9-, 10- and 13-Speed Transmissions

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Revised $ , 10- and 13-Speed Transmissions Maintenance Manual 26A Design Level One Design Level Two Service Notes This Maintenance Manual describes the correct service and repair procedures
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Revised $ , 10- and 13-Speed Transmissions Maintenance Manual 26A Design Level One Design Level Two Service Notes This Maintenance Manual describes the correct service and repair procedures for the nine-speed, ten-speed and thirteen-speed Design Level One and Design Level Two manual transmissions. You must follow your company safety procedures when you service or repair equipment. Be sure you understand all the procedures and instructions before you begin work on the unit. Meritor uses the following types of notes to give warning of possible safety problems and to give information that will prevent damage to equipment: WARNING A warning indicates procedures that must be followed exactly. Personal injury can occur if the procedure is not followed. CAUTION A caution indicates procedures that must be followed exactly. If the procedure is not followed, damage to equipment or components can occur. Personal injury can also occur in addition to damage or malfunctioning of equipment or components. TORQUE This symbol is used to indicate fasteners that must be tightened to a specific tourque value. NOTE A note indicates an operation, procedure or instruction that is important for correct service. A note can also give information that will make service easier and quicker. Some procedures require the use of special tools for safe and correct service. Failure to use these special tools when required, can cause injury to service personnel or damage to vehicle components. Silicone Gasket Materials WARNING When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent possible serious personal injury, make sure the work area is well-ventilated. If the silicone gasket material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a doctor as soon as possible. Loctite WARNING Take care when using Loctite to avoid serious personal injury. Follow the manufacturer's instructions to prevent irritation to the eyes and skin. If Loctite gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a doctor as soon as possible. Cleaning Solvents WARNING If you use solvents, hot solution tanks or alkaline solutions incorrectly, serious personal injury can occur. To prevent serious personal injury, follow the instructions supplied by the manufacturer of these products. Do NOT use gasoline to clean parts. Gasoline can explode and cause serious personal injury. CAUTION Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or water and alkaline solutions will damage these parts. You can use isopropyl alcohol, kerosene or diesel fuel for this purpose. If required, use a sharp knife to remove gasket material from parts. Take care not to damage ground or polished surfaces. Table of Contents SUBJECT PAGE Section 1 - General Information... 5 Description... 5 Identification... 6 Nine-Speed Manual Transmissions... 6 Ten-Speed Manual Transmissions... 6 Thirteen-Speed Manual Transmissions... 6 Design Level 1 Manual Transmissions... 6 Design Level 2 Manual Transmissions... 8 Gear Timing... 9 Gasket Sealant Removing Gasket Sealant Installing Gasket Sealant Inspecting Used Parts Repairing or Replacing Parts Cleaning Ground or Polished Parts Cleaning Rough Parts Drying the Cleaned Parts Preventing Corrosion or Rust on Cleaned Parts Section 2 - Lubrication and Maintenance Transmission Oil Specifications Transmissions Oil Coolers Scheduled Maintenance Checking and Adjusting the Oil Level Checking the Condition of the Breather Vent Checking Fastener Torque Inspecting the Transmission for Leaks and Damage Draining and Replacing the Transmission Oil Adjusting Remote Shift Housing Linkage Lubricating the Remote Shift Housing Section 3 - In Vehicle Service Removing the Shift Lever and Tower Assembly Installing the Shift Lever and Tower Assembly Removing the Slave Valve Installing the Slave Valve Removing the Air Filter and Regulator Assembly Installing the Air Filter and Regulator Assembly Removing the Output Yoke and Oil Seal Installing the Oil Seal and Output Yoke Removing and Installing the Remote Control Assembly Page 1 Table of Contents (Continued) SUBJECT PAGE Section 4 - Removing and Installing the Transmission Removing the Transmission Installing the Transmission Section 5 - Overhauling the Shift Lever and Tower Assembly Disassembling the Aluminum Tower Assembly Assembling the Aluminum Tower Assembly Disassembling the Cast Iron Tower Assembly Assembling the Cast Iron Tower Assembly Section 6 - Remote Control Assembly Disassembling the Remote Control Assembly Assembling the Remote Control Assembly Section 7 - Removing and Installing the Top Cover Assembly Removing the Top Cover Assembly Installing the Top Cover Assembly Section 8 - Overhauling the Top Cover Assembly Disassembling the Standard and Forward Position Top Cover Assembly Assembling the Standard and Forward Position Top Cover Assembly Disassembling the Standard and Forward Position X Bar Top Cover Assembly Assembling the Standard and Forward Position X Bar Top Cover Assembly Section 9 - Removing and Installing the Input Shaft Removing the Input Shaft Installing the Input Shaft Section 10 - Removing and Installing the Clutch Housing Removing the Clutch Housing Installing the Clutch Housing Section 11 - Removing and Installing the Auxiliary Case Removing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions Installing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions Removing the Auxiliary Case-Thirteen-Speed Transmissions Installing the Auxiliary Case-Thirteen-Speed Transmissions Removing the Auxiliary Drive Gear Installing the Auxiliary Drive Gear Section 12 - Overhauling the Main Case Removing the Mainshaft Removing the Input Shaft Removing the Main Countershafts Page 2 Table of Contents (Continued) SUBJECT PAGE Section 12 - Overhauling the Main Case(Continued) Removing the Reverse Idler Gear Assembly Removing the Oil Pump Removing the Magnets Removing the PTO Covers Installing the PTO Covers Installing the Magnets Installing the Oil Pump Installing the Reverse Idler Gear Assemblies Installing the Input Shaft Installing the Main Countershafts Installing the Mainshaft Section 13 - Overhauling the Auxiliary Drive Gear Disassembling the Auxiliary Drive Gear Assembly Assembling the Auxiliary Drive Gear Assembly Section 14 - Overhauling the Mainshaft Disassembling the Mainshaft Assembling the Mainshaft Section 15 - Overhauling the Main Countershafts Disassembling the Main Countershaft Assembling the Main Countershaft Section 16 - Overhauling the Auxiliary Case Disassembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions Assembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions Disassembling the Auxiliary Case-Thirteen-Speed Transmissions Assembling the Auxiliary Case-Thirteen-Speed Transmissions Section 17 - Main Countershaft End Play Adjustment Checking and Adjusting the End Play of the Main Countershafts Section 18 - Auxiliary Countershaft End Play Adjustment Checking and Adjusting the End Play of the Auxiliary Countershafts Section 19 - Troubleshooting General Information Troubleshooting Other Systems Troubleshooting Leaks Troubleshooting Vibrations Troubleshooting Noises Troubleshooting Operating Conditions Page 3 Table of Contents (Continued) SUBJECT PAGE Section 20 - Specifications Transmissions Oil Capacities Transmission Oil Specifications Fastener Torque Locations-Nine-Speed and Ten-Speed Transmissions Fastener Torque Chart-Nine-Speed and Ten-Speed Transmissions Fastener Torque Locations-Thirteen-Speed Transmissions Fastener Torque Chart-Thirteen-Speed Transmissions Air Line Locations-Nine-Speed and Ten-Speed Transmissions Air Line Identification Chart-Nine-Speed and Ten-Speed Transmissions Air Line Locations-Thirteen-Speed Transmissions Air Line Identification Chart-Thirteen-Speed Transmissions Holding Cover Template Special Tools Page 4 Description See Figure 1 1. This publication describes the service procedures for the following Meritor transmissions: Nine Speed Transmissions. Ten Speed Transmissions. Thirteen Speed Transmissions. Two design levels are described in this publication: Design Level One. This applies to transmissions with serial numbers LB and below. Snap rings are used to keep the tapered roller bearings in the case. Design Level Two. This applies to transmissions with serial numbers LB and above. Retainer plates are used to keep the tapered roller bearings in the case. Figure 1 1 Section 1 General Information The main case, which includes the mainshaft, the main countershafts, the input shaft, the reverse idler gear and the (optional) oil pump, are the same for all transmissions. The auxiliary case is the same design for nine-speed and ten-speed transmissions while the auxiliary case for the thirteenspeed transmission is different. The thirteen-speed transmission uses a different case, piston housing and output shaft assembly. The thirteen speed transmission also uses a splitter gear set in addition to a HI and LO range gear set. The input torque from the engine is distributed by two countershafts and one mainshaft. An auxiliary case provides the LO and HI ranges of operation. Tapered roller bearings are used to support the countershafts in the main transmission case and the auxiliary section. NINE-SPEED TRANSMISSION TEN-SPEED TRANSMISSION THIRTEEN-SPEED TRANSMISSIONS Page 5 Section 1 General Information An air shift system is used to select the LO or HI range of operation on all transmissions and the DIR and OD splitter range of operation on thirteen-speed transmissions. For more information, see Maintenance Manual Number 26B, Nine Speed Manual Transmissions Air Shift Systems or Maintenance Manual 26D, Thirteen-Speed Transmissions Air Shift Systems. Identification An identification plate is installed on the side of the transmission. Use the information on the identification plate when ordering parts. Figure 1 2. See Figure 1 2 for an explanation of the model identification number and the identification plate. Nine Speed Manual Transmissions The transmission is identified by the number 9 in the Speed portion of the model number. Figure 1 2. The transmission uses nine forward gears (five gears in the LO range and four gears in the HI range) and two reverse gears. The transmission may be either a Design Level 1 or a Design Level 2. See the explanation in this section. Ten Speed Manual Transmissions The transmission is identified by the number 10 in the Speed portion of the model number. Figure 1 2. The transmission uses ten forward gears (five gears in the LO range and five gears in the HI range) and two reverse gears. The transmission is a Design Level 2. See the explanation in this section. Thirteen Speed Manual Transmissions The transmission is identified by the number 13 in the Speed portion of the model number. Figure 1 2. The transmission uses thirteen forward gears (five gears in the LO range and eight gears in the HI range that are divided between four DIR gears and four O/D gears) and two reverse gears. The transmission may be either a Design Level 1 or a Design Level 2. The auxiliary case is different from the ninespeed and the ten-speed transmissions. Design Level 1 Manual Transmissions Design Level 1 Manual Transmissions apply to transmissions with serial numbers below LB The transmission is identified by the number 1 in the Design Level portion of the model number. Figure 1 2. Page 6 Section 1 General Information Figure 1 2 RMX10-145A2S002 Meritor Transmission Model Number O.E.M. Transmission Part Number Manufacturing Date CUST# Meritor Automotive MODEL SERIAL NO. & ASS'Y PLANT RATIO DATE Transmission Serial Number These Plugs Indicate Oil Pump R M X A 2 S 002 MERITOR TYPE A=Automated E= Electric/Air M=Manual S=Engine Synchro Shift W=Shift by Wire SPEED Progressive Forward Speeds SHIFT PATTERN No letter=direct drive standard H pattern X=overdrive standard H pattern O=overdrive 9-speed non-standard pattern OR overdrive 13-speed standard H pattern x 10 = Nominal Input Torque RATIO SHIFT BAR HOUSING POSITION F=Foward S=Standard DESIGN LEVEL 1=Serial Numbers LB and Below 2=Serial Numbers LB and Above SPECIFICATION Page 7 Section 1 General Information Snap rings are used to retain the bearing cups for the main countershaft in the main case and for the auxiliary countershafts in the auxiliary case and the main case. Selective snap rings are used to adjust the end play in the main case and the auxiliary case. Design Level 2 Manual Transmissions Design Level 2 Nine-Speed, Ten-speed and Thirteen-Speed Manual Transmissions apply to all transmissions with serial numbers LB and above. The transmission is identified by the number 2 in the Design Level portion of the model number. Figure 1 2. Retainer plates are used to retain the bearing cups for the main countershaft in the main case. The bearing cover and the selective washer are used to retain the cups for the auxiliary countershaft in the auxiliary case. Selective shims are used to adjust the end play in the main case. Selective washers are used to adjust the end play in the auxiliary case. Page 8 Section 1 General Information Gear Timing If the timing marks on the gears are not aligned in the main case or in the auxiliary case, the transmission will not operate. The timing marks must be correctly aligned when the transmission is serviced. The timing marks will not go out of alignment during normal vehicle operation unless the gear teeth are damaged. Timing Marks in Auxiliary Case NOTE: To make sure the timing marks are in the correct locations, count the number of gear teeth, divide the total teeth number by 2 and put the mark in the correct location. 1. Put timing marks on the auxiliary low gear. Mark one tooth with paint. Mark a second tooth opposite (180 o ) the first timing mark. Figure Use paint to put timing marks on two Figure 1 3 AUXILIARY LOW GEAR- MARK ONE TOOTH ON EACH SIDE 180 APART teeth next to each other on each countershaft low gear of the auxiliary countershafts. Make sure the marks are aligned with the O stamping on the countershaft. Figure During assembly, each of the two timing marks on the auxiliary low gear must be between the two marked teeth on each countershaft low gear. Figure 1 4. All the timing marks must be aligned if the transmission is to operate correctly. If the timing marks are not painted in the correct position on the gears, only one set of marks will be aligned. 4. To check the alignment of the timing marks, rotate the output shaft seven (7) complete revolutions. All the gears must rotate. 5. For complete service procedures, see Assembling the Auxiliary Case in Section 16, Overhauling the Auxiliary Case. COUNTERSHAFT LOW GEAR-MARK TWO TEETH OVER O STAMPING TIMING MARKs O STAMPING TIMING MARKS Page 9 Section 1 General Information Figure 1 4 Timing Marks in Transmission Case NOTE: To make sure the timing marks are in the correct locations, count the number of gear teeth, divide the total teeth number by 2 and put the mark in the correct location. 1. Put timing marks on the main drive gear on the input shaft. Mark one tooth with paint. Mark a second tooth opposite (180 o ) the first timing mark. Figure Use paint to put timing marks on two teeth next to each other on each driven gear of the main countershafts. Make sure the marks are aligned with the slot for the key or the O stamping on the countershaft. Figure During assembly, each of the two timing marks on the main drive gear must be between the two marked teeth on each countershaft drive gear. Figure 1 6 All the timing marks must be aligned if the transmission is to operate correctly. If the timing marks are not painted in the correct position on the gears, only one set of marks will be aligned. NOTE: The main shaft and the auxiliary drive gear must be installed when the alignment marks in the transmission case are checked. 4. To check the alignment of the timing marks, rotate the input shaft. All the gears must rotate. 5. For complete service procedures, see Assembling the Transmission Case in Section 12, Overhauling the Main Case. Page 10 Section 1 General Information Figure 1 5 MAINDRIVE GEAR MARK ONE TOOTH ON EACH SIDE 180 APART TIMING MARK COUNTERSHAFT DRIVEN GEAR MARK TWO TEETH OVER THE SLOT FOR THE KEY OR THE O STAMPING TIMING MARKS Figure 1 6 Page 11 Section 1 General Information Gasket Sealant The transmission uses Loctite RTV Sealant #5699 (Meritor Part Number 2297-A-7021) between the following components. NOTE: See Figures 1 9 to 1 11 for sealant patterns. Clutch housing and main case. PTO covers and main case. Top cover and main case. Auxiliary case and main case. Auxiliary countershaft covers and auxiliary case. Output bearing retainer on the auxiliary case. Input bearing retainer on the main case. Range piston housing to the auxiliary case. CAUTION Apply the sealant in a 1/8 inch (2 mm) bead. If too much sealant is used, the sealant that extends over the edges can break off and plug the oil passages. 2. Apply Loctite RTV Sealant #5699 (Meritor Part Number 2297-A-7021) with a sealant dispenser to one surface. Apply the sealant in a continuous pattern with a 1/8 inch (2 mm) bead. Make sure the bead encircles any fastener holes. 3. Install the component as described in the correct section of this manual. Figure 1 7 CAUTION Use Loctite RTV Sealant #5699 (Meritor Part Number 2297-A-7021) as a gasket. The use of any other gasket material (such as a corrosive sealant) can cause leaks and damage the transmission. Removing the Sealant See Figure Remove the component as described in the correct section of this manual. 2. Use a scraper to remove all sealant material from the surface. Installing the Sealant See Figure Clean the mounting surfaces with a chlorinated solvent such as Loctite Safety Solvent or equivalent. Figure 1 8 SEALANT DISPENSER Page 12 Section 1 General Information Figure 1 9 AUXILIARY COVER-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE AUXILIARY COVER TRANSMISSION CASE GASKET PATTERN AUXILIARY COVER GASKET PATTERN REAR COVER BOLT HOLE BEAD TRANSMISSION CASE BOLT HOLE NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD. CLUTCH HOUSING-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE PTO COVERS-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE NOTE: DO NOT BLOCK OIL FEED HOLE MAKE SURE THE PATTERN IS ON THE TRANSMISSION CASE AND NOT ON THE RETAINER NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD BOTTOM COVER NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD TRANSMISSION CASE BOLT HOLE PUT BEAD AROUND HOLE SIDE COVER SHIFT BAR HOUSING-TO-TRANSMISSION CASE GASKET PATTERN FOUR HOLES SURROUNDED BY SEALANT PUT THE PATTERN ON THE TRANSMISSION CASE TRANSMISSION CASE BOLT HOLE NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD OUTPUT BEARING RETAINER-TO-AUXILIARY COVER GASKET PATTERN PUT THE PATTERN ON THE OUTPUT BEARING RETAINER BOLT HOLE OIL SLOT NOTE: APPLY SEALANT IN A 1/8 INCH (3MM) BEAD OIL SLOT BEAD TO BE KEPT OUTSIDE OF OIL SLOTS RETAINER INPUT BEARING RETAINER-TO-TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE INPUT BEARING RETAINER RETAINER BEAD TO BE KEPT OUTSIDE OF OIL SLOTS OIL SLOT BOLT HOLE NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD Page 13 Section 1 General Information Figure 1 10 AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS -TO-AUXILIARY COVER GASKET PATTERN (NINE-SPEED AND TEN-SPEED TRANSMISSION) PUT THE PATTERN ON THE AUXILIARY COVER PISTON HOUSING SURROUND ALL HOLES WITH SEALANT AUXILIARY COUNTERSHAFT COVER NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD. Figure 1 11 AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS -TO-AUXILIARY COVER GASKET PATTERN (THIRTEEN-SPEED TRANSMISSION) PUT THE PATTERN ON THE AUXILIARY COVER PISTON HOUSING AUXILIARY COUNTERSHAFT COVER NOTE: APPLY SEALANT IN A 1/8 INCH (2MM) BEAD. Page 14 Section 1 General Information Inspecting the Parts It is imp
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