This page has been placed at the beginning of each SIL to

make it easier to navigate to the Help and Index pages.

To go to the Help or Index pages click on the appropriate button above.
Actual SIL information is on the following page(s)
Use the page forward button or click here to go to the first page of the SIL.
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 1 of 15

SUBJECT: AT 542/545R Retarder Release

EQUIPMENT AFFECTED: AT 542/545R

AFFECTED SERIAL NUMBERS: 3210798663 and Later

New input retarder models AT 542R/AT 545R have been released into production. The retarder allows for
auxiliary braking for downhill speed control.

The retarder has two-stage capacity - 50% apply and full apply.

The basic cross section of the retarder is shown in Figures 1 and 2. The rotating elements for the retarder are cast
on the OD of the forward clutch housing. Note that the PTO is not available with retarder-equipped transmissions.

The valve body for the retarder mounts to the transmission PTO pad. Transmission fluid is transferred to and
from the retarder through tubes that connect the retarder controls with the stationary retarder housing.

See the parts list pages for complete list of part numbers and description of parts unique to the AT 542R/AT 545R
models.

terc- .

The retarder requires the large main shaft and associated parts which were incorporated into production beginning
with S/N 3210775437 (SIL lo-TR-96).

S-vice I%rt~ Inhmm&m .

All of the current AT 500R parts listed are available from the Parts Distribution Center with the exception of
detail parts which are serviced only as an assembly.

Special Toolst.
The new tools required for rebuilding a transmission with a retarder are guide bolts. These can be made by
cutting the heads off of bolts with an M6xl thread and a minimum bolt length of 8Omm.
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 2 of 15

STATOR HOUSING

ROTOR
/- /-

ROTATING SEAL RINGSJ

F 1 i g u

T r o u
If the retarder is not performing properly, the transmission should be checked as follows:

1. Instrument the transmission for retarder-out pressure. The retarder-out pressure can be measured at the
retarder-out temperature probe port. Refer to Figure 14, Item 21, which shows the temperature probe port
Plug*

2. Operate vehicle in fourth range and fully apply the retarder. The pressure should be 50-62 psi. The
pressure should be less than 5 psi when the retarder is turned off or the transmission is in fast range.
Proper pressure is necessary for the retarder to function at full capacity. Preselecting transmission to lower
gears will provide better performance. Note that the retarder pressure will drop during the downshifts due
to the temporary suppression of main pressure during the shift.

3. Repeat Step 2 with retarder set at 50% apply. The pressure should be 20-32 psi.

4. If retarder pressure is low, check main pressure during retarder operation. Main pressure should be
minimum of 135 psi after retarder pressure stabilizes. The priority valve will inhibit retarder application if
main pressure is too low (pressure below 85 psi).
 SPI 21-TR-96
April, 1996
Product Code(s):
Page 3 of 15

JUMPER TUBES
STATOR HOUSING
r RETARDER CHANNEL PLATE
/-

RETARDER HOUSING
WITH BLADE INSERT

Figure 2

5. If main pressure checks OK and retarder-out pressure is low, perform checks as follows:

A. Verify that power (12124V) is applied to the F and H solenoids through pins A (H solenoid) and C (F
solenoid) during 100% retarder application.

B. Verify that power is supplied to the H solenoid through pin A during 50% retarder application.

C. Check continuity between pins A and B at the connector for the harness leading to the retarder valve
body. Reading should be 8 to 14 ohms (12V) or 30 to 60 ohms (24V).

D. Check continuity between pins C and D at the connector for the harness leading to the retarder valve
body. Reading should be I to 14 ohms (12V) or 30 to 60 ohms (24V).

E* Check continuity of pin B on the chassis connector which should be grounded. Repeat test for pin D
which should also be connected with chassis ground.
 SPI 2 1 -‘IX-96
April, 1996
Product Code(s):
Page 4 of 15

Note that the chassis wiring leading to the retarder connector is the responsibility of the OEM and installations
will vary. The recommended installation wiring schematic is shown in Figure 3 and is provided only as a guide.

RECOMMENDED RETARDER CONTROLS INSTALLATION

- R - E - f ~ X~
* “
p;:; ; l S ; ; ; R ; ; E U ;
I T Z w Ii ~ ~
I I
I I
I G I N I I
T I O
l
I I
C ; UC SU C T1 S U OT S MO T
S US P U SUPPLIED 1P P LP I L
I
CLOSED TO I C LN ; Ot IS ;E
REQUEST I A I T D I L E
RETARDER I
I I I ; N N S T
I L C l O L W U T
P ; l; ;C l PU I
I
S U
I
I M C ; A A I S N
I~ ~ ~ ~ J ~ ~ ~ ~

S
E E B L
E
o
RA E
p
AC C
1 0 ( 0 O % P
C 0

R swo _ 1
A E T l A R D - E
C O N T R O L
C O O N N N E C T
T B
R A OFF o-.-j 0 N C S U M S I
S U P
0 ,
I C U S T O
- - S U N P ° P F L
T H R E E
S ; C B 4 E L Y - ; O 6 ; S
P P S R I E
I B S N R Y A S
vo311

Figure 3

If the retarder-apply and solenoid circuitry check properly, the main pressure is within specifications and a
discrepancy in the expected retarder-out pressure exists, a problem with the solenoids may be indicated. If no
difference in r&u-der-out pressure is observed between retarder application and release, the H solenoid may be
defective or a valve may be stuck. If the same pressure is observed for 50% and 100% apply (providing there is a
pressure difference between retarder-off and retarder-apply), the F solenoid may be defective.

If the same retarder-out pressure is observed for retarder-off and 50% apply, but proper pressure (50-62 psi) is
observed for 100% apply, the power to the solenoids may be reversed. Verify that power is applied to pin A with
50% apply. If correct, the internal solenoid connections need to be verified. Connector with the white wires
attaches to the H solenoid and connector with the red wires attaches to the F solenoid.

The H solenoid is the upper solenoid on the transfer plate. The F solenoid is the lower solenoid. The transfer
plate has a narrow cavity extending into the F solenoid cavity.
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 5 of 15

Retarder Harness Repair - Solenoid Terminal

1. TooWTerminal

Crimping Tool J 38125-7

Remover Tool J 38125-13
Terminal P/N 12124639
Connector P/N 12092420

2. Terminal Removal

A. Depress lock tab on terminal (accessible in slot of connector) and push terminal out front of connector
(Figure 4).

B. If replacing terminal, cut terminal between core and insulation crimp (to minimize wire loss).

v J 38125-13

Figure 4
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 6 of 15

3. Terminal Crimping and Installation

A. Carefully strip insulation 6.5mm k 0.5mm (unless insulation crimp is over tight). Automatic wire
stripper, J 35615, will remove insulation and crimp from old terminal without damaging wire.

B. Place core crimp portion of terminal on bed of anvil C on crimping tool, J 38125-7, and squeeze
crimper enough to hold terminal from dropping (Figure 5).

C Position wire core in terminal and squeeze crimper tool to complete the core crimp.

D. Position insulation crimp of terminal on anvil D so that the entire insulation crimp area and a portion
of the terminal between the core and insulation crimp areas are supported by the anvil. Complete the
insulation crimp.

E. Do not install terminals in connector until terminals are installed through the retarder transfer plate.

F. Slip the wire through the slot in the connector and pull to fully seat the terminal(s). Terminals with
white wires install in one connector and terminals with red wires install in the other connector.

Figure 5
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 7 of 15

R H eR - aC teH rC
h apa n
oa r ar ne s
1. Tools/Terminal (Socket)

Crimping Tool J 38125-6

Remover Tool J 38125-10
Terminal (Socket) P/N12089188
Seal P/N12089679
Connector P/N 12015024

2. Terminal Removal

A. Unlatch the secondary lock on the connector.

B. On the front of the connector, insert removal tool J 38125-10 over the terminal. Push the tool over the
terminal and pull the terminal out of the back end of the connector (Figure 6).

C. If terminal is to be replaced, cut terminal between core and insulation crimp (to minimize wire loss).

F 6 k u r
 SPI 2 1 -TR-96
April, 1996
Product Code(s):
Page 8 of 15

3. Terminal Crimping and Installation

A. Place the wire seal onto the wire before stripping the wire (small diameter should be toward end of
wire).

B. Strip wire to 6.Omm k 0.25mm (0.226-0.246 inches).

C. Place terminal onto crimping tool J 38125-6 on anvil “2” (Figure 7).

VO3120

Figure 7

D. Slightly close crimping tool to hold terminal steady.

E. Insert wire so that the stripped portion of wire is in the core crimp area and the insulated portion of the
wire is in the insulation crimping area (Figure 8).

F. Crimp the stripped section of the wire.

I W N I S R U E L A T

S W T I R R I E P P

vo3121

Figure 8
 SPI 21-TR-96
April, 1996
Product Code(s):
Page 9 of 15

G. Remove the terminal from the crimping tool.

H. Push the wire seal into the terminal. The second crimp will wrap around the wire seal. This will seal
the insulated area of wire.

I. Use a pair of needle nose pliers, if necessary, to squeeze the terminal wings together to fit in anvil “5.”

J. Crimp wire seal in anvil “5” (Figure 9).

K. Tug on terminal and be sure crimp is tight.

L. Terminals with white wires install in connector locations A and B. Terminals with red wires install in
locations C and D. Insert the terminals into the connector. The terminals will “click’ into place and
should not pull out.

M. Secure the secondary lock. Both sides of the connector must be latched.

7 WIRE SEAL

INSULATION & SEAL CRIMP

VO3122

Figure 9

PARTS LIST
Figure Former Current Description
QtY
Ref. No.
13-10 29505990 *29525014 1 H.ousing Assembly, Main
13-11 29505894 29525015 1 **Housing, Main
13-20 29524146 1 Adapter, I/8 NPTF - 114NPTF
13-24 29524147 1 Adapter, 90 Degree
6774322 0 Cover, PTO
14-8 29501161 29524388 1 Gasket, PTO Cover
23046846 0 Bolt, 3/8-16 x 3/4 Long
13-18 29527689 1 Adapter, To Cooler
13-19 230 19664 1 O-ring
lo-16 29509636 29524366 1 Support and Bearing Assembly
10-17 29509635 29527550 1 **Support Assembly, Pump
10-21 29509633 29524364 1 **Support, Pump
lo-36 8626281 6 Washer, Rubber-Coated
lo-32 9409066 6 Bolt
10-33 23015883 29525 170 1 Gasket, Pump Cover to Case
12-3 29513445 295 15399 1 Plate, Third Clutch Backing
6884275 0 Ring, Retaining
11-11 29524368 1 Housing Assembly, Retarder
11-13 29524340 1 Housing, Retarder
11-12 29524343 1 Insert, Blade
* Service with Main Housing Kit, P/N 29512504,
 SPI 21-‘IX-96
April, 1996
Product Code(s):
Page 10 of 15

PARTS LIST (cant)

Figure Former Current Description
QtY
Ref. No.
1I-14 29524139 4 Screw, 1/4-28 x 1.25 Long
11-3, II-10 29524370 2 Ring, Rotating
II-4 29509660 29524371 1 Forward Cl Housing 8t Turbine Shaft Assembly
II-7 29506500 29524372 1 **Housing Assembly, Forward
II-8 29505896 29524338 1 **Rotor, Forward Clutch
II-I 29524341 1 Stator Housing
14-25 29524374 1 Body Retarder, Valve Assembly
14-30 29524342 1 Body, Valve Retarder
14-35 29524375 1 Valve, Auto Flow
14-36 23011981 1 Spring, Auto Flow
14-37 29524377 1 Plug, Auto Flow
14-39 29524142 1 Ring, Snap Internal
14-38 23040581 1 O-ring
14-31 29524378 1 Valve, Regulator
14-32 29524379 1 Spring, Regulator
14-33 29525195 1 Pin, Regulator
14-34 29525194 1 Plug, Regulator
14-27 29524380 1 Valve, Priority
14-28 2952442 1 1 Spring, Priority
14-26 29525 196 1 Plug, Priority
14-29 29525520 2 Pin, Retaining
14-23 29524382 1 Plate, Separator
14-22, 14-24 2952438 1 2 Gasket
14-12 29524383 1 Transfer Plate Assembly
14-20 29524339 1 Transfer Plate
14-13 29513751 2 Solenoid, 12 Volt
14-19 29524384 2 Pin, Solenoid Retaining
14-18 23016956 2 Plug, l/l 6 Pipe
14-16 29524385 1 Harness, Wiring
14-17 29503383 1 O-ring
14-14 12092420 2 Connector
14-15 29524143 1 Ring, Snap
14-21 29505796 1 Plug, Temperature Sensor
14-10 186601 4 Bolt, 1/2-20 x l-l/4 Long
14-11 9422845 4 Washer
14-3 9430725 4 Bolt, 3/8-16 x 4-114 Long
14-7 29524387 2 Tube, Jumper
14-6 29524141 1 Hose Assembly, To Cooler
14-4 29524148 1 Adapter, To Cooler
14-5 23015806 1 O-ring
14-2 29524149 1 Adapter, Main Feed
14-1 29524140 1 Hose Assembly, Main Feed
* Service with Main Housing Kit, P/N 29512504.
** Serviced as an assemblv. not detail Darts.
SPI 2 1 -‘IX-96
April, 1996
Product Code(s):
Page 11 of 15

vo3123
 SPI 2 1-‘IX-96
April, 1996
Product Code(s):
Page 12 of 15

Figure II
 SPI 2 1-‘IX-96
April, 1996
Product Code(s):
Page 13 of 15

Figure I2
 SPI 21-‘IX-96
April, 1996
Product Code(s):
Page 14 of 15

AT 1500 SERIES ,I’

Figure 13
 SPI 2 1-‘IX-96
April, 1996
Product Code(s):
Page 15 of 15

I 25.

Figure 14