TREMEC 10-Speed Commercial Vehicle Manual Transmission
Contents
1. np EE Regulator Assembly Air Fitting _ Clamp Bolt 5 Bearing Cap Bracket Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 47 Section 17 Component Drawings Main Case Opti Lube Figure 17 10 Mounting Plate Screw Oil Pump Subassembly Mounting Plate Housing Internal Tube m e d u ii Ring 7 ek E AU Xp i CHL a Si Loring Ee Wale Gerotor Element Goes UI Pump Drive Gear 48 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 ings Component Draw Air Line Schematic Section 17 Figure 17 11 LHOd L31NI didN Z2 ScV AlddNs Mi NOISIAOYd 1LNO H9O07 QHVOS8 Y00743 M0738 NMOWS Qv3HHl 1d N0S2 7TVILN3H334IO YOs LO ON3LX3 OL LSNVWHX3 HOI LHOd Q3u OVSYHL LN Oe CY M0973 VW A18W3SSV SATWA SS3NYVH ONISNL HIV MO LHOd SAIWA HLIM SONOdS3B8HO v H9IH LYOd SATIVA HLIM SONOdS3HHOO 8 SONY 13IHS Ab ad kv W l EPI LN i dn xs d n Ky H d d ONISNOH Oe aliis EN WA AX r FS ns verit prn tieta NK 49 TR T 10_0915 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM Section 12. TR T 10 Series TREMEC 10 Speed ege Dual Counter Shaft Manual Transmission Torque Transfer Solutions Service Manual SM TR T 10 0915 14700 Helm Ct Plymouth MI 48170 U S A 800 401 9866 www tremec com n A k o Group Company Copyright 2015 TREMEC All Rights Reserved SM TR T 10 0915 Table of Contents Section 1 General MON iio dmm 4 ate EE 4 G neral Salety e tele NE EO eS 4 Driver Instructions Shifting the TREMEC 10 Speed Transmtssion nennen 6 RE Lei ET 7 EECHER TETTE 9 Par Fedu te EE 9 UTE ere OTT ce pesmi ree etre te bee nese eee ee nate ae eo em 9 Section 3 General Disassembly nennen nnaa nnns n nsi ssssaa annii sss s asas assis iiis sana a assa sns anna a a 10 N te important TOC COWS poeseos tuto ospavetadutut unt dits meo tk tditumumuttkona cta o URS SLcS uu AE ten S dUNdUUKP UP SED CPU SEU eu UN fA 10 Sta e icd NE mm 11 S ction 4 Shift Tower Disassembly EE 12 Section 5 Remote Shift Control Disassembly eieiei gege EEE EE Dasasu An epu pERA a MU PSP MU UE 12 Section 6 External Component Disassembly EE 13 EE POC UE a UR 13 Secion 7 Eelere E 15 e O lep POCUS EET nen Eben Eege 15 Seccion 8 Man Case Disassembly aa ane et ge E E E AE EAE E E ees E 19 O O o lD reel 19 Section 9 Countershaft Disassembly and Heassembhy nennen nennen nennen nnn a arn nnns nnn 22 C ntershalt VIEWS seios Eeee EOE Ri ERNES e 22 Presong DIECON E 23 Section 10 Clean
3. 20 Lubricate and install new O rings on the regulator The two air filter regulator bolts are longer piston install the piston The counterbore on the than the other six bearing retainer bolts Torque to piston should face the new O ring on the range fork 34 41 Ib ft shaft Step 21 Install the retaining nut and torque to 52 62 Step 22 With the air inlet at the top install the range Ib ft Lubricate the piston O ring piston housing with four bolts Torque to 34 41 lb ft Step 23 Using a hoist place the transmission in a horizontal Step 24 Install air control valve gasket the backup position Install the two mechanical clutch housing retainer light switch and pin bolts 4 in hydraulic units Torque to 78 98 lb ft Bench shift transmission to ensure it is working correctly Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 31 Section 13 Range Case Reassembly Step by Step Procedures Figure 13 1 Step 25 Shift all forks into neutral install the three air control valve pins and the air control valve Torque the two retaining bolts to 52 62 lb ft Step 26 Using a wrench install the air lines refer to air line schematic To modify the length of the air lines use a razor sharp edge to cut the tubing squarely Never use side cuts L 2 a ge Step 25 Insert three poppet balls and springs
4. Inspect parts thoroughly for wear or damage Worn or damaged parts must be replaced to insure maximum rebuild life Suggested inspection procedures include the following Inspection Clutch Collars Both the internal and external teeth must have sharp edges Check for chipped or broken teeth or teeth with rounded corners Replace collars if any of these conditions exist Gears Examine for broken or cracked operating and clutching teeth Also check for any unusual wear patterns If any of the preceding exists replace the gear If a gear is replaced also replace the mating gear Thrust Washers Check for excessive face wear cracks scoring or signs of heat damage Replace if any of these conditions exists Snap Rings New snap rings are recommended with every rebuild Mainshaft Check for signs of twisting or misalignment Also check for worn or damaged splines Replace the shaft if any of these conditions exists Remote Shift Control Check the shift fingers bushing bores and rods for excessive wear or scuffing Replace springs bearing races boots and seals Clean all reusable parts thoroughly and apply a light coat of grease to the pivot points when reassembling Bearings New bearings are recommended with every rebuild See General Disassembly Bearings for further information Housings Inspect the housing sections for cracks If cracks exist replace that section of the housing Also inspect the shift bar
5. a shaft is reached it begins to bow A resonant hum can be heard and a vibration will be felt This type vibration can cause gear seizures broken synchronizer pins bearing failures brinelling and corrosion During acceleration and deceleration the shaft may pass through half critical vibration half the maximum RPM of the shaft A whine or boom may be heard at his point E Metallic rattles These noises within the transmission usually result from a variety of conditions Engine torsional vibrations are transmitted to the transmission through the clutch In heavy duty equipment clutch discs with vibration dampers are not used so a rattle particularly in neutral is common with diesel equipment In general engine speeds should be 600 RPM or above to eliminate objectionable rattles and vibration during the idle A defective or faulty injector would cause a rough or lower idle speed and possibly a rattle in the transmission A rattle can also be caused by excessive backlash between the PTO input gear and the transmission output gear Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 35 Section 16 Troubleshooting Noise in Neutral Possible Causes 1 Misalignment of transmission Worn flywheel pilot bearing Worn or scored countershaft bearings Sprung or worn countershaft Excessive backlash in ge
6. into case Place the interlock into the interlocking retaining plate and install the assembly Adjust to the proper position for a forward or center control Secure the plate with two bolts and torque to 52 62 lb ft Step 17 Reassembly is complete with the installation of the shift tower gasket and shift tower The gasket must be in place to ensure proper gear selection If this gasket is eliminated binding may occur the gasket also acts as a shim Do not apply sealant to the shift tower or housing as this may prevent proper interlock functioning Torque bolts to 31 45 Ib ft 32 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 14 Remote Shift Control Reassembly Step by Step Procedures Figure 14 1 Step 1 After packing the remote control housing cavity with grease install the rod Step 2 Set the shift finger in place and secure with a setscrew Torque to 40 50 lb ft Step3 Slide the boot over the rod onto the remote control housing Secure with two tie down straps Step 4 Put the outer shaft lever onto the splined end of the shift rod Install the setscrew and torque to 40 50 lb ft Step 5 Reassemble the selection lever subassembly and bolt into place Step 6 Screw the jam nuts turnbuckle and ball joints onto the tie rod Grease the ball joints Step 7 Place a spacer on t
7. keys with one another 22 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 9 Countershaft Disassembly and Reassembly Pressing Directions Figure 9 3 When pressing the gears onto the countershaft it is very important to assemble in the proper direction The bearing gear and thrust ring to the left of the black bar see photo are pressed on from one direction all other items are pressed on from the other direction The countershaft components shown here are from an overdrive transmission In a direct drive transmission the 4th and 5th gears would be switched The gears are aligned with a blind spline containing 3 drift keys Section 10 Cleaning and Inspection Procedures Cleaning Prior to reassembly wash all parts thoroughly Use a petroleum based solvent Refer A to the solvent manufacturer s safety precautions to prevent personal injury or transmission damage Do not use water or steam to clean internal components If you do it could cause corrosion of these components Do not use gasoline to clean parts Gasoline can explode causing serious physical injury Dry the parts immediately with compressed air Coat them with lubricant if they are to be reassembled immediately If the parts are to be stored coat them with a rust inhibitor and wrap them to keep contamination out
8. of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 9 Section 3 General Disassembly Note Important Procedure To locate and correct transmission and or auxiliary transmission issues a systematic procedure should be followed Road test whenever possible Technicians usually get second or third hand reports of trouble experienced with the transmission These reports do not always accurately describe the actual conditions Symptoms may indicate trouble in the transmission while actually the problem is with the axle driveshaft universal joints engine or clutch This is especially true of noise complaints Before removing the transmission to diagnose an issue road test to check the possibility of trouble in other closely associated components Road testing is most effective when the technician drives the vehicle However riding with the driver can be very informative Check Functioning Prior to Disassembly If a remote shift control is used a careful check of the remote and connecting linkages and their adjustment must be made The remote unit must be in good working order if the transmission is expected to shift properly Inspect Thoroughly During Disassembly As the transmission is di
9. support bracket for cracks or worn slots Replace if either of these conditions exists Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 23 Section 11 Front Bearing Retainer and Seal Assembly Step by Step Procedures Figure 11 1 comes with the seal kit to prevent serious damage to the oil seal Failure to use the seal sleeve will When installing the front bearing retainer and seal in the transmission use the red plastic sleeve that i void the seal warranty Steps 1 Install seal dry into bearing cap assembly 2 Hydrodynamic lip seal must be installed so that hydrodynamic lip faces inside of transmission 3 Install red sleeve over end of input shaft 4 Install bearing cap assembly to the transmission 24 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 12 Main Case Reassembly Step by Step Procedures Figure 12 1 amp Step 1 Install the input shaft Using a protective sleeve slide the front bearing retainer into place Torque the four cap bolts to 34 41 Ib ft Step 3 Install the overdrive and shift fork support bracket Continue by installing 5th speed in direct or 4th speed overdrive gear with the thrust face toward the input bearing The timing marks
10. the input shaft assembly remove the four bearing retaining bolts Pull the shaft from remove the snap ring Press the bearing off the shaft the housing It may be helpful to place 2 bolts in the threaded bearing retainer holes to remove the front bearing retainer Tap the input shaft out of the clutch housing Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 21 Section 8 Main Case Disassembly Comparison of Direct Drive Overdrive Shift Collar Figure 8 2 Overdrive Ath 5th collar Step 17 In an overdrive transmission notice that the fork slot of the 4th 5th speed shift collar is wider than the fork slot on the other collars In a direct transmission all collars will be the same Section 9 Countershaft Disassembly and Reassembly Countershaft Views 1st 2nd 3rd 5th Ath 6th 7th PT 8th 10th Oth EE 23 R a Esch pcm LLIL ge ees cl cl a A TITULI Figure 9 1 The countershaft shown here is Figure 9 2 If a straight edge is placed between the from an overdrive transmission In a direct drive teeth every gear on the countershaft will be in line transmission the 4th and 5th gears would be with the blind spline on the countershaft When the switched The gears are aligned with a blind spline shafts are in time these marks will be perfectly inline containing 3 drift
11. tight on the shaft usually the bearings will brinell as they must absorb the pounding force 2 If the bearing fit is loose the shaft will keep moving inward until it is stopped by the internal parts such as the pilot bearing thrust washers These conditions must be prevented Power Take Offs Refer to your owner s manual installation procedures and safety precaution when installing any PTO on your transmission Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 1 1 Section 4 Shift Tower Disassembly Shift Tower Figure 4 1 Steps 1 Remove shift bezel nut lock washer and washer 2 Disconnect air lines from shift knob 3 Remove shift knob 4 To separate upper lever from the lower lever remove nut and washer on top of the isolator Pull levers apart See Figure 17 12 for Shift Tower component identification Section 5 Remote Shift Control Disassembly Remote Shift Control Figure 5 1 oteps 1 Remove the six retaining bolts separate the remote shift control from the transmission 2 Disconnect the tie rod from the housing and the selection lever 3 Disconnect the selection lever from the outer shift lever p 4 Remove the bolts from the ear or outer shift lever Tap the lever Y d lt S i si A off the shift rod A L E FINGER SHIFT s 5 Cutthe t
12. when coasting Also notice whether the gear hop occurs on smooth roads or only on rough roads Items that would prevent full engagement of gears are Improperly positioned forward remote control which limits full travel forward and backward from the neutral position 4 Improper length shift rails or linkage that limits travel of forward remote from neutral position 5 Loose bell cranks sloppy ball and socket joints 6 Shift rails cables etc too spongy or flexible or not secured properly at both ends 7 Worn or loose engine mounts if forward unit is mounted to frame 8 Forward remote mount too flimsy or loose on the frame 9 Setscrews loose at remote control joints on shift forks inside remote 10 Shift fork pads or groove sliding gear or collar worn excessively 11 Transmission and engine out of alignment either vertically or horizontally A few items which could move the gear or shaft out of proper position particularly on rough roads are a Use of heavy shift lever extensions b Broken shift rail poppet springs c Worn shift rail poppet notches d Bent or sprung shift rails e Excessive end play in drive gear or countershaft caused by worn bearings or retainers f Worn or missing thrust rings 36 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 16 Troubleshootin
13. 2nd speed gears Step 6 Remove 2nd and 3rd speed clutch collar and fork Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 1 9 Section 8 Main Case Disassembly Step by Step Procedures Figure 8 1 Step 7 Remove the 3rd speed gear Step 8 Remove the 4th speed gear 5th gear if working on an overdrive transmission Step 9 Remove the countershafts Step 10 Remove the gasket Step 11 Remove the mainshaft and 4th 5th collar Step 12 If the 4th 5th speed shift fork shoes are worn replace them It is not necessary to remove the fork to replace the fork shoes 20 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 8 Main Case Disassembly Step by Step Procedures Figure 8 1 Step 13 The oth speed direct gear or 4th speed Step 14 To remove the 4th 5th speed shift fork overdrive gear is removed next remove the snap ring Push the pin through the bracket Lift the fork from the unit Remove the 4th oth shift fork support brackets lt gt Step 15 Remove the countershaft front bearing Step 16 Inspect O rings in clutch housing cups as shown WEI LE TEEN El 7l Step 17 To remove the input shaft and front bearing retainer Step 18 To disassemble
14. 7 Component Drawings Shift Tower Figure 17 12 50 Ca Bezel Lock Nut Washer Washer Upper mei Isolator plastic Shift Knob Lower Isolator plastic Castellated Nut Boot Pin Upper Shift Lever with Isolator Bushing amp Outer Ring SCH 3 Inner Ring 3 nner Ring Outer Ring Opposing Disk Springs Breather Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 51 TREMEC Torque Transfer Solutions 14700 Helm Ct Plymouth MI 48170 U S A U S Toll Free 800 401 9866 Outside of U S 734 456 3700 Fax 734 456 3739 www tremec com K O cw
15. S40 2 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 7 Section 1 General Information Specifications Torque Specification for Nuts and Cap Screws Wrench Toque lb ft Part Name Nominal Thread Size Locking Type DEE Bonded nylon patch Min Max N Cap Screw or Nut nen mm f Mi Max O1 QI O1 O1 w 2 O IO PTO Aperture Cover Cap Screw PTO Aperture Cover Cap Screw with Gasket 97 324 2 PTO Aperture Cover Cap Screw with Gasket 22P22 ut NO cO 8 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 2 Maintenance Filter Regulator Figure 2 1 The 10 speed uses an air filter regulator preset at 55 61 psi Do not disassemble the air filter regulator it is not field repairable If the filter regulator is not operating properly or is damaged replace it Lubrication CAUTION To ensure proper lubrication A3 and operating temperatures in this unit the proper lubricants must be used Correct oil levels must be maintained TREMEC recommends using only lubricants produced by reputable well known suppliers If you want to use a lubricant not specified below please contact your local truck dealer to determine whether the lubricant is suitable for your pur
16. Shift Lever with Isolator Bushing Snap Ring Ee Outer Ring Inner Ring Lower Shift Lever EL Imer Ring lt Outer Ring Opposing Disk Springs Breather 34 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 16 Troubleshooting Noisy Operation Noise is usually a very elusive problem and is generally not the fault of the transmission Technicians should road test the vehicle to determine if the driver s complaint of noise is actually in the transmission In numerous instances where drivers have insisted noise was coming from the transmission investigations revealed it was caused by one of the following conditions Fan out of balance or blades bent Defective vibration dampers Crankshaft out of balance Flywheel out of balance Loose flywheel mounting bolts Rough engine idle producing rattle in gear train Clutch assembly out of balance Loose or broken engine mounts Power take off engaged 10 Worn universal joints 11 Driveshaft out of balance 12 Universal joint angles out of phase or at excessive angles 13 Center bearings in driveline dry not mounted properly 14 Wheels out of balance 15 Tire treads humming or vibrating at certain speeds 16 Air leaks on suction side of induction System especially with turbo charg
17. ars Scuffed gear tooth contact surface Insufficient lubrication Use of incorrect grade of lubricant GE ae ee Noise In Gear Possible Causes 1 Rough chipped or tapered sliding gear teeth 2 Noisy speedometer gears 3 Excessive end play of countershaft gears 4 Refer to conditions listed under Noise in Neutral Cil Leaks Possible Causes 1 Oil level too high 2 Wrong lubricant in transmission 3 Seals defective wrong type or omitted from bearing cap 4 Transmission breather omitted or plugged internally 5 Capscrews loose omitted or missing from remote control shifter tower bearing caps PTO or covers 6 Oil drain back openings in bearing caps and or case plugged with varnish or dirt 7 Gaskets shifted or squeezed out of position broken gaskets with pieces still under the shift tower 8 Cracks or holes in castings 9 Loose drain plug 10 Oil leakage from engine 11 Loose speedometer adaptor or connections Walking or Jumping Out of Gear If the unit walks out of gear it could be caused by 1 External interference such as the floorboard opening preventing full engagement or 2 Aninternal malfunction such as worn clutching teeth allowing the transmission to shift out of position If a remote control is being used make sure it is functioning properly before the transmission is blamed for the problem Note whether the unit walks out of gear under drive while pulling a load or
18. ble However you should do this only when operating conditions allow Your speed the load the road type and condition should be considered Reminders V Double clutch when shifting V Use steady force on the shift lever to complete shifts Avoid forcing the shitt V Don t coast in neutral V Avoid downshifting at road speeds that are too fast V Never change ranges when the transmission is in reverse gear V Chassis and trailer brake life can be increased by downshifting through all the gear speeds when you are slowing down Reminders Double clutch when shifting This will A3 help components match speed better during shifts and will help ensure proper engagement Downshift through all gears when you are slowing down Chassis and trailer brake life can be increased by doing this Do not force the shift since this can cause damage to clutch collars and clutching teeth Use steady force on the shift lever to complete shifts Do not coast in neutral The vehicle could G lose RPM s during coasting and you may not be able to shift back into the proper gear Do not downshift at road speeds that are too fast This could prevent proper gear engagement and could damage clutching teeth Do not tow vehicles without first pulling the axles or disconnecting the driveshaft If you tow the vehicle without doing this you can damage drive train components because the lubrication system is inadequate when the vehicle is to
19. ch Troubleshooting Faulty clutch operation interferes with proper shifting of gears in any transmissions The two following paragraphs describe the most common problems encountered with clutches 1 Ifthe clutch slips or does not engage properly first check the internal clutch adjustment If adjustment does not remedy the situation check for weak pressure springs lack of free pedal and worn or oily clutch facings and binding release mechanism 2 Ifthe clutch drags or does not release properly check the internal clutch adjustment Some other causes for clutch drag are an intermediate plate sticking on drive pins or drive lugs the pressure plate not retracting a distorted or warped driven disc worn splines on the main drive gear of the transmission a damaged clutch release bearing or the bushing in the release sleeve dragging on the transmission drive gear Backup Lights If the backup lights do not function check the following 1 Continuity of the switch with the ball fully depressed 2 Electrical plug connection 3 Wiring 38 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 17 Component Drawings Input Shaft Group Figure 17 1 Input Shaft Input Bearing Snap Ring N Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are product
20. cured before the clutch can be released Do not leave these vehicles parked in gear 2 Sliding clutch gears tight on splines 3 Chips wedged between or under splines of shaft and gear 4 Improper adjustment excessive wear or lost motion in shifter linkage Sticking in Gear The service life of most transmissions main and auxiliary is governed by the life of the bearings The majority of bearing failures can be attributed to vibration and dirt Some other prominent reasons for unit bearing failures are Fatigue of raceways or balls Wrong type or grade of lubricant Lack of lubricant Broken retainers brinelled races and fret ting caused by vibration Bearings set up too tight or too loose Improper installation resulting in brinelled bearings Improper fit of shafts or bore Acid etching due to water in lube Vehicle overload or too large an engine for the transmission resulting in overload pese o oo N Dirt More than 90 of all ball bearing failures are caused by dirt which is always abrasive Dirt may enter the bearings during assembly of units or may be carried into the bearing by the lubricant while in service Dirt also may enter bearings through seals the breather or even dirty containers used for addition or change of lubricant Softer material such as dirt or dust usually forms abrasive paste or lapping compounds within the bearings The pressure between the balls and raceways makes a pe
21. ecure the unit with the 2 bolts and on each countershaft adjust shims accordingly torque to 34 41 lb ft Spin the Opti Lube pump gear to ensure that it spins freely Step 5 Install the countershaft reverse gears These Step 6 Position the reverse gear and the thrust plate gears only fit in one position because of the blind spline between the range countershaft gears Secure each gear with a washer and bolt Torque bolts to 78 98 lb ft 28 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 13 Range Case Reassembly Step by Step Procedures Figure 13 1 A E NU EN be Step 7 Slide the countershaft and reverse gear Step 8 Be sure to align the timing marks as the high assembly down over the mainshaft range gear is installed Step 9 Install the rear shift fork support bar Torque Step 10 Install the high range clutch gear and the the 2 bolts to 34 41 lb ft synchronizer cup Secure with washer and bolt Torque to 78 98 lb ft Step 11 Install the range synchronizer and range fork Step 12 Install new gasket with the synchronizer springs facing toward the output yoke or flange Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 29 Section 13 Range Case Reassembly Step b
22. embly Seal all openings before steam cleaning to prevent entry of dirt and water which can damage serviceable parts Dirt is abrasive and will cause premature wear of bearings and other parts TREMEC suggests that technicians have a wash tank available to clean parts just prior to reassembly Bearings When a transmission is removed at relatively low mileage bearings should be removed with pullers designed for this purpose Wrap the bearings to keep out dirt Clean inspect and lubricate all bearings just prior to reassembly If accumulated mileage is over 150 000 miles we suggest that all bearings be replaced If bearings are worn or damaged always replace them regardless of mileage Do not hammer on end yokes and flanges to remove or install them It is not only destructive to the yoke or the flange itself but can also cause serious internal transmission damage Hammering destroys or mutilates the pilot diameters and warps or bends the flange Hammering on end yokes will close in the bearing bores or misalign yoke lugs This will result in early failures of journal needle bearings Serious damage can be done internally to bearings thrust faces and washers by hammering on external parts In most designs when the yoke flange locknuts are tightened and secure the internal bearings and gears are in proper location When the yoke flange is driven on the shaft however two conditions can exist 1 If the bearing fit is
23. ent SM_TR T 10_0915 41 Section 17 Component Drawings Range Case Gears Figure 17 4 Range Countershaft Assembly Reverse Idler Gear Thrust Washer Bearing Bearing Bolt Clutch Washer Drive Gear NS Synchronizer Cu High Range N Drive Gear NS AX 92 Main Shaft N Range Synchronizer 42 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 17 Component Drawings Range Case Gears Figure 17 5 Bearing and Spacer Assembly Output Nut Washer 5 pacer or Speedometer Gear Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 43 Section 17 Component Drawings Main Case and Clutch Housing Figure 17 6 Bolt SES ei PTO _ Support Bracket Cover J Bolt 9 Es Oil Inlet O utlet Cover Gasket oun Pin e Mounting P in Oil Inlet Outlet Cover Si Bolt NE Dow Pin 7 s PTO Cover Support Bolt Bracket Countershaft Bolt Oil Trough N Lift Hook Bolt b N On Bolt eng a Oil Trough Front Peanng Bushings Inspection Housing Plate Subassembly Rer de Oil Seal and Front Bearing Retainer Mechanical Clutch Housing Hydraulic Clutch Housing 44 Copyright 2015 TREMEC All Right
24. ers IAS Iu oe Ss Technicians should try to locate and eliminate noise by means other than a transmission removal or an overhaul However if the noise appears to be in the transmission try to determine what position the gear shift lever is in when the noise occurs If the noise is evident in only one gear position the problem is generally traceable to the operating gears Next try to categorize the noise into the following classifications A Growling humming and grinding These noises are caused by worn chipped rough or cracked gears As gears continue to wear the grinding noise will be noticeable particularly in the gear position that throws the greatest load on the worn gear A lack of lubricant or use of improper lubricant can also result in growling and grinding noises This is because there is insufficient lubricant to cool and cover the gears which allows metal to metal contact B Hissing thumping and bumping Hissing noises can be caused by bad bearings As bearings wear and retainers start to break up etc the noise could change to a thumping or bumping C Gear whine This is usually caused by lack of backlash between mating gears Improper PTO shimming is the big offender here D Vibration Today s improved highways mean entire power trains are cruising at higher RPM s These higher speeds mean damage caused by driveline vibration is more obvious than in the past When the maximum RPM of
25. g Hard Shifting An improperly operating clutch will interfere with the proper shifting of gears in any transmission It is also important that the hydraulic air or similar release mechanism is in proper working order If full and complete clutch release is being made the following could be a few of the possible causes for hard shifting complaints 1 No lubricant in remote control unit Note The forward remote is isolated and is often overlooked Many remote controls used on transmissions and auxiliaries require separate lubrication 2 No lubrication in or grease fittings on u joints or swivels of remote controls 3 Lack of lubricant or wrong lubricant used causing buildup of sticky varnish and sludge deposits on splines of shaft and gears Badly worn or bent shift forks Improper adjustment on shifter linkage Sliding clutch gears tight on splines of shaft 7 Clutch teeth burred over and chipped or badly mutilated because of improper shifting 8 Binding or interference of shift lever with other objects or rods inside the cab or near the remote control island Clutch dragging 10 Free running gears seized or galled on either the thrust face or diameters p os Sticking in Gear Possible Causes 1 Clutch not releasing Also check remote units such as a hydraulic or air assist Note On some units employing a full air control for clutch release air pressure of approximately 60 lbs or more must be se
26. g Upshifting Starting Vehicle from a Stop d Then move the gear shift lever into 7th gear 1 a With the gear shift lever in neutral position b Clutch pedal depressed c And brakes set 8 a Continue the above procedure for 3rd hand d Start the engine Allow vehicle to build to position 8th gear 4th hand position 9th maximum air pressure gear and 5th hand positions 10th gear 2 a With the clutch pedal fully depressed to Trucking Tips engage the clutch brake see Clutch Downshifting Brake Downshifting is actually just the reverse b Position the of upshifting see Double Clutching range selector to uP tor Downshifting low range Move High Range gd the gear shift DOWN for Clutch Brake lever into 1st gear Low Range The clutch brake used with this transmission is position designed for stopping gear rotation so you can shift into 1st and reverse gears The last one inch 3 a Release the of clutch pedal travel activates the clutch brake tractor parking brakes and trailer parking On shifts other than 1st or reverse from a stop brakes where applicable only depress the clutch pedal enough to release b Release the clutch pedal gradually to full the clutch Depressing the pedal to the floorboard position will activate the clutch brake and could cause gear c Depress the throttle to start the vehicle hang up or hard shifting moving a When selecting a starting gear if you have a butt b Depress the clutch pedal tooth c
27. he ball joint studs Attach it to the selection lever subassembly and remote control housing Place the interlock in the rear position and install the interlock Step 8 Install the new remote control gasket and assembly onto the transmission Torque to 31 45 Ib ft Adjust the linkage according to the original equipment manufacturer s specifications Step 9 Check the remote control dimensions shown in Figure 12 1 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 33 Section 15 Shift Tower Reassembly Step by Step Procedures Figure 15 1 Step 1 Place the two opposing springs and the outer ring into the shift tower Step 2 Place the lever through the tower and support it in a vise Step3 Install the outer ring Once the outer ring clears the groove install the snap ring Step 4 Seat the boot properly and secure it with two tie down straps Step 5 When the tower is installed onto the transmission housing one single gasket must be in place under the tower assembly for proper gear selection Failure to use a gasket or using more than one gasket under the tower may cause binding and damage to the unit Bezel Lock Nut Washer Washer Upper Neu Isolator plastic Shift Knob Lower Isolator plastic Castellated Nut Boot e Upper
28. ie straps from the boot and remove it 6 Remove the shift finger bolts and tap the finger off the rod 7 Pull the rod from the housing 8 To disassemble the selection lever subassembly remove components in this order A Snap ring and retainer plate B Bearing race ball stud and retainer plate C Two springs and the boot 1 2 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 6 External Component Disassembly Step by Step Procedures Figure 6 1 Step 1 Start tear down by setting transmission on a Step 2 Remove air line from the fitting by pushing sturdy bench the bushing inwards with a small screwdriver and then pull out the tubing Never use side cuts to remove an air line Step 3 Remove all remaining air lines tower and shift tower gasket Step 5 Remove the 2 bolts securing the interlock plate to the transmission Remove the interlock plate and the interlock Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 1 3 Section 6 External Component Disassembly Step by Step Procedures Figure 6 1 Step 7 pum the 3 poppet balls located under Step 8 Remove 2 bolts securing the range control the springs valve to the transmission Remove range control valve a
29. ing and Inspection PDrocecdures nennen nnn nennen nan n nnne sss nasa nnns nnn n a 23 Section 11 Front Bearing Retainer and Seal Assembhy nennen nennen nennen nnn nnns 24 Step by Step Reeg 24 Section 12 Main CG asebHeassembhy nnne ne nnnnnan nnn nnns sssnnaa ains n sisi assa asas asi sss a saa assess anna 25 wir emo Eel Og Ee 25 S tion 13 Range EE EE 28 e Bel 28 Section 14 Remote Shift Control Heassembly un rune ront ah tnt ERO ee Ee EE e 33 Ee Ee ee ER Ee Ee re EE e EE 34 Sep Dy otep EE 34 EE EE 35 NOS OBE O PN m 35 NOCE IENE ME 36 Kieler 36 SUR EE 36 Walking or Jumping OU Ol GEAT eege 36 AE LEE or SE MI KEE 37 Blo dE 37 el 37 COROSO EE 38 SAF EE 38 Installation and Removal of Bearings icccnusrtrccncnctuconccabuanencntsacnenn her ondmeaneudnevaua mensanht yuosaneeunnendua av dde Rd xo MESE LPS C KE 38 PEM VRS aD ERR EE T m 38 leie Reeg ale a 6 pene Em 38 SEENEN 39 PFU a OUI oe oe ace Rm 39 PTE E ER Primary Gear WOUD EE 40 NEE 41 Klee 42 Main Case and Clutch Housing EEN 44 AC ON RI EE 45 FORK AR OU EE 46 Riet 47 Main Case Opti Lube sn ee a a a EEEa NET Erainn eNi Eni En i 48 Ar Ene CM UN EE 49 me EE 50 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 3 Section 1 General Information Safety First Carefully read this service manual before beginning any work on your TREMEC transmissi
30. inner race on the rotating shaft The result is that surface metal of the shafts scrub or wear off The force causing the inner race to rotate disappears when the bearing fits properly Installation and Removal of Bear ings Improper installation or removal of bearings especially hammering the bearing on the shaft with off center blows can result in brinelling Since such damage is seldom visible it does not become known until after failure or complete disassembly The correct drivers preferably under an arbor press and pullers should be used Removing bearings is more difficult than installing them In most cases it is necessary to remove the bearing by pulling on the outer race which can damage the balls or races Therefore it is a good idea to replace bearings during an overhaul to prevent problems However if a bearing is not going to be replaced avoid removal during low mileage rebuilds Interchangeability All ball bearings whether manufactured here or abroad are interchangeable in regard to standardized dimensions tolerances and fits However for a given shaft size there are standard bearings for light medium and heavy duty service Numbers and symbols stamped on inner and outer races of bearings designate size and type Note that the numbering systems of different bearing manufacturers have not been standardized Consult interchangeable tables and use the proper bearings for replacement parts Clut
31. ion standards at the time of shipment SM_TR T 10_0915 39 Section 17 Component Drawings Main Shaft Primary Gear Group Figure 17 2 4th Gear Oth Gear 4th 5th Shift Collar Input Shaft Oft 10th Shift Collar Input Bearing lst Gear e m Snap Ring 6th Gear 2nd 3rd Shift Collar 7th 8th Shift Collar 3rd Gear 8th Gear 5th Gear 10th Gear Reverse Gear lst Reverse Shift Collar For a direct drive transmission the head gear and Exploded parts view is for an overdrive transmission the overdrive gear are in the opposite position EN E O TR T 10_0915 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM 40 Section 17 Component Drawings Countershaft Gears Figure 17 3 Note Exploded parts view is for an overdrive transmission For a direct drive transmission the head gear and the overdrive gear are in the opposite position Thrust Ring 4th Gear 9th Gear Key Bearing Cone ZZ lstGear Cup 2nd Gear 6th Gear 7th Gear N My Countershaft Q PTO Gear y 3rd Gear 8th Gear 5th Gear 10th Gear Thrust Ring Reverse Gear N Retainer Plate N e Thrust Ring Bolt Bearing Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipm
32. nd 3 interlock pins Step 9 Remove range control valve gasket Step 10 Remove 4 clutch housing bolts from Remove the backup light switch and pin hydraulic clutch housing Note Mechanical clutch housing only has 2 bolts in the upper position on the clutch housing Remove all but 4 bolts securing the clutch housing to the main case 1 4 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SEM TR T 10 0915 Section 7 Range Case Disassembly Step by Step Procedures Figure 7 1 stand on end on a workbench that contains a Step 1 Lift the transmission with a hoist and A hole for the input shaft Step 3 Remove the 4 range case piston housing bolts and the range case piston housing Step 5 Remove the piston and the O ring under the piston Step 4 Remove the nut securing the range piston to the range fork amm Step 6 Remove the 8 countershaft bearing retainer cap bolts 4 per retainer Remove the retainer caps and the air filter regular Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 1 5 Section 7 Range Case Disassembly Step by Step Procedures Figure 7 1 Step 7 Remove the 4 bolts securing the rear bearing retainer to the transmission Then remove the rear bearing
33. nt possible eye injury due to small parts such as snap rings or metal chips that may fly up unexpectedly during a tear down or rebuild To avoid injury be careful when picking up gears or other sharp components Consider wearing heavy cloth gloves or covering sharp objects with shop towels before picking them up To avoid injury let the transmission cool down prior to draining the fluid It is recommended to drain the transmission fluid prior to disassembly of the unit 4 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 1 General Information Driver Instructions Shifting the TREMEC 10 Speed Transmission TREMEC 10 Speed Shift Pattern 5 a Continue the above procedures through 5th gear position Reverse 2nd Hand 4th Hand 6 a Tocontinue upshifting 6th gear through af N 10th gear H b Preselect high BONIN IOT Low Range range on the range selector c Depress the 1st Hand 3rd Hand 5th Hand clutch pedal Progressive Shift Pattern d Move the gear shift lever from the 5th N jab gear position to neutral See Double RHN 7 9 Clutching Upshifting RLJ 2 7 WE e Then move the gear shift lever into 6th gear position N Cen 8N Cox a After attaining optimal speed in 6th gear b Depress the clutch pedal V 17 3 7 V5 c Move the gear shift lever to neutral see Double Clutchin
34. on Throughout this manual you will see symbols that warn of potential physical danger or product damage if the accompanying instructions are not followed Note the following symbols and their meanings Warning A This symbol indicates a potentially haz ardous situation If the instructions are not followed the result could be death or serious injury Mandatory Action A3 This symbol indicates that you must do an activity in order for the transmission to function properly For example you must use only one gasket underneath the shift tower If it is eliminated or more than one gasket is used binding can occur This would prevent proper shifting of the transmission and could damage the unit Prohibited Ors symbol indicates that you must NOT do something in order to avoid damaging the transmission For example you must not use sealant underneath the shift tower Using sealant underneath the tower will prevent proper interlock functioning and could damage the unit Be sure you understand all procedures and instructions in this manual before you begin working on your TREMEC transmission If you have any questions contact Tremec customer service at 1 800 401 9866 General Safety Precautions Use a hoist whenever lifting the transmission or shaft assemblies Using a hoist can help prevent muscle strain or other possible injuries Aways wear safety glasses when working on the transmission to help preve
35. ondition gradually release the clutch SO the c Move the gear shift lever to neutral See drive gear can rotate to align the gear clutching Double Clutching Upshifting teeth to complete the shift d Then move the gear shift lever to 2nd gear After attaining optimal speed in 1st gear Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 5 Section 1 General Information Driver Instructions Shifting the TREMEC 10 Speed Transmission Double Clutching Upshifting The normal double clutching technique is suggested When you want to shift depress the clutch and move the lever to neutral Engage the clutch and allow the engine RPM to drop so engine speed and driveline soeed match Depress the clutch and move the gear shift lever into gear Engage the clutch and accelerate as conditions permit Downshifting Downshifting is the reverse of upshifting As the engine approaches the shift point start the downshift approximately 50 100 RPM above the shift point depress the clutch and move the gear shift lever to neutral Engage the clutch and raise the engine RPM until the engine and driveline speeds are equal normally governed speed Depress the clutch then shift into the next lower gear Engage the clutch Skip Shifting Experienced drivers sometimes want to skip some of the gear positions This is accepta
36. ove them The mainshaft reverse gear and rear thrust plate should come out at the same time ge Step 16 Remove the 2 retaining bolts for the Opti Lube pump housing Remove the Opti Lube pump assembly Step 18 Remove the oil bypass valve Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 1 1 Section 7 Range Case Disassembly Step by Step Procedures Figure 7 1 ui m T p R j Step 19 Remove the right 3 countershaft retaining Step 20 Remove the output shaft from the case plate bolts Remove the retaining plate and shims eco Step 21 The output bearings and spacers A are a matched set If necessary to replace any of the components replace the whole set to ensure proper end play 1 8 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 8 Main Case Disassembly Step by Step Procedures Figure 8 1 Step 1 Remove the four remaining case bolts Use hoist to help separate the case from the clutch housing The use of pry bars in the milled slots will make the removal of the case much easier Ac a M V i Step 3 Remove the 1st and Reverse clutch collar Step 4 Spread the countershafts apart and fork Step 5 Remove the 1st and
37. poses Recommended Lubricants The lubricants listed below are recommended for use in TREMEC commercial vehicle mechanical transmissions and auxiliary transmissions Lubricant Specifications For TREMEC mechanical transmissions and auxiliaries used in commercial vehicles the following lubricants are recommended All Temperature CD 50 Synthetic engine oil meeting MIL L 2104 D or MIL L 46152B API SF or API CD Oil Cooler See OEM application requirements Oil Changes Many factors influence oil change periods Changes should be scheduled at three years or 250 000 miles with synthetic engine oil for normal over the highway operations Off highway use usually requires an oil change every 1 000 hours The oil level in the transmission should be G checked every 5 000 miles 8 045 km on highway or every 40 hours in off highway operation When it is necessary to add oil TREMEC does not recommend mixing oil types or oil brands The correct oil level in this transmission is established by the fill plug opening Refill First remove all dirt around the fill plug Then refill the transmission with the recommended lubricant The lubricant should be level with the oil fill plug located on the left side of the transmission case Overfilling CAUTION Do not overfill the A transmission This usually results in oil breakdown due to exces sive heat and aeration from the churning action of the gears Early breakdown
38. retainer shims and speedo gear Step 9 The output shaft and low range gear will remain in the range case Remove the range synchronizer and range fork assembly Remove gasket www GR i Step 11 Remove the high range synchronizer cup and high range clutch gear by removing the retaining bolt and washer Step 8 Remove the 16 range case bolts A Use a chain hoist to lift the range case from the unit Using pry bars in the milled slots will make the removal easier Step 10 Be aware that separating the synchronizer will suddenly release the springs 4 ayn 55 Step 12 Lift and remove the high range gear from the case notice timing marks on gear 1 6 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 7 Range Case Disassembly Step by Step Procedures Figure 7 1 Step 13 Remove the 2 bolts securing the shift bar support bracket to the transmission Lift and remove the shift bar support bracket d TE o d Step 15 Remove the 2 bolts securing the countershaft reverse gears and washers Remove both countershaft reverse gears and washers ge X Step 17 Remove the 4 bolts for the left countershaft bearing retaining plate Lift and remove the retaining plate and shims Step 14 Simultaneously lift both countershafts straight up to rem
39. rfect pulverizer The rolling motion tends to entrap and hold the abrasives As the balls and raceways wear the bearings become noisy The lapping action tends to increase rapidly as the fine steel from the balls and rollway adds to the lapping material Hard coarse material such as metal chips may enter the bearings during assembly from tools such as hammers drifts and power chisels It may also be created within the unit during service from raking teeth These chips produce small indentations in balls and races When these hard particles jam between the balls and races it may cause the inner race to turn on the shaft or the outer race to turn in the housing Fatigue All bearings are subject to fatigue and must be replaced eventually Your own operating experience will dictate mileage replacement of bearings showing only normal wear Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 3 Section 16 Troubleshooting Corrosion Water acid and corrosive materials formed by deterioration of lubricant will produce a reddish brown coating and small etched holes over outer and exposed surfaces of the race Corrosive oxides also act as lapping agents Shaft Fits Bearing fits on rotating shafts are usually specified as tight Excessive looseness even 001 under a load produces a creeping or slipping of the
40. s Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 12 Component Drawings Air Control Valve Figure 17 7 Tee Swivel Elbow Air Control Valve Elbows ES G aep gt Pins Bolt i Interlock Retainer Plate Reverse Light Switch ___ Poppet Insert Reverse Light U e Actuator Pin ne Poppet S pring Interlock B M Poppet Ball Pp di Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 45 Section 17 Component Drawings Fork and Rail Group Figure 17 8 Ath 5th Direct Drive S hift R ail Ath 5th Overdrive 2nd 3rd S hift R ail S hift Fork and Rail 1st Reverse Shift Fork and Rail a Overdrive x Shift Fork Fork Pad Mounting V s Bracket C ral Mounting Bracket Kit 46 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 17 Component Drawings Range Case Figure 17 9 Range Piston Housing Assembly Air Piston Fitting Housing O Ring O Ring de Bearing MD Cap Mounting Stud e bot Air Seal Fitting A p IM TT SEI 9 Z Nam plate GA Drive P In Nameplate Range Air Filter
41. sassembled inspect each part to ensure that it is not worn damaged or no longer meets factory specifications After the transmission is completely disassembled check the lubricant for foreign particles This is a source of trouble often overlooked during the disassembly Repair or Replace Worn Parts All parts and components should be carefully examined All parts that are damaged worn or no longer meet specifications should be replaced Parts that are worn to the extent that they do not have a long service life remaining should be replaced Replacing these parts now will avoid another teardown in the near future Making the recommended changes or modifications will bring the transmission up to date and increase the service life of the unit 1 0 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 3 General Disassembly Before You Start Read this section before starting the A3 detailed disassembly procedures Follow procedures closely Rebuild Facilities A suitable holding fixture or overhaul stand with a hole for the input shaft is desirable For easier working conditions table height should be 28 30 inches A light chain hoist should be used to handle the mainshaft and countershafts during removal and reassembly procedures Cleanliness Transmissions should be steam cleaned prior to disass
42. should be positioned to align with the countershafts Step 5 Place the 4th 5th shift collar on the mainshaft and install into fork Set mainshaft into position p S Step 2 Install countershaft O rings and countershaft bearing cups the pin and two snap rings Step 6 Locate the blind spline on rear of countershaft All gears will align with blind spline except PTO drive gear Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 25 Section 12 Main Case Reassembly Step by Step Procedures Figure 12 1 Wii Step 7 Align timing marks on head end gear with Step 8 Slide 3rd gear clutch teeth up and 4th timing marks on countershaft head end gear Leave gear direct models 5th gear overdrive models the countershafts tilted outward as shown clutching teeth down over mainshaft Step 9 Tilt countershafts inward to engage 3rd and Ath Step 10 Install 2nd 3rd clutch collar and fork speed gears Make sure there is equal spacing around the mainshaft and internal teeth on both gears Step 11 Clutching teeth facing down slide Step 12 Install 1st speed gear by simultaneously pushing 2nd speed gear into place between the mating 1st speed gear away from you with your thumbs and pulling countershaft gears Make sure to maintain equal back on the countershaft with your fingers
43. until 1st gear spacing around the mainshaft drops into place as shown Clutching teeth facing up 26 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 12 Main Case Reassembly Step by Step Procedures Figure 12 1 Step 13 Note the equal spacing around the Step 14 Install the 1st reverse shift fork and collar mainshaft Double check timing by shifting each sliding collar into its mating or respective gear Step 16 Install new gasket Step 17 With the aid of a hoist lower the main case into position Install the case bolts and torque them to 78 98 lb ft Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 27 Section 13 Range Case Reassembly Step by Step Procedures Figure 13 1 Step 1 Install the countershaft m thin ones Step 2 Place the oil bypass valve into the opening rm first and retainer plate Install the 3 retainer in the main case oil passage Install the bearing plate inh and torque the bolts to 34 41 Ib ft retaining plate and shims Torque the 4 retainer plate bolts to 34 41 Ib ft t Step 3 Check the main box countershaft end Step 4 Install the Opti Lube M pump on the bearing play Verify that end play is between 001 003 retaining plate S
44. wed Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM TR T 10 0915 Section 1 General Information Specifications General Weight Output Sha Lube Capacity Gear Ratios Model No Overall Ratio TR T 10D Direct Drive PS O N Hg 14 95 n2 D C1 wi ch s wesch NJ 2 3 OD EM co CO IN BE CH wo t5 NO CO Oo wl NJ 2 cl gt CO Ol c wl CH Ol e Step TR TO 10S Overdrive NO C1 D co NO A O O Co n Co O Ge O O AN O co NO C co e O O NJ C1 s O s Co e co 8 Co e Co s O s Co s co s Co Yo Step TR T 10V Vocational Direct Drive Yo Step 19 02 21 27 19 02 14 02 10 13 7 28 5 20 3 66 2 70 1 95 1 40 1 00 s Oo g Co 8 cO NO s O s Co s cO H TR TO 10V Vocational Overdrive Step Co Co Co ak Wu co C1 NO CO N m oO M k LO NO M CO co O O O N NO s Oo s Co e NO s O gt s Co CO s B s Power Take Off Applications PTO Gear Data 66 7 Engine Speed 85 Engine Speed 45 Tooth 6 Pitch 45 Tooth 6 Pitch Positions 6 Bolt Right 8 Bolt Left 6 Bolt Right 8 Bolt Left End Fitting Reference End Yoke Part Number 1760 amp 1760HD HPL 25 25WY
45. y Step Procedures Figure 13 1 Step 13 Install the output shaft assembly into the range case The tapered bearing and spacer must be pressed onto the shaft Step 15 Install rear auxiliary countershaft bearings into range case The rear bearing retainer is installed next To shim the retainer measure the depth from the edge of the case to the bearing cup Distance A Step 17 Install speedo gear shims and rear bearing retainer Be sure to use sealant on the rear bearing retainer Secure with bolts tightened to 34 41 Ib ft Step 14 With the use of a hoist lower the range case into place Low range gear should be centered between the countershafts Torque the case bolts to 78 98 Ib ft NON uh g H 3 gt z Step 16 Measure the height of the lip on the rear bearing retainer Distance B Subtract the two figures and shim accordingly Tolerance is 001 004 Select shims accordingly so the tolerance is closest to 001 as possible Step 18 Install the bearing retainers with sealant Align the bearing retainers with the oil holes in the case to ensure proper lubrication Torque bolts to 34 41 lb ft 30 Copyright 2015 TREMEC All Rights Reserved Subject to design and or appearance modifications that are production standards at the time of shipment SM_TR T 10_0915 Section 13 Range Case Reassembly Step by Step Procedures Figure 13 1 Step 19 Assemble two spacers under the air filter Step
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