Maxitorq t307m, T308-Service

TRANSMISSIONS
T307M AND T308M

(MULTI-SPEED REVERSE)
SERVICE MANUAL JANUARY 2003
(NEW ISSUE)
10-119
front.fm Page -ii Friday, October 25, 2002 10:13 AM
-ii
newknow.fm Page 1 Thursday, May 21, 1998 2:23 PM
PLEASE LET US KNOW!

Your comments and suggestions will help
us improve this manual!
Please complete and mail this form or FAX
your comments to: (610) 709-3800.
Manual: _______________________________ Publication Number: _______
Vehicle Model: _________________________ Model Year: ______________
Do you find procedures properly organized and easy to follow? m Yes m No
If not, please explain: ______________________________________________
_______________________________________________________________
_______________________________________________________________
Manual page numbers: _____________________________________________
Are there any important procedures or other information presently not in this
manual that you would like to see included? m Yes m No
If yes, please describe: _____________________________________________
_______________________________________________________________
_______________________________________________________________
Did you find any errors in the procedures or illustrations? m Yes m No
If yes, what pages? _______________________________________________
Please explain: ___________________________________________________
_______________________________________________________________
Please include a copy of each page in question and mark your comments and
suggestions.
Name: ________________________________ Phone: (_____) _____-_______
Company: _______________________________________________________
Address: ________________________________________________________
City: _________________________________ State: _______ Zip: _______
Position Title: ____________________________________________________
Thank You For Your Assistance

Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)
DO NOT STAPLE — USE TRANSPARENT TAPE

Busreply.fm Page 1 Thursday, May 21, 1998 2:24 PM
FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA
POSTAGE WILL BE PAID BY ADDRESSEE
SERVICE PUBLICATIONS (RTS), 6S3

MACK TRUCKS INC
WORLD HEADQUARTERS
PO BOX M
ALLENTOWN PA 18105-9972
FOLD ALONG THIS LINE

TRANSMISSIONS
T307M AND T308M
SERVICE MANUAL
JANUARY 2003 © MACK TRUCKS, INC. 2003

(NEW ISSUE) 10-119
front.fm Page ii Friday, October 25, 2002 10:13 AM
ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including (but not limited to) electronic,
mechanical, photocopying, recording, or otherwise
without prior written permission of Mack Trucks, Inc.
ii
front.fm Page iii Friday, October 25, 2002 10:13 AM
TABLE OF CONTENTS
TABLE OF CONTENTS
iii
front.fm Page iv Friday, October 25, 2002 10:13 AM
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
T307M/T308M TRANSMISSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Identification Stamping (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Identification Stamping (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
T307M/T308M DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Splash Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transmission Case Oil Cooler Line Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Magnetic Oil Filter Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
T307M GEAR RATIOS AND SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
T308M GEAR RATIOS AND SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
T307M SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Using Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Obtaining Neutral in Compound Case (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stationary PTO Operation (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Road Operation (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
T308M SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Using Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Obtaining Neutral in Compound Case (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stationary PTO Operation (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Road Operation (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
T307M AND T308M POWER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
T307M Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
T308M Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRANSMISSION MAJOR COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
T307M Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
T308M Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Magnetic Oil Filter Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
iv
front.fm Page v Friday, October 25, 2002 10:13 AM
TABLE OF CONTENTS
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
T307M/T308M TRANSMISSION COMPOUND CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 42
T307M/T308M COMPOUND COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Rear Mainshaft Bearing Cover Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Rear Countershaft Bearing Cover Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . 54
Rear Case Shift Cover Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Range Shift Cylinder Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Rear Mainshaft Disassembly (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Rear Mainshaft and Synchronizer Disassembly (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rear Countershaft Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Reverse Idler Gear Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Shifter Forks, Sliding Clutches and Shift Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
T307M/T308M COMPOUND COMPONENT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Reverse Idler Gear Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Rear Countershaft Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rear Mainshaft and Synchronizer Reassembly (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Rear Mainshaft Reassembly (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Range Shift Cylinder Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear Case Shift Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Rear Countershaft Bearing Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . 118
Rear Mainshaft Bearing Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . 119
T307M/T308M TRANSMISSION COMPOUND CASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 121
Setting Rear Countershaft Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
T307M/T308M TRANSMISSION MAIN CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 134
T307M/T308M TRANSMISSION MAIN CASE COMPONENT DISASSEMBLY . . . . . . . . . . . . . . 142
Main Case Shift Cover Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Range Shift Valve Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Front Mainshaft Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Front Countershaft Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Main Drive Pinion Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Front Countershaft Front Bearing Cover Disassembly (T307M/T308M) . . . . . . . . . . . . . . . . . 170
Front Countershaft Rear Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Shifter Forks, Sliding Clutches and Shift Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
T307M/T308M TRANSMISSION MAIN CASE COMPONENT REASSEMBLY . . . . . . . . . . . . . . . 175
Front Countershaft Rear Bearing Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . 175
Front Countershaft Front Bearing Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . 176
Main Drive Pinion Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
v
front.fm Page vi Friday, October 25, 2002 10:13 AM
TABLE OF CONTENTS
Front Countershaft Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Front Mainshaft Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Range Shift Valve Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Main Case Shift Cover Reassembly (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
T307M/T308M TRANSMISSION MAIN CASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Setting Front Countershaft Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Final Transmission Main Case Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
T307M/T308M TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Overhaul Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
T307M Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
T308M Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
T307M Gear Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
T308M Gear Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Fits and Limits (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
General Specifications (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
T307M/T308M TRANSMISSION SPECIFICATIONS AND CAPACITIES . . . . . . . . . . . . . . . . . . . 230
SCHEMATIC & ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
T307M/T308M SCHEMATIC AND ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
T307M Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
T308M Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
TRANSMISSION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
T307M/T308M TRANSMISSION DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Compound Case Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Main Case Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
vi
10_119.bk Page 1 Friday, October 25, 2002 10:14 AM
INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:
Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.
Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.
Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.
A procedure, practice, or condition that is essential to emphasize.
A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.
Page 2
INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle, always be seated in the driver’s seat, place the
transmission in neutral, be sure that parking brakes are set, and
disengage the clutch.
2. Before working on a vehicle, place the transmission in neutral, set the
parking brakes, and block the wheels.
3. Before towing the vehicle, place the transmission in neutral and lift the
rear wheels off the ground, or disconnect the driveline to avoid damage to
the transmission during towing.
Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.
Do not work under a vehicle that is supported only by a hydraulic jack. The
hydraulic jack could fail suddenly and unexpectedly, resulting in severe
personal injury or death. Always use jackstands of adequate capacity to
support the weight of the vehicle.
REMEMBER,
SAFETY . . . IS NO ACCIDENT!
Page 3
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every r Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
r NEVER run engine indoors unless exhaust
potentially hazardous situations and taking
fumes are adequately vented to the outside.
necessary precautions. Performing service
procedures correctly is critical to technician safety r Be aware of hot surfaces. Allow engine to
and safe, reliable vehicle operation. cool sufficiently before performing any
service or tests in the vicinity of the engine.
The following list of general shop safety practices
r Keep work area clean and orderly. Clean up
can help technicians avoid potentially hazardous
any spilled oil, grease, fuel, hydraulic fluid,
situations and reduce the risk of personal injury.
etc.
DO NOT perform any services, maintenance
procedures or lubrications until this manual has r Only use tools that are in good condition,
been read and understood. and always use accurately calibrated torque
wrenches to tighten all fasteners to specified
r Perform all service work on a flat, level
torques. In instances where procedures
surface. Block wheels to prevent vehicle
require the use of special tools which are
from rolling.
designed for a specific purpose, use only in
r DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
r Do not store natural gas powered vehicles
vehicle.
indoors for an extended period of time
r ALWAYS wear safety glasses and protective (overnight) without first removing the fuel.
shoes. Avoid injury by being aware of sharp
r Never smoke around a natural gas powered
corners and jagged edges.
vehicle.
Page 4
INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
CODE
The organization of MACK service manuals has GROUP 500 — BRAKES, AUXILIARY
been upgraded to standardize manual content SYSTEMS
according to a reference system based on
component identification. The new reference GROUP 600 — CAB, TRUCK BODY
system will help to link the information contained
in this publication with related information GROUP 700 — ELECTRICAL
included in other MACK service/warranty
publications, such as associated service The second two digits of the three-digit code are
bulletins, warranty manuals, and MACK Service used to identify the system, assembly or
Labor Time Standards. subassembly, as appropriate, within each of the
groupings. The codes applicable to this
The system is based on a numerical code, the publication are shown at section headings, as
first digit of which identifies the general necessary, to guide you to specific component
component grouping as listed here: information.
GROUP 000 — GENERAL DATA Additionally, a two-character alpha code (i.e.,

[GA] CASE, MAIN) is shown with each operation.
GROUP 100 — CHASSIS This alpha code, in combination with the three-
digit Group number, identifies the specific
GROUP 200 — ENGINE assembly, subassembly or part, and directly
relates to the first five positions of the operation
GROUP 300 — CLUTCH, TRANSMISSION, code listed in MACK Service Labor Time
TRANSFER CASE AND PTO Standards.
Example of Numerical Code
Page 5
INTRODUCTION
CONVERSION CHART
Conversion Units Multiply By:
Length Calculations
Inches (in) to Millimeters (mm) 25.40
Inches (in) to Centimeters (cm) 2.540
Feet (ft) to Centimeters (cm) 30.48
Feet (ft) to Meters (m) 0.3048
Yards (yd) to Centimeters (cm) 91.44
Yards (yd) to Meters (m) 0.9144
Miles to Kilometers (km) 1.609
Millimeters (mm) to Inches (in) 0.03937
Centimeters (cm) to Inches (in) 0.3937
Centimeters (cm) to Feet (ft) 0.0328
Centimeters (cm) to Yards (yd) 0.0109
Meters (m) to Feet (ft) 3.281
Meters (m) to Yards (yd) 1.094
Kilometers (km) to Miles 0.6214
Area Calculations
Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2
Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452
Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0
Square Feet (sq-ft) to Square Meters (sq-m) 0.0929
Square Yards (sq-yd) to Square Meters (sq-m) 0.8361
Square Miles (sq-miles) to Square Kilometers (sq-km) 2.590
Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155
Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155
Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076
Square Meters (sq-m) to Square Feet (sq-ft) 10.76
Square Meters (sq-m) to Square Yards (sq-yd) 1.196
Square Kilometers (sq-km) to Square Miles (sq-miles) 0.3861
Volume Calculations
Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387
Cubic Inches (cu-in) to Liters (L) 0.01639
Quarts (qt) to Liters (L) 0.9464
Gallons (gal) to Liters (L) 3.7854
Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646
Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102
Liters (L) to Cubic Inches (cu-in) 61.024
Liters (L) to Quarts (qt) 1.0567
Liters (L) to Gallons (gal) 0.2642
Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308
Page 6
INTRODUCTION
Weight Calculations
Ounces (oz) to Grams (g) 28.5714
Pounds (lb) to Kilograms (kg) 0.4536
Pounds (lb) to Short Tons (US tons) 0.0005
Pounds (lb) to Metric Tons (t) 0.00045
Short Tons (US tons) to Pounds (lb) 2000
Short Tons (US tons) to Kilograms (kg) 907.18486
Short Tons (US tons) to Metric Tons (t) 0.90718
Grams (g) to Ounces (oz) 0.035
Kilograms (kg) to Pounds (lb) 2.205
Kilograms (kg) to Short Tons (US tons) 0.001102
Kilograms (kg) to Metric Tons (t) 0.001
Metric Tons (t) to Pounds (lb) 2205
Metric Tons (t) to Short Tons (US tons) 1.1023
Metric Tons (t) to Kilograms (kg) 1000
Force Calculations
Ounces Force (ozf) to Newtons (N) 0.2780
Pounds Force (lbf) to Newtons (N) 4.448
Pounds Force (lbf) to Kilograms Force (kgf) 0.456
Kilograms Force (kgf) to Pounds Force (lbf) 2.2046
Kilograms Force (kgf) to Newtons (N) 9.807
Newtons (N) to Kilograms Force (kgf) 0.10196
Newtons (N) to Ounces Force (ozf) 3.597
Newtons (N) to Pounds Force (lbf) 0.2248
Torque Calculations
Pound Inches (lb-in) to Newton Meters (N•m) 0.11298
Pound Feet (lb-ft) to Newton Meters (N•m) 1.3558
Pound Feet (lb-ft) to Kilograms Force per Meter (kgfm) 0.13825
Newton Meters (N•m) to Pound Inches (lb-in) 8.851
Newton Meters (N•m) to Pound Feet (lb-ft) 0.7376
Newton Meters (N•m) to Kilograms Force per Meter (kgfm) 0.10197
Kilograms Force per Meter (kgfm) to Pound Feet (lb-ft) 7.233
Kilograms Force per Meter (kgfm) to Newton Meters (N•m) 9.807
Radiator Specific Heat Dissipation Calculations
British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/°C) 0.000293
Kilowatt per Degree Celsius (kW/°C) to British Thermal Unit per Hour (BTU/hr) 3414.43
Temperature Calculations
Degrees Fahrenheit (°F) to Degrees Celsius (°C) (°F 32) 0.556
Degrees Celsius (°C) to Degrees Fahrenheit (°F) (1.8 x °C) + 32
Page 7
INTRODUCTION
Pressure Calculations
Atmospheres (atm) to Bars (bar) 1.01325
Atmospheres (atm) to Kilopascals (kPa) 101.325
Bars (bar) to Atmospheres (atm) 0.98692
Bars (bar) to Kilopascals (kPa) 100
Bar (bar) to Pounds per Square Inch (psi) 14.5037
Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377
Inches of Water (in H2O) to Kilopascals (kPa) 0.2491
Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895
Pounds per Square Inch (psi) to Bar (bar) 0.06895
Kilopascals (kPa) to Atmospheres (atm) 0.00987
Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612
Kilopascals (kPa) to Inches of Water (in H2O) 4.01445
Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145
Power Calculations
Horsepower (hp) to Kilowatts (kW) 0.74627
Kilowatts (kW) to Horsepower (hp) 1.34
Fuel Performance Calculations
Miles per Gallon (mile/gal) to Kilometers per Liter (km/L) 0.4251
Kilometers per Liter (km/L) to Miles per Gallon (mile/gal) 2.352
Velocity Calculations
Miles per Hour (mile/hr) to Kilometers per Hour (km/hr) 1.609
Kilometers per Hour (km/hr) to Miles per Hour (mile/hr) 0.6214
Volume Flow Calculations
Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32
Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531
Page 8
VISUAL IDENTIFICATION
Page 9
T307M/T308M TRANSMISSION IDENTIFICATION
1
Figure 1 — Location of Identification Stamping on Left Side of Main Case (T307M and T308M)
Unit Identification Stamping 1. Unit Symbol Identification

(T307M) T = transmission
3 = 300 series
The following model code information is stamped 07 = usable forward speeds
on the left side of the transmission, toward the
rear of the main case. Refer to Figure 1. M = multi-speed reverse
2
2. Transmission Serial No.
3. Transmission Assembly (Part) No.
* = digits may vary
4. Specific variant of the base Transmission
Assembly (Part) No.
Figure 2 — Unit Identification Stamping
Page 10
Unit Identification Stamping 1. Unit Symbol Identification
(T308M) T = transmission
3 = 300 series
The following model code information is stamped 08 = usable forward speeds
on the left side of the transmission, toward the
rear of the main case. Refer to Figure 1. M = multi-speed reverse
3
2. Transmission Serial No.
3. Transmission Assembly (Part) No.
* = digits may vary
4. Specific variant of the base Transmission
Assembly (Part) No.
4
Figure 3 — Unit Identification Stamping
Figure 4 — Cutaway View of T307M Transmission
Page 11
5
Figure 5 — Cutaway View of T308M Transmission — Optional Three-Position Cylinder

(with Compound Neutralizing) Shown
Page 12
DESCRIPTION AND OPERATION
Page 13

T307M/T308M DESCRIPTION 6
The T307M and T308M transmissions are

members of a new family of MACK transmissions
designated as MAXITORQUE® ES (T300)
Series. These transmissions are the next
evolution of the durable triple-countershaft
transmission. New features and product
enhancements have been engineered into
MAXITORQUE® ES transmissions to provide a
wide range of advantages that include the
following:
r New and revised gear ratios for greater
overall range and versatility
r Lower “LOs” in forward and reverse for
superior site maneuvering
r Shiftable multi-speed reverse for efficiency
while in reverse
Figure 6 — Equal Torque Distribution
r Improved shift quality through the use of
new sliding clutches with a fine-pitch tooth The T307M and T308M transmissions house five
design versus the coarse-pitch tooth design forward speeds in the main case along with Lo
of previous transmissions and Direct gear sets in the compound case. The
r Enhanced durability compound case gear sets for both transmissions
are controlled by a range selector and a FWD-
r Weight reduction versus previous REV selector that are both located on the main
transmissions shift lever. The T307M uses a sliding clutch on
the rear output shaft for range shifting, while the
The T307M and T308M transmissions are triple- T308M uses a rear output shaft and synchronizer
countershaft units. These transmissions consist assembly for range shifting.
of a compact transmission main case that houses
seven (T307M) or eight (T308M) usable forward Additionally, these units provide a multi-speed
gear speeds. A reverse gear set is located in the reverse feature by means of reverse gearing in
compound case. The T307M has seven forward the compound case that works in conjunction with
speeds and three reverse speeds and the T308M the first, second, and third speed gears in the
has eight forward speeds and three reverse main case.
speeds. The three countershafts of these units
are equally spaced around the mainshaft. This
design distributes the load equally among the
three countershafts, thus keeping normal
deflection and gear tooth loading to a minimum.
Refer to Figure 6.
Page 14

To use the multi-speed reverse feature, the FWD- The Lo range for the T307M is used in
REV selector must first be moved into the “REV” conjunction with the first speed gear and the
(Reverse) position before manually shifting main second speed gear to provide two “Lo” ratios. The
case gears, to achieve the desired reverse Lo range for the T308M is used in conjunction
speed. with the first speed gear, the second speed gear
and the third speed gear to provide three “Lo”
The main case and bell housing are a one-piece ratios. These Lo-range gears are intended for off-
casting made from aluminum and heat-treated for highway use and in slow moving applications
strength. such as curb pouring, material spreading, and
heavy load/steep grade operations.
The bearings are housed in cast-iron bearing 7
retainers (covers). Tapered roller bearings are

used at each end of all countershafts.
All gears are of the spur-type design and are in

constant mesh with mating gears. All shifting is
done by forks and sliding clutches. The main
case shift rails and forks are integral with the shift
cover.
A single gear shift lever is used to accomplish

shifting. The shift lever is equipped with a range
selector that directs air pressure to the compound
range shift cylinder for Lo or Hi (Direct) ranges. A
forward/reverse (FWD-REV) selector, also on the
shift lever, directs air pressure to a forward-
reverse cylinder for forward or reverse selection. Figure 7 — MACK RD600
For transmissions having compound neutral
control (compound neutralizing), a dash-mounted In Hi range (Direct), there are five forward gears
neutral switch is provided to obtain Neutral. that can be shifted in the standard manner. For
normal highway use, start in first gear Hi range
(Direct) and shift through second, third, fourth
and fifth. Make sure to double clutch when
moving up or down through the gears.
Page 15

TRANSMISSION LUBRICATION Transmission Case Oil Cooler Line
Plugs
Splash Lubrication
An integral oil cooler pump system has been
All parts inside the transmission are lubricated by developed for MACK transmissions. The oil
a splash-and-gravity system. To minimize cooler is optional for engine ratings under 400 hp
churning, only the lower countershaft dips into the and chassis ratings under 80,000 GVW.
lubrication oil. As the gears on the lower
countershaft spin, a constant spray of oil is The oil cooler system is required when the
directed to all internal parts of the transmission. engine rating is equal to or exceeds 400 hp, or
The oil cools as it circulates over the aluminum the chassis rating is greater than 80,000 GVW.
case. Troughs and passages, cast into the inside
of the case, capture and direct oil to the bearings. On transmissions that are not built with the oil
8
cooler pump system, the tube line openings are
plugged or capped. The main suction tube area
contains a metal plug threaded into the case and
the outlet fitting area receives a plastic cap.
9
Figure 8 — Splash Lubrication
Figure 9 — Transmission Case Oil Cooler Line Plugs
1. Outlet Plastic Cap 2. Suction Tube Plug
Page 16

Magnetic Oil Filter Plug
A magnetic oil filter plug is threaded into the right
side of the transmission case. The magnetic plug
removes ferrous metallic particles in the oil as the
oil passes the plug. After passing the magnetic
plug, the oil returns (by gravity) down into the
transmission case sump. The magnetic plug is
removable from the outside of the transmission
without the necessity of draining the oil since this
plug is above the oil level. The drain plug at the
bottom of the case is also magnetic.
10
Figure 10 — Plug Locations
1. Magnetic Filter Plug 3. Oil Drain Plug

2. Oil Temperature Sensor 4. Oil Fill and Level Plug
Page 17

T307M GEAR RATIOS AND SHIFT PATTERN
11
Figure 11 — Shift Pattern
T307M TRANSMISSION GEAR RATIOS

Main Case Gear Lo Direct Reverse
1 14.16 5.24 12.42
2 8.23 3.05 7.23
3 (4.70) 1.73 4.12
4 (2.70) 1.00 (2.37)
5 (1.61) 0.60 (1.42)
The ratios in parenthesis are not practical to use.
Page 18

T308M GEAR RATIOS AND SHIFT PATTERN
12
Figure 12 — Shift Pattern
T308M TRANSMISSION GEAR RATIOS

Main Case Gear Lo Direct Reverse
1 20.08 5.24 17.62
2 11.68 3.05 10.25
3 6.63 1.73 5.82
4 (3.84) 1.00 (3.37)
5 (2.29) 0.60
The ratios in parenthesis are not practical to use.
Page 19

T307M SHIFTING Downshifting
INSTRUCTIONS Downshift in reverse order from fifth through first
The T307M is a nonsynchronized transmission. gear (Direct), double clutching through each gear.
The transmission features a Lo and Direct The next downshift is to second gear Lo range
auxiliary compound section controlled by two (2nd Lo). Depress the clutch pedal and release
selectors located on the main shift lever (range the accelerator pedal. Push the shift lever to
selector and forward/reverse selector). Neutral and then move the range selector to Lo
range, double clutch and move the shift lever to
The T307M transmission also provides a multi- the second gear position. This is second gear Lo
speed reverse feature by means of reverse range (2nd Lo), which provides the next lower
gearing in the compound case that works in ratio. When ready for the lowest ratio available,
conjunction with the first, second, and third speed double clutch and downshift to first gear Lo range
gears in the main case. The forward/reverse (1st Lo).
(FWD-REV) selector must be moved to the “REV”
(Reverse) position in order to use the multi-speed
reverse feature.
Be careful not to overspeed the engine when
The Lo range provides two low ratios. Direct downshifting the transmission, damage to
provides five forward gears that can be shifted in powertrain components can result.
the standard manner. Remember to double clutch
when moving up or down through the gears. For
normal highway use, start in Direct first gear and Using Reverse
shift through second, third, fourth, and fifth. The
two gears in Lo range are designed for off- To use the reverse gear speeds proceed as
highway use and in slow moving applications follows:
(curb pouring, material spreading, heavy load/
steep grade operation). r Bring the vehicle to a complete stop. Check
that the shift lever is in the Neutral position.
r Move the forward/reverse (FWD-REV)
Upshifting selector to “REV” (Reverse). Depress the
To upshift the transmission begin in first gear (1st clutch pedal and move the shift lever to the
Lo) with the range selector in Lo range. Refer to first gear position. Release the clutch pedal
Figure 11. Double clutch and upshift in the normal and apply the accelerator to reach the top of
manner to second gear Lo range (2nd Lo). When the operating range. Shift through second
ready to upshift again, depress the clutch pedal and third gear positions as needed for
and release the accelerator pedal. Push the shift desired reverse speed, being sure to double
lever to Neutral, then move the range selector to clutch from one gear to the next.
“D” (Direct), double clutch and move the shift
lever back to the first gear position. This is first
gear Direct (1st Hi), which provides the next
higher ratio. Release the clutch pedal and apply
the accelerator to reach the top of the operating
range. Shift through second, third, fourth, and fifth
(Direct), being sure to double clutch from one
gear to the next.
Page 20

Obtaining Neutral in Compound T308M SHIFTING
Case (T307M) INSTRUCTIONS
The T307M transmission features an optional
dash-mounted neutral switch. Also, the standard
two-position range shift cylinder is replaced with
the three-position range shift cylinder, to obtain Make sure air pressure is at least 100 psi and unit
neutral in the compound case. Having compound is armed before making range shifts. Always start
neutralizing allows variable speed stationary in Lo range. This also applies to dynamometer
vehicle operation when the transmission is testing. When the vehicle is stationary, do not
equipped with a rear case side-mounted PTO. shift into Hi range and then start moving the
vehicle either in Forward or in Reverse. Damage
to the synchronizer can result. To avoid
Stationary PTO Operation (T307M) transmission damage, do not change range while
in reverse.
1. Depress the clutch pedal.
2. Apply the parking brake. The T308M transmission features a Lo and Direct
3. Move the shift lever to Neutral. auxiliary compound section controlled by two
selectors located on the main shift lever, a range
4. Move the dash-mounted neutral switch to selector and a forward/reverse selector. The
the Neutral position. compound section of the T308M is equipped with
5. Move the shift lever to the appropriate gear a synchronizer assembly to facilitate Lo or Direct
position (main case ratio) for required PTO range shifting.
operation.
The T308M transmission also provides a multi-
speed reverse feature by means of reverse
gearing in the compound case that works in
Very high PTO speed can cause equipment conjunction with the first, second, and third speed
damage. Select the lowest gear that provides gears in the main case. The forward/reverse
satisfactory PTO operation. (FWD-REV) selector must be moved to the “REV”
(Reverse) position in order to use the multi-speed
reverse feature.
6. Follow the applicable instructions for
engaging the PTO. The Lo range provides three low ratios. Never
7. Engage the clutch. attempt to move a vehicle from a stopped position
in any gear higher than 3rd Lo. It might be
necessary to start the vehicle in 1st Lo or 2nd Lo,
Road Operation (T307M) depending on the load, grade or road conditions.
1. Depress the clutch pedal and move the shift
Direct provides five forward gears that can be
lever to Neutral.
shifted in the standard manner. Remember to
2. Move the dash-mounted neutral switch from double clutch when moving up or down through
the Neutral position. the gears.
3. Move the FWD-REV selector to the desired
forward or reverse position.
4. Move the range selector to the L (Lo range)
or D (Direct) position as needed.
5. Operate the vehicle.
Page 21

Upshifting Using Reverse
To upshift the transmission through all eight To use the reverse gear speeds proceed as
forward speeds, use the following procedure: follows:
With the shift lever in Neutral, move the range
r Bring the vehicle to a complete stop. Check
selector to Lo range and shift the transmission
that the shift lever is in the Neutral position.
into 1st Lo. Refer to Figure 12. Double clutch and
upshift in the normal manner to second gear Lo r Move the forward/reverse (FWD-REV)
range (2nd Lo) and third gear Lo range (3rd Lo). selector to “REV” (Reverse). Depress the
When maximum engine rpm is reached in 3rd Lo, clutch pedal and move the shift lever to the
preselect Hi (Direct) with the range selector and first gear position. Release the clutch pedal
move the shift lever through Neutral to the first and apply the accelerator to reach the top of
gear position (1st Hi). As the shift lever passes the operating range. Shift through second
through Neutral, the transmission is put into Hi and third gear positions as needed for
range (Direct). Continue shifting through the desired reverse speed, being sure to double
normal sequence 2nd Hi, 3rd Hi, fourth and fifth. clutch from one gear to the next.
Make sure to double clutch between gears.
Downshifting
When the vehicle is stationary, do not shift to Hi
Downshift in reverse order from fifth through first range (Direct) and then start moving the vehicle
gear (Direct), double clutching through each gear. in reverse. Damage to the synchronizer can
While in first gear Hi range (Direct), preselect Lo result.
range with the range selector and move the shift
lever through Neutral to the third gear position
(3rd Lo). As the shift lever passes through Obtaining Neutral in Compound
Neutral, the transmission is put into Lo range.
Then down shift to 2nd Lo and then 1st Lo. Make Case (T308M)
sure to double clutch between all gears. The T308M transmission features an optional
dash-mounted neutral switch. Also, the standard
two-position range shift cylinder is replaced with
the three-position range shift cylinder, to obtain
Be careful not to overspeed the engine when Neutral in the compound case. Having compound
downshifting the transmission, damage to neutralizing allows variable speed stationary
powertrain components can result. vehicle operation when the transmission is
equipped with a rear case side-mounted PTO.
Page 22

Stationary PTO Operation (T308M) T307M AND T308M POWER
1. Depress the clutch pedal. FLOW DIAGRAMS
2. Apply the parking brake. T307M Transmission
3. Move the shift lever to Neutral.
Refer to Figure 11 for gear range and shift lever
4. Move the dash-mounted neutral switch to positions.
the Neutral position. 13
5. Move the shift lever to the appropriate gear

position (main case ratio) for required PTO
operation. Note that some operations (i.e.,
cement pumper) require 8th speed position.
Very high PTO speed can cause equipment

damage. Select the lowest gear that provides
satisfactory PTO operation.
6. Follow the applicable instructions for

engaging the PTO.
7. Engage the clutch.
Figure 13 — First Lo Speed (T307M)
14
Road Operation (T308M)

1. Depress the clutch pedal and move the shift
lever to Neutral.
2. Move the dash-mounted neutral switch from
the Neutral position.
3. Move the FWD-REV selector to the desired
forward or reverse position.
4. Move the range selector to the L (Lo range)
or D (Direct) position as needed.
5. Operate the vehicle.
Figure 14 — Second Lo Speed (T307M)
Page 23

15 18
Figure 15 — First Hi Speed (T307M) Figure 18 — Fourth Speed (T307M)

16 19
Figure 16 — Second Hi Speed (T307M) Figure 19 — Fifth Speed (T307M)

17 20
Figure 17 — Third Speed (T307M) Figure 20 — First Reverse Speed (T307M)
Page 24

21
T308M Transmission
Refer to Figure 12 for gear range and shift lever
positions.
23
Figure 21 — Second Reverse Speed (T307M)

22
Figure 23 — First Lo Speed (T308M)

24
Figure 22 — Third Reverse Speed (T307M)
Figure 24 — Second Lo Speed (T308M)
Page 25

25 28
Figure 25 — Third Lo Speed (T308M) Figure 28 — Third Hi Speed (T308M)

26 29
Figure 26 — First Hi Speed (T308M) Figure 29 — Fourth Speed (T308M)

27 30
Figure 27 — Second Hi Speed (T308M) Figure 30 — Fifth Speed (T308M)
Page 26

31 33
Figure 31 — First Reverse Speed (T308M) Figure 33 — Third Reverse Speed (T308M)
32
Figure 32 — Second Reverse Speed (T308M)
Page 27
NOTES
Page 28
COMPONENT LOCATOR
COMPONENT LOCATOR
Page 29
COMPONENT LOCATOR
TRANSMISSION MAJOR COMPONENT LOCATIONS
T307M Component Locations
34
Figure 34 — Component Locations for T307M
1. Main Drive Pinion Assembly 6. Rear Mainshaft Bearing Cover 11. Front Countershaft Rear Bearing
2. Main Case Shift Cover Assembly 7. Rear Mainshaft Assembly Cover
3. Reverse Idler Gear 8. Rear Countershaft Bearing Cover 12. Front Countershaft Assembly
4. Rear Case Shift Cover Assembly 9. Rear Countershaft Assembly 13. Front Countershaft Front Bearing
5. Range Shift Cylinder Assembly 10. Reverse Speed Gear Cover
14. Front Mainshaft Assembly
Page 30
COMPONENT LOCATOR
T308M Component Locations
35
Figure 35 — Component Locations for T308M — Optional Three-Position Cylinder

(with Compound Neutralizing) Shown
1. Main Drive Pinion Assembly 6. Range Shift Cylinder Assembly 11. Reverse Speed Gear
2. Main Case Shift Cover Assembly 7. Rear Mainshaft Bearing Cover 12. Front Countershaft Rear Bearing
3. Front Mainshaft Assembly 8. Rear Countershaft Bearing Cover Cover
4. Reverse Idler Gear 9. Rear Countershaft Assembly 13. Front Countershaft Assembly
5. Rear Case Shift Cover Assembly 10. Rear Mainshaft and Synchronizer 14. Front Countershaft Front Bearing
Assembly Cover
Page 31
NOTES
Page 32
TROUBLESHOOTING
TROUBLESHOOTING
Page 33
TROUBLESHOOTING
TROUBLESHOOTING CHARTS
NOISY TRANSMISSION
Probable Cause Remedy
a. Low oil level a. Fill to correct level.
b. Wrong oil used b. Drain and refill with correct oil.
c. Mismatched carrier ratios c. Install correct, matched gearing.
d. Resonating (ringing) driveshaft d. Install suitable dampening material, then high-
speed balance the driveshaft.
e. Side-mounted PTO mounted too loose or too tight e. Reinstall PTO correctly.
f. Loose bell housing to flywheel housing capscrews f. Install new capscrews using Loctite.
g. Incorrect clutch driven disks used g. Install correct clutch driven disks.
h. Gears worn, chipped, rough, cracked h. Replace gears.
i. Bearings worn, cracked, corroded, galled, etc. i. Replace bearings.
j. Improperly adjusted eccentric pin j. Adjust properly.
HARD SHIFTING
a. Incorrect driving practices a. Train driver in correct driving practices.
b. Low oil level b. Fill to correct level.
c. Improperly adjusted clutch, clutch linkage, clutch brake, or shift c. Adjust properly.
linkage
d. Wrong oil used d. Drain and refill with correct oil.
e. Remote shift linkage not lubricated e. Clean and lubricate.
f. Shift lever binding or interference f. Relieve binding or interference.
g. Poppet balls binding in their holes g. Clean holes and balls.
h. Loose setscrews in shifters or shift forks h. Tighten to correct torque.
i. Worn spigot bearing i. Replace bearing.
j. Clutch brake tangs broken j. Replace clutch brake.
k. Clutch disks worn into main drive pinion shaft splines k. Replace clutch disks and main drive pinion.
l. Mainshaft snap ring or thrust washer failure l. Replace snap rings or thrust washers.
Page 34
TROUBLESHOOTING
GEAR DISENGAGEMENT (JUMPING OUT OF GEAR)
a. Excessive weight and/or length of gear shift lever and/or knob a. Replace with standard lever and/or knob.
b. Shift lever interference b. Remove interference.
c. Improperly adjusted remote control linkage c. Adjust properly.
d. Worn or loose mounting insulators d. Replace insulators.
e. Loose, broken or missing capscrews between clutch housing and e. Replace capscrews, check threads in case.
flywheel housing
f. Weak or broken shifter rail poppet springs f. Replace springs.
g. Bent or worn shifter forks g. Replace forks.
h. Broken snap rings h. Replace snap rings.
i. Shift rail bent or poppet notches worn i. Replace shift rail.
j. Worn taper or chipped teeth on sliding clutch teeth j. Replace sliding clutch, and mating gear if its
clutch teeth are damaged.
k. Worn or damaged spigot bearing k. Replace bearing.
l. Engine flywheel housing misalignment l. Realign properly.
m. Chassis resonant ride m. Correct resonance.
OIL LEAKS
a. Oil level too high a. Drain to correct level.
b. Drain plug, fill plug, or magnetic filter plug loose b. Tighten plugs.
c. Loose or missing capscrews c. Tighten or replace.
d. Improper lubricant used d. Drain and refill with correct oil.
e. Clogged air breather e. Clean or replace.
f. Gaskets or O-rings broken, shifted, or squeezed out of position f. Replace gaskets or O-rings.
g. Worn oil seals g. Replace seals.
h. O-rings in range shift cylinder leaking air pressure into h. Replace O-rings.
transmission
i. Porous case or housing i. Replace case or housing.
BEARING FAILURE
a. Dirt in system a. Clean system, replace bearings as needed,
flush and refill with clean lubricant.
b. Wrong grade of oil, or contaminated oil b. Clean system, replace bearings as needed,
flush and refill with clean lubricant.
c. Excessive vibrations c. Eliminate vibrations, replace bearings.
d. Binding or seized propeller shaft slip yoke d. Clean and replace as needed.
e. Improper bearing clamping e. Replace bearings and re-clamp using correct
procedures.
f. Improper bearing installation (pre-loads, etc.) f. Replace using correct procedures.
Page 35
TROUBLESHOOTING
RANGE SHIFT MALFUNCTIONS
a. Low system air pressure a. Wait for pressure to build back up to normal.
b. Restricted or clogged air filter in range shift valve b. Replace air filter.
c. Restricted air line (bent, squeezed, twisted, etc.) c. Re-route and/or replace air lines.
d. Air lines too small d. Replace with correct size air lines.
e. Defective O-rings in range shift cylinder e. Replace O-rings.
f. Scored range shift cylinder or piston f. Repair or replace cylinder or piston.
g. Defective range shift valve and/or selector valve (on shift lever) g. Repair or replace as needed.
h. Improper range shift interlock pin height (T308M only) h. Check for incorrect reassembly of parts.
i. Defective synchronizer (T308M only) i. Repair or replace as needed.
j. Range synchronizer friction discs worn or burned (T308M only) j. Replace synchronizer discs as needed.
k. Intermixed synchronizer parts (T308M only) k. Install matched parts.
l. Interlock pin binding in cover bore (T308M only) l. Replace interlock pin and inspect cover bore.
Page 36
MAINTENANCE
MAINTENANCE
Page 37
MAINTENANCE
TRANSMISSION 37
MAINTENANCE
Checking Oil Level
Perform oil level check when the oil is at

operating temperature. The vehicle must be in a
level position, both front-to-rear and side-to-side.
Figure 37 — Correct Oil Level
r Check the transmission oil level at the
intervals specified in the Maintenance and r If oil can only be felt by reaching the finger
Lubrication Manual (TS494). down into the unit, the oil level is too low.
38
r To check the oil level in the transmission,

first remove the oil fill and level plug (2) from
the right side of the main case (Figure 36).
36
Figure 38 — Incorrect Oil Level
r If needed, add specified oil until the oil is

level with the bottom of the fill plug hole. Do
Figure 36 — Oil Fill and Level Plug NOT overfill. Use oil of the proper
specification (refer to “T307M/T308M
1. Magnetic Filter Plug (Not 2. Oil Fill and Level Plug TRANSMISSION SPECIFICATIONS AND
for Level Check) CAPACITIES” on page 230). Also, visit Mack
Trucks, Inc. internet website at
r The oil must be level with the bottom of the www.macktrucks.com for MACK-approved
fill plug hole as determined by feel or by oil suppliers.
visual inspection.
r Reinstall and tighten the oil fill and level plug
(Figure 36) as follows:
1. Check that the O-ring on the plug is not
Be careful not to burn your finger in hot gear cut or damaged.
oil when checking oil level in transmission. 2. Install the plug and tighten to
35–50 lb-ft (47–68 N•m) of torque.
Page 38
MAINTENANCE
Changing Oil OIL FILL
r Remove the oil fill and level plug (2)
(Figure 40), then fill the transmission using
specified oil until the oil is level with the
Preserve the environment! Drained gear oil is bottom of the fill plug hole (also see
classified as a hazardous-toxic material that must Figure 37). Do NOT overfill.
be recovered, handled, stored, and disposed of r Reinstall and tighten the oil fill and level plug
according to applicable State or Federal as follows:
guidelines.
1. Check that the O-ring on the plug is not
cut or damaged.
CHANGE INTERVAL 2. Install the plug and tighten to
r Change the oil at intervals specified in the 35–50 lb-ft (47–68 N•m) of torque.
40
Maintenance and Lubrication Manual
(TS494).
DRAINING OIL
r Before draining oil from the transmission,
the oil should be at normal operating
temperature.
r Remove the magnetic drain plug from the
bottom of the transmission main case and
drain the hot oil into an industry-approved
recovery container.
r Clean and replace the magnetic drain plug,
then tighten the plug to 25–30 lb-ft
(34–41 N•m) torque. Figure 40 — Oil Fill and Level Plug
39
1. Not for Oil Fill 2. Oil Fill and Level Plug
Be sure to add oil to the transmission through the

oil fill hole, NOT the magnetic filter plug hole.
Damage to the transmission and seals can occur
due to overfilling. The magnetic oil filter hole is
higher on the transmission case than the oil fill
hole.
Figure 39 — Plug Locations
1. Magnetic Filter Plug 3. Magnetic Drain Plug

2. Oil Temperature Sensor 4. Oil Fill and Level Plug
Page 39
MAINTENANCE
Magnetic Oil Filter Plug 41
Remove the magnetic oil filter plug and clean the

magnet in the plug every time the oil is changed.
Reinstall the magnetic filter plug and tighten to
20–23 lb-ft (27–31 N•m) torque.
Air Breather
These transmissions have one air breather
located on the main case shift cover. The air
breather should be removed and cleaned with a
suitable solvent every time the oil is changed.
Also check to make sure that airflow through the
breather is unobstructed. Reinstall the air
breather into the main case shift cover and
tighten until snug.
The optional three position range shift cylinder

(for compound neutralizing) contains a vent
screen that should be cleaned when the main
case shift cover breather is cleaned. The
following figure shows the breather vent removed
(1) and installed (2). Check the breather vent for
free airflow. Clean or replace as necessary.
Figure 41 — Shift Cylinder Breather Vent Removed (1)

and Installed (2)
Page 40
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
Page 41
REPAIR INSTRUCTIONS
T307M/T308M TRANSMISSION 1. Clean the transmission externally and mount
it in an overhaul stand. Drain the lubricant
COMPOUND CASE from the transmission. During disassembly,
DISASSEMBLY plug openings with clean shop rags to
prevent dirt from entering the transmission.
[320]
Lift and move the transmission with a hoist, using

Unless a complete overhaul is necessary, remove the two lifting brackets provided.
only those parts required to gain access to faulty
parts. Do not disturb parts with a heavy press fit
(interference fit) unless replacement is 2. Remove the clutch release bearing
necessary. When replacement is necessary, use assembly, shafts, yoke and clutch brake (if
proper press setups and pullers so that usable equipped).
parts are not damaged. 3. Disconnect the air lines attached to the
range shift cylinder and rear case shift cover.
Label the air lines to make sure that they can
be reinstalled correctly. Plug all openings so
that dirt or contamination cannot enter. Air
External inspection of the unit before cleaning lines are installed using a push/pull type
and disassembly often reveals information about fitting and are best removed using an air line
existing conditions. This can help when quick release tool from kit 9032-1800trk
diagnosing problems. which can be obtained through the MACK
parts system. Disconnect the air lines using
the following procedure:
a. Select the appropriate sized release
During disassembly, remember the sequence in tool from kit 9032-1800trk.
42
which parts are removed from the transmission. It
is good practice to keep related parts together in
groups when removed. Small parts such as
shims and spacers can be wired to the larger
pieces they go with. Groups of parts can be kept
together in boxes.
Keep parts such as shim packs, bearing cones,

bearing covers, bearing cups and gears with the
original countershaft from which they were
removed. Mark each countershaft and bearing
cover before removal. Mark the upper left front
and rear countershafts and bearing covers
Figure 42 — Air Line Quick Release Tools
(viewed from rear) as number 1. Mark the upper
right front and rear countershafts and bearing b. Insert the tool over the air line and
covers (viewed from rear) as number 2. Mark the release the line from the fitting by
lower front and rear countershafts and bearing pushing in toward the fitting and at the
covers as number 3. same time pulling on the line.
Page 42
REPAIR INSTRUCTIONS
43
6. Remove the main case shift cover assembly.
This must be done to place at least two
gears into engagement at the same time to
lock up the transmission for yoke (flange)
clamp plate capscrew removal.
45
Figure 45 — Removing Main Case Cover

Figure 43 — Removing Air Line (Typical)
7. Remove the capscrews from the rear case
1. Air Line Quick Release 2. Air Line Fitting Release shift cover and then, remove the cover.
Tool Ferrule 46
4. Plug the air line openings so that dirt or

contamination cannot enter. Label all
disconnected air lines for proper
reassembly.
5. Remove the main case shift cover
capscrews.
44
Figure 46 — Removing Rear Case Shift Cover

Capscrews
To remove the drive yoke clamp plate capscrew,

place at least two gears in both the main case
and compound case into engagement. This is
Figure 44 — Removing Main Case Cover Capscrews done to lock the gearing and prevent shaft
rotation while removing the drive yoke clamp
plate capscrew.
Page 43
REPAIR INSTRUCTIONS
8. Reach through the rear case shift cover 12. Remove the setscrew from the range shift
opening and verify that the forward/reverse fork inside the compound case.
sliding clutch and the range sliding clutch 49
(T308M synchronizer assembly sliding

clutch) are both engaged.
9. Reach through the main case shift cover
opening and move at least two sliding
clutches into engagement. This locks two
different gears to the mainshaft and prevents
the gears and shaft from rotating.
10. Remove the drive yoke (flange) clamp plate
capscrew and clamp plate.
47
Figure 49 — Removing Range Shift Fork Setscrew
13. Remove the capscrews holding the range

shift cylinder on the rear case.
50
Figure 47 — Removing Capscrew and Clamp Plate
11. Remove the drive yoke from the rear of the

transmission, using a suitable puller such as
J 07804-A, or equivalent.
48
Figure 50 — Removing Shift Cylinder Capscrews
Figure 48 — Removing Drive Yoke
Page 44
REPAIR INSTRUCTIONS
14. Remove the range shift cylinder cover and 17. Remove the range shift fork from the
O-ring, and set aside. compound case. Note the offset of the shift
fork. The straight side of the fork faces the
15. Remove the range shift cylinder from the
front of the transmission and the angled side
compound case.
51 of the fork faces the rear of the transmission.
53
Figure 51 — Removing Shift Cylinder

Figure 53 — Shift Fork Offset
16. For transmission models using the two
18. Shift the transmission gears into Neutral.
position range shift cylinder, remove the
Verify that the transmission is in Neutral.
gasket.
52
19. Number the rear countershaft bearing
covers using a grease pencil. Write number
1 on the upper left bearing cover, number 2
on the upper right bearing cover and number
3 on the lower bearing cover.
54
Figure 54 — Mark Rear Countershaft Bearing Covers for

Placement
Figure 52 — Removing Two Position Shift Cylinder
Gasket
Page 45
REPAIR INSTRUCTIONS
20. Remove all of the rear countershaft bearing 22. Remove the rear countershaft bearing
cover capscrews. covers. Jackscrew holes are provided to
55
assist removal.
57
Figure 55 — Removing Rear Countershaft Bearing

Cover Capscrews Figure 57 — Removing Bearing Cover
21. Remove the jackscrew plugs from the 23. Mark the rear countershafts so they can be
covers. installed in the same position during
reassembly.
58
Pry the plugs loose using a thin knife-edge or

similar tool. Do not cut through plugs during
removal. Save for reuse or replace as necessary.
56
Figure 58 — Marking Rear Countershafts
Figure 56 — Removing Jackscrew Plugs
Page 46
REPAIR INSTRUCTIONS
24. Remove the capscrews from the rear 61
mainshaft bearing cover. Remove the

jackscrew plugs from the cover.
59
Figure 61 — Removing “Inner” Case-to-Case Capscrews

(T308M Shown)
Figure 59 — Removing Rear Mainshaft Bearing Cover 27. Remove all of the remaining capscrews and
Capscrews
dowel bolts that hold the compound case to
the main case.
25. Remove the rear mainshaft bearing cover. 62
Jackscrew holes are provided to assist in
removal.
60
Figure 62 — Removing “Outer” Case-to-Case

Capscrews
63
Figure 60 — Removing Rear Mainshaft Bearing Cover
Using Jackscrews
26. Place the transmission in a vertical position

(compound case upward), and remove the
two capscrews located inside the rear case.
When separating the compound case from the

main case, make sure the transmission is in a
vertical position. The rear countershafts are
not supported when the case is removed.
They can fall out and cause damage or
personal injury.
Figure 63 — Removing Dowel Bolts
Page 47
REPAIR INSTRUCTIONS
30. For the T308M transmission, remove the
rear mainshaft and synchronizer assembly.
Use a hoist and threaded eye-bolt to remove
Be sure unit is vertical so that the countershafts the assembly.
will not fall out when the case is removed. 66
28. Using a hoist and chain, remove the rear

case from the main case. Only the
compound case should be lifted, not the rear
mainshaft and output assembly. If
necessary, tap on the end of the rear
mainshaft to loosen it from the rear case.
64
Figure 66 — Removing Rear Mainshaft and

Synchronizer Assembly from T308M
Figure 64 — Removing Compound Case from Main Case
29. For the T307M transmission, remove the

rear mainshaft assembly.
65
Figure 65 — Removing Rear Mainshaft Assembly from

T307M
Page 48
REPAIR INSTRUCTIONS
31. Remove the forward-reverse sliding clutch 32. Remove the three rear countershafts (see
from the mainshaft. arrows).
67 68
Figure 67 — Remove Sliding Clutch Figure 68 — Remove Rear Countershafts
Remember to mark the countershafts prior to

removal, so they can be reinstalled in the same
position as removed.
Page 49
REPAIR INSTRUCTIONS
33. Remove the compound reverse gear snap 35. Draw reference lines on the back face of the
ring and thrust washer from the mainshaft reverse idler cage along the bottom edge of
reverse gear. each reverse idler pin retaining strap. This is
69
done so that the reverse idler pins can be
properly oriented during reassembly.
36. Remove the capscrews and the three
reverse idler pin retaining straps from the
reverse idler cage.
71
Figure 71 — Removing Capscrews and Retaining Straps
37. Using a suitable puller such as J 34630 or

equivalent (Figure 72), remove the three
reverse idler pins (Figure 73).
72
Figure 69 — Remove Snap Ring and Thrust Washer
34. Remove the mainshaft reverse gear from

inside the reverse idler cage.
70
Figure 70 — Removing Reverse Gear Figure 72 — Removing Reverse Idler Pins
Page 50
REPAIR INSTRUCTIONS
73 74
Figure 73 — Reverse Idler Pins
38. Remove each reverse idler gear and rear

thrust washer.
The rear reverse idler gear thrust washers

(Figure 74) have a larger opening than the front
reverse idler gear thrust washers (Figure 75).
Note the orientation of these thrust washers for
proper reassembly.
Figure 74 — Reverse Idler Gear and Rear Thrust Washer
Page 51
REPAIR INSTRUCTIONS
39. Remove the front reverse idler gear thrust 40. Remove the capscrews retaining the reverse
washers from the three reverse idler gear idler cage to the main case and then,
locations. remove the reverse idler cage.
75 76
Figure 76 — Removing Reverse Idler Cage Capscrews
41. Clean the individual compound components.

Inspect the individual compound
components for damage or excessive wear.
Replace the components as necessary.
Refer to “T307M/T308M COMPOUND
Figure 75 — Front Reverse Idler Gear Thrust Washer
COMPONENT DISASSEMBLY” on page 53
for procedures.
Page 52
REPAIR INSTRUCTIONS
T307M/T308M COMPOUND The following procedure applies to both T307M
and T308M transmissions.
COMPONENT DISASSEMBLY
1. Remove the gasket from the bearing cover
Rear Mainshaft Bearing Cover and discard.
79
Disassembly (T307M/T308M)
[321]
77
Figure 79 — Removing Gasket from Bearing Cover
2. Remove the snap ring that retains the

bearing in the cover.
Figure 77 — Rear Mainshaft Bearing Cover Component

Locator
78
The large snap ring is very difficult to
compress and remove, and can fly off the
snap ring pliers, possibly causing personal
injury.
80
Figure 78 — Exploded View of Rear Mainshaft Bearing

Cover
1. Bearing Cover 4. Bearing

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 80 — Removing Bearing Snap Ring from Cover
Page 53
REPAIR INSTRUCTIONS
3. Remove the bearing from the rear mainshaft
bearing cover, using a suitable puller such
as OEM-4052, or equivalent.
81 This action destroys the oil seal. Make sure a
replacement oil seal is readily available.
5. Thoroughly clean the rear mainshaft bearing

cover and bearing, and inspect for damage.
Rear Countershaft Bearing Cover

Disassembly (T307M/T308M)
[321]
83
Figure 83 — Rear Countershaft Bearing Cover

Figure 81 — Removing Bearing from Cover Component Locator
84
4. Remove the oil seal from the rear mainshaft

bearing cover using a hammer and blunt
punch. Drive the seal out from the opposite
side. Discard the oil seal.
82
Figure 84 — Exploded View of Rear Countershaft

Bearing Cover
1. Bearing Cup 3. Shim(s)

2. O-Ring 4. Bearing Cover
Figure 82 — Removing Oil Seal
Page 54
REPAIR INSTRUCTIONS
The following procedure applies to both T307M Rear Case Shift Cover Disassembly
and T308M transmissions and all three rear
countershaft bearing covers. (T307M/T308M)
1. Remove the shim(s) and O-ring from the [323]
shoulder of the rear countershaft bearing
87
cover. Tag the shim(s) and record the
markings for use during reassembly.
85
Figure 87 — Rear Case Shift Cover Component Locator

88
Figure 85 — Removing Cover Shims and O-Ring
2. Remove the bearing cup from the bearing

cover using puller J 21834-4A, or equivalent.
86
Figure 88 — Exploded View of Rear Case Shift Cover
1. Rear Case Shift Cover 8. Shift Fork Setscrew

2. Shift Cover Gasket 9. Shift Fork
3. Snap Ring 10. Cover O-Ring
4. End Plug O-Ring 11. End Plug
Figure 86 — Removing Bearing Cup from Cover 5. End Plug 12. End Plug O-Ring
6. Cover O-Ring 13. Snap Ring
3. Thoroughly clean the bearing cover and 7. Shaft
inspect for damage.
Page 55
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. Slide the shaft out of the shift cover and at
and T308M transmissions. the same time, remove the shift fork. Note
the orientation of the shift fork. The offset
1. Remove the snap ring and end plug from
faces forward.
one shift cylinder boss of the cover. Repeat 91
this procedure on the opposite shift cylinder
boss of the cover.
89
Figure 91 — Removing Shaft and Shift Fork
4. Remove the O-rings from inside the shift

Figure 89 — Removing Snap Ring and End Plug
cylinder bosses of the shift cover.
92
2. Remove the setscrew securing the forward-
reverse shift fork to the shaft (piston).
90
Figure 92 — Removing O-Rings from Cover
Figure 90 — Removing Setscrew from Shift Fork
Page 56
REPAIR INSTRUCTIONS
5. Remove the reverse light switch from the top TWO-POSITION RANGE SHIFT CYLINDER
of the shift cover. WITHOUT COMPOUND NEUTRALIZING
93
95
Figure 93 — Remove Reverse Light Switch
Range Shift Cylinder Disassembly

(T307M/T308M)
[324]
Figure 95 — Cutaway View of Two-Position Range Shift
94 Cylinder
1. Shift Rail Seal 6. Cylinder Housing Cover

2. Piston Seal 7. Capscrew
3. Shift Cylinder Wiper Ring 8. Piston/Shift Rail
4. Shift Cylinder Housing Assembly
5. Housing-to-Cover O-Ring 9. Gasket
Figure 94 — Range Shift Cylinder Component Locator
Page 57
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 4. Remove the wiper ring from the piston
and T308M transmissions. groove.
98
1. With the range shift cylinder in hand, tap the
end of the piston shift rail on a firm surface
to begin removal of the piston/shift rail
assembly.
96
Figure 98 — Removing Wiper Ring from Piston Groove
5. Using a small screwdriver, remove the

Teflon® seal and O-ring expander from the
second piston groove.
Figure 96 — Piston Assembly Partially Removed 99
2. Continue moving the piston/shift rail out of

the cylinder housing to completely separate
the piston/shift rail from the housing.
3. Using a small screwdriver, remove the
Teflon® seal and O-ring from the shift rail
bore inside the cylinder housing.
97
Figure 99 — Removing Teflon® Seal and O-Ring from

Piston Grooves
Figure 97 — Removing Teflon® Seal and O-Ring

Expander
Page 58
REPAIR INSTRUCTIONS
THREE-POSITION RANGE SHIFT CYLINDER The following procedure applies to both T307M
WITH COMPOUND NEUTRALIZING and T308M transmissions.
100
1. With the range shift cylinder in hand, tap the
end of the piston shift rail on a firm surface
to remove the piston assembly.
101
Figure 101 — Piston Assembly Partially Removed
2. Remove the sleeve from the shift piston.

102
Figure 100 — Cutaway View of Three-Position Range
Shift Cylinder
1. Shift Fork 9. Shift Cylinder Cover

2. Rail 10. Piston/Rail Nut
3. O-Ring 11. O-Ring
4. Shift Piston 12. Cover Capscrew
6. Piston Sleeve 14. Breather Vent
7. Shift Cylinder 15. O-Ring
Figure 102 — Removing Sleeve from Piston
Page 59
REPAIR INSTRUCTIONS
3. Remove the shift piston and rail assembly 5. Remove the O-ring from the rear of the shift
from the range shift cylinder. piston.
105
4. Remove the O-ring from the outside front
end of the shift cylinder. Also remove the
shift rail O-ring located inside the cylinder,
using a pick or suitable tool.
103
Figure 105 — Removing O-Ring from Rear of Piston
6. Remove the front O-ring at the shift rail end

of the piston.
106
Figure 103 — Removing Shift Cylinder Outside O-Ring

104
Figure 106 — Removing O-Ring from Front of Piston
Figure 104 — Removing Shift Cylinder Inside O-Ring
Page 60
REPAIR INSTRUCTIONS
7. Remove the nut securing the shift piston to 9. Remove the O-ring from the piston sleeve.
the shift rail. Then separate the rail and 109
piston.
Do not clamp the shift piston or shift rail in a vise.

This can cause damage to the piston or rail,
preventing proper shifting.
To prevent damage to the shift rail or piston when

removing the nut, temporarily install the shift fork
and tighten the setscrew. This provides leverage Figure 109 — Removing O-Ring from Sleeve
for loosening the nut.
10. The breather vent is shown removed (1) and
107
installed (2). Check the breather vent for free
airflow. Clean or replace, if necessary.
110
Figure 107 — Removing Shift Piston Retaining Nut
8. Remove the O-ring located on the shift rail.

108
Figure 110 — Shift Cylinder Breather Vent
Figure 108 — Removing Shift Rail O-Ring
Page 61
REPAIR INSTRUCTIONS
Rear Mainshaft Disassembly 113
(T307M)
[322]
111
Figure 111 — T307M Rear Mainshaft Component Locator
The following procedure applies to the T307M

transmission only.
1. Remove the snap ring from the front end of
the rear mainshaft, using suitable snap ring
pliers. Also, remove the internal-toothed
Figure 113 — Snap Ring and Thrust Washers Removed
thrust washer and the external-toothed
thrust washer.
112
Figure 112 — Removing Snap Ring
Page 62
REPAIR INSTRUCTIONS
114
Figure 114 — Exploded View of T307M Rear Mainshaft Assembly
1. Shaft Snap Ring 9. Sliding Clutch 17. Spigot Bearing

2. Thrust Washer 10. Shaft Snap Ring 18. Rear Mainshaft
3. Thrust Washer 11. Thrust Washer 19. Snap Ring
4. Gear Snap Ring 12. Thrust Washer 20. Rear Mainshaft Bearing
5. Direct-Main Drive Gear 13. Gear Snap Ring 21. Bearing Cover Gasket
6. Thrust Washer 14. Lo-Range Gear 22. Bearing Cover
7. Thrust Washer 15. Thrust Washer 23. Bearing Cover Oil Seal
8. Shaft Snap Ring 16. Spigot Bearing Snap Ring
Page 63
REPAIR INSTRUCTIONS
2. Remove the direct-main drive gear from the 3. Remove the snap ring from inside the direct-
rear mainshaft. main drive gear.
115 116
Figure 115 — Remove Direct-Main Drive Gear
Figure 116 — Remove Snap Ring
Page 64
REPAIR INSTRUCTIONS
4. Remove the external-toothed thrust washer 118
and the internal-toothed thrust washer from

the rear mainshaft.
117
Figure 118 — Remove Internal-Toothed Thrust Washer
Figure 117 — Remove External-Toothed Thrust Washer
Page 65
REPAIR INSTRUCTIONS
5. Remove the second snap ring from the 6. Remove the sliding clutch from the end of
second groove of the rear mainshaft. the shaft.
119 120
Figure 119 — Removing Second Snap Ring Figure 120 — Removing Sliding Clutch
Page 66
REPAIR INSTRUCTIONS
7. Remove the shaft snap ring from inside the 122
Lo-range gear, using suitable snap ring

pliers. Also, remove the internal-toothed
thrust washer and the external-toothed
thrust washer from inside the Lo-range gear.
121
Figure 122 — Remove Snap Ring and Thrust Washers
Figure 121 — Removing Snap Ring
Page 67
REPAIR INSTRUCTIONS
8. Remove the Lo-range gear from the rear 10. Remove the remaining thrust washer from
mainshaft. the shaft. The oil groove side of the thrust
123
washer faces forward, toward the Lo-range
gear.
125
Figure 123 — Removing Lo-Range Gear
9. Remove the snap ring from inside the Lo- Figure 125 — Removing Thrust Washer
range gear.
124
Figure 124 — Removing Lo-Range Gear Snap Ring
Page 68
REPAIR INSTRUCTIONS
11. Remove the spigot bearing snap ring from 12. Using a suitable bearing puller, remove the
the front of the rear mainshaft. spigot bearing from the front end of the rear
126
mainshaft.
127
Figure 126 — Removing Spigot Bearing Snap Ring

Figure 127 — Removing Spigot Bearing
Page 69
REPAIR INSTRUCTIONS
Rear Mainshaft and Synchronizer 2. Remove the smaller shaft snap ring from the
front end of the rear mainshaft.
Disassembly (T308M) 130
[322]
128
Figure 130 — Removing Smaller Snap Ring
3. Remove the larger gear snap ring from

Figure 128 — T308M Rear Mainshaft and Synchronizer inside the direct-main drive gear.
131
Component Locator
The following procedure applies to the T308M

transmission only.
1. Place the rear mainshaft and synchronizer
assembly in a soft-jawed vise. Rest the Lo-
range gear on top of the vise jaws and
tighten on shaft.
129
Figure 131 — Removing Larger Snap Ring in Gear
Figure 129 — Position Assembly in Soft Jaw Vise
1. Rear Mainshaft 2. Lo-Range Gear

3. Soft Jaw Inserts
Page 70
REPAIR INSTRUCTIONS
132
Figure 132 — Exploded View of T308M Rear Mainshaft and Synchronizer Assembly
1. Snap Ring 13. Support Tube 23. Internal-Toothed Thrust Washer

2. Snap Ring 14. Synchronizer Pin 24. Lo-Range Gear Snap Ring
3. Direct-Main Drive Gear Bearing 15. Sliding Clutch 25. Lo-Range Gear Hub
4. Direct-Main Drive Gear 16. Preload Spring Assembly 26. Spigot Bearing Snap Ring
5. Snap Ring 16A. Inner Spring 27. Spigot Bearing
6. Snap Ring 16B. Outer Spring 28. Rear Mainshaft
7. Thrust Plate (Spacer) 17. Synchronizer Pin 29. Bearing Snap Ring
8. Friction Disc (4) 18. Clutch Housing 30. Lo-Range Gear
9. Reaction Disc (4) 19. Threaded Insert (3) 31. Rear Mainshaft Bearing
10. 12-Point Capscrew (3) 20. Reaction Disc (4) 32. Rear Mainshaft Bearing Cover
11. Nonthreaded Insert (3) 21. Friction Disc (4) Gasket
12. Clutch Housing 22. Snap Ring 33. Rear Mainshaft Bearing Cover
34. Bearing Cover Seal
Page 71
REPAIR INSTRUCTIONS
4. Remove the direct-main drive gear and ball 5. Remove the ball bearing from the direct-
bearing from the synchronizer assembly. main drive gear, using a suitable driver and
Place two long-handled pry bars between hammer. Place the gear on a suitable
the synchronizer thrust plate (spacer) and support to allow the bearing to be driven out
direct-main drive gear. Apply a steady of the front of the gear.
pressure on the gear to overcome the slight 134
interference fit between the shaft and ball

bearing inner race.
133
Figure 133 — Removing Direct-Main Drive Gear
Figure 134 — Removing Main Drive Gear Bearing
1. Bearing Driver 2. Gear Support
Page 72
REPAIR INSTRUCTIONS
6. Remove the snap ring from inside the direct- 8. Remove the thrust plate (spacer) from the
main drive gear. front synchronizer disc pack.
135 137
Figure 135 — Removing Gear Snap Ring Figure 137 — Removing Thrust Plate from Front
Synchronizer Disc Pack
1. Rear Snap Ring Groove 2. Gear Machining Relief
Grooves 9. Remove the first friction disc from the front
synchronizer disc pack.
138
7. Remove the remaining snap ring from the
front end of the rear mainshaft.
136
Figure 136 — Removing Shaft Snap Ring
Figure 138 — Removing Friction Disc
Page 73
REPAIR INSTRUCTIONS
10. Remove the first steel reaction disc from the 13. Set aside the synchronizer assembly for
front synchronizer disc pack. later disassembly.
139 141
Figure 141 — Synchronizer Assembly Removed
14. Remove the first steel reaction disc from the

rear synchronizer disc pack.
142
Figure 139 — Removing Reaction Disc
11. Continue removing the friction and reaction

discs until all are removed.
12. Remove the synchronizer assembly from the
rear mainshaft.
140
Figure 142 — Removing Reaction Disc
Figure 140 — Removing Synchronizer Assembly
Page 74
REPAIR INSTRUCTIONS
15. Remove the first friction disc from the rear 18. Remove the internal-toothed thrust washer
synchronizer disc pack. from inside the Lo-range gear hub.
143 145
Figure 143 — Removing Friction Disc from Output Shaft
16. Continue removing the friction and reaction

discs until all are removed.
17. Remove the shaft snap ring from inside the
Lo-range gear hub.
144 Figure 145 — Removing Hub Thrust Washer
19. Remove the larger snap ring that secures

the Lo-range gear to the gear hub.
146
Figure 144 — Removing Shaft Snap Ring
Figure 146 — Removing Gear-to-Hub Snap Ring
Page 75
REPAIR INSTRUCTIONS
20. Remove the Lo-range gear from the hub. 22. Remove the spigot bearing snap ring from
Notice that the ground surface on the gear inside the front of the rear mainshaft.
faces the front of the transmission. 149
147
Figure 147 — Removing Lo-Range Gear from Hub
21. Remove the Lo-range gear hub from the

rear mainshaft.
148
23. Using a suitable bearing puller, remove the

spigot bearing from the front end of the rear
mainshaft.
150
Figure 148 — Removing Lo-Range Gear Hub
Figure 150 — Removing Spigot Bearing
Page 76
REPAIR INSTRUCTIONS
SYNCHRONIZER DISASSEMBLY 2. Remove the clutch housing from the
151 assembly.
3. Remove the three support tubes and
preload springs from the synchronizer
assembly.
153
Figure 153 — Remove Synchronizer Support Tubes and

Preload Springs
Figure 151 — Exploded View of T308M Synchronizer
Assembly 4. Remove the sliding clutch from the
remaining clutch housing.
1. 12-Point Capscrew 7. Clutch Housing
2. Nonthreaded Insert 8. Threaded Insert
3. Clutch Housing 9. Support Tube
4. Synchronizer Pin 10. Preload Spring
5. Sliding Clutch Assembly
As you remove the synchronizer sliding clutch
6. Synchronizer Pin and pins, notice that the pins and the sliding
clutch are marked with the letter “R”, which
stands for “Rear.” All the R marks on either end of
1. Remove the 12-point capscrews and
the pins are placed on the same side of the
threaded and nonthreaded inserts from the
sliding clutch marked with the letter R. During
synchronizer assembly.
152
reassembly, make sure to coordinate all R marks
on both the pins and sliding clutch of the
synchronizer assembly. All R marks must face
the rear of the transmission when installed.
Figure 152 — Removing 12-Point Capscrews
Page 77
REPAIR INSTRUCTIONS
154
Rear Countershaft Disassembly
(T307M/T308M)
[322]
156
Figure 154 — Letter “R” on Sliding Clutch and

Synchronizer Pins
1. “R” on Sliding Clutch 2. “R” on Synchronizer Pins

Faces Rearward Faces Rearward
5. Remove the synchronizer pins from the Figure 156 — Rear Countershaft Component Locator
remaining clutch housing. 157
155

Figure 155 — Removing Synchronizer Pins
1. Front Bearing Cone 6. Rear Bearing Cone
6. Thoroughly clean the synchronizer 2. Reverse Speed Gear 7. Rear Countershaft
assembly and inspect for damage. 3. Spacer (Lo-Range Gear Part of
4. Direct-Main Drive Gear Shaft)
5. Key
Page 78
REPAIR INSTRUCTIONS
3. Using the press arrangement as shown
(Figure 159), continue to press the
countershaft through the main drive gear (1).
Before attempting to disassemble the rear Do not allow the countershaft to fall as the
countershaft, it is necessary to verify that the shaft exits the main drive gear.
reverse gear and main drive gear actually are
keyed to the shaft. If examination of gear and 4. Also, remove the key (2) from the
shaft construction reveals that these gears countershaft.
159
and shaft are made as one continuous part,
do NOT try to press these gears from the shaft
or deadly explosion of pieces can result.
Note that the Lo-range gear is designed as an

integral part of the rear countershaft and
cannot be removed.
The following procedure applies to both T307M

countershafts.
1. Support the countershaft main drive gear on
a press table as shown, then press the
countershaft through the following parts
(refer to Figure 158):
r Bearing cone (1)
r Countershaft reverse gear (2)
r Spacer (3)
2. As necessary, label and save the parts for Figure 159 — Pressing Shaft Through Main Drive Gear
reassembly.
158 5. Install a bearing separator such as J 8176 or
equivalent, below the rear bearing cone as
shown (Figure 160). To avoid damage to the
bearing cone during removal, make sure
that the bearing separator engages only the
bearing cone inner race. Press the
countershaft through the bearing cone. Do
not allow the countershaft to fall as the shaft
exits the bearing cone.
160
Figure 158 — Pressing Shaft Through Bearing Cone,

Reverse Gear and Spacer
Figure 160 — Pressing Shaft Through Bearing Cone
Page 79
REPAIR INSTRUCTIONS
Reverse Idler Gear Disassembly The following procedure applies to both the
T307M and T308M transmissions and all three
(T307M/T308M) reverse idler gears.
[322] 1. Press the bearing out of the reverse idler
gear using a suitable driver.
161 163
Figure 161 — Reverse Idler Gear Component Locator

162
Figure 163 — Pressing Out Reverse Idler Gear Bearing
2. Thoroughly clean the reverse idler gear and

inspect for damage.
Figure 162 — Exploded View of Reverse Idler Gear
1. Thrust Washer 4. Thrust Washer

2. Reverse Idler Gear 5. Reverse Idler Pin
3. Bearing
Page 80
REPAIR INSTRUCTIONS
INSPECTION OF PARTS
Inspection and Cleaning If a bearing cone or cup needs replacement, a
complete new assembly, including cup and
Thoroughly clean the case, cover and all other
mating cone, is required.
parts of the transmission. Remove all grease, oil
and foreign matter, using a suitable safety Do not remove a new bearing from its packing
solvent. Dry the parts with moisture-free before time of installation. Never clean protective
compressed air. grease from new bearings.
Do not handle bearings with dirty hands. Rags
Bearings must be clean and lint free.
[322]
Clean bearings that are satisfactory for
reinstallation. Wrap the bearings in clean, lint-free
Soak bearings in fresh, clean solvent to loosen all cloth and store for assembly.
hardened grease and foreign matter until the
bearings are clean. Blow them dry with filtered,
moisture-free compressed air. Gears
[322]
Do not spin the bearings with compressed air. Replace all gears with teeth that show signs of
Doing so can damage the bearings. abrasive wear, scratching (except normal
manufacturing tool marks), ridging, scoring,
surface fatigue, pitting, spalling, corrosive wear,
Inspect each bearing for flaking, cracks, digging in or cracking. Gears should always be
fractures, cavities, indentations, measurable inspected using magnaflux (or similar system) for
wear, brinelling, fretting, corrosion, nicking, cage cracks that would not otherwise be detected.
wear or deformation and other damage. If any of
these conditions are present, replace the bearing.
Apply a light coat of fresh, clean, specified gear

oil to the bearings. (Refer to Recommended SAE
Grade Gear Oil in “T307M/T308M
TRANSMISSION SPECIFICATIONS AND
CAPACITIES” on page 230.) Turn the races and
bearings slowly by hand to make sure they move
freely and are smooth. If there is resistance to
movement, or the bearing feels rough, replace
the bearing.
Page 81
REPAIR INSTRUCTIONS
Shifter Forks, Sliding Clutches and measurements taken at four locations. Compare
one side of the shaft to the other, AB–CD as
Shift Rails shown.
165
[323]
Replace forks and/or sliding clutches when the
groove side clearance (A) between the fork (2)
and sliding clutch (1) exceeds the limit specified
in “T307M/T308M TRANSMISSION
SPECIFICATIONS” on page 216.
164
Figure 165 — Measuring Shift Rail
Oil Seals
[321]
When an overhaul is required, replace all oil
seals. Be careful to ensure that the sealing
surface of any seal is not damaged, turned back
or cut. A nick on a shaft sealing surface can cut
the seal. Remove sharp edges that can damage
the seal (chamfer edges if possible). Press seals
into housings using smooth, even pressure to
prevent cocking the seal.
Be careful when using any abrasive polishing

methods, such as emery or crocus cloth, on a
sealing surface. It is possible to leave micro-
Figure 164 — Fork and Clutch Detail grooves on the sealing surface. This can cause
oil to leak past the sealing lip(s) of the oil seal.
1. Sliding Clutch 2. Shift Fork With this condition, a new seal will not stop the oil
leak.
Replace shift rails if they are cracked in either the
poppet or setscrew holes. If the clearance
between the shift rail and housing (cover) bore Be careful when installing a shaft through a new
exceeds 0.010-inch (0.254 mm) maximum, seal (or seal over shaft). Lubricate the shaft
determine which part is worn before replacing. before inserting it through the seal. Splines,
Shaft wear can be checked by measuring the keyways and holes in a shaft can damage seals
shaft at an unworn location. Then measure the unless care is taken. Lubricate the seal to prevent
shaft at the worn area and compare damage during the initial start-up period, before
measurements. When measuring a shift rail, the normal lubrication begins. Keep anti-seize and
reading should be an average of diameter sealing compounds away from oil seals.
Page 82
REPAIR INSTRUCTIONS
If an oil seal does not have a preapplied sealant General Inspection
on its outer diameter, apply an appropriate sealer
around the outside diameter to prevent leaks. A cracked transmission case should be replaced.
Check all components for wear or damage.
Lip-type oil seals are precision elements requiring Replace all parts as required. Replace all
close attention and care during installation. gaskets, O-rings and any part that shows
mutilation or damage. Repair all stripped threads,
using a thread repair insert that is compatible with
fasteners that have epoxy-coated threads.
The quality of the installation method and tools
used has a direct influence on the life of the seal. General Reassembly Instructions
Do not use a block of wood or discarded bearing
as a substitute for the proper seal driver. Refer to “T307M/T308M TRANSMISSION
However, a seal driver might not be available with SPECIFICATIONS” on page 216 for torque
some seal applications. In these situations, light specifications, tolerances and fits and limits.
tapping in a circular motion using a light, broad-
faced hammer is acceptable. All working metal parts, especially the bearings,
should be coated with fresh, clean, specified gear
oil while the transmission is being reassembled.
For the seal to function properly, install it squarely This ensures immediate lubrication and helps
with respect to the shaft center line. The seal prevent parts seizure during initial start-up. (Refer
should be kept square within 0.010-inch to Recommended SAE Grade Gear Oil in
(0.254-mm) Total Indicated Runout (TIR). “T307M/T308M TRANSMISSION
Squareness of the seal to the shaft is controlled SPECIFICATIONS AND CAPACITIES” on page
by using the proper seal installation tools as 230.)
shown in Figure 166.
When installing bearings, use proper bearing
Press seals into housings with smooth, even drivers. When pressing a bearing onto a shaft,
pressure to prevent cocking or distorting the seal. apply force only to the inner race of the bearing.
Gently press the seal into place. Correct When pressing a bearing into a housing (bearing
installation depth is achieved as the driver tool cover), apply force only to the outer race. Do not
bottoms against the positioning tool, as shown. apply force that is transmitted through the bearing
166
rollers, balls or cage. Damage and premature
bearing failure can result. Always apply even
pressure to the bearing to prevent it from cocking
or distorting during installation.
As moving parts are installed, check the parts

frequently to make sure that they are moving
freely.
Figure 166 — Rear Mainshaft Bearing Cover Oil Seal

Tools
Page 83
REPAIR INSTRUCTIONS
T307M/T308M COMPOUND The following procedure applies to both the
COMPONENT REASSEMBLY reverse idler gears.
Reverse Idler Gear Reassembly 1. Install a new bearing into the reverse idler
gear using a leader or piloted-type assembly
(T307M/T308M) tool or driver. Always assemble the bearing
with the stamped end (identification marks)
[322] against the angled shoulder of the press
167 tool.
2. Press the bearing until flush with the gear
surface. The bearing must not protrude on
either side of the gear surface. Verify that
the bearing is flush or below flush by using a
straightedge across the gear surface.
When the reverse idler gear bearings are

replaced, it is also necessary to replace the
reverse idler gear pins. The surface of the idler
gear pins is used as the inner race of the drawn
cup needle bearings used in these reverse idler
gears.
Figure 167 — Reverse Idler Gear Component Locator
168

3. Bearing
Page 84
REPAIR INSTRUCTIONS
Rear Countershaft Reassembly The following procedure applies to both the
(T307M/T308M) rear countershafts.
[322]
169
Remember to apply the recommended oil to all

shaft and gear surfaces before pressing parts.
1. Install the key into the keyway of the rear

countershaft using a soft-faced mallet.
171
Figure 169 — Rear Countershaft Component Locator

170
Figure 171 — Installing Key
2. Press the rear countershaft into the direct-

main drive gear. Place the gear onto the
countershaft with the protruding portion of
the hub facing the front of the countershaft.
During all pressing operations involving a key and

Figure 170 — Exploded View of Rear Countershaft keyway, watch the key to make sure that no
material is shaved off as each gear is being
1. Front Bearing Cone 6. Rear Bearing Cone pressed on. This material can collect between the
2. Reverse Speed Gear 7. Rear Countershaft gears and prevent proper seating.
3. Spacer (Lo-Range Gear Part of
5. Key
Page 85
REPAIR INSTRUCTIONS
172
4. Press the rear countershaft into the reverse
speed gear. Position the gear so that the
protruding hub portion of the gear faces the
rear of the countershaft.
174
Figure 174 — Press Countershaft into Reverse Speed

Gear
Figure 172 — Press Countershaft into Direct-Main Drive 5. Press a new rear bearing cone onto the rear
Gear
countershaft using a suitable driver. Apply
3. Install the spacer onto the rear countershaft. force to only the inner race of the bearing
173 cone.
175
Figure 173 — Install Spacer onto Countershaft

Figure 175 — Pressing on Rear Bearing Cone
Page 86
REPAIR INSTRUCTIONS
6. Press a new front bearing cone onto the 178
rear countershaft using a suitable driver.

Apply force to only the inner race of the
bearing cone.
176
Figure 176 — Pressing on Front Bearing Cone

Rear Mainshaft and Synchronizer Assembly
Reassembly (T308M) 1. 12-Point Capscrew 7. Clutch Housing

[322] 3. Clutch Housing 9. Support Tube
177
6. Synchronizer Pin
The following procedures apply to the T308M

transmission only.
Figure 177 — T308M Rear Mainshaft and Synchronizer

Component Locator
Page 87
REPAIR INSTRUCTIONS
SYNCHRONIZER REASSEMBLY 180
1. Install the synchronizer pins into one of the

two identical synchronizer clutch housings.
Install the pins with the marked letter “R”
facing up. Alternate pin heads as shown.
As you install the pins, notice that the pins and

the sliding clutch are marked with the letter “R”,
which stands for “rear.” All of the R marks on
either end of the pins are placed on the same
side of the sliding clutch marked with the letter R.
During reassembly, make sure to coordinate all R
marks on both the pins and sliding clutch of the Figure 180 — Letter “R” on Sliding Clutch and
synchronizer assembly. All R marks must face Synchronizer Pins
the rear of the transmission when installed.
1. “R” on Sliding Clutch 2. “R” on Synchronizer Pins
179
Faces Rearward Faces Rearward
181
Figure 181 — Installing Synchronizer Pins
Figure 179 — Synchronizer Pins Marked “R”
Page 88
REPAIR INSTRUCTIONS
2. Assemble the three synchronizer preload 3. Position the synchronizer sliding clutch on
springs. The preload springs are made up of the bench with the marked letter “R” facing
two pieces. Make sure that the preload up. Install the three preload springs into the
springs are assembled with the smooth- sliding clutch holes provided. The smaller
sided inner portion of the spring inside the holes are ramped and found halfway
notched (detent) outer portion of the spring. between the three largest holes.
182 183
Figure 182 — Assembling Preload Springs Figure 183 — Installing Preload Springs into Sliding
Clutch
Page 89
REPAIR INSTRUCTIONS
184

7. Thrust Plate (Spacer) 17. Synchronizer Pin 29. Bearing Snap Ring
Page 90
REPAIR INSTRUCTIONS
4. Install the sliding clutch (with preload 7. Install the three 12-point screws plus
springs) over the synchronizer clutch threaded and nonthreaded inserts into the
housing and pins. Make sure the marked largest holes of the synchronizer assembly.
letter “R” on the clutch is facing in the same 186
direction as the R marked on the pins.
With this sliding clutch design, it is very important

to make sure that the clutch is facing in the
correct direction when installed. This is due to the
differing number of clutch teeth on the Lo-range
and Direct (Hi)-range sides of the range clutch.
The Lo-range side contains 21 clutching teeth
and the Direct-range side contains 22 clutching
teeth. Incorrectly installing the sliding clutch
prevents proper shifting.
5. Install the three support tubes into the Figure 186 — Installing 12-Point Screws and Inserts
synchronizer assembly.
185
8. Tighten the three 12-point screws to
specification, using a suitable hex wrench to
hold the threaded inserts.
187
Figure 185 — Install Support Tubes into Assembly
6. Install the remaining synchronizer housing

over the pins, tubes and springs. Align the Figure 187 — Tightening 12-Point Screws
housing with the pin heads.
After the synchronizer has been assembled,
continue with rear mainshaft reassembly.
Page 91
REPAIR INSTRUCTIONS
REAR MAINSHAFT REASSEMBLY 189
1. Press a new spigot bearing into the front of

the rear mainshaft using a leader or piloted-
type assembly tool or driver. Always
assemble the bearing with the stamped end
(identification marks) against the angled
shoulder of the tool.
Drawn cup needle bearings (spigot bearings)

have a specific direction that they must be
installed. The radius end of the bearing is to be
installed first. The press tool should be used
against the flat end of the bearing, not the radius
end.
188
Figure 189 — Installation of Drawn Cup Bearings
1. Stamped End of Bearing 3. Rear Mainshaft

2. Press Tool Leader or
Pilot
Figure 188 — Pressing Spigot Bearing into Rear

Mainshaft
Page 92
REPAIR INSTRUCTIONS
2. Install the snap ring into the front end of the 4. Install the Lo-range gear onto the hub.
rear mainshaft to secure the spigot bearing. Notice that the ground surface on the gear
190
faces the front of the transmission (see
arrow in Figure 192).
192
Figure 192 — Installing Lo-Range Gear onto Hub
5. Using suitable snap ring pliers, install the

gear-to-hub snap ring into the groove in the
outside of the hub.
Figure 190 — Installing Spigot Bearing Snap Ring 193
3. Install the Lo-range gear hub onto the rear

mainshaft.
Make sure that the oil holes in the Lo-range gear

hub are open and free to channel oil to the
synchronizer discs.
191
Figure 193 — Installing Gear-to-Hub Snap Ring
Figure 191 — Installing Lo-Range Gear Hub onto Rear

Mainshaft
Page 93
REPAIR INSTRUCTIONS
6. Install the internal-toothed thrust washer into 8. Apply specified gear oil to both sides of each
the hub of the Lo-range gear. synchronizer friction disc before installation.
194
9. Install an internal-toothed friction disc onto
the machined surface of the Lo-range gear.
196
Figure 196 — Installing Friction Disc
10. Install an external-toothed steel reaction disc

onto the friction disc just installed.
197
Figure 194 — Installing Thrust Washer into Lo-Range

Gear Hub
7. Install the snap ring (into the groove marked

with an arrow) onto the rear mainshaft inside
the Lo-range gear hub.
195
Figure 197 — Installing Reaction Disc
11. Continue alternately installing the friction

and steel reaction discs until four of each
have been installed. Make sure to lubricate
each friction and reaction disc with specified
gear oil during installation. The last disc
Figure 195 — Installing Snap Ring Inside Lo-Range Gear installed should be an external-toothed steel
Hub reaction disc.
12. Align all external teeth of the steel reaction
discs and then install the synchronizer
assembly over the rear mainshaft. The side
of the synchronizer sliding clutch marked “R”
must face down, toward the rear of the shaft
when installed.
Page 94
REPAIR INSTRUCTIONS
14. Install an internal-toothed friction disc onto
the steel reaction disc just installed. Make
sure to lubricate both sides of the disc with
Rotating the synchronizer assembly back and the specified gear oil before installation.
forth during installation helps the assembly to 200
align with the external teeth of the steel reaction

discs.
198
Figure 198 — Installing Synchronizer Assembly
13. Install an external-toothed steel reaction disc

onto the front synchronizer clutch housing, Figure 200 — Installing Friction Disc Inside
aligning the teeth. Lubricate both sides of Synchronizer
the disc with the specified gear oil before
installation. 15. Continue alternately installing the remaining
199 friction and steel reaction discs until four of
each have been installed. Make sure to
lubricate each friction and reaction disc with
specified gear oil before installation. The last
disc installed should be an internal-toothed
friction disc.
Figure 199 — Installing Reaction Disc
Page 95
REPAIR INSTRUCTIONS
16. Install the synchronizer disc pack spacer 18. Install the gear snap ring into the second
onto the friction disc just installed. Lubricate from rear groove of the direct-main drive
the spacer with specified gear oil before gear.
installation.
201
There are four grooves on the inside of the direct-

main drive gear. The two outer grooves are relief
grooves and are not to be used to retain snap
rings. To properly retain the ball bearing, use only
the two inner snap ring grooves.
203
Figure 201 — Installing Spacer
17. Install the snap ring into the 2nd groove

shown, on the rear mainshaft.
202
Figure 203 — Installing Gear Snap Ring
1. Rear Snap Ring Groove 2. Gear Machining Relief

Grooves
Figure 202 — Installing Snap Ring onto Rear Mainshaft
Page 96
REPAIR INSTRUCTIONS
19. Align the internal teeth of the synchronizer 21. Using a brass drift and hammer, seat the ball
friction discs and then, install the direct-main bearing in the direct-main drive gear until the
drive gear into the friction disc teeth, over inner race contacts the shaft snap ring.
the rear compound mainshaft.
204
Force should be applied only to the inner race of

the ball bearing, not the balls, cage or outer race.
206
Figure 204 — Installing Direct-Main Drive Gear
20. Install the ball bearing into the direct-main

drive gear, over the end of the rear
mainshaft.
205
Figure 206 — Seating Ball Bearing
22. Install the shaft snap ring onto the front end
of the rear mainshaft and against the inner
race of the ball bearing, using suitable snap
ring pliers.
207
Figure 205 — Installing Ball Bearing
Figure 207 — Installing Snap Ring onto Rear Mainshaft
Page 97
REPAIR INSTRUCTIONS
23. Install the gear snap ring into the inner Rear Mainshaft Reassembly
groove of the direct-main drive gear.
208 (T307M)
[322]
210
Figure 208 — Installing Snap Ring onto Direct-Main

Drive Gear
24. Paint three sets of corresponding timing

Figure 210 — Rear Mainshaft Component Locator
marks on the teeth of both the direct-main
drive gear and the Lo-range gear as shown:
r Paint the gear teeth on either side of
every 10th space on the direct-main
drive gear.
r Paint the gear teeth on either side of
every 18th space on the Lo-range gear.
209
Figure 209 — Painting Timing Marks on Gears
Page 98
REPAIR INSTRUCTIONS
211

Page 99
REPAIR INSTRUCTIONS
The following procedure applies to the T307M 213
transmission only.
1. Press a new spigot bearing into the front of
the rear mainshaft using a leader or piloted-
type assembly tool or driver. Always
assemble the bearing with the stamped end
(identification marks) against the angled
shoulder of the tool.
Drawn cup needle bearings (spigot bearings)

have a specific direction that they must be
installed. The radius end of the bearing is to be
installed first. The press tool should be used
against the flat end of the bearing, not the radius
end.
212
Figure 213 — Installation of Drawn Cup Bearings
1. Stamped End of Bearing 3. Rear Mainshaft

2. Press Tool Leader or
Pilot
Figure 212 — Position Spigot Bearing
Page 100
REPAIR INSTRUCTIONS
214
2. Install the snap ring into the front end of the
rear mainshaft to secure the spigot bearing.
215
Figure 214 — Pressing Spigot Bearing into Shaft
Figure 215 — Installing Snap Ring
Page 101
REPAIR INSTRUCTIONS
4. Install the snap ring into the snap ring
groove of the Lo-range gear.
217
Prior to thrust washer installation, apply fresh

grease (MACK MG-C, or equivalent) to grooved
face of washer. Lubricate each thrust washer in
this manner for reassembly.
3. Install the thrust washer onto the shaft.

Install the thrust washer so that the
lubrication grooves face forward, toward the
Lo-range gear.
216
Figure 217 — Installing Snap Ring into Lo-Range Gear
5. Install the Lo-range gear onto the rear

mainshaft, over the thrust washer. The
clutching teeth of the gear face forward.
218
Figure 216 — Installing Thrust Washer
Figure 218 — Installing Lo-Range Gear
Page 102
REPAIR INSTRUCTIONS
6. Install the following parts into the Lo-range 7. Install the snap ring into its groove on the
gear over the rear mainshaft in the following rear mainshaft, using suitable snap ring
order: pliers.
220
r External-toothed thrust washer with oil
grooves facing up (forward)
r Internal-toothed thrust washer
r Snap ring
219
Figure 219 — Install Thrust Washers and Snap Ring
Page 103
REPAIR INSTRUCTIONS
8. Install the sliding range clutch into position 9. Install the shaft snap ring into the second
on the rear mainshaft. groove of the rear mainshaft.
221 222
Figure 221 — Install Sliding Range Clutch
Figure 222 — Installing Snap Ring into Second Groove

of Shaft
Page 104
REPAIR INSTRUCTIONS
10. Install the gear snap ring into the second 11. Install the internal-toothed thrust washer
groove inside the direct-main drive gear. onto the rear mainshaft over the snap ring
223
and then, install the external-toothed thrust
washer. Note that the lubrication grooves in
the external-toothed washer must face down
(rearward, toward internal-toothed thrust
washer).
224
Figure 223 — Install Snap Ring into Second Groove of

Gear
Figure 224 — Install Internal-Toothed Thrust Washer
Page 105
REPAIR INSTRUCTIONS
225
12. Install the direct-main drive gear onto the
rear mainshaft. Paint timing marks at every
10th groove on the direct-main drive gear.
Also paint corresponding timing marks at
every 16th groove of the Lo-range gear.
When completed, there should be three sets
of matching timing marks on both gears.
226
Figure 225 — Install External-Toothed Thrust Washer
Figure 226 — Install Direct-Main Drive Gear and Paint

Timing Marks
Page 106
REPAIR INSTRUCTIONS
13. Install the following parts into the direct-main 14. Install the snap ring into its groove on the
drive gear over the rear mainshaft in the rear mainshaft, using suitable snap ring
following order: pliers.
228
r External-toothed thrust washer with oil
grooves facing up (forward)
r Internal-toothed thrust washer
r Snap ring
227
Range Shift Cylinder Reassembly

(T307M/T308M)
[324]
229
Figure 227 — Install Thrust Washers and Snap Ring in

Order
Figure 229 — Range Shift Cylinder Component Locator
Page 107
REPAIR INSTRUCTIONS
THREE-POSITION RANGE SHIFT CYLINDER The following procedure applies to both T307M
WITH COMPOUND NEUTRALIZING and T308M transmissions.
230
1. The breather vent, shown removed (1) and
installed (2), should be cleaned and checked
to make sure air can flow through it. Replace
if needed.
231

Shift Cylinder

Figure 231 — Range Shift Cylinder Breather Vent
Lubricate all O-rings with a multi-purpose grease

meeting MACK specification MG-C before
installation.
Page 108
REPAIR INSTRUCTIONS
2. Install the O-ring onto the shift sleeve.
232
To prevent damage to the shift rail or piston when

installing the nut, temporarily install the shift fork
and tighten the setscrew. This gives a leverage
advantage for tightening the nut. Remove the
shift fork for later installation.
234
Figure 232 — Installing Shift Sleeve O-Ring
3. Install the small O-ring onto the shift rail.

233
Figure 234 — Tightening Shift Rail Nut
5. Install the middle O-ring onto the shift piston.

235
Figure 233 — Installing Shift Rail O-Ring
4. Insert the rail into the piston and then install

and tighten the shift rail nut to 75–105 lb-ft
(102–142 N•m) torque.
Do not clamp the shift piston or shift rail in a vise.

This can cause damage to the piston or rail,
preventing proper shifting.
Figure 235 — Installing Middle O-Ring onto Piston
Page 109
REPAIR INSTRUCTIONS
6. Install the rear O-ring onto the end of the 8. Install the shift rail O-ring into its location
shift piston. inside the cylinder.
236 238
Figure 236 — Installing Rear O-Ring onto Piston

Figure 238 — Installing Shift Cylinder Inside O-Ring
7. Install the O-ring onto the front end of the
shift cylinder. 9. Install the shift piston and rail assembly into
237
the shift cylinder.
10. Install the sleeve onto the shift piston.
239
Figure 237 — Installing O-Ring onto Cylinder
Figure 239 — Installing Sleeve onto Piston
Page 110
REPAIR INSTRUCTIONS
11. Push the piston assembly into the cylinder. TWO-POSITION RANGE SHIFT CYLINDER
240
WITHOUT COMPOUND NEUTRALIZING
241
Figure 240 — Push Piston Assembly into Cylinder
12. Set the range shift cylinder assembly aside,

along with the shift cylinder cover,
capscrews and new cover O-ring. The
assembly will be installed into the compound
case during reassembly.

Cylinder

The following procedure applies to both T307M

Installing the Teflon® seal into the shift rail bore

requires a special insertion tool to expand the
seal into the groove. This tool must be locally
fabricated from a length of nylon or plastic stock,
7-5/8 inches (19.4 mm) long and 1-1/8 inches
(2.9 mm) in diameter. Refer to Figure 242 for an
illustration of machining dimensions.
Page 111
REPAIR INSTRUCTIONS
242
Figure 242 — Shift Rail Teflon® Seal Insertion Tool
Page 112
REPAIR INSTRUCTIONS
1. Install a new O-ring into the groove in the 4. Align the relief of the insertion tool with the
shift rail bore. “V” fold of the seal. Gently insert the tool into
the bore and push the tool all the way into
2. Form the Teflon® seal into a kidney shape as
the bore until the relief at the end of the tool
243 is fully visible as shown in Figure 245 and
Figure 246.
Use care to avoid damaging the seal. For best

results, gently twist the tool while it is being
inserted. This will aid in reforming the “V” fold of
the Teflon® seal to the circumference of the shift
rail bore.
245
Figure 243 — Forming Teflon® Seal
3. Insert the Teflon® seal into the cylinder bore

and gently work the seal inside the bore and
around the O-ring so that the seal lips seat
over each side of the O-ring.
Note that the back side of the Teflon® seal is

contoured to the shape of the O-ring. It is Figure 245 — Inserting Seal Insertion Tool
important that the contour of the seal fits the 246
O-ring, and that the seal lips are not bent over.
Failure to properly fit the seal around the O-ring
results in damage to the seal during the next step
of the installation process.
244
Figure 246 — Insertion Tool Fully Inserted
Figure 244 — Inserting Teflon® Seal into Shift Rail Bore
Page 113
REPAIR INSTRUCTIONS
7. Using a small engine ring compressor or
other suitable type of ring compressor,
compress the Teflon® seal to facilitate
After the tool has been fully inserted, leave the installation into the cylinder housing.
tool in place while the remaining cylinder rebuild
procedures are performed. This allows the
Teflon® seal to form to the circumference of the
shift rail bore.
If a small engine ring compressor or other
suitable type of ring compressor is not available,
5. On the shift piston, install a new O-ring into a shielded hose clamp may be used. Use of any
the second groove of the piston. hose clamp other than a shielded hose clamp
247
results in damage to the Teflon® seal.
249
Figure 247 — Installing O-Ring in Second Groove on

Piston
Figure 249 — Installing a Shielded Hose Clamp to
6. Carefully install the Teflon® seal over the Compress the Teflon® Seal
O-ring on the second groove of the piston.
248
8. After installing the ring compressor, tighten
sufficiently so that the piston can be installed
into the assembly.
250
Figure 248 — Installing Teflon® Seal
Figure 250 — Tighten Ring Compressor (Shielded Hose

Clamp Shown)
Do not over-stretch the Teflon® seal. Be sure that
the seal lips seat over each side of the O-ring.
Page 114
REPAIR INSTRUCTIONS
11. Install the piston until the ring compressor
rests on the edge of the cylinder housing,
then push the piston into the cylinder far
It is recommended that the piston assembly be enough so that the Teflon® seal just enters
allowed to sit for 15 minutes with the ring the bore. The first ring groove on the piston
compressor (or shielded hose clamp) installed must remain above the cylinder housing so
before proceeding with the next step. This sizes that the wiper ring can be installed.
the seal to the piston. 252
9. With the cylinder housing properly secured

in a vise, install the piston assembly. Be sure
to install the piston with the shift fork locking
bolt hole in the rail facing the air line port in
the cylinder housing assembly as shown in
Figure 251.
251
Figure 252 — Piston Assembly Installed in Cylinder

Housing Bore
12. Remove the ring compressor or shielded

clamp from the second ring area.
13. Install the wiper ring in the first piston ring
groove.
253
Figure 251 — Installing Piston Assembly
10. As the piston/shift rail is installed, the

installation tool is pushed from the cylinder
bore. Do not remove the installation tool
prior to installing the piston/shift rail
assembly.
Figure 253 — Installing Wiper Ring
14. After installing the wiper ring, compress the

wiper with fingers and gently tap the piston
into the cylinder housing until the piston is
fully inside the housing bore.
Page 115
REPAIR INSTRUCTIONS
Rear Case Shift Cover Reassembly The following procedure applies to both T307M
(T307M/T308M)
1. Install the O-rings into the two end plugs.
[323] 2. Install the reverse light switch into the top of
254 the shift cover.
256
Figure 254 — Rear Case Shift Cover Component Locator

255 Figure 256 — Installing Reverse Light Switch
3. Install O-rings into the grooves of the shift

cover cylinder bosses.
257

3. Snap Ring 10. Cover O-Ring Figure 257 — Installing O-Rings into Cover
4. End Plug O-Ring 11. End Plug
5. End Plug 12. End Plug O-Ring
7. Shaft
Page 116
REPAIR INSTRUCTIONS
4. Slide the shaft into the cover and at the 6. Tighten the shift fork setscrew to the
same time, install the shift fork. Note the specified torque.
orientation of the shift fork. The offset faces
7. Install the snap ring and end plug into one
forward.
258 shift cylinder boss of the cover. Repeat this
procedure on the opposite shift cylinder
boss of the cover.
260
Figure 258 — Installing Shaft and Shift Fork
5. Install the setscrew to secure the forward-

Figure 260 — Installing Snap Ring and End Plug
reverse shift fork to the shaft (piston).
259
Figure 259 — Installing Setscrew into Shift Fork
Page 117
REPAIR INSTRUCTIONS
Rear Countershaft Bearing Cover The following procedure applies to both T307M
Reassembly (T307M/T308M) countershaft bearing covers.
[321] 1. Press a new bearing cup into the cover
using a suitable driver.
261 263
Figure 261 — Rear Countershaft Bearing Cover

Component Locator
262
Figure 263 — Pressing Bearing Cup into Cover
2. Keep the original shims and a new O-ring

with each cover for reassembly. Bearing
preload adjustments must be made before
installing.
264

Bearing Cover

Figure 264 — O-Ring and Shim Pack with Cover
Page 118
REPAIR INSTRUCTIONS
Rear Mainshaft Bearing Cover The following procedure applies to both T307M
Reassembly (T307M/T308M)
1. Press a new oil seal into the rear compound
[321] mainshaft bearing cover using J 39854 seal
driver, or equivalent. Refer to “Oil Seals” on
265
page 82 for installation instructions and seal
precautions.
267
Figure 265 — Rear Mainshaft Bearing Cover Component

Locator
266
Figure 267 — Pressing Seal into Bearing Cover

268
Figure 266 — Exploded View of Rear Mainshaft Bearing

Cover

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 268 — Oil Seal Driver
Page 119
REPAIR INSTRUCTIONS
2. Press the bearing into the rear mainshaft 3. Install the snap ring to secure the bearing in
bearing cover using a driver that applies the rear mainshaft bearing cover, using
force only to the outer race of the bearing. suitable snap ring pliers.
269 270
Figure 270 — Installing Snap Ring into Cover
4. Install a new rear mainshaft bearing cover

gasket. Make sure the oil passageways in
the gasket align with the passageways in the
cover.
271
Figure 269 — Pressing Bearing into Cover
Figure 271 — Installing Gasket onto Cover
Page 120
REPAIR INSTRUCTIONS
T307M/T308M TRANSMISSION 273
COMPOUND CASE
REASSEMBLY
[320]
1. Obtain the reverse idler cage. Observe the
word TOP, which is cast into the cage. This
is to aid in correct cage-to-main case
reassembly. Note that the cage capscrew
hole spacing is not symmetrical and so the
cage can only be installed one way.
2. With the transmission in the vertical position,
place the reverse idler cage onto the rear of
the main case. Position the case so that the
word TOP is facing toward the main case top
cover opening. This orients the cage with the
capscrew and idler pin holes in the main
case.
272
Figure 273 — Marking Cage
4. Temporarily move the reverse idler cage to a

clean workbench. Use a brass hammer to
partially install one of the reverse idler pins.
Make sure to align the cutout in the reverse
idler pin with the reference line marked on
the cage.
5. Reposition the cage to the rear of the main
case as described and finish installing the
reverse idler pin. Make sure the idler pin is
correctly aligned with the idler pin hole in the
Figure 272 — Positioning Reverse Idler Cage main case.
The installed pin (Figure 275) will act to
3. If not already done, position a reverse idler maintain correct cage-to-main case
pin retaining strap on the cage so that it lines alignment while capscrews are installed to
up with the capscrew holes in the cage. secure the reverse idler cage to the main
Make sure that the cup lip on strap faces up case.
(toward the top of the transmission case).
Mark a reference line along the bottom edge
of the retaining strap. This is done to assist
in aligning the reverse idler pins during
installation. Mark reference lines along the
remaining two retaining strap locations.
Page 121
REPAIR INSTRUCTIONS
274
6. Install capscrews that secure the reverse
idler cage-to-main case (Figure 276). Use a
5/8-inch offset box end wrench to snug the
capscrews. Tighten the screws to specified
torque using a 3/8-inch drive torque wrench
and shallow 5/8-inch socket (Figure 277) or
use carrier adapter tool J 28506 (5/8-inch
12 point) or equivalent. (Grind socket to fit if
needed.)
276
Figure 274 — Reverse Idler Cage Positioned and

Installing Reverse Idler Pin
275
Figure 276 — Reverse Idler Cage Capscrews

277
Figure 277 — Torquing Idler Cage Capscrews
Figure 275 — Reverse Idler Pin Installed
Page 122
REPAIR INSTRUCTIONS
7. Using a suitable puller such as J 34630, or b. Install reverse idler gear and second
equivalent, remove the temporarily installed thrust washer (Figure 280).
reverse idler pin that was used to maintain 280
cage-to-main case alignment during cage

bolt installation.
278
Figure 280 — Install Reverse Idler Gear and Second

Thrust Washer
c. Insert reverse idler pin into mating hole

Figure 278 — Removing Reverse Idler Pin in cage, being sure to align flat edge of
pin with reference line drawn on face of
8. Install three reverse idler gear assemblies the cage. Use a brass hammer to seat
with thrust washers as follows: the pin in cage and main case
(Figure 281).
a. Install first thrust washer (Figure 279). 281
279
Figure 281 — Seating Reverse Idler Pin

Figure 279 — Install First Thrust Washer
Page 123
REPAIR INSTRUCTIONS
d. Repeat the procedure for the remaining 10. Perform mainshaft reverse gear installation
two reverse idler gears to complete the as follows:
cage and reverse idler gear assembly
a. Paint three equally spaced sets of
(Figure 282).
282 “double” timing marks on gear teeth as
shown (Figure 284).
284
Figure 282 — Idler Gear Assembly Complete
9. Install three reverse idler pin retaining straps

with capscrews. Torque capscrews to Figure 284 — Painting “Double” Timing Marks
specification.
b. Install reverse gear onto mainshaft
(Figure 285).
285
Reverse idler pin retaining straps must face the

top of the idler cage transmission. This is required
to allow the cup-lip to properly collect and
channel oil through the idler pin and into the idler
gear bearing.
283
Figure 285 — Install Mainshaft Reverse Gear
Figure 283 — Tightening Retaining Strap Capscrews
Page 124
REPAIR INSTRUCTIONS
c. Paint single mating timing mark on 12. Rotate the reverse idler gears until the single
each idler gear so that mark is located timing mark on each idler gear lines up with
between “double” marks painted on center line of adjacent main case
mainshaft reverse gear (Figure 286). countershaft (see arrows in Figure 288).
286 288
Figure 286 — Paint Single Mating Timing Mark Figure 288 — Line Up Timing Mark with Countershaft
11. Install reverse gear thrust washer and snap 13. Create a “double” set of timing marks on
ring onto the mainshaft. each reverse idler gear by painting a second
287
mark on the tooth next to the first mark (see
Figure 289). Note that the second tooth
mark can be made to either side of the first
mark, but must be done on the SAME tooth
for each gear so that all three idler gears are
marked the same way.
289
Figure 289 — Paint Second Timing Mark to Create

Figure 287 — Install Thrust Washer and Snap Ring “Double” Set
Page 125
REPAIR INSTRUCTIONS
14. Proceed to make timing marks on each rear b. Also paint a corresponding timing mark
countershaft as follows: on reverse gear tooth positioned
directly above marked main drive gear
a. Observe “o” stamping at front side of
tooth (Figure 291).
main drive gear, then paint a 291
continuous mark across gear tooth
from “o” to backside of gear
(Figure 290).
290
Figure 291 — Paint Timing Mark on Countershaft

Reverse Gear
Figure 290 — Paint Timing Mark from “o”
Page 126
REPAIR INSTRUCTIONS
15. Position the transmission in assembly stand 16. Rotate the three rear countershafts until the
to allow stable vertical installation of the single timing mark on each countershaft
three rear countershafts onto the rear face of main drive gear lines up with the mainshaft
the main case. Install each countershaft in the middle (see arrows in Figure 293).
(“o” stamping facing forward) so that single 293
painted timing mark on the countershaft

reverse gear enters between the set of
“double” painted marks on the mating
reverse idler gear.
292
Figure 292 — Install Countershafts with Timing Marks

Aligned
Figure 293 — Align Timing Mark on Countershafts with
Mainshaft
Page 127
REPAIR INSTRUCTIONS
17. Tilt the three countershafts outward slightly 19. For the T308M transmission, suspend the
and install the forward-reverse sliding clutch rear mainshaft and synchronizer assembly
onto the mainshaft. using a hoist and threaded eye-bolt,
294
positioned for correctly “timed” installation.
The single timing mark on each countershaft
gear must enter between the double painted
marks on mating rear mainshaft gear. (See
arrows, Figure 296.)
296
Figure 294 — Install Sliding Clutch
18. For each countershaft, paint another timing

mark as shown on Lo-range gear tooth
positioned directly above the already
marked main drive gear tooth. Figure 296 — Position T308M Rear Mainshaft and
295 Synchronizer Assembly
20. For the T307M transmission, position the

rear mainshaft assembly for correctly “timed”
installation. The single timing mark on each
countershaft gear must enter between the
“double” painted marks on mating rear
mainshaft gear (see arrows, Figure 297).
Make sure the single timing mark on each

countershaft main drive gear and Lo-range gear
aligns with the double timing marks painted on
the rear mainshaft gears.
Figure 295 — Paint Timing Mark on Each Countershaft
Lo-Range Gear
Page 128
REPAIR INSTRUCTIONS
297
22. Using a hoist and chain, carefully lower the
compound case onto the main case
(Figure 299).
299
Figure 297 — Position T307M Rear Mainshaft Assembly

for “Timed” Installation
21. Install a new compound case-to-main case

gasket (Figure 298). Figure 299 — Install Compound Case
298
23. Install the dowel bolts and nuts, and tighten

them to specified torque.
24. Install the inner and outer (case-to-case)
capscrews to secure the compound case to
the main case. There are two inner
capscrews located just inside the compound
case shift cover opening. Tighten the inner
and outer case-to-case capscrews to the
specified torque.
300
Figure 298 — Install New Gasket (T307M Shown)
Figure 300 — Tightening Case-to-Case Capscrews
Page 129
REPAIR INSTRUCTIONS
25. Install a new gasket onto the rear mainshaft 302
bearing cover, if not already done. Note the

location of the lubrication hole.
26. Install the rear mainshaft bearing cover
assembly to the compound case and secure
with capscrews. Tighten the capscrews to
the specified torque.
301
Figure 302 — Measuring to Determine Shim Pack

Thickness
3. For each countershaft, remove the cover

and add enough shims to bring the space
under the bearing cover to zero. Then
subtract (take away) enough shims to obtain
the required 0.002- to 0.006-inch preload.
Figure 301 — Installing Rear Mainshaft Bearing Cover
Example:
r Begin procedure using NO shims under
Setting Rear Countershaft Bearing the cover.
Preload r Measure space under the cover. For
1. Install the rear countershaft bearing covers, this example, the space is 0.100 inch.
leaving the capscrews loose. No shims or r A 0.100-inch shim pack is needed to
O-rings should be used at this time. “fill” the measured space.
2. Measure the space between the rear r Remove (subtract) 0.002- to 0.006-inch
countershaft bearing covers and the shims from pack to obtain specified
compound case. Two or more preload.
measurements for each cover should be
taken. For each cover, average the results. r Final shim pack thickness to be
installed to obtain 0.002- to 0.006-inch
preload, must be 0.094 to 0.098 inch.
A more accurate measurement can be obtained if

the transmission is vertical, front end down, and
the covers are hand-held firmly against the rear Preload is negative end-play or “crush” and
countershaft bearings. cannot be measured directly. Measurements and
calculations must be done carefully as described,
to obtain the correct preload.
Page 130
REPAIR INSTRUCTIONS
4. Place the correct shim pack and new O-ring 6. Install the drive yoke (or flange), clamp plate
with each rear countershaft bearing cover and clamp plate capscrew onto the rear
for reassembly. mainshaft (output shaft).
303
To install the drive yoke, clamp plate and

capscrew, place at least two gears in both the
main case and the compound case into
engagement. This is done to lock the gearing and
prevent gear rotation while tightening the yoke
capscrew.
7. Reach into the compound case top opening

and verify that the forward-reverse sliding
clutch and the range sliding clutch
(synchronizer sliding clutch on T308M) are
both engaged at the same time with the
Figure 303 — Installing Shim Pack and O-Ring onto direct-main drive gear.
Bearing Cover 8. Reach into the main case top opening and
move at least two sliding clutches into
5. When all shim packs have been determined, engagement.
install the rear countershaft bearing covers,
shim packs, O-rings and cover capscrews. 9. Tighten the drive yoke (or flange) clamp
Tighten the cover capscrews to 40–50 lb-ft plate capscrew to 494–600 lb-ft
(54–68 N•m) torque. (670–814 N•m) torque. When finished, make
304 sure all sliding clutches in both the main
case and compound case are returned to
the normal neutral position.
305
Figure 304 — Tightening Bearing Cover Capscrews
Figure 305 — Tightening Clamp Plate Capscrew
Page 131
REPAIR INSTRUCTIONS
10. Install the range shift fork into the compound 12. Install the range shift cylinder cover, cover
case and engage the shift fork fingers with capscrews and new O-ring.
the range sliding clutch (synchronizer sliding 308
clutch on T308M). Note the orientation of the

fork. The straight side of the fork (1) faces
forward, and the angled side of the fork (2)
faces rearward.
306
Figure 308 — Installing Range Shift Cylinder Capscrews,

Cover and O-Ring
13. Tighten the range shift cylinder cover

Figure 306 — Installing Range Shift Fork
capscrews to 17–21 lb-ft (23–29 N•m)
torque.
11. Install the range shift cylinder into the
compound case. Line up the shift fork with
the shift rail as the cylinder is installed.
Install the cylinder so that the breather vent Do not overtighten the four long capscrews that
(if equipped) is facing down and the air line hold the range shift cylinder and cover to the
port is facing up. compound case. Overtightening the capscrews
can cause the cylinder cover to bend.
309
The two position (non-compound neutralizing)

range shift cylinder requires the installation of a
gasket when installing the cylinder. Install the
gasket with the red silicone bead of the gasket
facing the transmission case.
307
Figure 309 — Tightening Range Shift Cylinder Cover

Capscrews
Figure 307 — Installing Range Shift Cylinder
Page 132
REPAIR INSTRUCTIONS
14. Align the setscrew in the shift fork with the 17. Install a new gasket, then install the rear
setscrew hole in the shift rail. Tighten the case shift cover, lift bracket and shift cover
setscrew to 35–50 lb-ft (47–68 N•m) torque. capscrews. Align the shift fork with the
310
sliding clutch. Tighten the capscrews to the
specified torque.
The lift bracket capscrews are slightly longer than

the remainder of the shift cover capscrews. Make
sure the longer capscrews are used to secure the
lift bracket.
311
Figure 310 — Tightening Shift Fork Setscrew
15. Clean the gasket surface of the rear case

shift cover.
Figure 311 — Install Rear Case Shift Cover
16. Make sure the forward-reverse sliding clutch
is in the Neutral position.
Refer to “T307M/T308M TRANSMISSION MAIN

CASE REASSEMBLY” on page 203 to finish
transmission main case reassembly and properly
fill the transmission with the recommended
lubricant.
Page 133
REPAIR INSTRUCTIONS
T307M/T308M TRANSMISSION 1. Clean the transmission externally, and
mount it in an overhaul stand. The
MAIN CASE DISASSEMBLY transmission should be lifted and moved by
using a hoist of sufficient capacity attached
to the two lift brackets on the transmission.
Before attempting to perform any of the described 2. Remove the drain plug and drain lubricant
disassembly or reassembly procedures, it is first from the transmission. (Refer to
necessary to remove the rear compound “TRANSMISSION MAINTENANCE” on page
components. 38.)
Refer to the applicable section on T307M/T308M 3. During disassembly, plug openings with
transmission rear compound disassembly or clean shop rags to prevent dirt from entering
reassembly. the transmission.
4. If not previously done at compound
disassembly, disconnect the air lines
attached to the range shift cylinder and the
rear case shift cover and range shift cylinder.
r External inspection of the unit, before Air lines are installed using a push/pull type
cleaning and disassembly, can reveal fitting and are best removed using tool kit
information about the operating conditions 9032-1800trk which can be obtained through
that have existed, and may help in the MACK parts system. Disconnect the air
diagnosing problems. lines using the following procedure:
r Unless a complete overhaul is necessary, a. Select the appropriate sized release
remove only those parts required to gain tool from kit 9032-1800trk available
access to the faulty parts. through MACK Service Parts.
312
r Do not disturb parts having heavy press fits
(interference fits) unless replacement is
necessary. In that event, use proper press
set-ups and pullers so that usable parts are
not damaged.
r As parts are removed from the transmission,

remember the sequence in which they are
removed.
r It is a good practice to keep groups of
related parts together. Small parts such as
shims, spacers, etc., should be wired to the
larger piece with which they are assembled. Figure 312 — Air Line Release Tools
Groups of parts can be put in boxes to keep
them together. Example: Parts from each
countershaft should be kept together (i.e.,
shim packs, bearings, bearing retainers,
bearing races or cups, gears, etc.).
r It is a good practice to mark the upper left
countershaft (as viewed from the rear) as
No. 1, the upper right as No. 2, and the
bottom center as No. 3.
Page 134
REPAIR INSTRUCTIONS
b. Insert the tool over the air line and 7. This step applies only to the T308M
release the lines from the fittings by transmission. Remove the range shift valve
pushing in toward the fitting and at the interlock sleeve, spring, pin and O-ring from
same time pulling on the hose. the main case shift cover.
313 315
Figure 313 — Removing Air Lines
1. Air Line Removal Tool 2. Air Hose Fitting Release

9032-1800trk Ferrule
5. Label all disconnected air lines for proper

reassembly. Plug all air line openings so that
Figure 315 — Removing Range Shift Valve Interlock
dirt or other contamination cannot enter. Components (T308M Only)
6. Remove the range shift valve 5/32-inch
Allen screws (outer) and capscrews (inner), 1. Range Shift Valve 4. Interlock Spring
using the appropriate tools and then, (Reference) 5. Interlock Pin
2. O-Ring 6. Main Case Shift Cover
remove the valve from the cover. 3. Interlock Sleeve
314
8. Remove the dual double check valve (if

equipped with compound neutralizing) and
the air directional valve from the rear case, if
not previously done at compound
disassembly.
Figure 314 — Removing Range Shift Valve Screws
Page 135
REPAIR INSTRUCTIONS
9. Remove the clutch release bearing 11. If not previously done during compound
assembly, shafts, yoke and clutch brake (if disassembly, number the front countershaft
equipped). front bearing covers and the front
countershaft rear bearing covers, using a
10. Remove the main case shift cover
grease pencil. Write number 1 on the upper
capscrews and then, remove the shift cover.
316 right front cover, number 2 on the upper left
front cover and number 3 on the lower front
cover. Write number 1 on the upper left rear
cover, number 2 on the upper right rear
cover and number 3 on the lower rear cover.
318
Figure 316 — Removing Main Case Shift Cover

Capscrews
317
Figure 318 — Mark Front Countershaft Front Bearing

Covers for Placement
12. Position the case horizontally and remove

the main drive pinion bearing cover
capscrews.
319
Figure 317 — Removing Main Case Shift Cover
Figure 319 — Removing Capscrews from Main Drive

Pinion Bearing Cover
Page 136
REPAIR INSTRUCTIONS
13. Remove the main drive pinion assembly. 322
Jackscrew holes are provided to assist in

removal.
320
Figure 322 — Removing Main Drive Pinion Assembly
15. Remove the fourth/fifth (seventh/eighth)

sliding clutch from the front of the mainshaft.
Figure 320 — Using Jackscrews to Remove Main Drive 323
Pinion Assembly
14. Remove the main drive pinion assembly

from the case.
On units built with oil cooler circulation pumps,

the oil pump discharge line must be removed
before the main drive pinion assembly can be
removed.
321
Figure 323 — Removing Sliding Clutch
16. Remove the No. 2 (upper left) front

countershaft front bearing cover capscrews.
324
Figure 321 — Oil Pump Discharge Line (If Equipped)
1. Oil Pump Discharge Line
Figure 324 — Removing No. 2 Front Countershaft Front

Bearing Cover Capscrews
Page 137
REPAIR INSTRUCTIONS
17. Using jackscrews, remove the No. 2 (upper 19. Remove the snap ring that holds the
left) front countershaft front bearing cover. mainshaft rear bearing in place.
325 327
Figure 325 — Removing No. 2 Front Countershaft Front

Bearing Cover
If not already done, mark the front countershaft

rear bearing covers so they can be installed in the Figure 327 — Removing Mainshaft Rear Bearing Snap
same position during reassembly. Ring
20. Remove the mainshaft rear bearing from the

18. Remove the capscrews from the No. 2 case.
(upper right) front countershaft rear bearing 328
cover, and remove the cover. Jackscrew
holes are provided to assist in the removal of
the cover.
326
Figure 326 — Removing No. 2 Front Countershaft Rear

Bearing Cover
Figure 328 — Removing Mainshaft Rear Bearing
Page 138
REPAIR INSTRUCTIONS
21. Press the sleeve out of the mainshaft rear 22. Remove the front mainshaft rear bearing
bearing. spacer and spacer snap ring from the
329
mainshaft.
330
Figure 329 — Pressing Sleeve Out of Bearing
Figure 330 — Removing Front Mainshaft Bearing Spacer

and Snap Ring
Page 139
REPAIR INSTRUCTIONS
23. Remove the No. 2 (upper right) countershaft 25. Remove the No. 1 (upper left) front
from the case by tipping the front end away countershaft rear bearing cover capscrews
from the case and then lifting the and bearing cover. Use jackscrews to
countershaft through the opening. remove the cover.
331 333
Figure 331 — Removing Upper Right Countershaft
24. Fasten a chain around the mainshaft

assembly. Using a hoist, lift the mainshaft
assembly out of the case.
332
Figure 333 — Removing Front Countershaft Rear

Bearing Cover
Figure 332 — Removing Mainshaft Assembly from Case
Page 140
REPAIR INSTRUCTIONS
26. Remove the No. 1 (upper right, as viewed 28. Remove the No. 3 (lower) countershaft rear
from front) front countershaft front bearing bearing cover capscrews and bearing cover.
cover capscrews and bearing cover. Use Use jackscrews to remove the cover.
jackscrews to remove the cover. 336
334
Figure 336 — Removing Front Countershaft Rear

Figure 334 — Remove Front Countershaft Front Bearing Bearing Cover
Cover
29. Remove the No. 3 (lower) front countershaft
27. Move the No. 1 upper left countershaft front bearing cover capscrews and bearing
rearward until the front end of the shaft cover. Use jackscrews to remove the cover.
assembly can be angled out of the case, and 30. Move the No. 3 (lower) countershaft
then remove the countershaft. rearward until the front end of the shaft
335
assembly can be angled out of the case.
Remove the countershaft.
Figure 335 — Removing No. 1 Countershaft
Page 141
REPAIR INSTRUCTIONS
MAIN CASE COMPONENT

DISASSEMBLY
Main Case Shift Cover Disassembly
(T307M/T308M)
[321]
337
Figure 338 — Main Case Shift Cover Assembly
Figure 337 — Main Case Shift Cover Component Locator

(T308M Shown)
Page 142
REPAIR INSTRUCTIONS
339
Figure 339 — Exploded View of Main Case Shift Cover
1. 4th/5th Shift Fork 12. Washer 23. Breather Vent

2. 2nd/3rd Shift Fork 13. Interlock Pin* 24. Interlock Pin*
3. 1st Speed Shifter 14. Poppet Ball 25. Interlock Ball*
4. Shifter Body Spring (Interlock) 15. Poppet Ball Spring 26. 1st Speed Shift Rail
5. Shifter Body Plunger (Interlock) 16. Interlock Rocker Hardware* 27. 2nd/3rd Shift Rail
6. 1st Speed Shift Fork 17. Interlock Sleeve and O-Ring* 28. Interlock Ball
7. 4th/5th Shifter 18. Interlock Spring* 29. Interlock Pin
8. 4th/5th Rocker Pin 19. 4th/5th Rocker Pin Hardware 30. Interlock Ball
9. Washer 20. Interlock Rocker* 31. 4th/5th Shift Rail
10. 4th/5th Rocker Arm 21. Interlock Rocker Bolt* 32. 1st Speed Shifter Ball
11. Bushing 22. Pipe Plug 33. 1st Speed Shifter Spring
*T308M Only (with range shift interlock).
Page 143
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. T308M step only. Remove the interlock ball
and T308M transmissions. However, steps 1–3 from the cover.
apply to the T308M transmission only. 342
1. T308M step only. Remove the nut and

washers from the interlock rocker bolt.
340
Figure 342 — Removing Interlock Ball (T308M Only)
4. Remove the setscrew from first speed shift

fork.
343
Figure 340 — Interlock Rocker Assembly (T308M Only)
2. T308M step only. Remove the interlock

rocker and bolt from the shift cover.
341
Figure 343 — Removing Setscrew from First Speed Shift

Figure 341 — Removing Interlock Rocker and Bolt Fork
(T308M Only)
Page 144
REPAIR INSTRUCTIONS
5. Remove the setscrew from the first speed 6. Slide the first speed shift rail forward and
shifter. remove the interlock pin. (The interlock pin
344
applies only to the T308M shift cover.)
345
Figure 344 — Removing Setscrew from First Speed

Shifter
Figure 345 — Sliding Shift Rail and Removing Interlock

Pin (T308M Only)
7. Remove the spacer (B) as shown in

Figure 346.
346
Figure 346 — Removing Spacer
Page 145
REPAIR INSTRUCTIONS
8. Remove the first speed shift fork (A) from 9. Push the first speed shift rail forward using a
the cover. metal bar or large screwdriver. Hold a shop
347
towel over the top opening. The shop towel
prevents the spring and ball under the rail,
from popping out and becoming lost or
causing injury.
Poppet balls are spring loaded and can cause

injury if suddenly released.
348
Figure 347 — Removing First Speed Shift Fork
Figure 348 — Pushing First Speed Shift Rail Forward
Page 146
REPAIR INSTRUCTIONS
10. Remove the poppet ball and spring from 11. Remove the interlock ball from the horizontal
under the first speed shift rail vertical pocket, pocket between the first speed shift rail and
in line with the rail. the second/third shift rail.
350
A magnet is helpful in removing the poppet ball

and spring.
349
Figure 350 — Removing Interlock Ball
Figure 349 — Removing Poppet Ball and Spring
Page 147
REPAIR INSTRUCTIONS
12. Continue sliding the first speed shift rail 13. Slide the first speed shift rail out of the shift
forward and remove the first speed shifter. cover and at the same time, remove the
351
fourth/fifth shift fork.
352
Figure 351 — Removing First Speed Shifter
Figure 352 — Removing Fourth/Fifth Shift Fork
Page 148
REPAIR INSTRUCTIONS
14. Remove the setscrew from the second/third 15. Push the second/third shift rail forward using
shift fork. a metal bar or large screwdriver. Hold a
353
shop towel over the top opening. The shop
towel prevents the spring and ball under the
rail, from popping out and becoming lost or
causing injury.
Poppet balls are spring loaded and can cause

injury if suddenly released.
354
Figure 353 — Removing Setscrew from Second/Third

Shift Fork
Figure 354 — Pushing Second/Third Rail Forward
Page 149
REPAIR INSTRUCTIONS
16. Remove the poppet ball and spring from 17. Remove the interlock ball from the horizontal
under the second/third shift rail vertical pocket between the second/third shift rail
pocket in line with the rail. and the fourth/fifth shift rail.
356

and spring.
355
Figure 356 — Removing Interlock Ball
Page 150
REPAIR INSTRUCTIONS
18. Remove the interlock pin from the second/ 19. Slide the second/third shift rail further
third shift rail. forward and remove the second/third shift
357
fork.
358
Figure 357 — Removing Interlock Pin
Figure 358 — Removing Second/Third Shift Fork
20. Continue sliding the second/third shift rail

forward and remove it from the shift cover.
359
Figure 359 — Removing Second/Third Shift Rail
Page 151
REPAIR INSTRUCTIONS
21. Remove the setscrew from the fourth/fifth 361
shifter.
360
Figure 360 — Removing Fourth/Fifth Shifter Setscrew
22. Push the fourth/fifth shift rail forward using a

metal bar or large screwdriver. Hold a shop
towel over the top opening. The shop towel
prevents the spring and ball under the rail,
from popping out and becoming lost or
causing injury.
Figure 361 — Pushing Fourth/Fifth Rail Forward
23. Continue sliding the fourth/fifth shift rail

Poppet balls are spring loaded and can cause forward, out of the shift cover. At the same
injury if suddenly released. time, remove the fourth/fifth shifter.
362
Figure 362 — Removing Fourth/Fifth Shifter
Page 152
REPAIR INSTRUCTIONS
24. Remove the poppet ball and spring from the 26. Remove the nut and washers from the
fourth/fifth shift rail vertical pocket in line with fourth/fifth rocker pin.
the rail. 365

and spring.
363
Figure 365 — Loosening Fourth/Fifth Rocker Pin Nut
25. Remove the poppet ball and spring, and the

interlock plunger and spring, from the first
speed shifter.
364
Figure 364 — First Speed Shifter Disassembled
Page 153
REPAIR INSTRUCTIONS
366
27. Remove the fourth/fifth rocker pivot pin and
rocker arm.
367
Figure 367 — Removing Rocker Pivot Pin and Rocker

Figure 366 — Removing Washers and Nut Arm
28. Remove the shift cover breather vent.

368
Figure 368 — Removing Breather Vent
Page 154
REPAIR INSTRUCTIONS
Range Shift Valve Disassembly 2. Separate the cover from the valve housing
and remove the sintered bronze filter and
(T307M/T308M) silicone rubber O-ring.
[323]
369
The sintered bronze filter is the only part that is

serviceable on the range shift valve. Replace the
range shift valve as an assembly if any internal
component has failed or if the valve has become
contaminated.
371
Figure 369 — Cutaway View of Range Shift Valve

Assembly
1. 4 mm Screw 4. Sintered Bronze Filter

2. Top Cover Seal 5. Silicon Rubber O-Ring
3. Top Cover
The following procedure applies to both T307M Figure 371 — Removing Sintered Bronze Filter
1. Sintered Bronze Filter 3. Valve Housing
1. Remove the four (4 mm) interlock valve top 2. Cover
cover screws.
370
3. Inspect the top cover gasket and replace as
necessary.
Figure 370 — Valve Top Cover Screws
Page 155
REPAIR INSTRUCTIONS
Front Mainshaft Disassembly 373
(T307M/T308M)
[322]
372
Figure 372 — Front Mainshaft Component Locator Figure 373 — View of Mainshaft and Gears
(T308M Shown)
1. Fifth Speed Gear 4. Second Speed Gear

The splines on the mainshaft are usually not 2. Third Speed Gear 5. First Speed Gear
aligned for the whole length of the shaft. The 3. Sliding Clutch 6. Front Mainshaft
recommended procedure is to remove the fifth
and third speed gears, gear thrust washers and
snap rings, and third/second sliding clutch from
the front of the shaft (parts shown to the left of the
arrows). Remove the first speed sliding clutch,
the first and second speed gears, thrust washers
and snap rings from the rear of the shaft (parts
shown to the right of the arrows).
Page 156
REPAIR INSTRUCTIONS
374
Figure 374 — Exploded View of Front Mainshaft Assembly
1. Spigot Bearing Inner Race Snap 12. Mainshaft Snap Ring 25. Front Mainshaft
Ring 13. Sliding Clutch 26. Spigot Bearing Inner Race
2. Spigot Bearing Inner Race 14. Mainshaft Snap Ring 27. Spigot Bearing Inner Race Snap
3. Mainshaft Snap Ring 15. Internal-Toothed Thrust Washer Ring
4. Internal-Toothed Thrust Washer 16. External-Toothed Thrust Washer 28. Mainshaft Snap Ring
5. Fifth Speed Gear 17. Gear Snap Ring 29. Spacer
6. External-Toothed Thrust Washer 18. Second Speed Gear 30. Mainshaft Rear Bearing
7. Gear Snap Ring 19. Gear Snap Ring 31. Mainshaft Rear Bearing Sleeve
8. Gear Snap Ring 20. External-Toothed Thrust Washer 32. Mainshaft Snap Ring
9. External-Toothed Thrust Washer 21. Internal-Toothed Thrust Washer 33. Reverse Speed Gear
10. Internal-Toothed Thrust Washer 22. Mainshaft Snap Ring 34. Internal-Toothed Thrust Washer
11. Third Speed Gear 23. First Speed Gear 35. Mainshaft Snap Ring
24. Sliding Clutch 36. Sliding Clutch
Page 157
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. Remove the internal-toothed and external-
and T308M transmissions. toothed thrust washers from inside the first
speed gear. External-toothed thrust washer
1. Remove the first speed gear sliding clutch
oil grooves face the rear of the transmission.
from the mainshaft. 377
375
Figure 377 — Removing First Speed Gear Thrust

Figure 375 — Removing First Speed Gear Sliding Clutch Washers
2. Remove the first speed gear mainshaft snap 4. Remove the first speed gear from the
ring from inside the gear, using suitable snap mainshaft.
ring pliers. 378
376
Figure 376 — Removing Mainshaft Snap Ring

Figure 378 — Removing First Speed Gear
Page 158
REPAIR INSTRUCTIONS
5. Remove the snap ring from inside the first 7. Remove the second speed gear external-
speed gear using suitable snap ring pliers. toothed and internal-toothed thrust washers
379
from the mainshaft. External-toothed thrust
washer oil grooves face the front of the
transmission.
381
Figure 379 — Removing First Speed Gear Snap Ring

Figure 381 — Removing Second Speed Gear Thrust
6. Remove the second speed gear from the Washers
mainshaft and then, remove the snap ring
from inside the gear using suitable snap ring 8. Working at the front of the mainshaft,
pliers. remove the mainshaft snap ring from inside
380 the fifth speed gear, using suitable snap ring
pliers.
382
Figure 380 — Removing Second Speed Gear and Gear

Snap Ring
Figure 382 — Removing Fifth Speed Gear Mainshaft

Snap Ring
Page 159
REPAIR INSTRUCTIONS
9. Remove the fifth speed gear internal-toothed 11. Remove the snap ring from inside the fifth
and external-toothed thrust washers from speed gear using suitable snap ring pliers.
the mainshaft. 385
383
Figure 383 — Removing Fifth Speed Gear Thrust Figure 385 — Removing Fifth Speed Gear Snap Ring
Washers
12. Slide the third speed gear from the
10. Remove the fifth speed gear from the
mainshaft and then, remove the snap ring
mainshaft.
from inside the gear using suitable snap ring
pliers.
386
Note that the clutch teeth of the fifth speed gear

face forward.
384
Figure 386 — Removing Third Speed Gear and Gear

Snap Ring
Figure 384 — Removing Fifth Speed Gear
Page 160
REPAIR INSTRUCTIONS
13. Remove the third speed gear external- 15. Remove the second/third speed gear sliding
toothed and internal-toothed thrust washers clutch from the mainshaft.
from the mainshaft. 389
387
Figure 389 — Removing Second/Third Speed Sliding

Figure 387 — Removing Third Speed Gear Thrust Clutch
Washers
16. Remove the second speed gear mainshaft
14. Remove the third speed gear mainshaft snap ring using suitable snap ring pliers.
390
snap ring using suitable snap ring pliers.
388
Figure 390 — Removing Second Speed Gear Mainshaft

Figure 388 — Removing Third Speed Gear Mainshaft Snap Ring
Snap Ring
Page 161
REPAIR INSTRUCTIONS
17. Remove the snap ring retaining the spigot 19. Remove the snap ring retaining the spigot
bearing inner race at the front of the bearing inner race at the rear of the
mainshaft, using suitable snap ring pliers. mainshaft.
391 393
Figure 391 — Removing Front Spigot Bearing Inner

Figure 393 — Removing Rear Spigot Bearing Inner Race
Race Snap Ring
Snap Ring
18. Remove the front spigot bearing inner race 20. Remove the rear spigot bearing inner race,
using a suitable puller such as J 39477, or using a suitable puller such as J 39477, or
equivalent. equivalent.
392
394
Figure 392 — Removing Front Spigot Bearing Inner

Race Figure 394 — Removing Rear Spigot Bearing Inner Race
Page 162
REPAIR INSTRUCTIONS
Front Countershaft Disassembly The following procedure applies to both T307M
and T308M transmissions and all three front
(T307M/T308M) countershafts.
[322] 1. Press the front countershaft out of the main
drive gear using a suitable driver.
395
During pressing operations, do not allow the

countershaft to fall while pressing the shaft
out of the gears. Damage to the countershaft
and personal injury can result.
397
Figure 395 — Front Countershaft Disassembly

Component Locator (T308M Shown)
396
Figure 396 — Exploded View of Front Countershaft
1. Bearing Cup 6. Second Speed Gear Figure 397 — Pressing Countershaft Out of Main Drive
2. Main Drive Gear 7. Bearing Cone Gear
3. Fifth Speed Gear 8. Front Countershaft
4. Third Speed Gear 9. Key
5. Spacer
Page 163
REPAIR INSTRUCTIONS
2. Press the countershaft out of the fifth speed 3. Press the front countershaft out of the third
gear. speed gear.
398 399
Figure 399 — Pressing Countershaft Out of Third Speed

Gear
Figure 398 — Pressing Countershaft Out of Fifth Speed
Gear
Page 164
REPAIR INSTRUCTIONS
4. Remove the spacer that separates the 6. Using a bearing separator such as J 8176,
second speed gear and third speed gear. or equivalent, press the bearing cone off the
400
rear end of the countershaft.
402
Figure 402 — Pressing Off Rear Bearing

Figure 400 — Removing Spacer
7. Remove the key from the keyway of the front
5. Press the countershaft out of the second countershaft.
403
speed gear.
401
Figure 403 — Removing Key
Figure 401 — Pressing Countershaft Out of Second

Speed Gear
Page 165
REPAIR INSTRUCTIONS
8. Using a suitable puller such as OEM-4052, Main Drive Pinion Disassembly
or equivalent, pull the bearing cup out of the
front countershaft main drive gear. (T307M/T308M)
404
[322]
405
Figure 405 — Main Drive Pinion Component Locator

(T308M Shown)
406
Figure 404 — Removing Bearing Cup
Figure 406 — Exploded View of Main Drive Pinion
1. Main Drive Pinion Shaft 7. Bearing

2. Spigot Bearing 8. Spiral Snap Ring
3. Snap Ring 9. Gasket
4. Main Drive Pinion Gear 10. Pinion Bearing Cover
5. Spiral Snap Ring 11. Oil Seal
6. Snap Ring
Page 166
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. Remove the main drive pinion gear from the
and T308M transmissions. shaft.
409
1. Remove the gasket from the main drive
pinion bearing cover.
407
Figure 409 — Remove Main Drive Pinion Gear

Figure 407 — Removing Gasket from Cover
4. Remove the spigot bearing snap ring from
2. Remove the spiral snap ring retaining the the main drive pinion shaft, using suitable
main drive pinion gear at the rear end of the snap ring pliers.
410
shaft. Using a flat-blade screwdriver, roll the
snap ring out of the groove and over the
shoulder of the main drive pinion gear.
408

Figure 408 — Removing Main Drive Pinion Gear Snap
Ring
The action of removing the snap ring can destroy

the snap ring. Make sure a replacement snap ring
is available.
Page 167
REPAIR INSTRUCTIONS
5. Remove the spigot bearing from inside the 7. Separate the main drive pinion shaft and
end of the main drive pinion shaft. bearing assembly from the main drive pinion
411
bearing cover.
413
Figure 411 — Removing Spigot Bearing from Main Drive

Pinion Shaft Figure 413 — Removing Main Drive Pinion Shaft and
Bearing from Cover
6. Remove the main drive pinion bearing cover
snap ring, using suitable snap ring pliers. 8. Remove the spiral snap ring retaining the
bearing to the main drive pinion shaft. Using
a small flat-blade screwdriver, roll the spiral
snap ring out of the groove until released.
414
compress and remove, and can fly off the
snap ring pliers and cause injury.
412
Figure 414 — Removing Spiral Snap Ring
Figure 412 — Removing Main Drive Pinion Bearing

Cover Snap Ring The action of removing the spiral snap ring can
destroy the snap ring. Make sure a replacement
snap ring is available.
Page 168
REPAIR INSTRUCTIONS
9. Place the main drive pinion shaft and 10. Remove the oil seal from the main drive
bearing into a suitable press and remove the pinion bearing cover using a hammer and a
bearing. blunt punch.
415
Removing the oil seal destroys the seal. Make

sure a replacement oil seal is available.
416
Figure 416 — Removing Bearing Cover Oil Seal
Figure 415 — Pressing Main Drive Pinion Shaft Out of

Bearing
Page 169
REPAIR INSTRUCTIONS
Front Countershaft Front Bearing The following procedure applies to both T307M
Cover Disassembly (T307M/T308M) countershaft front bearing covers.
[321] 1. Remove the O-ring from the front
countershaft front bearing cover.
417 419
Figure 417 — Front Countershaft Front Bearing Cover Figure 419 — Removing Front Cover O-Ring
418
2. Remove the bearing cone from the front
countershaft front bearing cover, using a
suitable puller.
420

Front Bearing Cover
1. O-Ring 3. Front Bearing Cover

2. Bearing Cone Figure 420 — Removing Bearing Cone from Cover
3. Thoroughly clean the bearing cover and

inspect for damage.
Page 170
REPAIR INSTRUCTIONS
Front Countershaft Rear Bearing The following procedure applies to both T307M
Cover Disassembly countershaft rear bearing covers.
[321] 1. Remove the front and rear bearing cups
from the front countershaft rear bearing
421
cover.
423
Figure 421 — Front Countershaft Rear Bearing Cover

Component Locator (T308M Shown) Figure 423 — Removing Front Bearing Cup
422 424
Figure 422 — Exploded View of Front Countershaft Rear Figure 424 — Removing Rear Bearing Cup
Bearing Cover
2. Thoroughly clean the bearing cover and
1. Front Bearing Cup 3. Rear Bearing Cup inspect for damage.
2. Bearing Cover
Page 171
REPAIR INSTRUCTIONS
INSPECTION OF PARTS
Inspection and Cleaning If a bearing cone or cup needs replacement, a
complete new assembly, including cup and
Thoroughly clean the case, cover and all other
mating cone, is required.
parts of the transmission. Remove all grease, oil
and foreign matter, using a suitable safety Do not remove a new bearing from its packing
solvent. Dry the parts with moisture-free before time of installation. Never clean protective
compressed air. grease from new bearings.
Do not handle bearings with dirty hands. Rags
Bearings must be clean and lint free.
[322]
Clean bearings that are satisfactory for
reinstallation. Wrap the bearings in clean, lint-free
Soak bearings in fresh, clean solvent to loosen all cloth and store for assembly.
hardened grease and foreign matter until the
bearings are clean. Blow them dry with filtered,
moisture-free compressed air. Gears
[322]
Do not spin the bearings with compressed air. Replace all gears with teeth that show signs of
Doing so can damage the bearings. abrasive wear, scratching (except normal
manufacturing tool marks), ridging, scoring,
surface fatigue, pitting, spalling, corrosive wear,
Inspect each bearing for flaking, cracks, digging in or cracking. Gears should always be
fractures, cavities, indentations, measurable inspected using magnaflux (or similar system) for
wear, brinelling, fretting, corrosion, nicking, cage cracks that would not otherwise be detected.
wear or deformation and other damage. If any of
these conditions are present, replace the bearing.
Apply a light coat of fresh, clean, specified gear

oil to the bearings. (Refer to Recommended SAE
Grade Gear Oil in “T307M/T308M
TRANSMISSION SPECIFICATIONS AND
CAPACITIES” on page 230.) Turn the races and
bearings slowly by hand to make sure they move
freely and are smooth. If there is resistance to
movement, or the bearing feels rough, replace
the bearing.
Page 172
REPAIR INSTRUCTIONS
Shifter Forks, Sliding Clutches and measurements taken at four locations. Compare
one side of the shaft to the other, AB–CD as
Shift Rails shown.
426
[323]
Replace forks and/or sliding clutches when the
groove side clearance (A) between the fork (2)
and sliding clutch (1) exceeds the limit specified
in “T307M/T308M TRANSMISSION
SPECIFICATIONS” on page 216.
425
Figure 426 — Measuring Shift Rail
Oil Seals
[321]
When an overhaul is required, replace all oil
seals. Be careful to ensure that the sealing
surface of any seal is not damaged, turned back
or cut. A nick on a shaft sealing surface can cut
the seal. Remove sharp edges that can damage
the seal (chamfer edges if possible). Press seals
into housings using smooth, even pressure to
prevent cocking the seal.
Be careful when using any abrasive polishing

methods, such as emery or crocus cloth, on a
sealing surface. It is possible to leave micro-
Figure 425 — Fork and Clutch Detail grooves on the sealing surface. This can cause
oil to leak past the sealing lip(s) of the oil seal.
1. Sliding Clutch 2. Shift Fork With this condition, a new seal will not stop the oil
leak.
Replace shift rails if they are cracked in either the
poppet or setscrew holes. If the clearance
between the shift rail and housing (cover) bore Be careful when installing a shaft through a new
exceeds 0.010-inch (0.254 mm) maximum, seal (or seal over shaft). Lubricate the shaft
determine which part is worn before replacing. before inserting it through the seal. Splines,
Shaft wear can be checked by measuring the keyways and holes in a shaft can damage seals
shaft at an unworn location. Then measure the unless care is taken. Lubricate the seal to prevent
shaft at the worn area and compare damage during the initial start-up period, before
measurements. When measuring a shift rail, the normal lubrication begins. Keep anti-seize and
reading should be an average of diameter sealing compounds away from oil seals.
Page 173
REPAIR INSTRUCTIONS
If an oil seal does not have a preapplied sealant General Inspection
on its outer diameter, apply an appropriate sealer
around the outside diameter to prevent leaks. A cracked transmission case should be replaced.
Check all components for wear or damage.
Lip-type oil seals are precision elements requiring Replace all parts as required. Replace all
close attention and care during installation. gaskets, O-rings and any part that shows
mutilation or damage. Repair all stripped threads,
using a thread repair insert that is compatible with
fasteners that have epoxy-coated threads.
The quality of the installation method and tools
used has a direct influence on the life of the seal. General Reassembly Instructions
Do not use a block of wood or discarded bearing
as a substitute for the proper seal driver. Refer to “T307M/T308M TRANSMISSION
However, with some seal applications a seal SPECIFICATIONS” on page 216 for torque
driver might not be available. In these situations, specifications, tolerances and fits and limits.
light tapping in a circular motion using a light,
broad-faced hammer is acceptable. All working metal parts, especially the bearings,
should be coated with fresh, clean, specified gear
oil while the transmission is being reassembled.
For the seal to function properly, install it squarely This ensures immediate lubrication and helps
with respect to the shaft center line. The seal prevent parts seizure during initial start-up. (Refer
should be kept square within 0.010-inch to Recommended SAE Grade Gear Oil in
(0.254-mm) Total Indicated Runout (TIR). “T307M/T308M TRANSMISSION
Squareness of the seal to the shaft is controlled SPECIFICATIONS AND CAPACITIES” on page
by using the proper seal installation tools as 230.)
When installing bearings, use proper bearing
Press seals into housings with smooth, even drivers. When pressing a bearing onto a shaft,
pressure to prevent cocking or distorting the seal. apply force only to the inner race of the bearing.
Gently press the seal into place. Correct When pressing a bearing into a housing (bearing
installation depth is achieved as the driver tool cover), apply force only to the outer race. Do not
bottoms against the positioning tool, as shown. apply force that is transmitted through the bearing
427
rollers, balls or cage. Damage and premature
bearing failure can result. Always apply even
pressure to the bearing to prevent it from cocking
or distorting during installation.
As moving parts are installed, check the parts

frequently to make sure that they are moving
freely.
Figure 427 — Main Drive Pinion Oil Seal Tools
Page 174
REPAIR INSTRUCTIONS
T307M/T308M TRANSMISSION The following procedure applies to both T307M
MAIN CASE COMPONENT countershaft rear bearing covers.
REASSEMBLY 1. Press new front and rear bearing cups into
the front countershaft rear bearing cover,
Front Countershaft Rear Bearing using a suitable driver.
Cover Reassembly (T307M/T308M) 430
[321]
428
Figure 428 — Front Countershaft Rear Bearing Cover

429
Figure 430 — Pressing Front Bearing Cup into Cover

431
Figure 429 — Exploded View of Front Countershaft Rear

Bearing Cover
1. Front Bearing Cup 3. Rear Bearing Cup

2. Bearing Cover
Figure 431 — Pressing Rear Bearing Cup into Cover
2. Set the front countershaft rear bearing cover

aside for later installation.
Page 175
REPAIR INSTRUCTIONS
Front Countershaft Front Bearing The following procedure applies to both T307M
Cover Reassembly (T307M/T308M) countershaft front bearing covers.
[321] 1. Press a new bearing cone onto the front
countershaft front bearing cover, using a
432
suitable driver. Apply force to only the inner
race of the bearing.
434
Figure 432 — Front Countershaft Front Bearing Cover

433 Figure 434 — Pressing Bearing Cone onto Cover
2. Install a new O-ring onto the shoulder of the

front bearing cover.
435

Front Bearing Cover
1. O-Ring 3. Front Bearing Cover

2. Bearing Cone Figure 435 — Installing O-Ring onto Front Cover
3. Set the assembly aside for later installation.
Page 176
REPAIR INSTRUCTIONS
Main Drive Pinion Reassembly The following procedure applies to both T307M
(T307M/T308M)
1. Press the ball bearing onto the main drive
[322] pinion shaft. Support the inner race of the
bearing while pressing.
436 438
Figure 436 — Main Drive Pinion Component Locator

(T308M Shown)
437
Figure 438 — Installing Main Drive Pinion Bearing
1. Press 4. Main Drive Pinion Shaft

2. Spacer Tube 5. Sleeve
3. Driver 6. Bearing

6. Snap Ring
Page 177
REPAIR INSTRUCTIONS
2. Retain the ball bearing by installing the spiral 441
snap ring. To do this, use a circular motion

while pressing the snap ring tightly into the
groove on the shaft.
439
Figure 439 — Installing Spiral Snap Ring

Figure 441 — Installing Pinion Bearing Cover Oil Seal
3. Position a new oil seal in the main drive
pinion bearing cover. 5. Press the main drive pinion shaft and
440
bearing assembly into the main drive pinion
bearing cover.
442
Figure 440 — Positioning Bearing Cover Oil Seal
4. Install the oil seal into the front of the main

drive pinion bearing cover. Refer to “Oil
Seals” on page 173 for installation
instructions and seal precautions.
Figure 442 — Installing Main Drive Pinion Assembly into

Bearing Cover
Page 178
REPAIR INSTRUCTIONS
6. Install the main drive pinion bearing snap 7. Install the spigot bearing into the end of the
ring, using suitable snap ring pliers. main drive pinion shaft by hand and then,
install the retaining snap ring.

compress and install and can fly off the snap Drawn cup needle bearings (spigot bearings)
ring pliers and cause injury. have a specific direction in which they must be
installed. The radius end of the bearing must be
installed first. The flat end of the bearing faces
out.
444
One side of the large snap ring is bevelled and
faces out. The flat side of the snap ring goes
against the bearing.
443
Figure 444 — Installing Spigot Bearing and Snap Ring
8. Install the main drive pinion gear onto the

pinion shaft. Install the spiral snap ring using
Figure 443 — Installing Snap Ring into Main Drive Pinion a circular motion while pressing the snap
Bearing Cover ring tightly into the groove on the shaft.
445
Figure 445 — Installing Main Drive Pinion Gear and

Spiral Snap Ring
Page 179
REPAIR INSTRUCTIONS
9. Install a new bearing cover gasket using 448
sealant between the gasket and cover. Make

sure the oil passage hole and capscrew
holes in the gasket align with the cover
holes.
446
1. Bearing Cup 6. Second Speed Gear

2. Main Drive Gear 7. Bearing Cone
3. Fifth Speed Gear 8. Front Countershaft
4. Third Speed Gear 9. Key
Figure 446 — Installing Main Drive Pinion Bearing Cover
5. Spacer
Gasket
Front Countershaft Reassembly

(T307M/T308M)
Apply the recommended oil to all shaft and gear
[322] surfaces before pressing parts together.
447
Figure 447 — Front Countershaft Component Locator

(T308M Shown)
Page 180
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. Press the bearing cone onto the rear end of
and T308M transmissions and all three front the front countershaft. Carefully apply force
countershafts. to only the inner race of the bearing cone.
451
1. Press a new bearing cup into the front
countershaft main drive gear using a
suitable driver.
449
Figure 451 — Pressing Rear Bearing Cone onto

Countershaft
Figure 449 — Pressing Bearing Cup into Main Drive

Gear
2. Install the key into the keyway of the front

countershaft, using a soft-faced mallet.
450
Figure 450 — Installing Key into Keyway
Page 181
REPAIR INSTRUCTIONS
4. Align the countershaft with the second 6. Align the countershaft with the fifth speed
speed gear and then, press the countershaft gear and then, press the countershaft into
into the gear. the gear.
452 454
Figure 454 — Pressing Countershaft into Fifth Speed

Figure 452 — Pressing Countershaft into Second Speed Gear
Gear
5. Install the spacer (separates second and

third speed gears) onto the countershaft.
Align the countershaft with the third speed
gear and then, press the countershaft into
the gear.
453
Figure 453 — Pressing Countershaft into Third Speed

Gear
Page 182
REPAIR INSTRUCTIONS
7. Place the main drive gear on the press with The splines on the mainshaft are usually not
the protruding hub facing up (facing rear of aligned for the whole length of the shaft. The
countershaft). Align the countershaft with the recommended procedure is to install the fifth and
main drive gear and then, press the third speed gears, gear thrust washers and snap
countershaft into the gear. rings, and third/second sliding clutch onto the
455
front of the shaft (parts shown to the left of the
arrows). Install the first speed sliding clutch, the
first and second speed gears, thrust washers and
snap rings onto the rear of the shaft (parts shown
to the right of the arrows).
457
Figure 455 — Pressing Countershaft into Main Drive

Gear
Figure 457 — View of Mainshaft and Gears
Front Mainshaft Reassembly 1. Fifth Speed Gear 4. Second Speed Gear

2. Third Speed Gear 5. First Speed Gear
(T307M/T308M) 3. Sliding Clutch 6. Front Mainshaft
[322]
456
Figure 456 — Front Mainshaft Component Locator

(T308M Shown)
Page 183
REPAIR INSTRUCTIONS
458
Page 184
REPAIR INSTRUCTIONS
The following procedure applies to both T307M 3. Install a new spigot bearing inner race onto
and T308M transmissions. the rear of the front mainshaft, using a
suitable driver and press. Also, install the
1. Install a new spigot bearing inner race onto
inner race snap ring, using suitable snap
the front of the front mainshaft, using a
ring pliers.
suitable driver and press. 461
459
Figure 461 — Installing Spigot Bearing Inner Race

Figure 459 — Installing Spigot Bearing Inner Race 462
2. Install the inner race snap ring, using

suitable snap ring pliers.
460
Figure 462 — Installing Inner Race Snap Ring
Figure 460 — Installing Inner Race Snap Ring
Page 185
REPAIR INSTRUCTIONS
4. Working at the front of the mainshaft, install 6. Install the third speed gear mainshaft snap
the second speed gear mainshaft snap ring ring onto the shaft.
onto the shaft. 465
463
Figure 465 — Installing Third Speed Gear Mainshaft

Figure 463 — Installing Second Speed Gear Snap Ring Snap Ring
5. Install the second/third sliding clutch onto 7. Install the third speed gear internal-toothed
the mainshaft. and external-toothed thrust washers onto
464 the mainshaft. The external-toothed thrust
washer oil grooves face the rear of the
mainshaft, toward the internal-toothed thrust
washer.
466
Figure 464 — Installing Mainshaft Second/Third Sliding

Clutch
Figure 466 — Installing Third Speed Gear Thrust

Washers
Page 186
REPAIR INSTRUCTIONS
8. Install the snap ring into the snap ring 10. Install the snap ring into the fifth speed gear
groove of the third speed gear, using in the snap ring groove farthest away from
suitable snap ring pliers. the clutch teeth of the gear. Use suitable
467
snap ring pliers.
469
Figure 467 — Installing Snap Ring into Third Speed Gear

Figure 469 — Installing Snap Ring into Fifth Speed Gear
9. Install the third speed gear onto the
mainshaft with the clutch teeth facing 11. Install the fifth speed gear onto the
rearward and the snap ring facing forward. mainshaft with the clutch teeth facing
468
forward and the snap ring facing rearward.
470
Figure 468 — Installing Third Speed Gear onto

Mainshaft Figure 470 — Installing Fifth Speed Gear
Page 187
REPAIR INSTRUCTIONS
12. Install the fifth speed gear external-toothed 473
and internal-toothed thrust washers. The oil

groove side of the external-toothed thrust
washer faces forward toward the internal-
toothed thrust washer.
471
Figure 473 — Installing Second Speed Gear Thrust

Washers
15. Install the snap ring into the groove of the

second speed gear, farthest from the clutch
teeth.
474
Figure 471 — Installing Fifth Speed Gear Thrust
Washers
13. Install the fifth speed gear mainshaft snap

ring onto the mainshaft, inside the fifth
speed gear.
472
Figure 474 — Installing Snap Ring into Second Speed

Gear
16. Install the second speed gear onto the

mainshaft with the clutch teeth facing the
front of the shaft.
475
Figure 472 — Installing Fifth Speed Gear Snap Ring
14. Working at the rear of the mainshaft, install

the second speed gear internal-toothed and
external-toothed thrust washers. Slide them
forward against the snap ring previously
installed. The oil grooves of the external-
toothed thrust washer face forward toward
the internal-toothed thrust washer.
Figure 475 — Installing Second Speed Gear onto

Mainshaft
Page 188
REPAIR INSTRUCTIONS
17. Install the snap ring into the groove of the 20. Install the first speed gear mainshaft snap
first speed gear, farthest away from the ring onto the mainshaft inside the first speed
clutch teeth. gear.
476 478
Figure 478 — Installing First Speed Gear Mainshaft Snap

Ring
Figure 476 — Installing Snap Ring into First Speed Gear
21. Install the first speed gear sliding clutch onto
18. Install the first speed gear onto the the mainshaft.
mainshaft with clutch teeth facing rearward. 479
19. Install the first speed gear external-toothed

and internal-toothed thrust washers onto the
mainshaft. Make sure the oil groove side of
the external-toothed thrust washer faces
rearward toward the internal-toothed thrust
washer.
477
Figure 479 — Installing First Speed Gear Sliding Clutch
22. Set the assembly aside for later installation.
Figure 477 — Installing First Speed Gear Thrust

Washers
Page 189
REPAIR INSTRUCTIONS
Range Shift Valve Reassembly 2. Position a new top cover seal into the
groove of the top cover. Lightly lubricate the
(T307M/T308M) seal before installation, and make sure all
portions of the seal are properly seated in
[322] the grooves.
480 482
Figure 480 — Cutaway View of Range Shift Valve Figure 482 — Installing Top Cover
Assembly
1. Housing Top Cover 3. Valve Housing
1. 4 mm Screw 4. Sintered Bronze Filter 2. Top Cover Seal
3. Top Cover
3. Install the top cover over the range shift
valve body. Install the top cover screws and
1. Install the filter O-ring and bronze filter into
tighten the screws to the specified torque.
the filter bore of the housing. Set the filter on 483
the top of the O-ring.
Lightly lubricate the O-ring before installation.

Over-lubricating the O-ring can cause filter
restriction. Make sure to properly seat the O-ring.
481
Figure 483 — Installing Top Cover
4. Set the assembly aside for later installation

onto the main case shift cover.
Figure 481 — Installing O-Ring and Filter
1. Sintered Bronze Filter 3. Filter O-Ring

2. Valve Housing
Page 190
REPAIR INSTRUCTIONS
Main Case Shift Cover Reassembly 2. Install the fourth/fifth rocker pin and rocker
arm. Make sure to position the washer,
(T307M/T308M) bushing and washer on the rocker pin as
illustrated. The bottom washer is positioned
[323] between the rocker arm and main case shift
484 cover.
486
Figure 484 — Main Case Shift Cover Component Locator

(T308M Shown)
1. Install the shift cover breather vent into the
cover.
485
Figure 486 — Installing Fourth/Fifth Rocker Pin and

Rocker Arm
Occasionally, due to assembly tolerances,

particularly in units that have been operated, the
current production rocker pivot pin will not center
Figure 485 — Installing Breather Vent the fourth/fifth clutch sufficiently to prevent clutch
tooth contact when the fourth/fifth shift rail is in
Neutral. For transmissions with a history of clutch
tooth contact, the noncurrent eccentric pivot pin,
which is available for service, should be installed
and adjusted per instructions found in “T307M/
T308M TRANSMISSION MAIN CASE
REASSEMBLY” on page 203.
Page 191
REPAIR INSTRUCTIONS
487

Page 192
REPAIR INSTRUCTIONS
3. Install the fourth/fifth pin lock washer, flat 490
washer and nut. Tighten nut to the specified

torque.
488
Figure 490 — Installing Poppet Ball and Spring
5. Slide the fourth/fifth shift rail into the cover.

At the same time, install the fourth/fifth
shifter onto the shift rail.
491
Figure 488 — Installing Washers and Nut

489
Figure 489 — Tightening Nut
4. Install the poppet ball and spring for the

fourth/fifth shift rail.
Figure 491 — Installing Shift Rail and Shifter
Page 193
REPAIR INSTRUCTIONS
6. Press the poppet ball down while sliding the 7. Align the setscrew in the fourth/fifth shifter
fourth/fifth shift rail over the ball. A hollow with the notch in the shift rail. Tighten the
tube works well to press down the ball. setscrew to the specified torque.
492 493
Figure 493 — Tightening Setscrew
Figure 492 — Pushing Poppet Ball Down 8. Slide the second/third shift rail into the shift
cover. At the same time, install the second/
third shift fork onto the shift rail.
494
Figure 494 — Installing Second/Third Shift Rail
Page 194
REPAIR INSTRUCTIONS
495
9. Install the interlock pin into the second/third
shift rail.
496
Figure 495 — Installing Second/Third Shift Fork Figure 496 — Installing Pin into Second/Third Shift Rail
Page 195
REPAIR INSTRUCTIONS
10. Install the interlock ball between the second/ 498
third shift rail and the fourth/fifth shift rail.

497
12. Press the poppet ball down while sliding the

second/third shift rail over the ball. A hollow
tube works well to press down the ball.
Figure 497 — Installing Interlock Ball Between Rails 499
11. Install the poppet ball and spring for the

second/third shift rail.
Figure 499 — Pressing Poppet Ball Down
Page 196
REPAIR INSTRUCTIONS
13. Align the setscrew in the second/third shift 14. Slide the first speed shift rail into the shift
fork with the notch in the shift rail. Tighten cover. At the same time, install the fourth/
the setscrew to the specified torque. fifth shift fork onto the shift rail.
500 501
Figure 500 — Tightening Setscrew
Figure 501 — Installing Fourth/Fifth Shift Fork
15. Install the poppet ball and spring into the first
speed shifter, followed by the spring and
plunger. Depress the poppet ball to allow the
spring and plunger to pass. The poppet ball
rests in the radius of the plunger.
502
Figure 502 — Assembling First Speed Shifter
Page 197
REPAIR INSTRUCTIONS
16. Install the first speed shifter onto the shift 17. Install the interlock ball between the first
rail, behind the fourth/fifth shift fork. speed shift rail and the second/third shift rail.
503 504
Figure 503 — Installing First Speed Shifter

Figure 504 — Installing Interlock Ball
Page 198
REPAIR INSTRUCTIONS
18. Install the poppet ball and spring for the first 19. Press the poppet ball down while sliding the
speed shift rail. first speed shift rail over the ball. A hollow
505
tube works well to press down the ball.
506
Figure 506 — Pushing Poppet Ball Down

Page 199
REPAIR INSTRUCTIONS
20. Install the first speed shift fork (A) onto the 21. Continue sliding the first speed shift rail as
shift rail. shown and then, install the interlock pin into
507
the rail. (The interlock pin applies only to the
T308M transmission.)
508
Figure 507 — Installing First Speed Shift Fork
Figure 508 — Sliding First Speed Shift Rail
22. Install the spacer (B) onto the shift rail.

509
Figure 509 — Installing Spacer
Page 200
REPAIR INSTRUCTIONS
23. Finish sliding the shift rail through the fork 25. Align the setscrew in the first speed shift fork
(A), spacer (B) and into position. with the notch in the shift rail. Tighten the
510
setscrew to the specified torque.
512
Figure 510 — Sliding Shift Rail into Position
24. Align the setscrew in the first speed shifter

with the notch in the shift rail. Tighten the
setscrew to the specified torque.
511
Figure 512 — Tightening Shift Fork Setscrew
Figure 511 — Tightening Shifter Setscrew
Page 201
REPAIR INSTRUCTIONS
26. T308M step only. Install the interlock ball 28. T308M step only. Install the nut and washers
into the opening next to the interlock rocker onto the interlock rocker bolt, and tighten to
location of the shift cover. the specified torque.
513 515
Figure 513 — Installing Interlock Ball (T308M Only) Figure 515 — Installing Washers and Nut (T308M Only)
27. T308M step only. Install the interlock rocker

and bolt into the cover.
514
Figure 514 — Installing Interlock Rocker and Bolt

(T308M Only)
Page 202
REPAIR INSTRUCTIONS
T307M/T308M TRANSMISSION
MAIN CASE REASSEMBLY
[320] Locate the three gear tooth spaces on the
mainshaft fifth speed gear, stamped with the
letter “o.” Paint the front of each tooth space with
white paint for greater visibility when timing the
countershafts. If there are no stamped letters,
Locate the stamped letter “o” on the front of each count the number of gear teeth (result should be
front countershaft fifth speed gear that aligns with divisible by three). Place a white paint mark on
the keyway. Paint the front of the corresponding any tooth space. Then, count around one-third of
gear tooth with white paint for greater visibility the total spaces and place the second white
when timing the countershafts later. Do this for mark. Finally, count around one-third of the total
each of the three front countershafts. spaces again and place the third white mark. The
516 three marks should now be evenly spaced
around the gear.
517
Figure 516 — Gear Tooth Marked for Timing
Figure 517 — Gear Tooth Spaces Marked for Timing
Page 203
REPAIR INSTRUCTIONS
1. Install the No. 3 (lower) countershaft into the 4. Place the transmission in a horizontal
case. position. Insert a pry bar into one of the
518
inertia holes of the No. 3 (lower)
countershaft fifth speed gear to align the
shaft with the front bearing cover opening.
While holding the shaft with one hand, insert
the front bearing cover. Use a new O-ring on
the cover. Carefully tap the cover in place
using a soft-faced mallet. Tighten the
capscrews to specification. Also, install the
No. 1 (upper right) front countershaft front
bearing cover as described.
Do not use bearing cover capscrews to pull any

bearing cover into place. Damage to the bearing
or bearing cover can result. Make sure all
Figure 518 — Installing No. 3 (Lower) Countershaft
components are properly in place before
tightening the capscrews.
2. Temporarily install the No. 3 (lower) front
countershaft rear bearing cover, to hold the 520
countershaft in place and to protect the rear

bearing. This cover is removed later to
determine end play and proper bearing shim
pack. Tap cover in place using a soft-faced
mallet.
3. Loosely install the three capscrews onto the
No. 3 (lower) bearing cover. This holds the
bearing in place while the transmission is
rotated to allow installation of the
countershaft front bearing cover.
519
Figure 519 — Temporarily Installing Rear Bearing Cover
Figure 520 — Aligning Countershaft with Bearing Cover
Page 204
REPAIR INSTRUCTIONS
521
6. Temporarily install the No. 1 (upper left) rear
bearing cover to hold the countershaft in
place and to protect the bearing. This cover
is removed later to determine end play and
proper bearing shim pack. Tap cover in
place using a soft-faced mallet.
523
Figure 521 — Bearing Covers Installed
5. Install the No. 1 (upper left) countershaft into

the case.
522
Figure 523 — Temporarily Installing Rear Bearing Cover
7. Fasten a chain around the mainshaft

assembly between the second and third
speed gears. Using a hoist, install the
mainshaft assembly into the case and align
the timing marks on the mainshaft with the
marks on the countershaft gears.
Installing and timing the mainshaft is easier if the

transmission is horizontal, and rotated
Figure 522 — Installing No. 1 Countershaft 15 degrees counterclockwise as viewed from the
rear of the transmission.
Page 205
REPAIR INSTRUCTIONS
524
9. Install the No. 2 (upper right) countershaft
into the case. Align the timing marks
properly with the mainshaft.
526
Figure 524 — Installing Mainshaft Assembly
8. Position the mainshaft No. 3 (lower)

countershaft and No. 1 (upper left)
countershaft so that the timing marks on the Figure 526 — Installing No. 2 Countershaft
gears are aligned. Roll the shafts into place
and make sure gear timing is correct. 10. Align the timing marks on the No. 2
525 countershaft with the mainshaft. All three
countershafts and mainshaft timing marks
should be aligned at this point.
527
Figure 525 — Timing Gears with Mainshaft in Place
Figure 527 — Gear Timing Marks Aligned
Page 206
REPAIR INSTRUCTIONS
11. Install the No. 2 countershaft front bearing 13. Press the sleeve into the mainshaft rear
cover. Install and tighten the bearing cover bearing, being careful to support the bearing
capscrews to specified torque. by the inner race to prevent damage.
528 530
Figure 528 — Tightening Front Bearing Cover

Capscrews
12. Install the snap ring onto the mainshaft,

followed by the spacer (thrust washer).
Figure 530 — Pressing Sleeve into Bearing

The arrow in Figure 529 points to the snap ring
location. 14. Install the mainshaft rear bearing onto the
mainshaft.
529 531
Figure 529 — Installing Snap Ring and Spacer Figure 531 — Installing Mainshaft Rear Bearing
Page 207
REPAIR INSTRUCTIONS
15. Install the front mainshaft rear bearing 18. Install the main drive pinion assembly into
mainshaft snap ring. the front of the main case (using a new
532
gasket), and tighten the capscrews to the
proper torque specification.
534
Figure 532 — Installing Mainshaft Rear Bearing Snap

Ring
Figure 534 — Tightening Main Drive Pinion Capscrews
16. Temporarily install the No. 2 (upper right)
rear bearing cover and capscrews to hold
the countershaft in place and to protect the
bearing. This cover is removed later to
determine end play and proper bearing shim
pack. Tap cover in place using a soft-faced
mallet.
17. Install the fourth/fifth sliding clutch onto the
front of the mainshaft.
533
Figure 533 — Installing Sliding Clutch onto Mainshaft
Page 208
REPAIR INSTRUCTIONS
Setting Front Countershaft Bearing Example:
Preload a. Begin the procedure using enough
shims under the cover to produce
1. Install enough shims under each front measurable end play.
countershaft rear bearing cover to produce
measurable countershaft end play. Reinstall b. Measure countershaft end play. For this
the covers and tighten the capscrews to example, the end play is 0.100 inch.
36–54 lb-ft (49–73 N•m) torque. Measure c. Remove 0.100-inch shims from the
the end play of each countershaft using a pack to obtain zero end play.
dial indicator.
d. Remove (subtract) additional
0.003–0.007 inch shims from the pack
to obtain the specified preload.
Use a pry bar to move the countershafts up and e. Total shim thickness removed from the
down while measuring end play on the dial shim pack to obtain 0.003–0.007 inch
indicator. preload must be 0.103–0.107 inch.
535
Preload is negative end play or “crush.” It cannot

be measured directly. Determining shim
thickness must be done carefully as described, to
obtain the correct preload on the bearings.
3. Perform the following for each of the three

countershafts and rear bearing covers:
Remove the countershaft rear bearing cover
and measure the thickness of the shim pack.
Remove shims as needed, then install the
final shim pack and cover. Tighten the
capscrews to specified torque.
536
Figure 535 — Measuring Countershaft End Play
1. Dial Indicator Set J 05959-A
2. For the example No. 3 (lower) countershaft,

measured end play determines the
thickness of shims that must be removed
from the shim pack to obtain zero end play.
Then remove additional shim thickness to
obtain the required 0.003–0.007 inch
preload.
Figure 536 — Tightening Countershaft Rear Bearing

Cover Capscrews
Page 209
REPAIR INSTRUCTIONS
Final Transmission Main Case 5. Align the shift forks with the sliding clutches
and install the main case shift cover.
Reassembly 538
1. If equipped, reinstall the oil pump discharge

tube that was removed during transmission
disassembly. Tighten the upper and lower
fittings of the discharge tube to 36–39 lb-ft
(49–53 N•m) using a crowfoot adapter and
torque wrench.
537
Figure 538 — Installing Main Case Shift Cover
6. Install the lifting bracket and longer

capscrews at the left front corner of the main
case shift cover.
Figure 537 — Tightening Discharge Tube Fittings

The lift bracket capscrews are slightly longer than
1. Upper Discharge Tube 2. Lower Discharge Tube the remainder of the shift cover capscrews. Make
Fitting Fitting sure the longer capscrews are used to secure the
lift bracket.
2. Clean the gasket surface of the main case 539
shift cover.
3. Install a new main case shift cover gasket.
Use a small amount of adhesive or grease to
hold the gasket in place.
4. Make sure the shifters on the shift cover and
the sliding clutches on the mainshaft are in
the Neutral position for shift fork alignment.
If the rear compound is not yet installed, delay

main case shift cover installation until after full
compound reassembly. This is due to the
installation of the drive yoke (flange). Tightening
the drive yoke fastener requires locking gears in Figure 539 — Lift Bracket Placement
the main case and compound case together, to
lock up the transmission.
Page 210
REPAIR INSTRUCTIONS
7. Install the remaining shorter shift cover 8. This step applies to T308M only. Install the
capscrews and tighten to specification. interlock valve O-ring, pin, spring and sleeve
into the main case shift cover.
On the rare occasion of clutch tooth contact, the

noncurrent eccentric pin (available for service), Although both T307M and T308M transmissions
should be installed. Adjustment of the eccentric are equipped with the range shift valve, only the
pivot pin is as follows: T308M transmission is equipped with the range
shift interlock components. T307M transmissions
a. Loosen the locknut on the eccentric pin.
are plugged in the interlock pin bore. Make sure
While rotating the transmission input
this cup plug is installed. The cup plug (part
shaft by hand, adjust the eccentric pin
No. 79AX59Z) can be obtained through the
until gear clash occurs. Note the
MACK Parts System.
position of the eccentric pin.
541
b. Turn the eccentric pin in the other
direction until gear clash occurs again
and note the position of the eccentric
pin.
c. Return the eccentric pin to a point
midway between the two positions.
d. Tighten the locknut to 40–50 lb-ft
(54–68 N•m).
540
Figure 541 — Range Shift Interlock (T308M Only)
1. Interlock Pin 4. O-Ring

2. Interlock Spring 5. Main Case Shift Cover
3. Interlock Sleeve
Figure 540 — Adjusting Eccentric Pin
Page 211
REPAIR INSTRUCTIONS
9. Position the range shift valve over the tip of 11. Install the neutral control check valve (if
the interlock pin (or plug T307M). Install the equipped), air directional valve (forward and
two (outer) Allen-head 5/32-inch screws and reverse control) and associated brackets
tighten to specification. onto the transmission. Tighten all fasteners
542
to specification.
544
Figure 542 — Tightening Range Shift Valve Screws
1. Allen-Head Screws 2. Range Shift Valve

(5/32-inch)
10. Install the two (inner) hex head screws and

tighten to specification.
543
Figure 544 — Air Control Valve Positions
1. Range Shift Valve 3. Air Directional Valve

2. Neutral Control Valve (If
Equipped)
Figure 543 — Tightening Remaining Range Shift Valve

Screws
1. Hex Head Screws 2. Range Shift Valve
Page 212
REPAIR INSTRUCTIONS
12. Reconnect the air lines to all transmission 13. Install the transmission drain plug and
valves, range shift cylinder and compound magnetic filter plug and tighten to
case shift cover. Install air lines by holding specification.
approximately 6 inches (152 mm) away from
14. Install the clutch release bearing assembly,
air fitting. Insert air line straight into fitting
shafts, yoke and clutch brake (if equipped).
until seated. Slightly tug on air line to make
sure it is seated and captured by fitting. 15. Install the compound components as
545
necessary. Refer to “T307M/T308M
TRANSMISSION COMPOUND CASE
REASSEMBLY” on page 121.
16. Reinstall the transmission into the vehicle.
17. After transmission installation, remove the
oil fill and level plug. Fill the unit with the
specified gear oil. Add the gear oil until even
with the bottom of the fill hole. Refer to
“Changing Oil” on page 39.
18. Allow time for distribution of the lubricant.
Then check the level again.
19. Install the oil fill and level plug and tighten to
specification.
Figure 545 — Installing Air Line
1. Air Line Fitting 2. Air Hose
Page 213
NOTES
Page 214
SPECIFICATIONS
SPECIFICATIONS
Page 215
SPECIFICATIONS
SPECIFICATIONS
Overhaul Symbols
The following symbols can appear in this manual
to identify actions or specifications required for
overhaul of various transmission components.
Figure 546 — Overhaul Symbols
1. Exert force in direction of arrow 4. Assure or record clearance dimension

2. Wear limit 5. Weight in pounds (275 lbs.)
3. Axial or vertical 6. Adjust or place into contact
Page 216
SPECIFICATIONS
T307M Torque Specifications
547
Figure 547 — Torque Specifications (T307M without Compound Neutralizing)
Page 217
SPECIFICATIONS
Item and Location Torque — Lb-Ft (N•m)
1. Main Drive Pinion Bearing Cover Capscrews* 36–54 (49–73)
2. Main Case Shift Cover Capscrews* 24–36 (33–49)
3. Fourth/Fifth Pivot Pin Nut 40–50 (54–68)
4. Shifter and Shift Fork Setscrews* 35–50 (47–68)
5. Case-to-Case Capscrews* 62–78 (84–106)
Case-to-Case Dowel Bolts 55–65 (75–88)
6. Reverse Idler Pin Retaining Strap Capscrews 17–21 (23–28)
7. Forward/Reverse Shift Fork Setscrew* 35–50 (47–68)
8. Range Shift Fork Setscrew* 35–50 (47–68)
9. Rear Case Shift Cover Capscrews* 24–36 (33–49)
10. Rear Mainshaft Bearing Cover Capscrews* 40–50 (54–68)
11. Range Shift Cylinder Capscrews* 17–21 (23–29)
12. Drive Yoke (or Flange) Clamp Plate Capscrew 494–600 (670–813)
13. Rear Countershaft Bearing Cover Capscrews* 40–50 (54–68)
14. Front Countershaft Rear Bearing Cover Capscrews* 36–54 (49–73)
15. Magnetic Drain Plug 25–30 (34–41)
16. Front Countershaft Front Bearing Cover Capscrews* 36–54 (49–73)
— Oil Fill and Level Plug 35–50 (47–68)
— Magnetic Filter Plug 20–23 (27–31)
— Reverse Idler Cage Capscrews 40–50 (54–68)
— Range Shift Piston-to-Rail Retaining Nut (When Equipped) 75–105 (102–142)
— Range Shift Valve Mounting Screws 84–96 lb-in (9–11)
— Range Shift Valve Top Cover Screws 30–40 lb-in (3.4–4.5)
* Indicates that fastener has epoxy-coated threads. Fastener can be reused a maximum of five times.
Page 218
SPECIFICATIONS
T308M Torque Specifications
548
Figure 548 — Torque Specifications (T308M with Compound Neutralizing)
Page 219
SPECIFICATIONS
Item and Location Torque — Lb-Ft (N•m)
1. Main Drive Pinion Bearing Cover Capscrews* 36–54 (49–73)
2. Main Case Shift Cover Capscrews* 24–36 (33–49)
3. Fourth/Fifth Pivot Pin Nut 40–50 (54–68)
4. Shifter and Shift Fork Setscrews* 35–50 (47–68)
5. Case-to-Case Capscrews* 62–78 (84–106)
Case-to-Case Dowel Bolts 55–65 (75–88)
6. Reverse Idler Pin Retaining Strap Capscrews 17–21 (23–28)
7. Forward/Reverse Shift Fork Setscrew* 35–50 (47–68)
8. Range Shift Fork Setscrew* 35–50 (47–68)
9. Rear Case Shift Cover Capscrews* 24–36 (33–49)
10. Range Shift Piston-to-Rail Retaining Nut (When Equipped) 75–105 (102–142)
11. Range Shift Cylinder Cover Capscrews 17–21 (23–28)
12. Rear Mainshaft Bearing Cover Capscrews* 40–50 (54–68)
13. Drive Yoke (or Flange) Clamp Plate Capscrew 494–600 (670–813)
14. Rear Countershaft Bearing Cover Capscrews* 40–50 (54–68)
15. Synchronizer 12-Point Screws (Inserts) 24–28 (33–38)
16. Front Countershaft Rear Bearing Cover Capscrews* 36–54 (49–73)
17. Magnetic Drain Plug 25–30 (34–41)
18. Front Countershaft Front Bearing Cover Capscrews* 36–54 (49–73)
— Oil Fill and Level Plug 35–50 (47–68)
— Magnetic Filter Plug 20–23 (27–31)
— Reverse Idler Cage Capscrews 40–50 (54–68)
— Range Shift Interlock Rocker Nut 20–25 (27–34)
— Range Shift Valve Mounting Screws 84–96 lb-in (9–11)
— Range Shift Valve Top Cover Screws 30–40 lb-in (3.4–4.5)
* Indicates that fastener has epoxy-coated threads. Fastener can be reused a maximum of five times.
Page 220
SPECIFICATIONS
T307M Gear Identification
549
Figure 549 — Gear Identification (T307M)
Page 221
SPECIFICATIONS
Item Number Item Number of Teeth Outside Diameter
Main Case Mainshaft Gears
1 Main Drive Pinion (Fourth Speed Straight Through) 36 6.162
2 Mainshaft Fifth Speed Gear 27 4.692
3 Mainshaft Third Speed Gear 48 7.632
4 Mainshaft Second Speed Gear 51 9.156
5 Mainshaft First Speed Gear 57 10.307
Compound Case Mainshaft and Countershaft Gears
6 Front Mainshaft Reverse Speed Gear 30 4.601
7 Reverse Idler Gear 33 4.969
8 Rear Mainshaft Main Drive Gear 30 5.204
9 Rear Mainshaft Lo-Range Gear 48 8.029
10 Rear Countershaft Lo-Range Gear (Part of Shaft) 29 5.082
11 Rear Countershaft Main Drive Gear 49 8.001
12 Rear Countershaft Reverse Speed Gear 43 6.310
Main Case Countershaft Gears
13 Countershaft First Speed Gear (Part of Shaft) 13 2.814
14 Countershaft Second Speed Gear 20 3.952
15 Countershaft Third Speed Gear 33 5.589
16 Countershaft Fifth Speed Gear 54 8.514
17 Countershaft Main Drive Gear 43 7.052
Page 222
SPECIFICATIONS
T308M Gear Identification
550
Figure 550 — Gear Identification (T308M with Compound Neutralizing)
Page 223
SPECIFICATIONS
Item Number Item Number of Teeth Outside Diameter
Main Case Mainshaft Gears
1 Main Drive Pinion (Fourth Speed Straight Through) 36 6.162
2 Mainshaft Fifth Speed Gear 27 4.692
3 Mainshaft Third Speed Gear 48 7.632
4 Mainshaft Second Speed Gear 51 9.156
5 Mainshaft First Speed Gear 57 10.307
Compound Case Mainshaft and Countershaft Gears
6 Front Mainshaft Reverse Speed Gear 30 4.601
7 Reverse Idler Gear 33 4.969
8 Rear Mainshaft Main Drive Gear 30 5.204
9 Rear Mainshaft Lo-Range Gear 54 8.996
10 Rear Countershaft Lo-Range Gear (Part of Shaft) 23 4.205
11 Rear Countershaft Main Drive Gear 49 8.001
12 Rear Countershaft Reverse Speed Gear 43 6.310
Main Case Countershaft Gears
13 Countershaft First Speed Gear (Part of Shaft) 13 2.814
14 Countershaft Second Speed Gear 20 3.952
15 Countershaft Third Speed Gear 33 5.589
16 Countershaft Fifth Speed Gear 54 8.514
17 Countershaft Main Drive Gear 43 7.052
Page 224
SPECIFICATIONS
Fits and Limits (T307M/T308M)
ALL FORKS AND SLIDING CLUTCHES
ALL FORKS AND SLIDING CLUTCHES

Minimum New Maximum New Maximum Wear
1. Clearance between shift fork pad and sliding clutch 0.005 inch 0.020 inch 0.050* inch
groove
2. Clearance between synchronizer shift fork pads and 0.073 inch 0.087 inch 0.135 inch
sliding clutch groove
* If unit has experienced disengagement, clearance must not exceed 0.030-inch maximum.
551
Figure 551 — Sliding Clutch Clearances
Page 225
SPECIFICATIONS
SHIFT RAILS TO SHIFT COVER BORES
552
Figure 552 — Shift Rail to Shift Cover Bore Clearance
Page 226
SPECIFICATIONS
SPRING SPECIFICATIONS
SPRING SPECIFICATIONS
Length Under Load
Springs Free Length (A) Load in Lbs. (B) (C)
First Speed Shifter Ball Spring 1.562 inches 41.8 ± 5 0.875 inch
First Speed Shifter Plunger Spring 1.500 inches 22.0 ± 2 0.625 inch
Shift Rail Poppet Ball Springs 2.250 inches 25 ± 2.5 1.539 inches
Range Shift Interlock Pin Spring 1.310 inches 18.7 1.120 inches
31.2 1.000 inch
553 554
Figure 553 — Free Length and Loaded Length
Figure 554 — Compressing Spring
Page 227
SPECIFICATIONS
General Specifications (T307M/T308M)
555
Figure 555 — T307M Gear End Play and Bearing Preloads
Component Specification
1. Mainshaft 5th-to-3rd Speed Floating Gear End Play 0.024–0.081 inch
2. Mainshaft 1st-to-2nd Speed Floating Gear End Play 0.020–0.080 inch
3. Reverse Idler Gear End Play 0.002–0.022 inch
4. Rear Mainshaft Main Drive (Direct) Gear End Play 0.006–0.040 inch
5. Rear Mainshaft Lo-Range Gear End Play 0.006–0.034 inch
6. Rear Countershaft Bearing Preload 0.002–0.006 inch
7. Mainshaft Reverse Gear End Play 0.005–0.041 inch
8. Front Countershaft Bearing Preload 0.003–0.007 inch
Page 228
SPECIFICATIONS
556
Figure 556 — T308M Gear End Play and Bearing Preloads
Component Specification
1. Mainshaft 5th-to-3rd Speed Floating Gear End Play 0.024–0.081 inch
2. Mainshaft 1st-to-2nd Speed Floating Gear End Play 0.020–0.080 inch
3. Reverse Idler Gear End Play 0.002–0.022 inch
4. Rear Mainshaft Main Drive (Direct) Gear End Play 0.006–0.040 inch
5. Rear Mainshaft Lo-Range Gear End Play 0.006–0.034 inch
6. Rear Countershaft Bearing Preload 0.002–0.006 inch
7. Mainshaft Reverse Gear End Play 0.005–0.041 inch
8. Front Countershaft Bearing Preload 0.003–0.007 inch
Page 229
SPECIFICATIONS
T307M/T308M TRANSMISSION SPECIFICATIONS AND
CAPACITIES
Make Mack Trucks, Inc.
Type MACK Triple Countershaft Design
Controls Selective, One Lever Manual with Air-Shifted Compound Case
T307M Speeds Seven Forward, Three Usable Reverse
T308M Speeds Eight Forward, Three Usable Reverse
Bell Housing SAE No. 1, Integral with Main Case
Cases Cast Aluminum, Heat Treated
Gears Spur Type
Shaft Splines Fine Pitch Rolled Involute
Lubrication Splash Lubrication
Oil Filter Magnetic Filter Plug
Drain Plug Magnetic
Seal Type Positive Lip
PTO Openings:
Left Side Standard SAE 8-Hole (Main Case and Compound Case)
Right Side Standard SAE 6-Hole (Main Case and Compound Case)
Oil Capacity Approximately 30 Pints (depends on angle of installation)
Recommended SAE Grade Gear Oil for All

Temperature Operations, MACK GO-J and GO-J
Plus* or TO-A Plus* Specification:
r SAE 90, 140, 80W-90, 80W-140, 85W-140
for Mineral Base
r SAE 50, 75W-90, 75W-140, 80W-140 for
Synthetic Base
* GO-J Plus or TO-A Plus is required for MACK-

geared component extended service drain
intervals.
For further information regarding recommended,

approved, and current transmission lubricants,
access Mack Trucks, Inc. web site at
www.macktrucks.com.
Page 230
SCHEMATIC & ROUTING DIAGRAMS
Page 231

T307M/T308M SCHEMATIC AND ROUTING DIAGRAMS
[543]
T307M Transmission
557
Figure 557 — T307M Air Control Schematic without Compound Neutralizing
1. Selector Control Valve 4. Forward/Reverse Cylinder (Rear Case Shift Cover)

2. Range Shift Cylinder 5. Air Directional Valve
3. Range Shift Valve 6. Pressure Reducing Valve (30 psi)
Page 232

558
Figure 558 — T307M Air Control Schematic with Compound Neutralizing
1. Selector Control Valve 5. Range Shift Valve

2. Dash-Mounted Neutral Control Valve 6. Forward/Reverse Cylinder (Rear Case Shift Cover)
3. Double Check Valve 7. Air Directional Valve
4. Range Shift Cylinder 8. Pressure Reducing Valve (30 psi)
Page 233

T308M Transmission
559
Figure 559 — T308M Air Control Schematic without Compound Neutralizing
1. Selector Control Valve 4. Forward/Reverse Cylinder (Rear Case Shift Cover)

2. Range Shift Cylinder 5. Air Directional Valve
3. Range Shift Valve
Page 234

560
Figure 560 — T308M Air Control Schematic with Compound Neutralizing
1. Selector Control Valve 5. Range Shift Valve

2. Dash-Mounted Neutral Control Valve 6. Forward/Reverse Cylinder (Rear Case Shift Cover)
3. Double Check Valve 7. Air Directional Valve
4. Range Shift Cylinder
Page 235
NOTES
Page 236
SPECIAL TOOLS & EQUIPMENT
Page 237

TRANSMISSION SPECIAL TOOLS
J 02619-A Slide Hammer
J 05959-A Dial Indicator Set
J 07804-A Yoke and Flange Puller
J 1313-B 0–150 lb-ft Torque Wrench
J 21834-4A Two Jaw Adjustable Puller
J 22912-01 Bearing Separator
J 23775-01 100–600 lb-ft Torque Wrench
J 24407 30–250 lb-ft Torque Wrench
J 28506 Carrier Adapter
J 29048 Tapered Feeler Gauge
J 29369-1 Bearing Puller
J 29369-2 Bearing Puller
J 34629 Snap Ring Pliers Set
J 34630 Reverse Idler Shaft Removal Tool
J 36052 Positioning Tool
J 36053 Seal Driver
J 39477 Bar-Type Puller
J 39854 Seal Driver
J 8092 Driver Handle
J 8176 Bearing Separator
OEM-4052 Internal Puller
9032-1800trk Air Line Quick Disconnect Fitting Tool Kit
Available through MACK Parts System
Above tools are available from Kent-Moore

(except as noted):
KENT-MOORE
O.E. TOOL AND EQUIPMENT GROUP
SPX CORPORATION
28635 MOUND ROAD
WARREN, MICHIGAN 48092-3499
TELEPHONE: 1-800-328-6657
FAX: 1-800-578-7375
Page 238
DISASSEMBLED VIEWS
DISASSEMBLED VIEWS
Page 239
DISASSEMBLED VIEWS
DISASSEMBLED VIEWS
Compound Case Components
561

3. Snap Ring 10. Cover O-Ring
Figure 561 — Exploded View of Rear Mainshaft Bearing 4. End Plug O-Ring 11. End Plug
Cover 5. End Plug 12. End Plug O-Ring
7. Shaft
2. Oil Seal 5. Snap Ring 564
3. Gasket
562

Bearing Cover

Cylinder

Page 240
DISASSEMBLED VIEWS
565

Shift Cylinder

Page 241
DISASSEMBLED VIEWS
566

Page 242
DISASSEMBLED VIEWS
567

7. Thrust Plate (Spacer) 17. Synchronizer Pin 29. Rear Bearing Snap Ring
Page 243
DISASSEMBLED VIEWS
568 570

3. Bearing

Assembly
1. 12-Point Capscrew 7. Clutch Housing

3. Clutch Housing 9. Support Tube
6. Synchronizer Pin
569
1. Front Bearing Cone 6. Rear Bearing Cone

2. Reverse Speed Gear 7. Rear Countershaft
3. Spacer (Lo-Range Gear Part of
5. Key
Page 244
DISASSEMBLED VIEWS
Main Case Components
571

Page 245
DISASSEMBLED VIEWS
572
Figure 572 — Cutaway View of Range Shift Valve

Assembly
1. 4 mm Screw 4. Sintered Bronze Filter

3. Top Cover
Page 246
DISASSEMBLED VIEWS
573
Page 247
DISASSEMBLED VIEWS
574 576

Front Bearing Cover
1. Bearing Cup 6. Second Speed Gear
2. Main Drive Gear 7. Bearing Cone
3. Fifth Speed Gear 8. Front Countershaft 1. O-Ring 3. Front Bearing Cover
4. Third Speed Gear 9. Key 2. Bearing Cone
5. Spacer
577
575
Figure 577 — Exploded View of Front Countershaft Rear

Bearing Cover
1. Front Bearing Cup 3. Rear Bearing Cup

2. Bearing Cover

6. Snap Ring
Page 248
Index.fm Page 249 Friday, October 25, 2002 10:13 AM
INDEX
INDEX
Page 249
INDEX
A GENERAL SPECIFICATIONS
(T307M/T308M) . . . . . . . . . . . . . . . . . . . . 228
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . .2
AIR BREATHER . . . . . . . . . . . . . . . . . . . . . . .40
I
B INSPECTION AND CLEANING . . . . . . . 81, 172
INSPECTION OF PARTS . . . . . . . . . . . . 81, 172
BEARINGS . . . . . . . . . . . . . . . . . . . . . . .81, 172
M
C
MAGNETIC OIL FILTER PLUG . . . . . . . . 17, 40
CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . .39
MAIN CASE COMPONENTS . . . . . . . . . . . . 245
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .38
MAIN CASE SHIFT COVER DISASSEMBLY
COMPOUND CASE COMPONENTS . . . . . .240
(T307M/T308M) . . . . . . . . . . . . . . . . . . . . 142
CONVERSION CHART . . . . . . . . . . . . . . . . . . .6
MAIN CASE SHIFT COVER REASSEMBLY
D (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 191
MAIN DRIVE PINION DISASSEMBLY
DOWNSHIFTING . . . . . . . . . . . . . . . . . . . .20, 22 (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 166
MAIN DRIVE PINION REASSEMBLY
E (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 177
EXPLANATION OF NUMERICAL CODE . . . . .5
O
F OBTAINING NEUTRAL IN COMPOUND
FINAL TRANSMISSION MAIN CASE CASE (T307M) . . . . . . . . . . . . . . . . . . . . . 21
REASSEMBLY . . . . . . . . . . . . . . . . . . . .210 OBTAINING NEUTRAL IN COMPOUND
FITS AND LIMITS (T307M/T308M) . . . . . . . .225 CASE (T308M) . . . . . . . . . . . . . . . . . . . . . 22
FRONT COUNTERSHAFT DISASSEMBLY OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . 82, 173
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .163 OVERHAUL SYMBOLS . . . . . . . . . . . . . . . . 216
FRONT COUNTERSHAFT FRONT BEARING
COVER DISASSEMBLY R
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .170 RANGE SHIFT CYLINDER DISASSEMBLY
FRONT COUNTERSHAFT FRONT BEARING (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . 57
COVER REASSEMBLY RANGE SHIFT CYLINDER REASSEMBLY
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .176 (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 107
FRONT COUNTERSHAFT REAR BEARING RANGE SHIFT VALVE DISASSEMBLY
COVER DISASSEMBLY . . . . . . . . . . . . .171 (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 155
FRONT COUNTERSHAFT REAR BEARING RANGE SHIFT VALVE REASSEMBLY
COVER REASSEMBLY (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 190
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .175 REAR CASE SHIFT COVER DISASSEMBLY
FRONT COUNTERSHAFT REASSEMBLY (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . 55
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .180 REAR CASE SHIFT COVER REASSEMBLY
FRONT MAINSHAFT DISASSEMBLY (T307M/T308M) . . . . . . . . . . . . . . . . . . . . 116
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .156 REAR COUNTERSHAFT BEARING COVER
FRONT MAINSHAFT REASSEMBLY DISASSEMBLY (T307M/T308M) . . . . . . . 54
(T307M/T308M) . . . . . . . . . . . . . . . . . . . .183 REAR COUNTERSHAFT BEARING COVER
REASSEMBLY (T307M/T308M) . . . . . . . 118
G REAR COUNTERSHAFT DISASSEMBLY
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . .81, 172 (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . 78
GENERAL INSPECTION . . . . . . . . . . . . .83, 174 REAR COUNTERSHAFT REASSEMBLY
GENERAL REASSEMBLY (T307M/T308M) . . . . . . . . . . . . . . . . . . . . . 85
INSTRUCTIONS . . . . . . . . . . . . . . . .83, 174 REAR MAINSHAFT AND SYNCHRONIZER
DISASSEMBLY (T308M) . . . . . . . . . . . . . 70
Page 250
INDEX
REAR MAINSHAFT AND SYNCHRONIZER T307M/T308M DESCRIPTION . . . . . . . . . . . . 14
REASSEMBLY (T308M) . . . . . . . . . . . . . .87 T307M/T308M SCHEMATIC AND
REAR MAINSHAFT BEARING COVER ROUTING DIAGRAMS . . . . . . . . . . . . . . 232
DISASSEMBLY (T307M/T308M) . . . . . . . .53 T307M/T308M TRANSMISSION
REAR MAINSHAFT BEARING COVER COMPOUND CASE DISASSEMBLY . . . . 42
REASSEMBLY (T307M/T308M) . . . . . . .119 T307M/T308M TRANSMISSION COMPOUND
REAR MAINSHAFT CASE REASSEMBLY . . . . . . . . . . . . . . . 121
DISASSEMBLY (T307M) . . . . . . . . . . . . . .62 T307M/T308M TRANSMISSION
REAR MAINSHAFT DISASSEMBLED VIEWS . . . . . . . . . . . . 240
REASSEMBLY (T307M) . . . . . . . . . . . . . .98 T307M/T308M TRANSMISSION
REVERSE IDLER GEAR DISASSEMBLY IDENTIFICATION . . . . . . . . . . . . . . . . . . . 10
(T307M/T308M) . . . . . . . . . . . . . . . . . . . . .80 T307M/T308M TRANSMISSION MAIN CASE
REVERSE IDLER GEAR REASSEMBLY COMPONENT DISASSEMBLY . . . . . . . . 142
(T307M/T308M) . . . . . . . . . . . . . . . . . . . . .84 T307M/T308M TRANSMISSION MAIN CASE
ROAD OPERATION (T307M) . . . . . . . . . . . . .21 COMPONENT REASSEMBLY . . . . . . . . 175
ROAD OPERATION (T308M) . . . . . . . . . . . . .23 T307M/T308M TRANSMISSION MAIN CASE
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . 134
S T307M/T308M TRANSMISSION MAIN CASE
SAFETY INFORMATION . . . . . . . . . . . . . . . . . .2 REASSEMBLY . . . . . . . . . . . . . . . . . . . . 203
SERVICE PROCEDURES AND T307M/T308M TRANSMISSION
TOOL USAGE . . . . . . . . . . . . . . . . . . . . . . .3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . 216
SETTING FRONT COUNTERSHAFT T307M/T308M TRANSMISSION
BEARING PRELOAD . . . . . . . . . . . . . . . .209 SPECIFICATIONS AND CAPACITIES . . 230
SETTING REAR COUNTERSHAFT T308M COMPONENT LOCATIONS . . . . . . . . 31
BEARING PRELOAD . . . . . . . . . . . . . . . .130 T308M GEAR IDENTIFICATION . . . . . . . . . 223
SHIFTER FORKS, SLIDING CLUTCHES AND T308M GEAR RATIOS AND SHIFT
SHIFT RAILS . . . . . . . . . . . . . . . . . . . . . .173 PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . 19
SHIFTER FORKS, SLIDING CLUTCHES AND T308M SHIFTING INSTRUCTIONS . . . . . . . . 21
SHIFT RAILS . . . . . . . . . . . . . . . . . . . . . . .82 T308M TORQUE SPECIFICATIONS . . . . . . 219
SPLASH LUBRICATION . . . . . . . . . . . . . . . . .16 T308M TRANSMISSION . . . . . . . . . . . . . . . . 234
STATIONARY PTO OPERATION T308M TRANSMISSION . . . . . . . . . . . . . . . . . 25
(T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . .21 TRANSMISSION CASE OIL COOLER
STATIONARY PTO OPERATION LINE PLUGS . . . . . . . . . . . . . . . . . . . . . . . 16
(T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . .23 TRANSMISSION LUBRICATION . . . . . . . . . . 16
TRANSMISSION MAINTENANCE . . . . . . . . . 38
T TRANSMISSION MAJOR COMPONENT
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 30
T307M AND T308M POWER FLOW TRANSMISSION SPECIAL TOOLS . . . . . . . 238
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . .23 TROUBLESHOOTING CHARTS . . . . . . . . . . 34
T307M COMPONENT LOCATIONS . . . . . . . .30
T307M GEAR IDENTIFICATION . . . . . . . . . .221 U
T307M GEAR RATIOS AND SHIFT
PATTERN . . . . . . . . . . . . . . . . . . . . . . . . .18 UNIT IDENTIFICATION STAMPING
T307M SHIFTING INSTRUCTIONS . . . . . . . .20 (T307M) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
T307M TORQUE SPECIFICATIONS . . . . . .217 UNIT IDENTIFICATION STAMPING
T307M TRANSMISSION . . . . . . . . . . . . .23, 232 (T308M) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
T307M/T308M COMPOUND UPSHIFTING . . . . . . . . . . . . . . . . . . . . . . . 20, 22
COMPONENT DISASSEMBLY . . . . . . . . .53 USING REVERSE . . . . . . . . . . . . . . . . . . . 20, 22
T307M/T308M COMPOUND
COMPONENT REASSEMBLY . . . . . . . . .84
Page 251
NOTES
Page 252
TRANSMISSIONS
T307M AND T308M
SERVICE MANUAL
PRINTED IN U.S.A.
10-119 © MACK TRUCKS, INC. 2003

Maxitorq t307m, T308-Service

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maxitorq t307m, T308-Service

Uploaded by

Copyright:

Available Formats

TRANSMISSIONS

T307M AND T308M

PLEASE LET US KNOW!

Thank You For Your Assistance

DO NOT STAPLE — USE TRANSPARENT TAPE

FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BY ADDRESSEE

SERVICE PUBLICATIONS (RTS), 6S3

FOLD ALONG THIS LINE

JANUARY 2003 © MACK TRUCKS, INC. 2003

Activities associated with Danger indicate that death or serious personal

A procedure, practice, or condition that is essential to emphasize.

GROUP 000 — GENERAL DATA Additionally, a two-character alpha code (i.e.,

Example of Numerical Code

Unit Identification Stamping 1. Unit Symbol Identification

Figure 2 — Unit Identification Stamping

Figure 3 — Unit Identification Stamping

Figure 4 — Cutaway View of T307M Transmission

Figure 5 — Cutaway View of T308M Transmission — Optional Three-Position Cylinder

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

The T307M and T308M transmissions are

DESCRIPTION AND OPERATION

retainers (covers). Tapered roller bearings are

All gears are of the spur-type design and are in

A single gear shift lever is used to accomplish

DESCRIPTION AND OPERATION

Figure 8 — Splash Lubrication

Figure 9 — Transmission Case Oil Cooler Line Plugs

1. Outlet Plastic Cap 2. Suction Tube Plug

DESCRIPTION AND OPERATION

Figure 10 — Plug Locations

1. Magnetic Filter Plug 3. Oil Drain Plug

DESCRIPTION AND OPERATION

Figure 11 — Shift Pattern

T307M TRANSMISSION GEAR RATIOS

The ratios in parenthesis are not practical to use.

DESCRIPTION AND OPERATION

Figure 12 — Shift Pattern

T308M TRANSMISSION GEAR RATIOS

The ratios in parenthesis are not practical to use.

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

5. Move the shift lever to the appropriate gear

Very high PTO speed can cause equipment

6. Follow the applicable instructions for

Road Operation (T308M)

Figure 14 — Second Lo Speed (T307M)

DESCRIPTION AND OPERATION

Figure 15 — First Hi Speed (T307M) Figure 18 — Fourth Speed (T307M)

Figure 16 — Second Hi Speed (T307M) Figure 19 — Fifth Speed (T307M)

Figure 17 — Third Speed (T307M) Figure 20 — First Reverse Speed (T307M)

DESCRIPTION AND OPERATION

Figure 21 — Second Reverse Speed (T307M)

Figure 23 — First Lo Speed (T308M)

Figure 22 — Third Reverse Speed (T307M)

Figure 24 — Second Lo Speed (T308M)

DESCRIPTION AND OPERATION

Figure 25 — Third Lo Speed (T308M) Figure 28 — Third Hi Speed (T308M)