servicio g3

8/13/2019 Servicio g3

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Warnings & Cautions

Warnings & Cautions

Follow the specified procedures in the indicated order to avoid personal injury

Note: Additional relevant information not covered in the service procedure.

Before starting a vehicle:

Sit in the driver's seat

Place shift lever in neutral

Set the parking brake

Before working on a vehicle or leaving the cab with engine running:


Set the parking brake Block the wheels

When parking the vehicle or leaving the cab:


Set the parking brake

Follow the specified procedures in the indicated order to avoid equipment malfunction or damage.

Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.

To avoid damage to the transmission during towing:


Lift the drive wheels off of the ground or disconnect the driveline

Do not operate the vehicle if alternator lamp is lit or if gauges indicate low voltage.

WARNING

CAUTION


3/94

Table of Contents

General Information

Transmission Overview ............................................... 1How to use this Manual ............................................... 5Serial Tag Information and Model Nomenclature ........ 6

Service Procedure

Lubricant Filter Removal (AW3 Models Only) ............. 8Lubricant Filter Installation (AW3 Models Only) ........ 10Gear Select Sensor Removal ..................................... 12Gear Select Sensor Installation ................................. 14Rail Select Sensor Removal ...................................... 16Rail Select Sensor Installation ................................... 18Input Shaft Speed Sensor Removal ...........................20Input Shaft Speed Sensor Installation ....................... 22Main Shaft Speed Sensor Removal ........................... 25

Main Shaft Speed Sensor Installation ....................... 27Output Shaft Speed Sensor Removal ........................ 29Output Shaft Speed Sensor Installation ..................... 31Splitter Valve Removal .............................................. 33Splitter Valve Installation ........................................... 35Range Valve Removal ............................................... 37Range Valve Installation ............................................ 39Air Filter/Regulator Removal ..................................... 41Air Filter/Regulator Installation .................................. 43Inertia Brake Removal ............................................... 45Inertia Brake Installation ...........................................48Electric Shifter Removal ............................................ 51Electric Shifter Installation ........................................53Transmission Controller Removal .............................56Transmission Controller Installation ......................... 59Transmission Harness Removal ................................ 62Transmission Harness Installation ............................ 64Shift Control Removal ............................................... 66Shift Control Installation ........................................... 68Cobra Lever Removal ................................................ 70Cobra Lever Installation ............................................ 72

AppendixOperation .................................................................. 74Lubrication Specifications ......................................... 75

Inspection Procedures .............................................. 81Basic Troubleshooting .............................................. 82Air System Operation and Troubleshooting ............... 83Tool Specifications .................................................... 84Torque Specifications ................................................ 85Torque Overview ....................................................... 88


4/94

1

General Information

Transmission Overview

Heavy Duty 13-Speed DM3 & 18-Speed AS3

Air Filter Requlator

Range Valve Solenoid

Rail Select Sensor

Gear Select Sensor

Electric Shifter

Input ShaftSpeed Sensor

Main ShaftSpeed Sensor

Splitter Valve Solenoid

Output Shaft Speed Sensor

Transmission ECU

Inertia Brake(13-Speed DM3 Only)

Transmission Harness


5/94

2

General Information

Heavy Duty 10-Speed AS3 & DM3

Air Filter Regulator


Rail Select Sensor

Gear Select Sensor

Electric Shifter

Input ShaftSpeed Sensor

Output ShaftSpeed Sensor

Main ShaftSpeed Sensor

Transmission ECU

Inertia Brake(10-Speed DM3 Only)



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3

General Information

Medium Duty 6 & 5-Speed DM3


Rail Select Sensor

Gear Select Sensor

Electric Shifter

Transmission ECU

Inertia Brake

Input ShaftSpeed Sensor Location



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4

General Information

Medium Duty 6-Speed AW3

Electric Shifter

Gear Select Sensor

Rail Select Sensor


Transmission ECU

Inertia Brake

Input ShaftSpeed Sensor Location

Wetclutch SolenoidConnector

Oil Pan and Filters



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5

General Information

How to use this Manual

This publication is divided into three sections General Information, Service Repair Procedures and the Appendix.

General Information

This section contains the basic information like Transmission Overview, How to Use This Manual, and Serial Tag and ModelNomenclature.

Service Repair ProceduresA parts assembly view is included at the beginning of each procedure for disassembly, assembly, removal and installation. Belowthe parts assembly views is a numerical listing for each part with the component name.

AppendixThis section contains information like: Operation, Lubrication Specifications, Inspection (in base box manuals), Powerflow (inbas box manuals), Air System Operation and Troubleshooting (in base box manuals), Basic Troubleshooting (in base box manu-als), Tool Specifications, Torque Specifications, and the Torque Overview.

The service procedures in this manual are for transmission automation components only. To find the information you need, sim-ply locate the procedure in the Table of Contents, turn to the page specified, and follow the procedure. If you are unsure of a com-ponents name, you can reference the Transmission Overview pages.

To service the mechanical portion of the transmission system, refer to the specific transmission service manual.


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6

General Information

Serial Tag Information and Model Nomenclature

Transmission model designation and other transmission identification information are stamped on the serial tag. To identify thetransmission model and serial number, locate the tag on the transmission and then locate the numbers as shown. Figure 1-1below shows the tag location for these transmissions.

When calling for service assistance or parts, have the model and serial numbers handy.

Do not remove or destroy the transmission identification tag!

Fig 1-1

Model

Serial

EatonTransmissions

R

Made In

RTLO-16913L-DM3

Eaton CorporationTransmission Div.Kalamazoo, MI. 49003

FullerR


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7

General Information

Model NumberThe model number gives basic information about the transmission and is explained below. Use this number when calling for ser-vice assistance or replacement parts.

Transmission Tag

Serial NumberThe serial number is the sequential identification number of the transmission. Before calling for service assistance, write thenumber down as it may be needed.

Bill of material or Customer numberThis number may be located below the model and serial numbers. It is a reference number used by Eaton.

R

Roadranger

Twin Countershaft

Overdrive

T O -

Torque x 100

Design Level

Generation 3 Electronics

Gear Ratio

Forward Speeds

1 X 1 09 X - D M 310-Speed

Automaticw/DM Autoclutch

RoadrangerTwin Countershaft

OverdriveTorque x 100Design Level

R T O - 1 X 9 1 0 X - A S 3

Generation 3 ElectronicsAutoShiftGear RatioForward Speeds

F

Fuller

Overdrive

- 3

Torque x 100

Design Level


Gear Ratio

Forward Speeds

X 4 0 6 X - D M


X

RoadrangerTwin Countershaft

Low-InertiaOverdrive

R T L O M - 1 X 9 1 3 X - D M 3

Gen 3 ElectronicsAutomatic w/DM AutoclutchGear RatioForward SpeedsDesign LevelTorque x 100

1750 lb.ft. Torque inTop Two Gears Only

3

Fuller

Overdrive

Torque x 100

Design Level

AutoShift with WetClutch

Gear Ratio

Forward Speeds

F X X 0 64- X - A W


10-Speed

6-Speed

6-Speed

13-Speed

F

FullerOverdrive

- 3

Torque x 100

Design Level


Gear Ratio

Forward Speeds

X 4 0 5 X - D M


X5-Speed

Roadranger

Twin CountershaftLow-Inertia

Overdrive

R T L O - 1 X 9 1 8 X - A S 3

Gen 3 ElectronicsAutoShiftGear RatioForward SpeedsDesign LevelTorque x 100

18-Speed


11/94

8

Service Procedure

Lubricant Filter Removal (AW3 Models Only)

Special Instructions

None

Special Tools

Basic Hand Tools

1. High Pressure Oil Filter (Large opening)2. Low Pressure Oil Filter (Small opening)3. Gasket4. Oil Pan5. Short Capscrew6. Long Capscrew7. Drain Plug

3

1

2

4

5

6

7


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9

Service Procedure

Fluid may be hot.

1. Remove the drain plug and drain the fluid from the Wet-

Clutch portion of the transmission.

2. Using a 15mm socket, remove the oil pan mountingbolts. Record location of the long and short bolts.

3. Remove the WetClutch oil pan and gasket.

4. Using a 1/2 drive at the filter base, remove the two (2)WetClutch filters. Make sure filter seals are removed.

Note: The filters will contain fluid when they are removed.

WARNING


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Service Procedure

Lubricant Filter Installation (AW3 Models Only)


None

Special Tools

Basic Hand Tools

1. High Pressure Oil Filter (Large opening)2. Low Pressure Oil Filter (Small opening)3. Gasket4. Oil Pan5. Short Capscrew6. Long Capscrew7. Drain Plug

3

1

2

4

5

6

7


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Service Procedure

1. Lubricate each filter seal ring with synthetic Dexron IIIprior to installation.

Note: The High and Low pressure filters are non-interchange-able.

Note: Clean filter seal mating surfaces on the transmission.

Note: Clean and remove all old gasket material from the mat-ing surfaces of the clutch housing and the oil pan.

2. Install the High-pressure filter with a 1/2 drive andtighten to 25-30 lbs. ft. (34-41 Nm).

3. Install the Low-pressure filter by hand and turn until theseal touches. Then, tighten with a 1/2 drive 3/4 to 1 fullturn.

4. Install a new gasket and the WetClutch oil pan.

Make sure to put the long and short bolts back in their

proper location to avoid damaging the transmission. Theshort bolts are used in the back of the oil pan.

5. Using a 15mm socket, install the mounting bolts andtighten to 30-35 lbs. ft. (41-47 Nm) using a cross pat-tern.

6. Install the oil pan drain plug and tighten to 34-48 lbs. ft.(46-64 Nm).

Note: Fill the WetClutch portion with the proper fluid (seepage 75)

CAUTION


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Service Procedure

Gear Select Sensor Removal


None

Special Tools

Basic Hand Tools

1. Capscrew2. Sensor3. Gasket

1

2

3


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13

Service Procedure

1. Disconnect the Transmission Harness from the GearSelect Sensor.

Carefully allow the sensor to rotate (not snap) to a relaxedposition, or the sensor can snap when the hex key mountingscrews are removed.

2. Using a 5/32 hex key wrench, remove the two (2) sensorhex key mounting screws.

3. Remove the Gear Select Sensor and gasket from thehousing.

CAUTION


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Service Procedure

Gear Select Sensor Installation


Torques given below are in lbs. in.

Special Tools

Basic Hand Tools


1

2

3


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15

Service Procedure

1. Align the sensors tabs with the slots in the ElectricShifter rail. Then, insert the Gear Select Sensor, with gas-ket, into its mounting location.

Note: Install the sensor so the connector opening faces the

front of the transmission.

Carefully hold the sensor in position while installing the hexkey mounting screws, or the sensor can snap.

2. Using a 5/32" hex key wrench, install the hex key mount-ing screws and tighten to 21-27 lbs. in. (2.3-3.0 Nm).

3. Reconnect the Transmission Harness to the Gear SelectSensor.

CAUTION


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Service Procedure

Rail Select Sensor Removal


None

Special Tools

Basic Hand Tools


1

2

3


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17

Service Procedure

1. Disconnect the Transmission Harness from the RailSelect Sensor.

Carefully allow the sensor to rotate to a relaxed position, orthe sensor can snap when the hex key mounting screws areremoved.

2. Using a 5/32 hex key wrench, remove the two (2) sensorhex key mounting screws.

3. Remove the Rail Select Sensor and gasket from thehousing.

CAUTION


21/94


22/94

19

Service Procedure

1. Align the sensors tabs with the slot in the Electric Shifterrail. Then, insert the Rail Select Sensor, with gasket, intoits mounting location.

Note: Install the sensor, so the connector opening faces the

right side of the transmission. (As viewed from the rearof the transmission)

Carefully hold the sensor in position while installing the hexkey mounting screws, or the sensor can snap.

2. Using a 5/32" hex key wrench, install the two (2) hex keymounting screws and tighten to 21-27 lbs. in. (2.3-3.0Nm).

3. Reconnect the Transmission Harness to the Rail SelectSensor.

CAUTION


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20

Service Procedure

Input Shaft Speed Sensor Removal


Input Shaft Speed Sensor location varies as follows:

Medium Duty - Top of Inertia Brake

Heavy Duty - Right front of Shift Bar Housing

Special Tools

Basic Hand Tools

1. Capscrew2. Sensor

3. O-ring

1

2

3


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21

Service Procedure

Heavy Duty Procedure1. Disconnect the Transmission Harness from the Input

Shaft Speed Sensor.

2. Using a 3/8" socket, remove the sensor retaining bolt.

3. Remove the Input Shaft Speed Sensor, with o-ring, fromthe transmission housing.

Medium Duty Procedure1. Disconnect the Transmission Harness from the Input

Shaft Speed Sensor.

Note: Drain the lubricant before removing the sensor.

2. Using a 3/8" wrench, remove the sensor retaining bolt.

3. Remove the Input Shaft Speed Sensor, with o-ring, fromthe transmission housing.


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Service Procedure

Input Shaft Speed Sensor Installation


Input Shaft Speed Sensor location varies as follows:

Medium Duty - Top of Inertia Brake

Heavy Duty - Right front of Shift Bar Housing.

Special Tools

Basic Hand Tools

1. Capscrew2. Sensor

3. O-ring

1

2

3


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Service Procedure

Heavy Duty Procedure

Clean the mounting surface on the housing and remove any

burrs or sharp edges.

Lubricate the o-ring with Eaton Fuller silicone #71214 orequivalent.

1. Using a smooth, twisting motion, fully insert the InputShaft Speed Sensor in the transmission housing opening.

2. Using a 3/8" socket, install the retaining bolt and tightento 8-10 lbs. ft. (11-13 Nm).

3. Reconnect the Transmission Harness to the Input ShaftSpeed Sensor.

Medium Duty Procedure




1. Using a smooth, twisting motion, fully insert the InputShaft Speed Sensor in the Inertia Brake opening.

2. Using a 3/8" wrench, install the sensor retaining bolt andtighten to 8-10 lbs. ft. (11-13 Nm).

IMPORTANT IMPORTANT


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Service Procedure

3. Reconnect the Transmission Harness to the Input ShaftSpeed Sensor.

Note: Fill the transmission with lubricant (see page 75).


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Service Procedure

Main Shaft Speed Sensor Removal


None

Special Tools

Basic Hand Tools

1. Capscrew2. Sensor3. O-ring

1

2

3


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26

Service Procedure

1. Disconnect the Transmission Harness from the MainShaft Speed Sensor.

2. Using a 3/8 socket, remove the sensor retaining bolt.

3. Remove the Main Shaft Speed Sensor, with o-ring, from

the transmission housing.


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Service Procedure

Main Shaft Speed Sensor Installation


None

Special Tools

Basic Hand Tools


1

2

3


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28

Service Procedure

Clean the mounting surface on the housing and remove anyburrs or sharp edges.


1. Using a smooth, twisting motion, fully insert the MainShaft Speed Sensor in the transmission housing opening.

2. Using a 3/8 socket, install the retaining bolt and tightento 8-10 lbs. ft. (11-13 N m).

3. Reconnect the Transmission Harness to the Main ShaftSpeed Sensor.

IMPORTANT


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Service Procedure

Output Shaft Speed Sensor Removal


The Output Shaft Speed Sensor location may vary depending on OEM design specifications. The sensor will be located at the 10oclock position for Heavy Duty and the 12 oclock for Medium Duty on the Output Shaft Housing.

Special Tools

Basic Hand Tools


1

2

3


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Service Procedure

Heavy Duty1. Disconnect the Transmission Harness from the Output

Shaft Speed Sensor.

2. Using a 13mm socket, remove the sensor retaining bolt.

3. Remove the Output Shaft Speed Sensor, with o-ring,from the transmission housing.

Medium Duty1. Disconnect the Transmission Harness from the Output

Shaft Speed Sensor.

2. Using a 3/8 socket, remove the sensor retaining bolt.

3. Remove the Output Shaft Speed Sensor, with o-ring,from the transmission housing.


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Service Procedure

Output Shaft Speed Sensor Installation


None.

Special Tools

Basic Hand Tools


1

2

3


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32

Service Procedure





1. Using a smooth, twisting motion, fully insert the OutputShaft Speed Sensor in the transmission housing opening.

2. Using a 13mm socket, install the retaining bolt andtighten to 15-19 lbs. ft. (20-25 Nm).

3. Reconnect the Transmission Harness to the Output ShaftSpeed Sensor.





1. Using a smooth, twisting motion, fully insert the OutputShaft Speed Sensor in the transmission housing opening.

2. Using a 3/8 socket, install the retaining bolt and tightento 8-10 lbs. ft. (11-13 Nm).

3. Reconnect the Transmission Harness to the Output ShaftSpeed Sensor.

IMPORTANT IMPORTANT


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Service Procedure

Splitter Valve Removal


The Splitter Valve may be difficult to remove from the housing because of the o-rings.

Special Tools

Basic Hand Tools

1. Capscrew2. Valve3. O-rings

1

2

3


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Service Procedure

1. Relieve system air pressure by draining the air tanks onthe vehicle. When air pressure is relieved, disconnect theTransmission Harness from the Splitter Valve assembly.

Note: The harness should be removed from the Splitter Valve

tie-down, prior to removing the capscrews.

2. Using a 5/16 wrench, remove the four (4) mounting cap-screws from the Splitter valve.

Do not use a hammer to loosen the Splitter Valve in thehousing or it could be damaged.

3. Lift and remove the Splitter Valve from the housing.

CAUTION


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Service Procedure

Splitter Valve Installation


Torques give below are in lbs. in.

Special Tools

Basic Hand Tools


1

2

3


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36

Service Procedure

Lubricate o-rings with Eaton Fuller silicone #71214 orequivalent.

The valve is keyed to fit its mounting location. Take care toalign the key in the valve with the notch in the housing.

1. Install and push the Splitter Valve down into the housing.

2. Using a 5/16 wrench, install the four (4) mounting cap-screws and tighten to 21-27 lbs. in.(2.3-3.0 Nm) using across pattern.

3. Reconnect the Transmission Harness to the Splitter Valveand close all air tank drains.

Note: Install the Splitter harness back into the tie-down on theSplitter Valve.

IMPORTANT


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37

Service Procedure

Range Valve Removal


The Range Valve may be difficult to remove from the transmission housing because of the o-rings.

Special Tools

Basic Hand Tools


1

2

3


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38

Service Procedure

1. Relieve system air pressure by draining air tanks on thevehicle. When air pressure has been relieved, disconnectthe Transmission Harness from the Range Valve.

Note: The harness should be removed from the Range Valve

tie-down prior to removing the capscrews.

2. Using a 5/16 socket, remove the four (4) mounting cap-screws from the Range Valve.

Do not use a hammer to loosen the Range Valve in thehousing or it could be damaged.

3. Lift and remove the Range Valve from the housing.

CAUTION


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Service Procedure

Range Valve Installation



Special Tools

Basic Hand Tools


1

2

3


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Service Procedure

Lubricate o-rings with Eaton Fuller silicone #71214 orequivalent.

The valve is keyed to fit its mounting location. Take care toalign the key in the valve with the notch in the housing.

1. Install and push the Range Valve down into the housing.

2. Using a 5/16 socket, install the (4) Range Valve mount-ing capscrews and tighten to 21-27 lbs. in. (2.3-3.0 N m)using a cross pattern.

3. Reconnect the Transmission Harness to the Range Valveand close all air tanks drains.

Note: Install the Range harness back into the tie-down on theRange Valve.

IMPORTANT


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41

Service Procedure

Air Filter/Regulator Removal


The Air Filter/Regulator has two (2) o-rings located between the Air Filter/Regulator and the Range Cylinder Cover.

Special Tools

Basic Hand Tools

1. Air Filter Regulator2. Capscrew

2

1


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Service Procedure

1. Relieve system air pressure by draining all air tanks onthe vehicle. Then, remove the vehicle air supply line fromthe Air Filter Regulator.

2. Using a 7/16 socket, remove the two (2) mounting cap-screws.

3. Remove the Air Filter/Regulator assembly.

Note: Be careful not to let the o-rings drop out of the RangeCylinder Cover when removing the Air Filter Regulator.


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Service Procedure

Air Filter/Regulator Installation


The Air Filter/Regulator has (2) o-rings located between the Air Filter/Regulator and the Range Cylinder Cover.

Special Tools

Basic Hand Tools

1. Air Filter Regulator2. Capscrew

2

1


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Service Procedure

Lubricate o-rings with Eaton Fuller silicone #71214 orEquivalent.

1. If removed, press the two o-rings into the recesses in theRange Cylinder Cover.

Note: Apply Eaton Fuller sealant #71205 or equivalent to thetwo (2) mounting capscrews.

2. Using a 7/16 socket, install the two (2) mounting cap-screws and tighten to 8-12 lbs. ft. (11-16 N m).

Note: Hold the Air Filter Regulator flush with the Range Cylin-der Cover until its in place to prevent the o-rings fromdropping out.

3. Reinstall the vehicle air supply line to the Air Filter Regu-lator and close all air tank drains.IMPORTANT


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Service Procedure

Inertia Brake Removal


None

Special Tools

Basic Hand Tools

Heavy Duty Medium Duty

1. Capscrew2. Inertia Brake3. Gasket

1. Capscrew2. Inertia Brake3. Gasket4. Spacer (Used on all Medium Duty ratios except the N)5. Gasket (Used on all Medium Duty ratios except the N)

1

2

3 5

4

3

2

1


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Service Procedure

Heavy Duty Procedure1. Drain the lubricant from the transmission and disconnect

the Transmission Harness from the Inertia Brake Coil.

2. Using a 7/8 wrench, disconnect the Inertia Brake lubri-cant supply line from the transmission.

The Inertia Brake is heavy. Be prepared to handle theweight of the Inertia Brake when the mounting bolts areremoved.

3. Using a 9/16 socket, remove the six (6) mounting boltsfrom the Inertia Brake.

4. Remove the Inertia Brake and gasket from the transmis-sion.

Medium Duty Procedure1. Drain the lubrication from the transmission and discon-

nect the Transmission Harness from the Input Shaft

Speed Sensor and the Inertia Brake Coil.

2. Using a 3/8 wrench, remove the Input Shaft Speed Sen-sor.

WARNING


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Service Procedure

3. Using a 7/8 wrench, remove the lubricant supply linefrom the transmission.

The Inertia Brake is heavy. Be prepared to handle theweight of the Inertia Brake when the mounting bolts areremoved.

4. Using a 9/16 wrench, remove the (6) mounting boltsfrom the Inertia Brake.

5. Remove the Inertia Brake, gaskets, and spacer (depend-ing on model) from the transmission.

Note: The Inertia Brake will contain some lubricant.

Note: The spacer and extra gasket are used on all transmis-

sion ratios except the N.

CAUTION


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Service Procedure

Inertia Brake Installation


None

Special Tools

Basic Hand Tools


1. Capscrew2. Inertia Brake3. Gasket

1. Capscrew2. Inertia Brake3. Gasket4. Spacer (Used on all Medium Duty ratios except the N)5. Gasket (Used on all Medium Duty ratios except the N)

1

2

3 5

4

3

2

1


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Service Procedure


The Inertia Brake is heavy. Be prepared to handle the

weight of the Inertia Brake until the mounting bolts areinstalled.

1. Clean and remove all old gasket material. Then, install theInertia Brake and new gasket, being careful to align theInertia Brake gear with the drive gear.

2. Using a 9/16 socket, install the six (6) mounting bolts.Tighten mounting bolts to 35-45 lbs. ft. (47-60 N m)using a cross pattern.

3. Using a 7/8 wrench, reconnect the Inertia Brake lubri-cant supply line to the transmission and tighten to 20-22lbs. ft. (27-29 N m).

4. Reconnect the Transmission Harness to the Inertia BrakeCoil.


WARNING


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Service Procedure


The Inertia Brake is heavy. Be prepared to handle the

weight of the Inertia Brake until the mounting bolts areinstalled.

1. Install the Inertia Brake, gaskets, and spacer (dependingon model) being careful to align the Inertia Brake gearwith the drive gear.

Note: The spacer and extra gasket are used on all transmis-sion ratios except the N.

2. Using a 9/16 socket, install the (6) mounting bolts.Tighten mounting bolts to 35-45 lbs. ft. (47-60 N m)using a cross pattern.

3. Using a 7/8 wrench, reconnect the Inertia Brake lubri-cant supply line to the transmission and tighten to 20-22lbs. ft. (27-29 N m).

4. Using a 3/8 wrench, install the Input Shaft Speed Sensorand tighten to 8-12 lbs. ft. (11-16 N m).

5. Reconnect the Transmission Harness to the Input ShaftSpeed Sensor and the Inertia Brake Coil.


WARNING


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Service Procedure

Electric Shifter Removal


None

Special Tools

Basic Hand Tools

1. Capscrew2. Electric Shifter3. Gasket

1

2

3


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Service Procedure

1. Remove nylon cable ties from the motor wires. Discon-nect the Transmission Harness from the Rail Select Sen-sor and the Gear Select Sensor.

2. Disconnect the Rail Select and Gear Select Motors fromthe Transmission ECU.

3. Using a 9/16 socket, remove the four (4) mounting cap-screws.

Possible Pinch Point - Make sure battery is disconnectedbefore removal of Electric Shifter.

4. Remove the Electric Shifter and gasket.

WARNING


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Service Procedure

Electric Shifter Installation


None

Special Tools

Basic Hand Tools

1. Capscrew2. Electric Shifter3. Gasket

1

2

3


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Service Procedure

1. Check to ensure the shift blocks are in the neutral posi-tion, then move the shift finger to the center (neutral)location.

Note: If the shift finger is not properly aligned, the Electric

Shifter will not fit properly at its mounting location.

2. Clean and remove old gasket material from the Shift BarHousing. Then, install the new gasket on the Shift BarHousing.

Note: Apply Eaton sealant #71205 or equivalent to the mount-ing capscrews before installing.

3. The Dowel pin on the Electric Shifter must be alignedwith the hole in the Shift Bar Housing (used on 10 and 13& 18-Speed models only).

4. Position the Electric Shifter on the Shift Bar Housing.Then using a 9/16 socket, install the mounting cap-screws and tighten in a cross pattern as follows:

5, and 6-Speed (Aluminum Housing)- Tighten to 20-

25 lbs. ft. (27-33 N m).

10, 13, and 18-Speed (Cast Iron Housing) Tighten to34-45 lbs. ft. (45-60 N m).

5. Reconnect the Rail Select Sensor and Gear Select Sensor.

6. Reconnect the Transmission Harness to the Rail Selectand Gear Select motors. Using nylon ties, secure themotor wires to the transmission in their previous posi-tion.


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Service Procedure

The Electric Shifter must be calibrated before the vehicle isplaced into operation.

7. To operate properly, the system must be calibrated as fol-lows:

Turn the ignition switch on and allow the transmis-sion to power up.

Turn the ignition switch to off and wait two minutes.

IMPORTANT


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Service Procedure

Transmission Controller Removal


None

Special Tools

Basic Hand Tools


1. Nut2. Bracket3. Transmission ECU4. 38-Way Connectors5. Capscrew (Located inside 38-Way connectors)

1. Capscrew2. Transmission ECU3. 38-Way Connectors4. Capscrew (Located inside 38-Way connectors)

12 3

4

12

3


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Service Procedure


The battery negative must be disconnected prior to unhook-ing the Transmission ECU 38-Way connectors.

Do not allow contamination into the Transmission ECU orconnectors.

1. Disconnect the following connectors:

Using a 5/32 allen wrench, unscrew and disconnectthe Transmission Harness 38-way connector andVehicle Interface 38-way connector.

2. Using a 7/16 socket, remove the three (3) mountingnuts.

3. Remove the Transmission Controller retaining bracket.

4. Remove the Transmission Controller assembly from thelocating studs.

CAUTION


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58

Service Procedure






2. Using a 7/16 socket, remove the three (3) mountingbolts.

3. Remove the Transmission Controller assembly from thelocating studs.

CAUTION


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Service Procedure

Transmission Controller Installation



Special Tools

Basic Hand Tools


1. Nut2. Bracket3. Transmission ECU4. 38-Way Connectors

1. Capscrew2. Transmission ECU3. 38-Way Connectors

12 3

4

12

3


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Service Procedure


Battery negative must remain disconnected until the Trans-mission ECU 38-Way connectors are installed.


1. Position the Transmission Controller on the locatingstuds.

2. Place the Transmission Controller retaining bracket overthe Transmission ECU.

3. Using a 7/16 socket, install the three (3) TransmissionController mounting nuts and tighten to 7 - 9 lbs. ft. (9.5 -12.2 Nm).

Do not exceed the torque on the Transmission Harness orVehicle Harness connector or bolt failure will occur.

4. Reconnect the following connectors:

Using a 5/32 wrench, reconnect the TransmissionHarness 38-way connector and tighten to 25 +/- 3lbs. in. (2.82 +/- .33 Nm).

Using a 5/32 wrench, reconnect the Vehicle Inter-face 38-way connector and tighten to 25 +/- 3 lbs. in.(2.82 +/- .33 Nm).

Reconnect the negative battery cable.

CAUTION

CAUTION


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Service Procedure

The Electric Shifter must be calibrated before the vehicle isplaced in operation.



Turn the ignition off and wait two minutes.


Battery negative must remain disconnected until the Trans-

mission ECU 38-Way connectors are installed.


1. Position the Transmission Controller on the locatingstuds.

2. Using a 7/16 socket, install the three (3) TransmissionController mounting bolts and tighten to 7 - 9 lbs. ft. (9.5- 12.2 Nm).

Do not exceed the torque on the Transmission Harness or

Vehicle Harness connector or bolt failure will occur.

3. Reconnect the following connectors:

Using a 5/32 wrench, reconnect the TransmissionHarness 38-way connector and tighten to 25 +/- 3lbs. in. (2.82 +/- .33 Nm).

Using a 5/32 wrench, reconnect the Vehicle Inter-face 38-way connector and tighten to 25 +/- 3 lbs. in.(2.82 +/- .33 Nm).

Reconnect the negative battery cable.

The Electric Shifter must be calibrated before the vehicle isplaced in operation.



Turn the ignition off and wait two minutes.

Note: UltraShift AW3- Perform clutch calibration: (seepage 75).

IMPORTANT

CAUTION

CAUTION

IMPORTANT


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Service Procedure

Transmission Harness Removal


None

Special Tools

Basic Hand Tools


1. Transmission ECU 38-way connector2. Gear Sensor connector3. Rail Sensor connector4. 4-way Transmission Diagnostic connector

5. Input Shaft Speed Sensor connector6. Inertia Brake connector (DM3 models)7. Range Solenoid connector8. Output Shaft Speed Sensor connector9. Splitter Solenoid connector (13,18-speeds only)10. Mainshaft Speed Sensor connector11. Electric Shifter connector

1. Transmission ECU 38-way connector2. Gear Sensor connector3. Rail Sensor connector4. (Future position of 4-way Transmission Diagnostic connec-

tor5. Input Shaft Speed Sensor connector6. Inertia Brake connector7. WetClutch Solenoid connector (AW3 only)8. Output Shaft Speed Sensor connector9. Electric Shifter connector

1

2

3

45

6

7

8

9

10

11

1

2 3

5

4

6

7

8

9


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Service Procedure






2. Disconnect the following harness connectors:

Inertia Brake Coil (if equipped)

Input Shaft Speed Sensor

Main Shaft Speed Sensor

Gear Select Sensor and Rail Select Sensor


Range and Splitter Valve Solenoids

4-Way Transmission Diagnostic connector

Electric Shifter [see page 1]




1. Using a 5/32 allen wrench, disconnect the TransmissionHarness 38-way connector.

2. Disconnect the following harness connectors:



Gear Select Sensor and Rail Select Sensor

WetClutch solenoid (AW3 only)

Output Shaft Speed sensor (location may vary)

4-way Transmission Diagnostic connector

Electric Shifter [see page 1]

CAUTION CAUTION


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Service Procedure

Transmission Harness Installation


None

Special Tools

Basic Hand Tools


1. Transmission ECU 38-way connector2. Gear Sensor connector3. Rail Sensor connector4. 4-way Transmission Diagnostic connector

5. Input Shaft Speed Sensor connector6. Inertia Brake connector (DM3 models)7. Range Solenoid connector8. Output Shaft Speed Sensor connector9. Splitter Solenoid connector (13,18-speeds only)10. Mainshaft Speed Sensor connector11. Electric Shifter connector

1. Transmission ECU 38-way connector2. Gear Sensor connector3. Rail Sensor connector4. (Future position of) 4-way Transmission Diagnostic connec-

tor5. Input Shaft Speed Sensor connector6. Inertia Brake connector7. WetClutch Solenoid connector (AW3 only)8. Output Shaft Speed Sensor connector9. Electric Shifter connector

1

2

3

45

6

7

8

9

10

11

1

2

3

5

4

6

7

8

9


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Service Procedure


Do not allow contamination into the Transmission ECU con-

nectors.

Do not over tighten ty-raps.

You need to leave a service loop in the Transmission Har-ness.

Do not put sharp bends in the Transmission Harness.

The battery negative must be disconnected, while installingthe Transmission ECU connectors.

1. Reconnect the following harness connectors:

Gear Select and Rail Select Sensor

Main Shaft Speed Sensor





Electric Shifter

Range and Splitter Valve Solenoids [see page 1]

Do not exceed the torque on the Transmission Harness orVehicle harness connector or bolt failure will occur.

Using a 5/32 allen wrench, reconnect the Transmission Har-ness 38-way connector and tighten to 25 +/- 3 lbs. in. (2.82 +/- .33 Nm).


Do not allow contamination into the Transmission ECU con-nectors.

Do not over tighten ty-raps.

You need to leave a service loop in the Transmission Har-ness.

Do not put sharp bends in the Transmission Harness.

The battery negative must be disconnected, while installingthe Transmission ECU connectors.

1. Reconnect the following harness connectors: Gear Select and Rail Select Sensor


Inertia Brake Coil



Electric Shifter

WetClutch solenoid (AW3 only) [see page 1]

Do not exceed the torque on the Transmission Harness orVehicle harness connector or bolt failure will occur.

2. Using a 5/32 allen wrench, reconnect the TransmissionHarness 38-way connector and tighten to 25 +/- 3 lbs. in.(2.82 +/- .33 Nm).

CAUTION

CAUTION

CAUTION

CAUTION


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Service Procedure

Shift Control Removal


The exact location varies depending on vehicle manufacturer.

Special Tools

Basic Hand Tools

1. Nut

2. Washer3. Push Button Shift Control 30-Way Connector4. Backing Plate5. Push Button Shift Control

12

3

4

5


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Service Procedure

1. Using a 1/4 socket, loosen the retaining bolt and discon-nect the 30-way connector from the back of the ShiftControl.

2. Using a 11/32 wrench, remove the two (2) nuts and lockwashers from the back of the Shift Control and removethe Shift Control.

Note: Shift Control location and use varies with each truck.


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Service Procedure

Shift Control Installation



Special Tools

Basic Hand Tools

1. Nut

2. Washer3. Push Button Shift Control 30-Way Connector4. Backing Plate5. Push Button Shift Control

12

3

4

5


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Service Procedure

1. Install the Shift Control in its mounting location. Then,using a 11/32 wrench, install the two (2) lock washersand nuts and tighten to 14-16 lbs. in. (1.6-1.8 N m).

2. Using a 1/4 wrench, reconnect the 30-way connector tothe back of the Shift Control and tighten to 7.1 - 13.3 lbs.in. [0.8 - 1.5 N m]


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Service Procedure

Cobra Lever Removal


None

Special Tools

Basic Hand Tools

1. Tower2. Screw3. 8-Way Cobra Lever Harness Connector

1

2

3

4


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Service Procedure

1. Using a phillips screwdriver remove the four screws fromthe Cobra Lever Housing.

2. Disconnect the 8-Way Cobra Lever harness connectorand remove the Cobra Lever from the Housing.


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Service Procedure

Cobra Lever Installation


None

Special Tools

Basic Hand Tools

1. Tower2. Screw3. 8-Way Cobra Lever Harness Connector

1

2

3

4


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Service Procedure

1. Connect the 8-Way Cobra Lever harness connector andplace the Cobra Lever into the tower.

1. Using a phillips screwdriver install the four screws intothe Cobra Lever Housing.


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Appendix

Operation

For more detailed information on transmission operation and shifting go to the Roadranger.com Literature Center(www.roadranger.com) and look for the drivers manual on your model transmission.

Generation III UltraShift - TRDR-0940

Generation III AutoShift - TRDR-0930


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Appendix

Lubrication Specifications

5,6,10,13, and 18-Speed UltraShift DM3 and 10,18-Speed AutoShift

Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubri-cants, all areas of each affected component must be thoroughly drained.

Do not introduce additives and friction modifiers.

Do not mix lubricants of different grades.

Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 or call 1-800-826-HELP (4357).

Note: The use of lubricants not meeting these requirements will affect warranty coverage.

Note: For lubrication change and inspection intervals see TCMT-0021.

Buy from a reputable dealerFor a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013,Kalamazoo, MI 49003

Transmission Operating AnglesIf the transmission operating angle is more than 12 degrees, improper lubrication will occur. The operating angle is the transmis-sion mounting angle in the chassis plus the percent of upgrade (expressed in degrees). For operating angles over 12 degrees, thetransmission must be equipped with an oil pump or cooler kit to insure proper lubrication.

Operating Temperatures with Oil CoolersThe transmission must not be operated consistently at temperatures above 250 F. Operation at temperatures above 250F[121C] causes loaded gear tooth temperatures to exceed 350F [177C] which will ultimately destroy the heat treatment of thegears. If the elevated temperature is associated with an unusual operating condition that will reoccur, a cooler should be added,or the capacity of the existing cooling system increased.The following conditions in any combination can cause operating temperatures of over 250 F [121C]:

Operating consistently at slow speed.

High ambient temperatures.

Restricted air flow around transmission.

Use of engine retarder. High horsepower operation.

Note: Transmission coolers must be used to reduce the operating temperatures when the above conditions are encountered.

CAUTION


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Appendix

Oil Cooler Chart

Transmission Oil Coolers are:

Recommended

With engines of 350 H.P. and above.

Required

With engines 399 H.P. and above and GCWs over 90,000 lbs.

With engines 399 H.P. and above and 1400 lbs. ft. or greater torque.

With engines 1500 lbs. ft. and above

18-speed AutoShift transmissions require use of an Eaton supplied oil-to-water cooler or approved equivalent.

With engines 450 H.P. and above.


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Appendix

UltraShift ASW Models

Never mix engine oils and synthetic transmission oils in the same transmission. When switching between types of lubri-cants, all areas of each affected component must be thoroughly drained.

Do not introduce additives and friction modifiers.

Do not mix lubricants of different grades.

Note: For a list of Eaton Approved Synthetic Lubricants, see TCMT-0021 or call 1-800-826-HELP (4357).

Note: The use of lubricants not meeting these requirements will affect warranty coverage.

Note: For lubrication change and inspection intervals see TCMT-0021.

Buy from a reputable dealerFor a complete list of approved and reputable dealers, write to: Eaton Corporation, Worldwide Marketing Services, P.O. Box 4013,Kalamazoo, MI 49003

Synthetic Dextron III ATF

Synthetic Dextron III ATF must be used in the WetClutch portion of the transmission.

CD-50

CD-50 must be used in the gearbox portion of the transmission.

Maintenance/Lubricant Change Intervals

Transmission inspections and lubricant changes are outlined below.

For a list of Eaton Roadranger approved lubricants, order publication TCMT-0020.

Table 1: Lubricant Inspection and Change Interval (On-highway)

Interval Description

First 1,000 to 1,500 miles Inspect oil levels. Check for leaks.

Every 2,500 miles Inspect lubricant level. Perform Transmission Inspection.

Every 3 years or 150,000 miles, whichever oc-curs first

Change WetClutch oil and filters.

CAUTION


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Appendix

Checking WetClutch Lubricant

The WetClutch portion is checked using a dipstick located in the engine compartment.

Proper WetClutch Lubricant Level

WetClutch lubricant level should be checked when idling in neutral, with the transmission temperature between 60 F and 120 F(15.5 C and 48.8 C) and when the vehicle has been idling in neutral for at least two (2) minutes. Proper lubricant level isobtained when the lubricant is between the cold ADD mark and the cold FULL marks on the dipstick. Due to thermal expansion ofthe lubricant, it is not recommended to check the level when the transmission is above 120 F (48.8 C).

Checking Gearbox Lubricant

The gearbox portion is checked at the lubricant fill plug located on the right side of the gear case.

Cooler

A transmission clutch cooler must be used with the Eaton UltraShift AW3 transmission. The cooler sizing must meet the require-ments specified in this TRIG-0930

Proper Gearbox Lubricant Level

The gearbox lubricant is at the proper level when it is even with bottom of the fill hole. When you remove the plug to check thelubricant level, lubricant should seep out. Do not use your finger to feel for the lubricant. Even if you can touch the lubricant, itmay not be at the proper level. In a transmission, one inch of lubricant level equals about one gallon of lubricant.

Actual Lube

LevelActual Lube

Level


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Appendix

Drain the Transmission Gearbox and WetClutch Housing

1. Locate the drain plugs at the bottom of the transmission gear case and on the clutch housing oil pan.

2. Place a drain pan under each drain plug.

3. Remove both drain plugs and allow the lubricants to drain completely.

4. Disconnect both cooler lines at the WetClutch housing.

5. Pressurize one line with 20 PSI until all lubricant is forced out of the cooler.

6. Reconnect both cooler lines.

Change WetClutch Filters

Change the lubricant filters when the transmission lubricant is changed. Detailed information can be found on removal andreplacement of the oil filters in this service manual.

Fill the Transmission

1. Install the transmission gearbox drain plug and tighten to 45-55 lbs. ft. (60-73 Nm). Sealant is not required on thedrain plug threads.

2. Install the clutch housing oil pan drain plug and torque to 34-48 lbs. ft. (45-64 Nm). Sealant is not required on thedrain plug thread.

3. Fill the transmission gearbox with the recommended lubricant until the lubricant seeps out of the fill hole.

4. Install the fill plug and torque to 25-35 lbs. ft. (33-47 Nm).

5. Slowly fill the clutch through the dipstick tube with an initial fill of 18 pints (8.5 liters) of the recommended lubricant.

6. Place the transmission in neutral position apply the parking brakes. Start the engine and let idle for five (5) minutes,

(this allows oil to fill the WetClutch system and cooling system), add oil as needed to obtain a level at the proper tem-perature range. Total oil quantity at this time varies depending on the cooling system capacity.

7. Increase the engine idle slowly to 1500 RPM for two (2) minutes. Now, recheck the oil level at normal idle speed in neu-tral, again adding oil to obtain a level at the proper temperature range.

8. Install the dipstick and tighten securely.


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Appendix

Clutch Calibration

The ASW system automatically provides for clutch wear. The system will initiate a clutch calibration once per vehicle power up,when certain vehicle conditions are right. Of these conditions, the most important ones include: when the engine is running atidle speed, during normal operating temperature, when the vehicle is stopped, and when neutral is selected on the Shift Control.During the calibration, the clutch is partially engaged until the engine begins to slightly lug down. It will then disengage the clutchand repeat this process several times. The calibration process usually takes as little as thirty seconds but can take as long astwo(2) minutes. The calibration will be aborted when any position other than neutral is selected on the Shift Control.

If it appears that the vehicle is not engaging smoothly from a stop, it is possible that the clutch needs to be re-calibrated. If it hasnot been previously calibrated during the current power up, stop the vehicle with the engine idling at its normal operating tem-perature and place the Shift Control in neutral and wait two(2) minutes. If the calibration is being performed you should hear theengine slightly lug down and then return to its no load condition several times.

If calibration does not occur a Power Down/Power Up will initiate a calibration.


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Appendix

Inspection Procedures

For all inspection procedures on assembly and disassembly refer to the service manual covering the base box procedures. Thesemanuals can be found on roadranger.com under the Literature Center.


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Appendix

Basic Troubleshooting

For all Basic Troubleshooting questions refer to the appropriate service manual covering the base box procedures. These manu-als can be found on roadranger.com under the Literature Center.


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Appendix

Air System Operation and Troubleshooting

For all air system operation and troubleshooting questions refer to the "Gen III Troubleshooting Guide" TRTS-0930, which is foundon Roadranger.com under the Literature Center.


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Appendix

Tool Specifications

General Tools

The following General Tools are available from several tool manufacturers such as Snap-On, OTC, and many others.

Table 5 General Tools

TOOL PURPOSE

0 - 100 lbs. ft. (0-135 Nm) 1/2" (12.7mm) drive TorqueWrench

General torquing of fasteners (Typically 15-80 lbs. ft. (20-108Nm))

0 - 600 lbs. ft. (0-810 Nm) 3/4" or 1" (19mm or 25.4mm)drive Torque Wrench

Torquing of Output Nut

0 - 50 lb. in. (0-5.62 Nm) 3/8" (9.52mm) drive TorqueWrench

General torquing of fasteners

2 3/4" (70mm) or Socket - Standard Depth To remove the Output Yoke/Flange NutLarge Brass Drift 3/4" x 12" (19mm x 304.8mm) Used to protect shafts and bearings during removal

Large Dead Blow Hammer or Maul 32 ounces To provide force for shaft and bearing removal

(2) Air Pressure Gauges (0-150 PSI) 0-10.34 BAR To troubleshoot and verify correct operation of air system

3/8" Drive Deepwell socket set 3/8"- 1" (9.5mm - 25.4mm) To remove/install capscrews and nuts

3/8" Drive Shallow socket set 3/8" - 1" (9.5mm - 25.4mm) To remove/install capscrews and nuts

Snap Ring Pliers - Large Standard External To remove the snap rings at the auxiliary drive gear, input shaftbearing, and countershaft bearings

Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearingendplay

Open-end wrench set 3/8" - 1" (9.52mm -25.4mm) To remove certain airline connections


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Appendix

Torque Specifications

Correct torque application is extremely important to assure long transmission life and dependable performance. Overtighteningor under-tightening can result in a loose installation and, in many instances, eventually cause damage to transmission gears,shafts or bearings. Use of a thread sealer/locking compound is recommended for all capscrews. Do not torque capscrews dry.

Description Torque Valuelbs. ft. [Nm]

Thread size Additional Comments

Transmission-to-Engine capscrews Refer to OEMfor specification

Clutch-to-Flywheel capscrews

7/16 x 2.25 x 14 40 - 50 lbs. ft.[54 - 68 Nm]

7/16 x 2.25 x 14 40 - 50 lbs. ft. [54 - 68 Nm]

3/8 x 2.25 x 16 30 - 35 lbs. ft.[41 - 47 Nm]

3/8 x 2.25 x 16 30 - 35 lbs. ft. [41 - 47 Nm]

M10 x 1-3/8 26 - 35 lbs. ft.[35 - 47 Nm]

M10 x 1-3/8 26 - 35 lbs. ft. [35 - 47 Nm]

M10 x 1-3/4 26 - 35 lbs. ft.[35 - 47 Nm]

M10 x 1-3/4 26 - 35 lbs. ft. [35 - 47 Nm]

6 (Small PTO Cover Capscrews) 20 - 25 lbs. ft.[27 - 34 Nm]

3/8"-16 Apply Loctite 242 to threads.

8 (Large PTO Cover Capscrews) 50 - 65 lbs. ft.[68 - 88 Nm]


4 Electric Shifter Capscrews 30 - 45 lbs. ft.[48 - 61 Nm]cast and 20 - 25

lbs. ft. [27 - 34Nm] aluminum

3/8" - 16

1 Reverse switch 20 - 25 lbs. ft.[27 - 34 Nm]

9/16"-18

1 Neutral switch/cap 20 - 25 lbs. ft.[27 - 34 Nm]

3/4"-16

3 ECU Capscrews (Medium Duty) 7 - 9 lbs. ft. (9.5- 12.2 Nm)

1/4" - 20 3 ECU Nuts (Heavy Duty) 7 - 9 lbs. ft. [9.5

- 12.2 Nm]1/4" - 20

2 Transmission ECU 38-Way Connectors Cap-screws

25 +/- 3 lbs. in.[2.82 +/- .33Nm]

M5 - .8

3 ECU Bracket Nuts 20 - 25 lbs. ft.[27 - 34 Nm]

.3125" - 18

3 ECU Bracket Studs 35 - 45 lbs. ft.[48 - 61 Nm]

3/8" - 16

2 Harness Bracket Capscrews 20-25 lbs. ft.[27-34 Nm]

.3125-18


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Appendix

1 Push Button Shift Controller 30-Way Connec-tor Capscrew

10 +/- 3 lbs. in.[14 +/- 4 N m]

2 Push Button Shift Controller Backing Platenuts and lockwashers

14-16 lbs. in.[1.6-1.8 N m]

6 Inertia Brake Capscrews 40-45 lbs. ft.[54- 61.0 Nm]


2 Inertia Brake Hose Fittings 30-40 lbs. ft.[41-54 Nm]

3/4"-16

4 Splitter Solenoid Capscrews 21-27 lbs. in.[2.4-3.1 Nm]

#10-24

4 Range Solenoid Capscrews 21-27 lbs. in.[2.4-3.1 Nm]

#10-24

1 Output Shaft Speed Sensor Capscrew (MD) 8-10 lbs. ft.[10.8-13.6

Nm]

1/4"-20

1 Main Shaft Speed Sensor Capscrew 8-10 lbs. ft.[10.8-13.6Nm]

1/4"-20

1 Input Shaft Speed Sensor Capscrew 8-10 lbs. ft.[10.8-13.6Nm]

1/4"-20

2 Rail Sensor Capscrews 21-27 lbs. in.[2.4-3.1 Nm]

2 Gear Sensor Capscrews 21-27 lbs. in.[2.4-3.1 Nm]

2 Air Filter Regulator Capscrews 8-12 lbs. ft.[10.8-16.02Nm]


1 Lubricant fill plug (6-Speed) 45 - 55 lbs. ft.[61 - 75 Nm]

3/4-NPT

1 Lubricant fill plug (13,10,18-speed) 60 - 75 lbs. ft.[47 - 61 Nm]

1-NPT

2 Lifting Bracket Capscrews 35 - 45 lbs. ft.[47 - 61 Nm]

3/8"-16

Transmission Nodal Mount Capscrews

(10,13,18-Speed)

Refer to OEM

for Specification2 Transmission Rear Mount Nuts (10,13,18-Speed)

Refer to OEMfor Specification

6 - Speed AW3 Specific

Oil cooler line fitting 50 - 60 lbs. ft.[68 - 81 Nm]

Oil cooler line nut 50 - 60 lbs. ft.[68 - 81 Nm]


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Appendix

2 Dipstick tube fitting 60 - 70 lbs. ft.[81 - 95 Nm]

1 5/8"-12

1 WetClutch drain plug 34 - 48 lbs. ft.[46 - 65 Nm]

12 Flywheel to Drive Coupler Capscrews 3/8 x 16 x 1-1/4 35 - 40 lbs. ft.[47 - 55 Nm]

High Pressure Oil Filter 25 - 35 lbs. ft.[34-41 Nm]

Low Pressure Oil Filter Turn until seal touches, then tighten witha 1/2" drive 3/4 to 1 full turn.


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Appendix

Torque Overview

Heavy Duty

Air Filter Requlator


Rail SelectSensor Capscrews

Gear SelectSensor Capscrews

Electric ShifterCapscrews

Input ShaftSpeed Sensor Capscrew

Main ShaftSpeed Sensor Capscrew

Splitter ValveSolenoid Capscrew

Output ShaftSpeed Sensor Capscrew

Transmission ECU Nuts

Inertia Brake Capscrews

ECU BracketNuts & Studs


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89

Appendix

Medium Duty

Electric Shifter Capscrews

Gear Select

Sensor Capscrews

Rail SelectSensor Capscrews

Output ShaftSpeed Sensor Capscrew

Transmission ECU Nuts

Inertia Brake CapscrewsOil Pan Capscrews

Oil Pan Drain Plug

Input ShaftSpeed Sensor Capscrew


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servicio g3

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