifting in Manual
mode
Manual selection of start gear X X X
Idle Governor driving mode X X X X
Manual selection of idle driving
X X X
gears
Economy mode X X X X
Performance/Performance Plus (P+)
XA, D XA XA
mode
Kick-Down XB XB XB XB
Eco-Roll XC XC XC
Engine Brake Performance mode X X X X
Auto Neutral when parking brake
X X X X
applied
Auto Neutral at key-off if gear
X X X X
engaged
Hill Start Assist Optional Optional Optional Optional
STD PTO features X X X X
Enhanced PTO features Optional Optional Optional Optional
Feature upgradeability Unlimited within family and between families with gear shifter change
Engine Torque upgradeability Unlimited by clutch, transmission and prop shaft

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS 1 of 2

Application Thread Ft. Lbs. (N.m)

Main Housing
Housing vent, fitting (design level C transmission only) M26x1.5 (5)

Suction pipe, flange M8 21 ± 4 (28 ± 5) (6)

Oil drain plug M26x1.5 26 ± 4 (35 ± 5)
Oil filler plug M26x1.5 26 ± 4 (35 ± 5)
Oil filter housing drain, plug M12x1.5 12 ± 1 (16 ± 2)
Oil filter housing, bolt M8 15 ± 2 (20 ± 3)(3)
Oil filter, cover M80x2 37 ± 4 (50 ± 5)
Oil cooler, nut M22x1.5 41 ± 6 (55 ± 8)
Oil level glass M26x1.5 26 ± 4 (35 ± 5)
Oil pressure, plug M12x1.5 12 ± 1 (16 ± 2)
Oil distribution pipe 184 ± 25 (250 ± 35)
Main shaft, nut 295 ± 37 (400 ± 50)
Main shaft rear cover, bolt 30 ± 4 (40 ± 5)
Reversing gear, screw 35 ± 6 (48 ± 8)
Companion Flange Nut 406 (550)
Countershaft front cover 33 ± 4 (45 ± 5) 0
Countershaft rear cover 30 ± 4 (40 ± 5) 0
Countershaft speed sensor 53 ± 5 In. Lbs. (6 ± 0.6)
Main shaft speed sensor 53 ± 5 In. Lbs. (6 ± 0.6)
Overflow valve, bolt M22 35 ± 4 (47 ± 6)
Lifting bracket, bolts M16 81 ± 7 (110 ± 10)
Control Housing
Circuit Board Cover Screws (mDrive) 26-44 INCH Lbs. (3-5)
Control Housing M12 81 ± 7 (110 ± 10)(1)(6)
Control Housing (mDrive) 77-88 (100-120)
Control Housing, upper cover, bolt M8 18 ± 3 (24 ± 4)0
Control Housing, upper cover, bolt (mDrive) 15-21 (20-28)
Push lock, fittings M16x1.5 15 ± 2 (20 ± 3)(2)
Gear position sensor, bolts M6 7 ± 1 (10 ± 1)
Range cylinder rear cover, screw 13 ± 1.1 (18 ± 1.5)
2nd/3rd cylinder rear cover, screw 13 ± 1.1 (18 ± 1.5)
Split cylinder rear cover, screw 13 ± 1.1 (18 ± 1.5)
1st/R cylinder front cover, screw 13 ± 1.1 (18 ± 1.5)
Selector fork cover, screw 13 ± 1.1 (18 ± 1.5)
Speed sensor, screw 53 ± 5 In. Lbs. (6 ± 0.6)
Clutch/Range Housing
Countershaft brake, bolt M10 30 ± 4 (45 ± 5)(4)
Brake pipe, nut M8x1.5 15 ± 2 (20 ± 3)
Brake pipe, fitting M10x1 18 ± 3 (25 ± 4)
Brake pipe, reduction fitting M16x1.5 35 ± 4 (48 ± 5)
Clutch pressure plate, nut 39 ± 4 (53 ± 5) (7)
Clutch position sensor, bolt 7 ± 1 (10 ± 2)
Clutch control valve, bolt M8 15 ± 2 (20 ± 3)
 Clutch control valve, service plug 5 ± 1 (7 ± 2)
Clutch cylinder, air intake hose fitting, bolt M4x12 2 ± 1 (2.5 ± 0.4)
Clutch cylinder, bolt M10 33 ± 4 (45 ± 5)
Clutch housing, to engine bolt 68 ± 6 (92 ± 8)
Clutch housing, bolts M12 81 ± 7 (110 ± 10) (4)(6)
Range housing, bolts M12 81 ± 7 (110 ± 10) (4)(6)
Overflow valve 33 ± 4 (45 ± 5)
Shift fork, locking screw M16x1 55 ± 5 (75 ± 7)
PTO mounting, bolt 63 ± 11 (85 ± 15)
PTO oil feed line to transmission oil filter housing 15 (20)
PTO oil feed line to oil port 11 (15)
PTO solenoid mounting bolts 80 in/lb (9)
PTO cover M12 30 ± 4 (40 ± 5)
Speedometer sensor M18x1.5 18 ± 3 (25 ± 4)
Companion flange, nut M60x2 406 (550)
Drive shaft end yoke, bolt M14 140 (190)
Drive shaft intermediate bearing, bolt 129 ± 22 (175 ± 30)
Drive shaft universal joint cap, bolt 122 ± 7 (166 ± 10)
Heat exchanger, bolt 63 (85)
Range gear assembly to range gear housing, bolt 87 ± 7 (110 ± 10)
Retarder to range housing, bolt 22 (30) (8)

Retarder
Retarder stud connections M14 30 ± 4 (40 ± 5)
Heat exchanger, bolts M12 63 ± 7 (85 ± 10)
Retarder oil fill, plug M26x1.5 37 ± 4 (50 ± 5)
Retarder case, plugs M12x1.5 10 ± 1 (13 ± 2)
Retarder bypass valve, plug M22x1.5 33 ± 4 (45 ± 5)
tapered (Plugs) M22x1.5 Max 59 (80) (9)
PSS-DUAL gear, bolts M12 74 ± 7 (100 ± 10)
PSS-DUAL pump, bolts M10 33 ± 4 (48 ± 5)
PSS-DUAL cover, bolts M10 33 ± 4 (48 ± 5)
Oil filter cover M10 30 ± 6 (40 ± 8)
Reconnectors
Transmission air tank mounting fasteners 63 (85)
Standard Bolts Class
M6 standard bolt 7 ± 1 (10 ± 1)
M8 standard bolt 18 ± 3 (24 ± 4)
M10 standard bolt 35 ± 6 (48 ± 8)
M12 standard bolt 63 ± 11 (85 ± 15)
M14 standard bolt 103 ± 18 (140 ± 25)
M16 standard bolt 140 ± 26 (190 ± 35)
(1) Tightened diagonally. Use final torque with cover in contact with housing.

(2) Install nipple so counterhold nut touches control housing.

(3) Tightened diagonally. Full torque only when cover is in contact with housing.

(4) Tightened diagonally. Apply final torque with cover in contact with housing.

(5) Loosely tightened, approx 2 turns, stop at 45 degree upward angle.

(6) Self-tapping flange screw.

(7) Tighten diagonally a few turns at a time.

(8) Tightened by hand diagonally. Angle tighten 45 degree.

(9) To be tightened flush with housing surface.

TORQUE SPECIFICATIONS 2 of 2

Application Ft. Lbs. (N.m)

Air Supply Tube 18 ± 3 (25 ± 4)
Air Supply Tube P-Clamp 15 ± 2 (20 ± 2)
Clutch Cylinder 33 ± 4 (45 ± 5)
Clutch Housing Top Bolts 68 ± 6 (92 ± 8)
Clutch Valve 15 ± 2 (20 ± 2)
Clutch Control Valve Service Plug 5 ± 1 (7 ± 2)
Companion Flange Nut 332 ± 37 (450 ± 50)
Intermediate Bearing Support 129 ± 22 (175 ± 30)
Intermediate Bearing to Support 122 ± 7 (166 ± 10)
Intermediate Shaft Brake Cover 33 ± 4 (45 ± 5)
Transmission Drain Plug 26 ± 4 (35 ± 5)
U-Joint Yoke Mounting Bolts 140 ± 11 (190 ± 15)
U-Joint Cap Bolts 122 ± 7 (166 ± 10)
Fig 1: Identifying Retarder To Range Housing Bolt Tightening Sequence

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