SM2148EN

Service Manual
MD Product Line
On-Highway Transmissions
SM2148EN
Allison Transmission MD Product Line Service Manual SM2148EN

SM2148EN
Service
Manual
Allison Transmission
MD PRODUCT LINE:
3000MH
MD 3060, MD 3060P, MD 3060PR, MD 3060R
MD 3066, MD 3066P, MD 3066PR, MD 3066R
MD 3070PT
MD 3560, MD 3560P, MD 3560PR, MD 3560R
B 300, B 300P, B 300PR, B 300R
B 400, B 400P, B 400PR, B 400R
T 200, T 300
2001 December
Division of General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com
Printed in the U.S.A. Copyright © 2001 General Motors Corp.

MD PRODUCT LINE ON-HIGHWAY SERVICE MANUAL
ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL

DISPLAYS AND BUTTON NAMES
Shift Selector, Diagnostic Data Reader/Tool (DDR), and Allison Transmission Diagnostic Tool™ (ATDT™) button
and display names are printed in bold capital letters (UP () arrow, DOWN () arrow, DISPLAY MODE,
MONITOR, SELECT, etc.).
The actual message displayed (text and/or letters) is printed within double quotation marks (“O L”, “O K”, etc.).
TRADEMARK USE
The following trademarks are the property of the companies indicated:

• Pro-Link® is a registered trademark of Micro Processor Systems, Inc.
• DEXRON® is a registered trademark of General Motors Corporation.
• Biobor® JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel
Additives Company.
• Teflon® is a registered trademark of the DuPont Corporation.
• Viton™ is a trademark of DuPont Corporation.
• Spiralock® is a registered trademark of Spiralock of Michigan.
• Allison Diagnostic Optimized Connection™ (Allison DOC™) is a trademark of General Motors
Corporation.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by letter suffix to the publication number. Check with your Allison
Transmission service outlet for the currently applicable publica-
tion. Additional copies of this publication may be purchased from
authorized Allison Transmission service outlets. Look in your tele-
phone directory under the heading of Transmissions — Truck,
Tractor, etc.
ii Copyright © 2001 General Motors Corp.

IMPORTANT SAFETY NOTICE
IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cau-

tions described in this Service Manual. These Warnings and Cautions advise against the
use of specific service methods that can result in personal injury, damage to the equip-
ment, or cause the equipment to become unsafe. It is, however, important to understand
that these Warnings and Cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in which
service might be done or of the possible hazardous consequences of each way. Conse-
quently, Allison Transmission has not undertaken any such broad evaluation. Accord-
ingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this Ser-
vice Manual are effective methods for performing service operations. Some of these ser-
vice operations require the use of tools specifically designed for the purpose. The special
tools should be used when and as recommended.
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
Copyright © 2001 General Motors Corp. iii

LIST OF WARNINGS
This manual contains the following warnings —
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
• If you leave the vehicle and the engine is running, the vehicle can move suddenly
and you or others could be injured. If you must leave the engine running, do not
leave the vehicle until you: Put the transmission in N (Neutral)…and — Apply the
parking brake and emergency brakes and make sure they are properly
engaged…and — Chock the wheels and take any other steps necessary to keep the
vehicle from moving.
• Avoid contact with the hot fluid or the sump when draining transmission fluid.
Direct contact with the hot fluid or the hot sump may result in bodily injury.
• While conducting a stall check, the vehicle must be positively prevented from
moving. Apply the parking brake and service brake, and chock the wheels
securely. Warn personnel to keep clear of the vehicle and its travel path. Failure to
do so can cause serious injury.
• Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
• Do not burn discarded Teflon® seals; toxic gases are produced by burning
Teflon®.
• Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also,
spinning a bearing without lubrication can damage the bearing.
• MD Product Line transmission dry weights are as follows: basic configuration — 245 kg
(540 lbs); with retarder — 275 kg (550 lbs); with PTO provision — 260 kg (575 lbs);
with PTO provision and retarder — 300 kg (660 lbs), MD 3070PT — 530 kg (1170).
• The transfer case module assembly weighs approximately 270 kg (595 lb).
• The control module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personnel injury or control module damage. The control
module assembly used in an MD 3070PT weighs approximately 29 kg (65 lb).
• The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
• Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
• Transmissions installed in overhaul stands must be positioned vertically before
installing control module. Failure to do so could result in personal injury.
iv Copyright © 2001 General Motors Corp.

MD PRODUCT LINE
TABLE
ON-HIGHWAY
OF CONTENTS
SERVICE MANUAL
Section 1. GENERAL INFORMATION 1–9. RESTORING TRANSMISSION
TO SERVICE
1–1. SCOPE OF MANUAL
a. Transmission Exterior. . . . . . . . . . . . . . . 1–9
a. Content and Organization . . . . . . . . . . . .1–1 b. Sealed Breather and Openings . . . . . . . . 1–9
b. Illustrations . . . . . . . . . . . . . . . . . . . . . . . .1–1 c. New Transmissions. . . . . . . . . . . . . . . . . 1–9
c. Maintenance Information . . . . . . . . . . . 1–1 d. Stored Without Fluid . . . . . . . . . . . . . . . 1–9
1–2. SUPPLEMENTARY INFORMATION . . . .1–1 e. Stored With Fluid . . . . . . . . . . . . . . . . . . 1–9
1–3. ORDERING PARTS 1–10. OPERATING INSTRUCTIONS . . . . . . . . . 1–9

a. Transmission Nameplate . . . . . . . . . . . . .1–1 1–11. SPECIFICATIONS AND DATA . . . . . . . . 1–9
b. Parts Catalog. . . . . . . . . . . . . . . . . . . . . . .1–6 1–12. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 1–11
1–4. GENERAL DESCRIPTION
a. Major Modules . . . . . . . . . . . . . . . . . . . . .1–6 Section 2. PREVENTIVE MAINTENANCE
b. Unique Features . . . . . . . . . . . . . . . . . . . .1–6 2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
1–5. MAJOR MODULES 2–2. PERIODIC INSPECTION
a. Input Module . . . . . . . . . . . . . . . . . . . . . .1–6 AND CARE
b. Torque Converter . . . . . . . . . . . . . . . . . . .1–6 a. Exterior Cleaning and Inspection . . . . . 2–1
c. Power Takeoff Provision . . . . . . . . . . . . .1–6 2–3. IMPORTANCE OF PROPER
d. Main Housing and Gear Module . . . . . . .1–7 FLUID LEVEL
a. Transmission Fluid . . . . . . . . . . . . . . . . . 2–1
e. Range Clutches. . . . . . . . . . . . . . . . . . . . .1–7
b. Oil Level Sensor . . . . . . . . . . . . . . . . . . . 2–1
f. Gearing Ratios . . . . . . . . . . . . . . . . . . . . .1–7
c. Electronic Controls and
g. Control System and Electronic Protection Circuits . . . . . . . . . . . . . . . . 2–1
Control Unit (ECU). . . . . . . . . . . . . . . .1–7
2–4. ELECTRONIC FLUID LEVEL CHECK
h. Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . .1–7
(WHEN AN OPTIONAL OLS IS
i. Transmission Fluid Coolers . . . . . . . . . . 1–7 PRESENT — FULL-FUNCTION
j. Output Configuration . . . . . . . . . . . . . . . .1–7 PUSHBUTTON OR LEVER SHIFT
SELECTORS)
1–6. MODEL DESIGNATION CODE . . . . . . . . .1–7 a. Fluid Level Check Procedure. . . . . . . . . 2–1
1–7. DIAGNOSIS 2–5. ELECTRONIC FLUID LEVEL CHECK
a. Before Starting . . . . . . . . . . . . . . . . . . . . .1–7 (WHEN AN OPTIONAL OLS IS
b. DO NOT SHIFT or CHECK TRANS PRESENT — STRIP TYPE PUSHBUTTON
Light . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7 SHIFT SELECTORS)
c. Entering Diagnostic Mode . . . . . . . . . . . .1–7 a. Fluid Level Check Procedure
(WTEC II) . . . . . . . . . . . . . . . . . . . . . . 2–3
d. Diagnostic Codes . . . . . . . . . . . . . . . . . . .1–8
b. Fluid Level Check Procedure
e. Displaying Diagnostic Codes . . . . . . . . . .1–8 (WTEC III) . . . . . . . . . . . . . . . . . . . . . 2–3
f. Diagnostic Code Displays . . . . . . . . . . . .1–8 2–6. MANUAL FLUID LEVEL
g. Exiting Diagnostic Mode . . . . . . . . . . . . .1–8 CHECK PROCEDURE
1–8. PRESERVATION AND STORAGE a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 2–4
a. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 b. Consistency of Readings . . . . . . . . . . . . 2–4
b. Preservation Methods. . . . . . . . . . . . . . . .1–8 2–7. COLD CHECK
c. One Year Storage (Without Fluid) . . . . . .1–8 a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
d. One Year Storage (With Fluid). . . . . . . . .1–9 b. Cold Check Procedure . . . . . . . . . . . . . . 2–4
Copyright © 2001 General Motors Corp. v

2–8. HOT CHECK d. Possible Points of Fluid Leaks
a. Procedure . . . . . . . . . . . . . . . . . . . . . . . . .2–5 and Their Causes . . . . . . . . . . . . . . . . 2–17
2–9. KEEPING FLUID CLEAN e. Repairing the Leak . . . . . . . . . . . . . . . . 2–18
a. Foreign Material. . . . . . . . . . . . . . . . . . . .2–5 2–18. OUTPUT FLANGE/YOKE AND
OIL SEAL MAINTENANCE
2–10. FLUID RECOMMENDATIONS . . . . . . . . .2–5
(All, Except MD 3070PT)
2–11. FLUID AND FILTER CHANGE INTERVAL a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2–18
a. Fluid and Filter Changes . . . . . . . . . . . . .2–6 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 2–19
b. Fluid Analysis. . . . . . . . . . . . . . . . . . . . . .2–6
2–19. YOKE AND OIL SEAL MAINTENANCE
2–12. FLUID CONTAMINATION (MD 3070PT)
a. Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–6 a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2–19
b. Engine Coolant . . . . . . . . . . . . . . . . . . . . .2–7 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 2–20
c. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–7 2–20. ON-VEHICLE MAINTENANCE . . . . . . . 2–20
2–13. FLUID AND FILTER
CHANGE PROCEDURE Section 3. GENERAL OVERHAUL
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . .2–7 INFORMATION
b. Replace Filters — MD Product Line . . . .2–7
3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
c. Replace Filters — MD 3070PT . . . . . . . 2–8
d. Refill Transmission. . . . . . . . . . . . . . . . . .2–9 3–2. TOOLS AND EQUIPMENT
a. Improvised Tools and Equipment . . . . . 3–1
2–14. BREATHER b. Special Tools . . . . . . . . . . . . . . . . . . . . . 3–1
a. Location and Purpose. . . . . . . . . . . . . . . .2–9
c. Mechanic’s Tools and
b. Maintenance . . . . . . . . . . . . . . . . . . . . . . .2–9 Shop Equipment . . . . . . . . . . . . . . . . . 3–1
2–15. CHECKING CLUTCH PRESSURES 3–3. REPLACEMENT PARTS
a. Transmission and Vehicle a. Ordering Information . . . . . . . . . . . . . . . 3–5
Preparation. . . . . . . . . . . . . . . . . . . . . .2–10
b. Parts Normally Replaced at Overhaul . . 3–5
b. Recording Data . . . . . . . . . . . . . . . . . . . .2–10
c. Comparing Recorded Data 3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–5
to Specifications . . . . . . . . . . . . . . . . .2–11 3–5. CLEANING AND INSPECTION
2–16. TRANSMISSION STALL TEST a. Dirt Causes Malfunction. . . . . . . . . . . . . 3–5
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2–15 b. Cleaning Parts. . . . . . . . . . . . . . . . . . . . . 3–6
b. Stall Testing Preparation . . . . . . . . . . . 2–15 c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 3–6
c. Stall Test Procedures — Without d. Keeping Bearings Clean . . . . . . . . . . . . . 3–6
Diagnostic Tools . . . . . . . . . . . . . . . . 2–15 e. Inspecting Bearings . . . . . . . . . . . . . . . . 3–6
d. Stall Test Procedures — With f. Inspecting Cast Parts and
Diagnostic Tools . . . . . . . . . . . . . . . . 2–16 Machined Surfaces . . . . . . . . . . . . . . . 3–6
e. Stall Test Procedures — Smoke g. Inspecting Bushings and Thrust
Controlled Engines . . . . . . . . . . . . . . .2–16 Washers . . . . . . . . . . . . . . . . . . . . . . . . 3–7
f. Neutral Cool-Down Check h. Inspecting Sealrings and Gaskets . . . . . . 3–7
Procedure. . . . . . . . . . . . . . . . . . . . . . 2–16 i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 3–8
g. Stall Test Results . . . . . . . . . . . . . . . . . .2–16 j. Inspecting Splined Parts . . . . . . . . . . . . . 3–8
2–17. FLUID LEAK DIAGNOSIS k. Inspecting Threaded Parts . . . . . . . . . . . 3–8
a. Finding the Leak. . . . . . . . . . . . . . . . . . 2–17 l. Inspecting Retaining Rings. . . . . . . . . . . 3–8
b. Powder Method . . . . . . . . . . . . . . . . . . 2–17 m. Inspecting Springs . . . . . . . . . . . . . . . . . 3–8
c. Black Light and Dye Method. . . . . . . . 2–17 n. Inspecting Clutch Plates . . . . . . . . . . . . . 3–8
vi Copyright © 2001 General Motors Corp.

MD PRODUCT LINE
TABLE
ON-HIGHWAY
OF CONTENTS
SERVICE MANUAL
3–5. CLEANING AND INSPECTION (cont’d) e. Removal of Power Takeoff(s) . . . . . . . . 4–3
o. Inspecting Swaged and f. Removal of Transfer Case
Interference-Fit Parts . . . . . . . . . . . . . . .3–8 Module — MD 3070PT . . . . . . . . . . . 4–3
p. Inspecting Retainer and Ball Assembly g. Removal of Control Module. . . . . . . . . . 4–4
in Retarder Stator. . . . . . . . . . . . . . . . . .3–9 h. Removal of Torque
q. Inspecting Sealing Surfaces . . . . . . . . . . .3–9 Converter Module . . . . . . . . . . . . . . . . 4–4
3–6. ASSEMBLY PROCEDURES i. Removal of Converter
a. Parts Lubrication. . . . . . . . . . . . . . . . . . . .3–9 Housing Module . . . . . . . . . . . . . . . . . 4–5
b. Grease Used for Assembly . . . . . . . . . . . .3–9 j. Removal of Retarder Module
c. Sealing Compounds and Nonsoluble (Units Built Prior To 1/98) . . . . . . . . . 4–6
Greases. . . . . . . . . . . . . . . . . . . . . . . . . .3–9 k. Removal of Retarder Module
d. Clutches and Pistons. . . . . . . . . . . . . . . . .3–9 (Units Built Starting 1/98) . . . . . . . . . . 4–7
e. Threaded Plugs and Hydraulic l. Removal of Transfer Case Adapter
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . .3–9 Housing Module . . . . . . . . . . . . . . . . . 4–7
f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . . .3–9 m. Removal of Rear Cover Module . . . . . . 4–7
g. Butt-Joint Sealrings . . . . . . . . . . . . . . . . .3–9 n. Removal of Main Shaft Module. . . . . . . 4–7
h. Bearings . . . . . . . . . . . . . . . . . . . . . . . . .3–10 o. Removal of P2 Module, C5
i. Electrical Components . . . . . . . . . . . . . .3–10 Clutch Plates, and P1 Module . . . . . . . 4–8
p. Removal of Front Support/Charging
3–7. REMOVING (OR INSTALLING) Pump Module and Rotating
TRANSMISSION Clutch Module. . . . . . . . . . . . . . . . . . . 4–8
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . .3–10 q. Removal of C3/C4 Clutch Assembly
b. Disconnecting Controls . . . . . . . . . . . . .3–10 From Main Housing Module. . . . . . . . 4–9
c. Uncoupling From Driveline, Vehicle,
and Engine . . . . . . . . . . . . . . . . . . . . . .3–12
Section 5. MODULE REBUILD
d. Removing the Transmission. . . . . . . . . .3–12
5–1. SCOPE
3–8. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . .3–12
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
3–9. SPRING SPECIFICATIONS. . . . . . . . . . . .3–12 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . 5–1
3–10. TORQUE SPECIFICATIONS. . . . . . . . . . .3–12 5–2. GENERAL INFORMATION FOR
MODULE REBUILD . . . . . . . . . . . . . . . . . 5–1
Section 4. TRANSMISSION DISASSEMBLY 5–3. TORQUE CONVERTER MODULE
4–1. SCOPE a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–1
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–2
b. Procedures. . . . . . . . . . . . . . . . . . . . . . . . .4–1
5–4. TORQUE CONVERTER
c. Illustrations . . . . . . . . . . . . . . . . . . . . . . . .4–1 HOUSING MODULE (Models Without
d. General Information . . . . . . . . . . . . . . . . .4–1 PTO Provision)
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–3
4–2. DISASSEMBLY OF TRANSMISSION b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–4
a. Mounting Transmission on 5–5. TORQUE CONVERTER
Repair Stand . . . . . . . . . . . . . . . . . . . . .4–1 HOUSING MODULE (Models With
b. Removal of Common Externally- PTO Provision)
Mounted Parts . . . . . . . . . . . . . . . . . . . .4–1 a. Module Disassembly . . . . . . . . . . . . . . . 5–4
c. Removal of Speed Sensors . . . . . . . . . . . .4–2 b. Disassembly of the Bearing
d. Removal of Integral Oil Cooler . . . . . . . .4–3 Retainer. . . . . . . . . . . . . . . . . . . . . . . . 5–4
Copyright © 2001 General Motors Corp. vii

5–5. TORQUE CONVERTER 5–12. RETARDER MODULE
HOUSING MODULE (Models With a. Disassembly of Retarder Valve Body
PTO Provision) (cont’d) (Units Built Prior To 1/98) . . . . . . . . 5–19
c. Disassembly of the PTO b. Removal of Wiring Harness
Gear Assembly . . . . . . . . . . . . . . . . . . 5–4 and Temperature Sensor . . . . . . . . . . 5–20
d. Assembly of the PTO Gear c. Disassembly of Retarder Housing . . . . 5–20
Assembly . . . . . . . . . . . . . . . . . . . . . . 5–4 d. Disassembly of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . 5–21
e. Assembly of the Bearing
e. Disassembly of Retarder
Retainer Assembly . . . . . . . . . . . . . . . 5–5
Stator Assembly . . . . . . . . . . . . . . . . 5–22
f. Module Assembly . . . . . . . . . . . . . . . . . 5–5 f. Assembly of Retarder Stator . . . . . . . . 5–22
5–6. FRONT SUPPORT AND CHARGING OIL g. Assembly of P3 Planetary
PUMP MODULE Carrier Assembly . . . . . . . . . . . . . . . 5–22
h. Assembly of Retarder Housing
a. Module Disassembly . . . . . . . . . . . . . . . 5–5
Assembly . . . . . . . . . . . . . . . . . . . . . 5–23
b. Assembly of the Front Support . . . . . . . 5–7 i. Installation of Wiring Harness
c. Assembly of the Pump Housing . . . . . . 5–8 Assembly . . . . . . . . . . . . . . . . . . . . . 5–24
j. Assembly and Installation of Retarder
5–7. ROTATING CLUTCH MODULE Control Body Assembly . . . . . . . . . . 5–25
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–9 k. Disassembly of Retarder Valve
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–11 Body (Units Built Starting 1/98) . . . . 5–25
l. Disassembly of Retarder Housing . . . . 5–25
5–8. C3/C4 AND MAIN HOUSING MODULE
m. Disassembly of P3 Planetary Carrier
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–12 Assembly . . . . . . . . . . . . . . . . . . . . . . 5–27
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–14 n. Disassembly of Retarder Stator
Assembly . . . . . . . . . . . . . . . . . . . . . . 5–27
5–9. MAIN SHAFT MODULE o. Assembly of Retarder Stator . . . . . . . . 5–27
a. Disassembly (MD Product Line Models, p. Assembly of P3 Planetary Carrier
Except MD 3560 and MD 3070PT) . 5–15 Assembly . . . . . . . . . . . . . . . . . . . . . . 5–28
b. Assembly (MD Product Line Models, q. Assembly of Retarder Housing
Except MD 3560 and MD 3070PT) . 5–15 Assembly . . . . . . . . . . . . . . . . . . . . . . 5–28
c. Module Disassembly r. Assembly and Installation of Retarder
(MD 3560 Transmission Models) . . . .5–15 Control Body Assembly . . . . . . . . . . 5–29
s. Disassembly of Retarder Valve Body
d. Module Assembly
(Units Built Starting With
(MD 3560 Transmission Models) . . . .5–15
S/N 6510262246). . . . . . . . . . . . . . . . 5–30
e. Module Disassembly t. Disassembly of Retarder Housing . . . . 5–30
(MD 3070PT Transmission Model) . .5–15 u. Disassembly of P3 Planetary
f. Module Assembly Carrier Assembly . . . . . . . . . . . . . . . 5–31
(MD 3070PT Transmission Model) . .5–16 v. Disassembly of Retarder Stator
Assembly . . . . . . . . . . . . . . . . . . . . . . 5–32
5–10. P1 PLANETARY MODULE
w. Assembly of Retarder Stator . . . . . . . . 5–32
a. Disassembly. . . . . . . . . . . . . . . . . . . . . 5–16 x. Assembly of P3 Planetary Carrier
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–16 Assembly . . . . . . . . . . . . . . . . . . . . . . 5–32
y. Assembly of Retarder Housing
5–11. P2 PLANETARY MODULE
Assembly . . . . . . . . . . . . . . . . . . . . . . 5–33
a. Disassembly. . . . . . . . . . . . . . . . . . . . . 5–17 z. Assembly and Installation of Retarder
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–18 Control Body Assembly . . . . . . . . . . 5–33
viii Copyright © 2001 General Motors Corp.

MD PRODUCT LINE
TABLE
ON-HIGHWAY
OF CONTENTS
SERVICE MANUAL
5–13. REAR COVER MODULE 5–16. CONTROL VALVE MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–34 a. Removal of Filters . . . . . . . . . . . . . . . . 5–50
b. Disassembly of the P3 Planetary b. Removal of Electrical Components
Carrier Assembly . . . . . . . . . . . . . . . 5–35 and Sensors. . . . . . . . . . . . . . . . . . . . 5–50
c. Disassembly of the Rear Cover c. Disassembly of the Rotating Clutch
Assembly . . . . . . . . . . . . . . . . . . . . . 5–35 Solenoid Body . . . . . . . . . . . . . . . . . 5–51
d. Assembly of Rear Cover . . . . . . . . . . . 5–35 d. Disassembly of the Stationary Clutch
e. Assembly of the P3 Planetary Solenoid Body . . . . . . . . . . . . . . . . . 5–51
Carrier Assembly . . . . . . . . . . . . . . . 5–36 e. Disassembly of C6 Control Valve
Body . . . . . . . . . . . . . . . . . . . . . . . . . 5–51
f. Completion of the Rear
Cover Module . . . . . . . . . . . . . . . . . . 5–37 f. Disassembly of the Main Valve
Body . . . . . . . . . . . . . . . . . . . . . . . . . 5–51
5–14. ADAPTER HOUSING AND P3 OVERHAUL g. Disassembly of the Channel Plate . . . . 5–52
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .5–38
h. Assembly of the Channel Plate . . . . . . 5–52
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .5–38 i. Assembly of the Main Valve Body . . . 5–53
5–15. TRANSFER CASE MODULE j. Assembly of C6 Control Valve Body . . 5–53
a. Disassembly of Transfer Case k. Assembly of the Stationary Clutch
Module . . . . . . . . . . . . . . . . . . . . . . . . 5–39 Solenoid Body . . . . . . . . . . . . . . . . . 5–53
b. Disassembly of C6 Clutch . . . . . . . . . . 5–41 l. Assembly of the Rotating Clutch
c. Assembly of C6 Clutch . . . . . . . . . . . . 5–41 Solenoid Body . . . . . . . . . . . . . . . . . 5–53
d. Disassembly of C7 Clutch . . . . . . . . . . 5–42 m. Installation of the Wiring Harness
Assembly and Cover Plate . . . . . . . . 5–54
e. Assembly of C7 Clutch Housing . . . . . 5–42
f. Disassembly of Oil Pump . . . . . . . . . . . . .5–43
Section 6. TRANSMISSION ASSEMBLY
g. Assembly of Oil Pump . . . . . . . . . . . . . .5–43
h. Disassembly of P4 Carrier . . . . . . . . . . 5–43 6–1. SCOPE
i. Assembly of P4 Carrier . . . . . . . . . . . . 5–43 a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . 6–1
j. Disassembly of Drive, Idler, and
Driven Gears. . . . . . . . . . . . . . . . . . . 5–44 c. Illustrations . . . . . . . . . . . . . . . . . . . . . . 6–1
k. Assembly of Drive, Idler, and d. General Information . . . . . . . . . . . . . . . 6–1
Driven Gears . . . . . . . . . . . . . . . . . . . 5–44 e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
l. Disassembly of the Front Output 6–2. ASSEMBLY OF TRANSMISSION
Housing and Front Output Shaft . . . 5–44 a. Assembly of C3/C4 Clutch. . . . . . . . . . . 6–1
m. Assembly of the Front Output b. Installation of the Rotating
Housing and Front Output Shaft . . . . 5–44 Clutch Module . . . . . . . . . . . . . . . . . . 6–1
n. Disassembly of the Rear Output c. Installation of the Front Support/
Housing . . . . . . . . . . . . . . . . . . . . . . . 5–45 Charging Pump Module . . . . . . . . . . . 6–1
o. Assembly of the Rear Output d. Installation of the P1 Planetary
Housing. . . . . . . . . . . . . . . . . . . . . . . 5–45 Module . . . . . . . . . . . . . . . . . . . . . . . . 6–2
p. Output Housing Bearing Preload e. Installation of the P2 Planetary
Procedures . . . . . . . . . . . . . . . . . . . . . .5–45 Module . . . . . . . . . . . . . . . . . . . . . . . . 6–2
q. Disassembly of C7 Control Valve f. Installation of the C5 Clutch Pack . . . . . 6–2
Body. . . . . . . . . . . . . . . . . . . . . . . . . . .5–46 g. Installation of the Main Shaft. . . . . . . . . 6–2
r. Assembly of C7 Control Valve h. Main Shaft Selective Shim
Body Assembly . . . . . . . . . . . . . . . . . .5–46 Measurement For Models
s. Assembly of Transfer Case Module . . 5–46 With Retarder . . . . . . . . . . . . . . . . . . . 6–3
Copyright © 2001 General Motors Corp. ix

6–2. ASSEMBLY OF TRANSMISSION (cont’d) 6–2. ASSEMBLY OF TRANSMISSION (cont’d)
i. Main Shaft Selective Shim u. Installation of Speed Sensors . . . . . . . . 6–12
Measurement (Wide Ratio) . . . . . . . . 6–4 v. Installation of Common Externally-
j. Selective Shim Measurement For Mounted Parts . . . . . . . . . . . . . . . . . . 6–14
MD 3070PT . . . . . . . . . . . . . . . . . . . . . .6–5 w. Removal of Transmission From
k. Installation of Retarder Module Repair Stand . . . . . . . . . . . . . . . . . . . 6–15
(Units Built Prior To 1/98) . . . . . . . . . 6–6
l. Installation of Retarder Module Section 7. WEAR LIMITS AND
(MD Product Line Units Built SPRING DATA
Starting 1/98) . . . . . . . . . . . . . . . . . . . . .6–6
m. Installation of Rear Cover Module. . . . . 6–7 7–1. WEAR LIMITS DATA
n. Installation of Transfer Case a. Maximum Variations . . . . . . . . . . . . . . . 7–1
Adapter Housing . . . . . . . . . . . . . . . . . 6–8 b. Cleaning and Inspection . . . . . . . . . . . . . 7–1
o. Installation of Transfer Case Module. . . 6–8 7–2. SPRING DATA
p. Installation of the Converter Housing a. Spring Replacement . . . . . . . . . . . . . . . . 7–1
Module . . . . . . . . . . . . . . . . . . . . . . . . 6–9 b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7–1
q. Installation of the Torque
Converter Module . . . . . . . . . . . . . . . . .6–9
Section 8. CUSTOMER SERVICE
r. Installation of the Control Module . . . . .6–11
s. Installation of Power Takeoff(s). . . . . . .6–12 8–1. OWNER ASSISTANCE . . . . . . . . . . . . . . . 8–1
t. Installation of Integral Oil Cooler . . . . .6–12 8–2. SERVICE LITERATURE . . . . . . . . . . . . . . 8–2
x Copyright © 2001 General Motors Corp.

TABLE OF CONTENTS
LIST OF SUPPORTING ILLUSTRATIONS
(Back of Service Manual)
CROSS-SECTION VIEWS
1. MD Product Line Transmission
2. MD Product Line Transmission with Retarder (Prior To January 1, 1998)
3. MD Product Line Transmission with PTO Provision and Retarder (Beginning January 1, 1998)
4. MD Product Line Transmission with PTO Provision and Retarder (Starting with S/N 6510262246)
5. Model MD 3560 Transmission
6. Model MD 3070PT Transmission
EXPLODED VIEWS
7. Torque Converter Module
8,A. Converter Housing Module, Without PTO Provision
8,B. Torque Converter Housing Module, With PTO Provision
9,A. Front Support and Oil Pump Module
9,B. Rotating Clutch Module
10,A. Main Housing Module
10,B. Main Shaft Module (MD 3060)
11,A. Main Shaft Module (MD 3560)
11,B. Main Shaft Module (MD 3070PT)
12,A. P1 Planetary Module
12,B. P2 Planetary Module
13,A. Retarder and P3 Planetary Module (Prior To 1/98)
13,B. Retarder and P3 Planetary Module (Starting 1/98)
13,C. Retarder and P3 Planetary Module (Starting with S/N 6510262246)
13,D. Rear Cover and P3 Planetary Module
14,A. Transfer Case, Special Tools
14,B. Transfer Case, Special Disassembly/Assembly Instructions
15. Front Main Transfer Case
16. Rear Main Transfer Case
17,A. Control Valve Module (Prior To S/N 6510032369)
17,B. Control Valve Module (S/N 6510032369 To S/N 6510096670)
17,C. Control Valve Module (Starting With S/N 6510096671)
18,A. Output Flange and Yoke
18,B. Transfer Case Adapter Housing
19,A. Oil Cooler
19,B Support Equipment
HYDRAULIC SCHEMATIC
20. MD Product Line— Neutral
Copyright © 2001 General Motors Corp. xi

NOTES
xii Copyright © 2001 General Motors Corp.

SECTION 1 — GENERAL INFORMATION
1–1. SCOPE OF MANUAL 1. The organization or individual has the required
knowledge of the task through:
a. Content and Organization. This Service
• Formal instruction at Allison Transmission
Manual describes overhaul procedures for MD
Division (ATD) or a Distributor training
Product Line automatic transmissions (Figures 1–1 facility.
through 1–8).
• On-the-job instruction by an ATD or
• The major transmission components are Distributor representative.
described and their functions explained.
• Experience in performing the task.
• Detailed instructions are provided for
2. The work environment is suitable to prevent
disassembly, rebuild, and re-assembly.
contamination or damage to transmission parts
• Part inspection instructions are in Section 3. or assemblies.
• Wear limits and spring data are in Section 7.
3. Required tools and fixtures needed are shown
Power Takeoff (PTO) and output retarder options may in Figure 3–3 and Table 3–1 (Section 3 of this
be added to a base transmission model. The MD Prod- manual).
uct Line consists of the following transmission series
4. Reasonable and prudent maintenance prac-
and models:
tices are used.
• MD 3000 Series
—MD 3060/MD 3066/MD 3560 Models
NOTE:
—MD 3070PT Model Service organizations and individuals are
• T 200 Series encouraged to contact their local ATD Distributor
—T 250/T 255/T 260/T 265/T 270/T 280 for information and guidance on any task outlined
Models in this manual.
• T 300 Series
—T 310/T 325/T 350 Models
• B 300 Model
1–2. SUPPLEMENTARY
INFORMATION
• B 400 Model
• 3000MH Model
Supplementary information will be issued, as required,
if any changes occur after publication of this manual.
b. Illustrations Check with your dealer or distributor to be sure you
have the latest information.
1. The text is supported with line drawings and
cross-sectional views. Overhaul procedures are
illustrated by line drawings. Cross-sections
show the relationship of assembled parts.
1–3. ORDERING PARTS
Cross-sections and exploded views are on fold-
out pages in the back of the manual. a. Transmission Nameplate. The nameplate
(Figure 1–9) is located on the right side of the
2. Illustrations show correct procedures for all transmission. The nameplate used prior to
models — including models not illustrated. April 14, 1998, is imprinted with the transmission
serial number, part number (assembly number), and
c. Maintenance Information. Each task described model number. Use all three numbers when ordering
in this manual has been successfully completed by replacement parts or requesting service information.
service organizations and individuals. Not every The nameplate used beginning April 14, 1998, is
service organization or individual possesses the imprinted with the transmission model, serial number,
required special tooling, training, or experience to date code, TransID number, and engineering groups.
perform all described tasks. However, any task may be Use all of these numbers when ordering replacement
performed if the following conditions are met: parts or requesting service information.
Copyright © 2001 General Motors Corp. 1–1
FEEDTHROUGH HARNESS CONNECTOR

ASSEMBLY PADS
(BOTH SIDES)
BREATHER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
OIL FILL TUBE AND

DIPSTICK
(AVAILABLE BOTH SIDES)
MAIN-PRESSURE TAP
NOTE: Inch Series Threads
PTO PROVISION
V05552
Figure 1–1. MD Product Line Transmission with PTO Provision — Left-Front View
BREATHER
ASSEMBLY PADS
OUTPUT SPEED SENSOR

PTO PROVISION
INPUT SPEED SENSOR
OIL FILL TUBE AND DIPSTICK

TO COOLER
NOTE: Inch Series Threads OPTIONAL FRONT
NAMEPLATE COOLER PORTS
FROM COOLER
MAIN-PRESSURE TAP
NOTE: Inch Series Threads V01652.02
Figure 1–2. MD Product Line Transmission with PTO Provision — Right-Rear View
1–2 Copyright © 2001 General Motors Corp.

GENERAL INFORMATION
BREATHER ASSEMBLY PADS

(BOTH SIDES)
TORQUE CONVERTER
WITH LOCKUP CLUTCH OUTPUT
AND TORSIONAL DAMPER RETARDER
OIL FILL TUBE AND

DIPSTICK
TO RETARDER
ACCUMULATOR
MAIN-PRESSURE TAP
NOTE: Inch Series Thread
V05554
Figure 1–3. MD Product Line Transmission with Retarder (Prior To 1/98) — Left-Front View
BREATHER
ASSEMBLY PADS
OUTPUT SHAFT
INPUT SPEED SENSOR
TO COOLER NAMEPLATE
RETARDER CONNECTOR (ON SIDE)
FROM COOLER
NOTE: Inch Series Threads MAIN-PRESSURE TAP
V05555
Figure 1–4. MD Product Line Transmission with Retarder (Prior To 1/98) — Right-Rear View

BREATHER
ASSEMBLY PADS
RETARDER
TEMPERATURE
SENSOR
OUTPUT SPEED
SENSOR
MAIN PRESSURE TAP

NOTE: Inch series threads
TACHOGRAPH PROVISION
NOTE: Metric series threads
SPEEDOMETER PROVISION
V05134
Figure 1–5. MD Product Line Transmission with Retarder (Beginning 1/98) — Left-Rear View
BREATHER
ASSEMBLY PADS
RETARDER TEMPERATURE
SENSOR
OUTPUT SPEED SENSOR
REMOTE SUMP
MANIFOLD
MAIN PRESSURE TAP

V07393
Figure 1–6. MD Product Line Transmission with Retarder (Starting with S/N 6510262246)

GENERAL INFORMATION
TRANSFER CASE FEEDTHROUGH HARNESS CONNECTOR

BREATHER
Wor
ld Tr
Man an
ufac sm
d By issi
Divis ture
SER ion
IAL
NO.
of Gene
India ralon
XX XX napo Moto
lis, rs Corp
India orati
XX na on
O BI L E A E R O S PACE
UAW
AND A
G
RICU
PAR
L T U R A L I M P L E M E NT
933
UTOM
MOD
A
T NO.
TED
UNI
A
RIC
EL
WO
RK ERS OF AME
NO.
XX XX XX
XXXX XX X
OIL FILL TUBE AND DIPSTICK

NAMEPLATE
SCAVENGE PUMP
V01953.01
Figure 1–7. Model MD 3070PT Transmission — Right Front-View
ASSEMBLY PADS
(BOTH SIDES)
TRANSFER CASE
PTO PROVISION
OIL FILL TUBE

AND DIPSTICK
V05553
Figure 1–8. Model MD 3070PT Transmission — Left-Rear View

b. Unique Features. Features unique to MD Prod-
uct Line transmissions are:
World Transmission • Four, five, or six forward speed configurations
Manufactured By AN
D
AGR
ICULTURA
L
IM
PL
(Mechanically, every MD Product Line
EM
ILE AEROSPAC
UAW
ENT
WORKERS
933
OB
Division of General Motors Corporation
OM
OF
UT AM
DA ERI
UNITE CA
Indianapolis, Indiana transmission model is a six speed transmission.

SERIAL NO. PART NO. Options are available to convert it to a four or
XXXXXXXXXX 29509045 five speed model.) The MD 3070PT has a
MODEL
transfer case and seven forward speeds.
NO. XX XXXX
• Lockup clutch with torsional damper
Prior to 4/14/98 V02003.02
• Integral retarder (optional)
RI CULTURAL I
AG MP
L
D
AN
EM
E , A EROSPACE
EN
• Integral oil filters, serviceable without
T WORKERS O
Div. of General Motors Corp.
BIL
MO
F
AM
O ER
UT ICA
UNITED A
Indianapolis, Indiana, USA

complete loss of transmission fluid
01-XXX 02-XXX 05-XXX 08-XXX
10-XXX 14-XXXX 15-XXX 16-XXXX
20-XXX 21-750 • Adaptive, electronic, closed-loop controls with
24-XXX 25-XXX
31-XXX 34-XXX 38-XXX self-diagnostic capabilities
39-XXX
50-XXX 70-XXX
GROUPS RESERVED FOR
Model XX XXX XXXXXXX
PRODUCTION 1–5. MAJOR MODULES
USE ONLY
S/N XXXXXXXXXX XXXXX TIDX
DATE TRANS ID
a. Input Module. The Input Module includes:
Beginning 4/14/98
NUMBER V05116.01
• Engine adaptation
Figure 1–9. Transmission Nameplate
• Torque converter
b. Parts Catalog. Replacement parts are listed in
• Power takeoff gearing
Parts Catalog PC2150EN. Do not order by the item
numbers used on exploded views in this manual. Use b. Torque Converter
the Parts Catalog to determine the correct part
number. Order all replacement parts from your 1. The torque converter includes a lockup clutch
distributor. Check the Yellow Pages for your nearest and torsional damper for direct and smooth
authorized service outlet. Listings are under transfer of engine power.
Transmission — Truck, Tractor, Etc. Service outlets
can also be located on the Allison Transmission 2. The available torque converter models are:
website at www.allisontransmission.com.
Torque Converter Model
1–4. GENERAL DESCRIPTION TC 411

TC 413
Allison Transmission MD Product Line transmissions
are a complete transmission system that includes all TC 415
hardware needed for vehicle applications.
TC 417
a. Major Modules. MD Product Line transmissions TC 418
contain the following major modules:
TC 419
• Input Module TC 421
• Main Housing and Gear Module
• Control Module c. Power Takeoff Provision. Provision for a direct,
• Output Module engine-driven PTO is available at two positions.

GENERAL INFORMATION
d. Main Housing and Gear Module. The Main 1–6. MODEL DESIGNATION CODE
Housing and Gear Module includes:
The following explains the transmission model desig-
• Main Housing nation code stamped on the transmission nameplate:
• Oil pump charging system
B — Indicates North American bus or transit
• Three planetary gear sets
application
• Two rotating clutches
T — Indicates non-North American transit
• Three stationary clutches
application
e. Range Clutches. Range clutches are multiple- MH — Indicates Motor Home application
disc, wet-type clutches. Exhaust backfill pressure is MD — Indicates MD Series transmission
used to reduce fill time for quick response and smooth
shifts. 2, 3, — Indicates model
or 4
f. Gearing Ratios. Gear ratios are listed in Table 1–1 0 or 5 — Indicates close or wide ratio (0 = close)
following Paragraph 1–11.
6 or 7 — Indicates six or seven forward speeds
g. Control System and Electronic Control Unit (not used on B 300/B 400/T 200/T 300)
(ECU). The control system is capable of recognizing 0 — Indicates major revision
hydraulic and electronic conditions that are not within
P — Indicates power takeoff provision
the operating limits of the programmed calibration.
Some out-of-limit conditions can be corrected by the R — Indicates integral retarder
control system. All out-of-limit condition diagnostic T — Indicates transfer case (MD 3070 only)
codes are stored for later retrieval by a technician.
The Electronic Control System includes:
1–7. DIAGNOSIS
• Electronic Control Unit (ECU)
• Control module
NOTE:
• Shift selector
Refer to TS2470EN and/or TS2973EN, WTEC II
• Sensors
and/or WTEC III Troubleshooting Manual for in-
• Wiring harness (customer-furnished) depth troubleshooting procedures.
The ECU is a high-speed digital computer that re-
ceives information from the sensors and shift selector.
This information is processed and shift commands are a. Before Starting. Before attempting to repair the
sent to the control module for range selection. transmission, identify the faulty condition and its
probable cause.
h. Oil Filters. Two disposable external-access oil
b. DO NOT SHIFT or CHECK TRANS Light.
filters are part of the control module. Each filter is in a
Continued illumination of the DO NOT SHIFT or
separate cavity which permits removal and replace-
CHECK TRANS light during vehicle operation
ment without complete loss of transmission fluid.
indicates the ECU has signaled a diagnostic code. At
i. Transmission Fluid Coolers. The main housing start-up, the DO NOT SHIFT or CHECK TRANS
accepts remote or integral transmission fluid coolers. light will briefly illuminate.
j. Output Configuration. The output module in- c. Entering Diagnostic Mode

cludes either an integral retarder and an output flange,
or a rear cover that includes pads for mounting a park- NOTE:
ing brake and a flange or yoke. A yoke is not available The Strip Pushbutton Shift Selector has no display
with parking brake equipped transmissions. The or diagnostic capabilities. Use the Allison DOC™ or
MD 3070PT has a transfer case and adapter as an out- the Pro-Link® to display diagnostic trouble codes.
put module.

1. Pushbutton Shift Selector. Begin by pressing 2. Select any range. The transmission will enter
the UP () and DOWN () arrow keys the selected range if the range is not inhibited.
simultaneously. Diagnostics will be displayed
immediately, if no oil level sensor (OLS) is 3. Turn off the ignition switch.
present. Press the UP () and DOWN () 4. The ECU diagnostic mode is exited automati-
arrow keys simultaneously a second time to cally after approximately two minutes have
enter the Diagnostic Mode when an OLS is elapsed without an operator input.
present. The display will list the diagnostic
codes logged positions (d1, d2, d3, etc.).
1–8. PRESERVATION AND STORAGE
2. Lever Shift Selector. Begin by pressing the
DISPLAY MODE button. Diagnostics will be a. Storage (New Transmissions, Before Installa-
displayed immediately, if no oil level sensor tion). New transmissions are filled with transmission
(OLS) is present. Press the DISPLAY MODE fluid and drained before shipment. The residual fluid
button a second time to enter Diagnostic Mode in the transmission provides adequate protection to
when an OLS is present. The display will list safely store the transmission for one full year without
the diagnostic codes logged positions (d1, d2, further treatment if stored indoors, in conditions of
d3, etc.). normal climate, and with all shipping plugs installed.
d. Diagnostic Codes. Diagnostic codes can be dis-
played on the display portion of the shift selector or on CAUTION:
the Diagnostic Data Reader (DDR), the Pro-Link®, or Whenever a transmission is overhauled,
the Allison DOC™. A diagnostic code is either active exchanged, or has undergone repairs, the
or historical. An active code is any code that is current Electronic Control Unit (ECU) must be “RESET
in the ECU decision-making process. Historical codes TO UNADAPTED SHIFTS”. This will cause the
are codes that are retained in the ECU memory and ECU to erase previous adaptive information and
will not necessarily affect the ECU decision-making begin to adapt in Fast Adaptive Mode from the
process. Active codes are indicated on the shift selec- base calibration. Use the Allison DOC™ to reset
unadapted shifts or use the Pro-Link® 9000 DDR
tor by the MODE ON indicator being illuminated.
and select “RESET TO UNADAPTED SHIFTS”
e. Displaying Diagnostic Codes. Press and release from the “ACTION REQUESTS” menu. Be sure
the MODE button to sequentially display the logged that YES is bracketed and press ENTER to finish
diagnostic codes. the reset.
f. Diagnostic Code Displays. A diagnostic code’s
logged position (d1, d2, d3, d4, and d5) is the first item b. Preservation Methods. When the transmission is
of a diagnostic code display. After two seconds the stored or inactive for an extended period (one or more
main code and sub code are displayed (example: years), specific preservation methods are required to
25 11). A WTEC III shift selector displays one prevent damage from rust, corrosion, and organic
character at a time. Each character is displayed for growth in the transmission fluid. Preservation methods
about one second. The code’s logged position and the described are for storage with or without transmission
diagnostic code are displayed sequentially until the fluid. The methods are the same whether a transmis-
MODE button is pressed. Press the MODE button to sion is in or out of a vehicle.
display the next code. When all codes have been
displayed by pressing the MODE button, the first code c. One Year Storage (Without Fluid)
is re-displayed. Any log position not containing a 1. Drain the fluid.
diagnostic code displays “– –” at the code and sub
code positions. No codes are logged after a “– –” 2. Seal all openings and the breather with mois-
display. ture-proof tape.
g. Exiting Diagnostic Mode 3. Coat all exposed, unpainted surfaces with pre-
1. Press the same buttons used to enter the diag- servative grease such as petrolatum (MIL-C-
nostic mode. 11796, Class 2).

GENERAL INFORMATION
4. Remove the breather and spray 30 ml (one 8. Coat all exposed, unpainted surfaces with pre-
ounce) of VCI #10 (or equivalent) into the trans- servative grease such as petrolatum (MIL-C-
mission through the breather hole. Also, spray 11796), Class 2.
30 ml (one ounce) through the fill tube hole.
9. If additional storage time is required, repeat
5. If additional storage time is required, repeat Steps (2) through (8) at yearly intervals, ex-
Steps (3) and (4) at yearly intervals. cept, it is not necessary to drain the transmis-
sion each year. Just add VCI #10 and
d. One Year Storage (With Fluid) Biobor® JF (or equivalents).
1. Drain the fluid and replace the oil filter ele-
ments.
1–9. RESTORING TRANSMISSION
2. Fill the transmission to operating level with a TO SERVICE
mixture of one part VCI #10 (or equivalent) to
30 parts transmission fluid. Add 3 ml of a. Transmission Exterior. Wash all external grease
Biobor® JF (or equivalent) per 10 liters (1⁄4 tea- from the transmission with mineral spirits.
spoon per gallon) of fluid in the system.
b. Sealed Breather and Openings. Remove all tape
from openings and the breather.
NOTE:
c. New Transmissions. If the transmission is new,
When calculating the amount of Biobor® JF re- drain the residual preservative fluid. Refill the
quired, use the total volume of the system, not just transmission to the proper level with an Allison
the quantity required to fill the transmission. In- approved transmission fluid.
clude external lines, filters, and the cooler.
d. Stored Without Fluid. If the transmission was
prepared for storage without fluid, drain the residual
3. Operate the transmission for approximately fluid and replace the oil filter elements. Refill the
five minutes at 1500 rpm with the transmission transmission to the proper level with an Allison ap-
in neutral. proved transmission fluid.
4. Make sure the transmission shifts through all e. Stored With Fluid. If the transmission was pre-
ranges and that the lockup clutch is also acti- pared for storage with fluid, it is not necessary to drain
vated. and refill the transmission with new transmission fluid.
Check for proper fluid level. Add or drain transmission
5. Continue operating the transmission in neutral fluid, as required, to obtain the proper level.
at 1500 rpm until normal operating tempera-
ture is reached.
1–10. OPERATING INSTRUCTIONS
CAUTION:
Detailed transmission operation information is in the
If the unit does not have a converter-out temper- MD/HD/B Series Principles of Operation Manual,
ature gauge, do not stall the converter.
PO2454EN or WTEC III Operator’s Manual,
OM2995EN. Refer to the latest edition.
6. If normal operating temperature is less than
107°C (225°F), shift the transmission to
forward range and stall the converter. Do not 1–11. SPECIFICATIONS AND DATA
exceed 107°C (225°F).
The following specifications and data provide a quick
7. As soon as the transmission is cool enough to reference to the major characteristics of the transmis-
touch, seal all openings and the breather with sion. More detailed information may be obtained from
moisture-proof tape. Sales Tech Data books.

Table 1–1. Specifications and Data Chart*
MD Product
Range MD 3560** MD 3070PT**
Line**
First 3.49:1 4.59:1 6.93:1
Second 1.86:1 2.25:1 4.18:1
Third 1.41:1 1.54:1 2.24:1
Fourth 1.00:1 1.00:1 1.69:1
Fifth 0.75:1 0.75:1 1.20:1
Sixth 0.65:1 0.65:1 0.90:1
Seventh N/A N/A 0.78:1
Reverse –5.03:1 –5.00:1 –6.03:1
HYDRAULIC SYSTEM:
Fluid type . . . . . . . TranSynd™, MIL-L-2104, MIL-L-46167, MIL-PRF-21260,
DEXRON®-III, C-4 (Refer to Section 2, Paragraph 2–10.)
Filters, main
and cooler . . . . . . . Dual integral, replaceable cartridge type
Cooler. . . . . . . . . . Remote mounted, optional integral
MD Product Line With PTO

Base With PTO Provision and
SIZES: Transmission Provision With Retarder Retarder MD 3070PT
Length (transmission 715.2 mm† 826.1 mm† 719.4 mm 826.1 mm 1294.8 mm
mounting face to end (28.16 in.) (32.52 in.) (28.32 in.) (32.52 in.) (50.98 in.)
of output shaft) 719.4 mm†† 821.9 mm††
(28.32 in.) (32.36 in.)
Depth (centerline to 325.3 mm 325.3 mm 325.3 mm 325.3 mm 555.3 mm
lowest point) (12.81 in.) (12.81 in.) (12.81 in.) (12.81 in.) (21.87 in.)
Dry Weight 245 kg (535 lb) 260 kg (575 lb) 275 kg (610 lb) 300 kg (655 lb) 530 kg (1170 lb)
(Refer to drawings AS66-001 through AS66-005 for more information.)
* All data and specifications are subject to change without notice.

** Gear ratios do not include torque converter multiplication.
† Models prior to 1995
†† 1995 models

GENERAL INFORMATION
1–12. ELECTROMAGNETIC/RADIO or adversely affect vehicle operation. Manufacturers
FREQUENCY INTERFERENCE and installers of EMI/RFI emitting equipments are
responsible for adhering to FCC regulations and other
All electrical and electronic systems generate guidelines concerning emitted radio frequency
electromagnetic fields that can interfere with other interference for transportation electronics. Radio or
electronic systems. Allison Transmission’s electronic other two-way communication antenna, power, or
transmission controls comply with Federal ground leads near the transmission wiring harness,
Communications Commission (FCC) regulations and control devices, or power leads may create or be
other guidelines concerning emitted radio frequency subject to electromagnetic interference (EMI). Refer
interference for transportation electronics. Some to the latest edition of WTEC II Troubleshooting
radio-telephone or two-way communications radios Manual, TS2470EN, or WTEC III Troubleshooting
(land-mobile radio), or the manner in which they are Manual, TS2973EN, for detailed instructions
installed, can be affected by other vehicle components regarding EMI problems.

SECTION 2 — PREVENTIVE MAINTENANCE
2–1. SCOPE b. Oil Level Sensor. The optional oil level sensor
(OLS) allows the operator to check the fluid level from
Proper care and regular maintenance ensures the either a full-function pushbutton or a lever shift selector.
transmission meets its duty requirements. Perform the When a WTEC II version strip type pushbutton selector
maintenance procedures described in this section on a is used, the OLS fluid level information can be read
regular basis to prevent premature transmission or from the strip type pushbutton selector. There is no fluid
support equipment failure. Allison transmissions are level reading capability for a WTEC III strip type push-
manufactured to provide long term, efficient service in button selector; use the Allison DOCTM or
their designed applications. Pro-Link 9000® to obtain fluid level data from the OLS.
2–2. PERIODIC INSPECTION NOTE:

AND CARE • The oil level sensor compensates for transmission
fluid temperatures from 60–104°C (140–220°F).
Any temperature below 60°C (140°F) or above
a. Exterior Cleaning and Inspection
104°C (220°F) will result in an “Invalid for Dis-
1. Clean and inspect the exterior of the play” condition.
transmission at regular intervals. Severity of • To accurately check the transmission fluid level
service and operating conditions determine the with the dipstick, the transmission fluid must be
frequency of inspections. at operating temperature.
2. Inspect the transmission for: c. Electronic Controls and Protection Circuits.

• Loose bolts — transmission and mounting The electronic controls and protection circuits alert the
components operator to a transmission malfunction or the need for
service. The electronic controls and protection circuits
• Fluid leaks — repair immediately
do not replace regular, manual fluid level checks.
• Loose, dirty, or improperly adjusted throttle Check the fluid level at the intervals specified in vehi-
sensor linkage cle service instructions.
• Damaged or loose fluid hoses
2–4. ELECTRONIC FLUID LEVEL
• Worn, frayed, or improperly routed
electrical harnesses CHECK (WHEN AN OPTIONAL
OLS IS PRESENT — FULL-
• Dented, worn, or out-of-phase driveline
U-joints and slip fittings FUNCTION PUSHBUTTON OR
LEVER SHIFT SELECTORS)
CAUTION:
NOTE:
DO NOT pressure-wash the transmission electri-
The WTEC II full-function pushbutton and lever
cal connectors. Water and detergent cause the
electrical contacts to corrode and become faulty. shift selectors can display two characters at one
time. One character is displayed under the SE-
LECT label and one under the MONITOR label.
2–3. IMPORTANCE OF The WTEC III full-function pushbutton and lever
selectors display one character at a time.
PROPER FLUID LEVEL
a. Transmission Fluid. Transmission fluid cools, a. Fluid Level Check Procedure

lubricates, and transmits hydraulic power. Always 1. Park the vehicle on a level surface and shift to
maintain the correct fluid level. If the level is too low, N (Neutral). Apply the parking brake.
the torque converter and clutches do not receive
enough fluid and the transmission overheats. If the 2. On the full-function pushbutton shift selector,
level is too high, the fluid aerates causing the transmis- simultaneously press the UP () and DOWN
sion to shift erratically and overheat. () arrow buttons once.

3. On the lever shift selector, press the DISPLAY
MODE pushbutton once. CAUTION:
Low or high fluid level can cause overheating and
irregular shift patterns. These conditions can
NOTE: damage the transmission if not corrected.
The ECU may delay the fluid level check until the
following conditions are met: 7. An Invalid for Display condition is reported
when “O L” is displayed, followed by “– –”
• The fluid temperature is above 60°C (140°F) or and a number display. The displayed number is
below 104°C (220°F). a fault code, and indicates improper conditions
• The transmission is in neutral. or a system malfunction. Example (WTEC II
• The vehicle has been stationary for approxi- selector): “O L,– –,70” — indicates an Invalid
mately two minutes to allow the fluid to settle. for Display condition and fault code 70. (For a
• The engine is at idle.
WTEC III selector, the display would be
The delayed fluid level display signal for a WTEC II “o,L,–,7,0.”)
selector is a flashing indicator under the SELECT
8. Invalid for Display is activated when
display and a countdown from 8 to 1 under the
conditions do not allow the fluid level to be
MONITOR display. For a WTEC III selector, the
checked. Review the following codes and
delayed fluid level display is a countdown from 8 to
conditions, and correct as necessary. If these
1 in the display window.
conditions cannot be corrected, contact the
nearest distributor or dealer in your area.
4. Correct fluid level is reported when “O L” is (Check the Allison Transmission website
displayed (“O L” indicates the Oil Level www.allisontransmission.com or a telephone
Check Mode), followed by “O K”. The “O K” directory for the Allison Transmission service
display indicates the fluid level is within the outlet nearest you.)
“O K” zone. The sensor display and the trans-
mission dipstick may not agree exactly be- Code Cause of Code
cause the oil level sensor compensates for fluid “O L – – 5 0” — Engine speed (rpm) too low
temperature. Example (WTEC II selector): “O L – – 5 9” — Engine speed (rpm) too high
“O L O K” — indicates correct fluid level. (For “O L – – 6 5” — N (Neutral) must be selected
a WTEC III selector, the display would be “O L – – 7 0” — Sump fluid temperature too low
“o,L,o,K.”) “O L – – 7 9” — Sump fluid temperature too high
“O L – – 8 9” — Output shaft rotation
5. Low fluid level is reported when “O L” is dis-
played, followed by “L O” and a number. “O L – – 9 5” — Sensor failure
“L O” indicates a low fluid level and the num-
ber of quarts of fluid the transmission requires. NOTE:
Confirm a low fluid level condition by making Report sensor failure to a distributor or dealer in
a manual fluid level check. Example (WTEC II your area. (Check the Allison Transmission website
selector): “O L, L O, 0 2” — indicates 2 addi- www.allisontransmission.com or a telephone
tional quarts of fluid will bring the fluid level directory for an Allison Transmission distributor or
within the middle of the “O K” zone. (For a dealer nearest you.)
WTEC III selector, the display would be
“o,L,L,o,2.”) 9. To exit the oil level display mode (WTEC II
6. High fluid level is reported when “O L” is selector):
displayed, followed by “H I”. “H I” indicates • Pushbutton shift selector — press the
high fluid level and the number of quarts the R (Reverse), N (Neutral), or D (Drive)
transmission is overfilled. Example (WTEC II pushbutton.
selector): “O L, H I 0 1” — indicates 1 quart • Lever shift selector — press the DISPLAY
of fluid past the full level. (For a WTEC III MODE pushbutton two times or move the
selector, the display would be “o,L,H,I,1.”) lever.

PREVENTIVE MAINTENANCE
10. To exit the oil level display mode (WTEC III 3. Correct fluid level is indicated by a flashing red
selector): LED on the N (Neutral) pushbutton. When this
occurs, the fluid level is within the “OK” zone.
• Pushbutton shift selector — press the The selector display and the transmission dip-
N (Neutral) pushbutton or press UP () stick may not agree exactly because the oil
and DOWN () arrow pushbuttons simul- level sensor compensates for fluid temperature.
taneously two times.
4. Low fluid level is indicated by a flashing red
• Lever shift selector — press the DISPLAY LED on the R (Reverse) pushbutton and a
MODE pushbutton two times or move the tone. The number of times the tone sounds is
lever.
the number of quarts of fluid which need to be
added to produce an “OK” level. The
2–5. ELECTRONIC FLUID LEVEL N (Neutral) pushbutton red LED will remain
CHECK (WHEN AN OPTIONAL on during this display.
OLS IS PRESENT — STRIP TYPE 5. High fluid level is indicated by a flashing red
PUSHBUTTON SHIFT LED on the D (Drive) pushbutton and a tone.
The number of times the tone sounds is the
SELECTORS) number of quarts of fluid which need to be
drained to produce an “OK” level. The
NOTE: N (Neutral) pushbutton red LED will remain
on during this display.
The WTEC II strip type pushbutton shift selectors
can give fluid level information. The WTEC III
CAUTION:
strip type pushbutton selector has no display capa-
bility. Fluid level must be checked manually or with Low or high fluid level can cause overheating and
a diagnostic tool. irregular shift patterns. These conditions can
damage the transmission if not corrected.
a. Fluid Level Check Procedure (WTEC II) 6. An Invalid for Display condition is indicated
by flashing red LEDs in a repeated sequence
1. Park the vehicle on a level surface and shift to from R (Reverse) down through the lowest
N (Neutral). Apply the parking brake. D (Drive) range while the N (Neutral) red LED
remains constantly illuminated. A constant
2. Activate switch provided by the vehicle manu- tone sounds until the fluid level mode is exited.
facturer to initiate display of fluid level infor- (Reasons for Invalid For Display are the same
mation. as those in the chart in Paragraph 2–4 above.)
7. To exit the fluid level display mode, press any
NOTE: pushbutton or deactivate the switch provided
The ECU may delay the fluid level check until the by the vehicle manufacturer that was used to
following conditions are met: enter the fluid level display mode in Step 2.
• The fluid temperature is above 60°C (140°F) or b. Fluid Level Check Procedure (WTEC III)
below 104°C (220°F). 1. Connect the Allison DOCTM or Pro-Link®
• The transmission is in neutral. 9000 to the diagnostic connector on the wiring
• The vehicle has been stationary for approxi- harness.
mately two minutes to allow the fluid to settle. 2. For the Pro-Link® 9000, scroll (down) the Di-
• The engine is at idle. agnostic Data List to “OIL LVL” display.
The delayed fluid level display signal for a WTEC II 3. For the Allison DOC™, follow the instructions
selector is a flashing indicator under the SELECT in the Allison DOC™ User’s Guide.
display and a countdown from 8 to 1 under the
MONITOR display. 4. Read the fluid level. Repeat to confirm the first
reading.

5. An Invalid for Display condition is indicated
CALIBRATION WITH RESPECT TO SPLIT LINE AND FILL TUBE
by a message on the Allison DOC™ and the SCALE: NONE
Pro-Link® 9000. (Reasons for Invalid For BLADE WIDTH WHEN 6.35 mm REF
Display are the same as those in the chart in CHARACTERS ARE STAMPED (0.250 in.)
BLADE WIDTH WHEN 4.76 mm REF
Paragraph 2–4 above under “Cause Of Code.”) CHARACTERS ARE DOT-MATRIX (0.187 in.)
FILL TUBE
FULL
HOT
2–6. MANUAL FLUID LEVEL HOT
RUN
CHECK PROCEDURE BAND
DIMENSION A
WARNING! SEE CHART
BELOW
HOT
ADD
If you leave the vehicle and the engine is running,
COLD
FULL
COLD
DIMENSION B RUN
the vehicle can move suddenly and you or others SEE CHART BAND
could be injured. If you must leave the engine BELOW
86.6 mm
running, do not leave the vehicle until you: (3.41 in.)
DIMENSION C
• Put the transmission in N (Neutral)…and SEE CHART
COLD
ADD
BELOW
• Apply the parking brake and emergency
brakes and make sure they are properly en- TRANSMISSION
DIMENSION D
CONTROL MODULE 5.9 mm REF
gaged…and SPLIT LINE (0.23 in.) DETERMINED BY
INSTALLATION
• Chock the wheels and take any other steps OIL TRANSMISSION SUMP DIMENSION DIMENSION DIMENSION
necessary to keep the vehicle from moving. SUMP DESCRIPTION A B C*
101.6 mm 63.5 mm 45.7 mm
4 INCH DEEP SUMP (4.00 in.) (2.50 in.) (1.80 in.)
101.6 mm 73.7 mm 50.8 mm
a. Preparation. Clean all dirt from around the end 2 INCH SHALLOW SUMP (4.00 in.) (2.90 in.) (2.00 in.)
of the fluid fill tube before removing the dipstick. Do 101.6 mm 63.5 mm 45.7 mm
7 INCH STANDARD** (4.00 in.) (2.50 in.) (1.80 in.)
not allow dirt or foreign matter to enter the transmis- *Reference only dimension. Actual dimension determined by installation.
sion. Dirt or foreign matter in the hydraulic system **MD 3070PT has 7.00 in. oil sump.
V01832
may clog passages and cause undue transmission part
wear or sticking valves. Figure 2–1. Fluid Dipstick Markings
b. Consistency of Readings. Always check the fluid b. Cold Check Procedure

level reading at least twice using the following proce- 1. Park the vehicle on a level surface, chock the
dure. Consistency (repeatable readings) is important to wheels, and apply the parking brake.
maintaining proper fluid level. If inconsistent readings
persist, check the transmission breather to be sure it is 2. Run the engine at idle (500–800 rpm) for about
not clogged. If readings are still inconsistent, contact one minute. Shift to D (Drive) and then to
your nearest Allison distributor or dealer. R (Reverse) to clear the hydraulic system of
air. Then shift to N (Neutral) and allow the en-
gine to remain at idle (500–800 rpm).
2–7. COLD CHECK (Figure 2–1)
3. With the engine running, remove the dipstick
a. Purpose. The purpose of the cold check is to de- from the tube and wipe clean.
termine if the transmission has enough fluid to be op-
erated safely until a hot check can be made. 4. Insert the dipstick into the tube and remove.
Check the fluid level. Repeat the check proce-
CAUTION: dure to verify the reading.
DO NOT start the engine until the presence of 5. If the fluid level is within the “COLD RUN”
sufficient transmission fluid has been confirmed. band, the transmission can be operated until
Remove the transmission fluid dipstick and be the fluid is hot enough to perform a “HOT
sure the static fluid level is near the HOT FULL RUN” check. If the fluid level is not within the
mark. “COLD RUN” band, add or drain as necessary

to bring the fluid level to the middle of the 5. If the fluid level is not within the “HOT RUN”
“COLD RUN” band. band, add or drain as necessary to bring the
fluid level to within the band. Safe operating
6. Perform a hot check at the first opportunity
level is within the “HOT RUN” band on the
after normal operating temperature is
dipstick (refer to Figure 2–1).
reached — 71–93°C (160–200°F).
2–8. HOT CHECK (Figure 2–1) 2–9. KEEPING FLUID CLEAN
WARNING! CAUTION:
If you leave the vehicle and the engine is running, Containers or fillers that have been used for an-
the vehicle can move suddenly and you or others tifreeze or engine coolant solution must NEVER
could be injured. If you must leave the engine be used for transmission fluid. Antifreeze and
running, do not leave the vehicle until you: coolant solutions contain ethylene glycol which,
• Put the transmission in N (Neutral)…and if put into the transmission, can cause clutch
plate failure.
• Apply the parking brake and emergency
brakes and make sure they are properly en-
gaged…and a. Foreign Material. Prevent foreign material from
entering the transmission by using clean containers,
• Chock the wheels and take any other steps
fillers, etc. Lay the dipstick in a clean place while fill-
necessary to keep the vehicle from moving. ing the transmission.
CAUTION:
2–10. FLUID RECOMMENDATIONS
An accurate fluid level check cannot be made un-
less the engine is idling (500–800 rpm) in N (Neu- 1. The hydraulic fluids (oils) used in Allison
tral), the transmission fluid is at the proper transmissions directly affect transmission
temperature, and the vehicle is on a level surface. performance, reliability, and durability. Use
TranSyndTM or DEXRON®-III fluid for regular
a. Procedure duty, on-highway applications.
1. Operate the transmission in D (Drive) range
2. TranSyndTM and some DEXRON®-III fluids
until normal operating temperature is reached:
are also qualified as Type C-4 fluids. To ensure
• Sump temperature — your fluid is qualified for use in Allison trans-
71–93°C (160–200°F) missions, check for a TranSyndTM label or a
• Converter-out temperature — DEXRON®-III or Type C-4 fluid license, or
82–104°C (180–220°F) approval number on the fluid container, or con-
If a transmission temperature gauge is not sult the lubricant manufacturer. Consult your
present, check fluid level when the engine wa- Allison Transmission dealer or distributor be-
ter temperature gauge has stabilized and the fore using any fluid types except those fluids
transmission has been operated under load for qualified for use in Allison transmissions.
at least one hour.
CAUTION:
2. Park the vehicle on a level surface and shift to
N (Neutral). Apply the parking brake and Disregarding minimum fluid temperature limits
block the wheels. Allow the engine to idle can result in transmission malfunction or re-
(500–800 rpm). duced transmission life.
3. With the engine running, remove the dipstick 3. When choosing the optimum viscosity grade of
from the tube and wipe clean. fluid to use, duty cycle, preheat capabilities,
4. Insert the dipstick into the tube and remove. and/or geographical location must be taken
Check fluid level. Repeat the check procedure into consideration. Table 2–1 lists the
to verify the reading. minimum fluid temperatures at which the

transmission may be safely operated. Preheat
with auxiliary heating equipment or by running CAUTION:
the equipment or vehicle with the transmission Transmission fluid and filters must be changed
in neutral for a minimum of 20 minutes before whenever there is evidence of dirt or a high tem-
attempting range operation. perature condition. A high temperature condi-
tion is indicated when the transmission fluid is
Table 2–1. Transmission Fluid Operating discolored, has a strong odor or has exceeded oil
Temperature Requirements analysis limits shown in Table 2–3.
(Ambient Temperature Below Which Preheat Is Required)
b. Fluid Analysis. Transmission protection and fluid
Viscosity Grade Celsius Fahrenheit change intervals can be optimized by monitoring fluid
0W-20 or TranSyndTM* –37 –35 oxidation according to the tests and limits shown in
DEXRON®-III –32 –25 Table 2–3. Consult your local telephone directory for
SAE 10W –20 –4 fluid analysis firms. To ensure consistent and accurate
fluid analysis, use only one fluid analysis firm. Refer
SAE 15W-40 –15 5 to the Technician’s Guide for Automatic Transmission
SAE 30 0 32 Fluid, GN2055EN, for additional information.
SAE 40 10 50
* “Arctic” as defined by MIL-L-46167B
Table 2–3. Fluid Oxidation Measurement Limits
2–11. FLUID AND FILTER Test Limit

CHANGE INTERVAL Viscosity ±25% change from new fluid
Total Acid Number +3.0* change from new fluid
CAUTION: Water 0.2% by volume maximum
* mg of KOH to neutralize a g of fluid.
Transmission fluid and filter change frequency is
determined by the severity of transmission ser-
vice. More frequent changes may be necessary 2–12. FLUID CONTAMINATION
than recommended in the general guidelines
when operating conditions create high levels of
contamination or overheating. CAUTION:
Upon discovering transmission fluid contamina-
a. Fluid And Filter Changes. Table 2–2 is given tion, if there is any doubt about the total clean-up
only as a general guide for fluid and filter change of the cooler, replace the cooler. Contamination
interval. Refer to SIL 10-TR-99. remaining in the cooler can re-contaminate the
transmission fluid.
Table 2–2. Transmission Fluid and Filter Change
a. Water
Transmission Fluid Filter
MD Product 240 000 km 120 000 km 1. At each fluid change, examine the drained fluid
Line (150,000 miles) (75,000 miles) for evidence of dirt or water. A normal amount
of condensation will appear in the fluid during
(On-highway) 48 month 36 months
operation.
4000 hours* 3000 hours*
MD Product 120 000 km 120 000 km 2. Obvious water contamination of the transmis-
Line (75,000 miles) (75,000 miles) sion fluid requires inspecting and pressure test-
(Off-highway) 36 months 36 months ing the cooler (heat exchanger) for leaks between
3000 hours* 3000 hours* the water and fluid areas. Transmission fluid in
the water side of the cooler (heat exchanger) is
* Whichever occurs first. another sign of a leak.

1. Drain the transmission fluid when the fluid is at
NOTE: operating temperature — 71–93°C (160–200°F).
Cooler water can also be contaminated by engine Hot fluid flows quicker and drains more
oil. Be sure to locate the correct source of cooler wa- completely.
ter contamination.
2. For all models except the MD 3070, remove
b. Engine Coolant. Engine coolant (ethylene gly- drain plug assembly 11 (Figure 2–2) from the
col) in the transmission hydraulic system requires im- control module and allow the fluid to drain into
mediate action to prevent malfunction and possible se- a suitable container. For an MD 3070, remove
rious damage. The transmission must be completely drain plug assemblies 8 and 11 (Figure 2–3)
disassembled, inspected, and cleaned. Remove all from the control module and transfer case. Al-
traces of the coolant and varnish deposits resulting low the fluid to drain into suitable containers.
from engine coolant contamination. Replace friction
clutch plates, seals, gaskets, and bearings contami- 3. Examine the fluid as described in Paragraph
nated with engine coolant. 2–12.
c. Metal
b. Replace Filters — MD Product Line
Transmission (Figure 2–2)
CAUTION:
If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all CAUTION:
bearings in the transmission. Do not interchange filters for the deep and shal-
low sump. Installation of the wrong filter can
Visible metal particles in the transmission fluid (ex- cause damage to the transmission.
cept for the minute particles normally trapped in the
oil filter) may indicate internal transmission damage.
When these particles are found in the sump, the trans- 1. To replace the oil filters on units prior to
mission must be disassembled and closely inspected to S/N 6510069120, remove twelve bolts 5, two
find the source. Metal contamination requires complete filter covers 4, two O-rings 2, two square cut
transmission disassembly. Clean all internal and external seals 3, and two filters 1 from the bottom of the
hydraulic circuits, cooler, and all other areas where the control module.
particles could lodge.
2. To replace the oil filters on units beginning
with S/N 6510069120, remove twelve bolts 5,
2–13. FLUID AND FILTER two filter covers 4, two gaskets 8, two
CHANGE PROCEDURE O-rings 7, two O-rings 6 and two filters 1 from
the bottom of the control module.
NOTE:
3. When reinstalling parts on units prior to
If only filters are being replaced, do not drain the S/N 6510069120, lubricate and install an
fluid. O-ring 2 on each cover 4. Install a square cut
seal 3 on each cover 4. Lubricate filter O-ring
a. Drain Fluid and install filters 1 onto covers 4.
4. When reinstalling parts on units beginning

WARNING! with S/N 6510069120, lubricate and install
Avoid contact with the hot fluid or the sump new O-ring 6 and 7 on each cover 4. Lubricate
when draining transmission fluid. Direct contact O-ring inside filter 1 and push filter onto each
with the hot fluid or the hot sump may result in cover 4. Install new gasket 8 on each cover 4
bodily injury. and align holes in gasket with holes in cover.

2. To replace the oil filters on units beginning
CAUTION: with S/N 6510069120, remove 12 bolts 5, two
Do not use the bolts to draw filter covers to the filter covers 4, two gaskets 14, two O-rings 13,
sump. This can damage the covers, seals, or sump. and two O-rings 12.
5. Install filter 1 and cover 4 assemblies into the 3. When reinstalling parts on units prior to
filter compartment. Index each filter/cover as- S/N 6510069120, lubricate and install an
sembly to the holes in the channel plate/sump. O-ring 2 on each cover 4. Install a square cut
Push the filter/cover assemblies in by hand to seal 3 on each cover 4. Lubricate filter O-ring
seat the seals. and install filters 1 onto covers 4.
6. Install six bolts 5 into each cover 4 and tighten 4. When reinstalling parts on units beginning with
them to 51–61 N·m (38–45 lb ft). S/N 6510069120, lubricate and install new
O-rings 6 and 7 on cover 5. Lubricate O-ring in-
c. Replace Filters — MD 3070PT side filter 1 and push filter onto cover 5. Install
Transmission (Figure 2–3) new gasket and align holes with those in cover 5.
CAUTION: CAUTION:
Do not interchange filters for the deep and shal- Do not use the bolts to draw filter covers to the
low sump. Installation of the wrong filter can sump. This can damage the covers, seals, or sump.
cause damage to the transmission.
5. Install filter 1 and cover 4 assemblies into the
1. To replace the oil filters on units prior to filter compartment. Index each filter/cover as-
S/N 6510069120, remove twelve bolts 5, two sembly to the holes in the channel plate/sump.
filter covers 4, two O-rings 2, two square cut Push the filter/cover assemblies in by hand to
seals 3, and two filters 1 from the bottom of the seat the seals.
control module.
LUBE
MAIN
LUBE
MAIN
PRIOR TO
S/N 6510069120 6
1 9 8 7
11 1
10
2 6 9
PRIOR TO 7 2 11
S/N 6510069120 3 12 10
8 3 13
4 MD PRODUCT LINE 14
5 LUBE starting with 4
S/N 6510069120, and STARTING WITH
MAIN T 200/T 300 5 LUBE S/N 6510069120
V07380 MAIN V05557
Figure 2–2. Filter Change Figure 2–3. MD 3070PT Filter Change

6. Install six bolts 5 into each cover 4 and tighten Table 2–4. Fluid Fill Quantities (cont’d)
them to 51–61 N·m (38–45 lb ft).
Item Being Filled Initial Fill*
d. Refill Transmission
Additional Fill For Cooler*
1. For all models except the MD 3070, and if re- 2.3 liters
moved, inspect drain plug assembly 11 Remote Non-retarder
2.1 quarts
(Figure 2–2) and replace O-ring 9 or plug 10 as
3.4 liters
required. For an MD 3070, remove and inspect Remote Retarder
3.6 quarts
drain plug assemblies 8 and 11 (Figure 2–3)
1.0 liters
and replace O-rings or plugs as required. Direct-mount Non-retarder
1.1 quarts
2.0 liters
Direct-mount Retarder
NOTE: 2.1 quarts
Whenever metallic particles larger than those nor- Additional Fill For Retarder Accumulator*
mally found in filters are present on plug 10, the 1.2 liters
transfer case must be disassembled to find and re- Remote Accumulator
1.3 quarts
pair the source of the contamination. * Does not include hoses or fittings.
2. Tighten drain plugs to 25–32 N·m (18–24 lb ft) 2–14. BREATHER

after inspection is completed.
a. Location and Purpose. The breather is located
on top of the transmission converter housing. It serves
3. After refill, check the fluid level (refer to Para-
to prevent air pressure buildup within the transmission
graphs 2–6 and 2–7).
and must be kept clean and open.
b. Maintenance
NOTE:
1. The amount of dust and dirt encountered will
When the transmission is not completely disassem-
determine the frequency of breather cleaning.
bled or when just filters or fluid is changed, some
Use care when cleaning the transmission exte-
fluid will remain in the transmission so that refill
rior. Spraying steam, water, or cleaning solu-
quantity will be less than for a dry unit.
tion directly at the breather can force the water
or cleaning solution into the transmission.
4. Refer to Table 2–4 for typical initial fill (dry
unit) and for fluid amounts required to fill cool- 2. Always use a properly sized wrench to remove
ers and the remote retarder accumulator. or replace the breather. Pliers or a pipe wrench
can crush or damage the stem and produce
metal chips which could enter the
Table 2–4. Fluid Fill Quantities transmission.
Item Being Filled Initial Fill*
2–15. CHECKING CLUTCH
27.0 liters PRESSURES
MD Product Line 4.00 inch Sump
29.0 quarts Checking individual clutch pressures helps to
determine if a transmission malfunction is due to a
25.0 liters mechanical or an electrical problem. Properly making
MD Product Line 2.00 inch Sump
26.0 quarts these pressure checks requires transmission and
vehicle (or test stand) preparation, recording of data,
37.0 liters and comparing recorded data against specifications
MD 3070PT 7.00 inch Sump provided. These instructions are for all MD Product
39.0 quarts
Line transmissions.

Consult the Allison DOCTM User’s Guide or
NOTE: Pro-Link® 9000 operating instructions for
Check to see if there are diagnostic codes set which Action Request and select Clutch Test Mode.
are related to the transmission difficulty you are Follow instructions to select individual ranges.
evaluating. Proceed to make mechanical prepara- Record pressures in the desired range(s).
tions for checking clutch pressures after codes have
first been evaluated.
NOTE:
Check lockup clutch pressure by driving the vehicle
a. Transmission and Vehicle Preparation in a range where lockup can be obtained. Record
the pressure values at the engine speed and sump
1. Remove the plugs from the pressure tap loca-
fluid temperature values shown in Table 2–5. The
tions where measurement is desired (refer to
lockup clutch is functioning correctly when engine
Figure 2–4).
speed and turbine speed values are equal as record-
ed from the Allison DOCTM or Pro-Link® 9000.
CAUTION:
Be sure that the hydraulic fittings have the same
thread as the plugs removed (7⁄16-20 UNF-2A).
Fittings must be straight thread, O-ring style. MD PRODUCT LINE
Failure to do this will result in damage to the
control module. C6 (MD 3070PT ONLY)
C3 C5
2. Install hydraulic fittings suitable for attaching
pressure gauges or transducers.
3. Connect pressure gauges or transducers. Pres-

sure gauge set J 26417-A is available for this
purpose. See Table 2–6 for pressure levels ex-
pected.
MAIN
4. Check that engine speed can be monitored. C2
LU C4
(The Allison DOCTM or Pro-Link® 9000 may
BOTTOM VIEW C1
be used for this purpose.)
5. Be sure that transmission sump fluid tempera- MD 3070PT TRANSFER CASE

ture can be measured. (The Allison DOCTM or
Pro-Link® 9000 may be used for this purpose.)
6. Be sure that the transmission has enough fluid

for cold operation until an operating tempera-
ture fluid level can be set.
7. Bring the transmission to normal operating

temperature of 71–93ºC (160–200ºF). Check T-CASE MAIN
for fluid leaks in the added pressure gauge/ C7
transducer lines. Repair leaks as needed. Be
sure that fluid level is correct.
T-CASE
b. Recording Data CONNECTOR
1. Use the Allison DOCTM or Pro-Link® 9000
diagnostic tool J 38538, which allows selecting FRONT VIEW
V01834.02
individual ranges so that clutch pressures can
be measured with the vehicle stationary. Figure 2–4. Clutch Pressure Check Points

2. Consult Table 2–5 and locate the transmission 3. If clutch pressures are within specifications, re-
model that you are testing. turn the transmission and vehicle to their origi-
nal configuration and proceed with electrical
3. Operate the transmission at the conditions troubleshooting.
shown in Table 2–5 and record engine speed,
transmission sump fluid temperature, main hy- 4. If clutch pressures are not within specification,
draulic pressure, and clutch pressures in the take corrective action to replace the internal
ranges where a problem is suspected. parts of the transmission necessary to correct
the problem.
c. Comparing Recorded Data to Specifications
5. Recheck pressure values after the transmission
1. Be sure that engine speed and transmission has been repaired.
sump fluid temperatures were within the values
specified in Table 2–5. 6. Return the transmission to its original configu-
ration. (Remove instrumentation and reinstall
2. Compare the main pressure and clutch- any components removed for the pressure test-
pressure data, recorded in Step b, with the ing. Pressure tap plugs should be reinstalled
specifications in Table 2–6. and tightened to 10–13 N·m (7–10 lb ft).)
Table 2–5. Clutch Pressure Test Conditions
Transmission Model/ Engine Sump Fluid Clutches
Test Type rpm Temp Range Pressurized
All (except MD 3070) 580–620 71–93ºC Neutral C5
— Idle Check (160–200ºF) Reverse C3 C5
1C C1 C5
2C (2nd gear start) C1 C4
MD 3070PT 580–620 71–93 ºC Neutral C5
— Idle Check (160–200ºF) Reverse C3 C5
LowC C3 C6
1C C1 C5
All (except 3070) 2080–2120 Reverse C3 C5
— High Speed Neutral C5
1C C1 C5
2C C1 C4
2L C1 C4 LU
3L C1 C3 LU
4L C1 C2 LU
5L C2 C3 LU
6L C2 C4 LU
MD 3070 2080–2120 Reverse C3 C5
— High Speed Neutral C5
LoC C3 C6
1C C1 C5
2C C1 C4
2L C1 C4 LU
3L C1 C3 LU
4L C1 C2 LU
5L C2 C3 LU
6L C2 C4 LU

2–12
Table 2–6. Main Pressure and Clutch Pressure Specifications

(Sump Fluid Temperature Same as in Table 2–5)
Transmission Main Press. Range Clutch Conv. Out Lube LU Clutch T-Case Main

Model/Test Engine Clutches Spec. Press. Spec.* Press. Spec Press. Spec Press. Spec. Press. Spec.
Type rpm Range Applied kPa / [psi] kPa / [psi] kPa/[psi] kPa/[psi] kPa / [psi]* kPa / [psi]
All (except 580–620 Neutral C5 1400–2000 0–40 (C5) —
MD 3070) [203–290] [0–5.8]
— Idle
Reverse C3 C5 1400–2000 0–40 (C3 & C5) 3.5 min.
[203–290] [0–5.8] [0.5 min.]
1C C1 C5 1300–1970 0–70 (C1) 3.5 min.
[189–286] [0–10] [0.5 min.]
0–40 (C5)
Copyright © 2001 General Motors Corp.
[0–5.8]
2C C1 C4 1300–1970 0–70 (C1) 3.5 min.
[189–286] [0–10] [0.5 min.]
0–40 (C4)
[0–5.8]
MD 3070 Neutral C5 1400–2000 0–40 (C5) — 1400–2000
— Idle [203–290] [0–5.8] [203–290]
Reverse C3 C5 1400–2000 0–40 (C3 & C5) 3.5 min. 1400–2000
[203–290] [0–5.8] [0.5 min.] [203–290]
LoC C3 C6 1300–1970 0–40 (C3 & C6) 3.5 min. 1300–1970
[203–290] [0–5.8] [0.5 min.] [203–290]
1C C1 C5 1300–1970 0–70 (C1) 3.5 min. 1300–1970
[189–286] [0–10] [0.5 min.] [203–290]
0–40 (C5)
[0–5.8]
* Subtract clutch pressure from main pressure; the difference must fall within the specifications given (unless a pressure range is supplied).
Table 2–6. Main Pressure and Clutch Pressure Specifications (cont’d)
All (except 2080–2120 Neutral C5 1825–1965 0–40 (C5) 310–410 130–230
MD 3070) [265–285] [0–5.8] [45–60] [19-33]
— High Speed
Reverse C3 C5 1825–1965 0–40 (C3 & C5) 310–410 130–230
[265–285] [0–5.8] [45–60] [19-33]
1C C1 C5 1550–1690 0–70 (C1) 310–410 130–230
[225–245] [0–10] [45–60] [19-33]
0–40 (C5)
[0–5.8]
2C C1 C4 1550–1690 0–70 (C1) 310–410 130–230
[225–245] [0–10] [45–60] [19-33]
0–40 (C4)
[0–5.8]
2L C1 C4 LU 1100–1240 0–70 (C1) 310–410 130–230 0–60
[160–180] [0–10] [45–60] [19-33] [0–8.7]
0–40 (C4)
[0–5.8]
3L C1 C3 LU 1100–1240 0–70 (C1) 310–410 130–230 0–60
[160–180] [0–10] [45–60] [19-33] [0–8.7]
0–40 (C3)
[0–5.8]
4L C1 C2 LU 1100–1240 0–70 (C1) 310–410 120-225 0–60
[160–180] [0–10] [45–60] [17-32] [0–8.7]
0–70 (C2)
[0–10]
5L C2 C3 LU 1100–1240 0–70 (C2) 310–410 150–190 0–60
[160–180] [0–10] [45–60] [22–28] [0–8.7]
0–40 (C3)
[0–5.8]
6L C2 C4 LU 1100–1240 0–70 (C2) 310–410 150–190 0–60
[160–180] [0–10] [45–60] [22–28] [0–8.7]
0–40 (C4)
[0–5.8]
2–13
Table 2–6. Main Pressure and Clutch Pressure Specifications (cont’d)
2–14

MD 3070 2080–2120 Neutral C5 1825–1965 0–40 (C5) 310–410 150–190 1440–1700
— High Speed [265–285] [0–5.8] [45–60] [22–28] [209–247]
Reverse C3 C5 1825–1965 0–40 (C3 & C5) 310–410 150–190 1440–1700
[265–285] [0–5.8] [45–60] [22–28] [209–247]
LoC C3 C6 1550–1690 0–40 (C3 & C6) 310–410 150–190 1440–1700
[225–245] [0–5.8] [45–60] [22–28] [209–247]
1C C1 C5 1550–1690 0–70 (C1) 310–410 150–190 1440–1700
[225–245] [0–10] [45–60] [22–28] [209–247]

0–40 (C5)
[0–5.8]
2C C1 C4 1550–1690 0–70 (C1) 310–410 150–190 1440–1700
[225–245] [0–10] [45–60] [22–28] [209–247]
0–40 (C4)
[0–5.8]
2L C1 C4 LU 1100–1240 0–70 (C1) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
0–40 (C4)
[0–5.8]
3L C1 C3 LU 1100–1240 0–70 (C1) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
0–40 (C3)
[0–5.8]
4L C1 C2 LU 1100–1240 0–70 (C1 & C2) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
5L C2 C3 LU 1100–1240 0–70 (C2) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
0–40 (C3)
[0–5.8]
6L C2 C4 LU 1100–1240 0–70 (C2) 310–410 150–190 0–60 1440–1700
[160–180] [0–10] [45–60] [22–28] [0–8.7] [209–247]
0–40 (C4)
[0–5.8]
2–16. TRANSMISSION STALL TEST 7. Start the engine and let the transmission sump
warm to normal operating temperature — 71–93˚C
a. Purpose (160–200˚F).
1. Stall testing is performed to determine whether 8. Perform a hot check of the transmission fluid
a power complaint is due to an engine problem level and adjust as necessary.
or transmission malfunction.
9. Turn all engine accessories “OFF.”
2. Stall speed is the maximum engine rpm attain-
able when the engine is at full throttle and 10. Notify everyone to stay clear of the vehicle.
when the torque converter turbine is not mov-
ing, or “stalled.” CAUTION:
3. During a stall test, compare actual engine Fluid temperature rises rapidly during a stall
speed at full throttle stall with established test. Never maintain the stall condition for more
vehicle manufacturer’s specifications. than 30 seconds at any one time. Do not let the
converter-out fluid temperature exceed 149˚C
(300˚F). Use a converter-out fluid temperature
NOTE: gauge to limit the length of the stall condition. If
Engine stall point data can be obtained from the the stall test is repeated, do not let the engine
vehicle manufacturer or from the equipment dealer overheat.
or distributor.
CAUTION:
4. Stall tests are used as troubleshooting proce- Stall testing may produce torque values in excess
dures only — do not perform them as general of driveline or axle manufacturer recommenda-
checks or maintenance. tions. DO NOT conduct a stall test if the stall test
may cause driveline or axle damage.
b. Stall Testing Preparation
1. Make sure the fuel control linkage goes to full
NOTE:
throttle and does not stick when released.
• If Allison DOC™ or Pro-Link® (J 38538) diagnos-
2. Check the engine air induction system and ex- tic tools are not available, proceed with Paragraph c.
haust system for restrictions. • If Allison DOC™ or Pro-Link® (J 38538) diagnos-
tic tools are available, skip Paragraph c, and pro-
3. Perform a cold check of the transmission fluid ceed with Paragraph d.
level and adjust as necessary.
4. Install an accurate tachometer (do not rely on c. Stall Test Procedures — Without
the vehicle tachometer). Diagnostic Tools
1. Apply the vehicle parking and service brakes.
5. Install a temperature gauge with the probe in
the transmission converter-out (to cooler) line. 2. Shift to D (Drive).
3. Slowly accelerate to full throttle.
WARNING! 4. When the tachometer levels off, record the
While conducting a stall check, the vehicle must maximum engine rpm attained.
be positively prevented from moving. Apply the
parking brake and service brake, and chock the 5. Slowly release the throttle.
wheels securely. Warn personnel to keep clear of 6. Shift to N (Neutral).
the vehicle and its travel path. Failure to do so
can cause serious injury. 7. Skip Paragraph d and proceed immediately
with Paragraph e — Neutral Cool-Down
6. Chock the wheels. Check Procedure.

d. Stall Test Procedures — With Diagnostic Tools f. Stall Test Results
NOTE: NOTE:
• The Allison DOCTM or Pro-Link® can be used to
Environmental conditions, such as ambient temper-
select a specific range while the vehicle is not mov-
ature, altitude, and engine accessory loss variations,
ing. This allows a higher range to be used for stall
affect the power input to the converter. Under such
testing, lowering the possibility of damage due to
conditions, stall speed can vary from specification
excessive output torque. Refer to the Allison
by ±150 rpm and still be accepted as within normal
DOCTM User’s Guide for Allison DOCTM stall test
range.
procedures.
• The Allison DOCTM or Pro-Link® can also be used
to monitor engine rpm. 1. An engine stall speed 150 rpm or more below
the stall speed specification, indicates an
1. Plug the Pro-Link® into the diagnostic connec- engine problem. An engine stall speed 150 rpm
tor. or more above stall speed specification
indicates a transmission problem. Possible
2. Scroll through the Pro-Link® menus to “AC- transmission problems include slipping
TION REQUESTS” and select “Clutch Test.” clutches, improper oil level causing cavitation,
or torque converter failure.
3. Apply the vehicle parking and service brakes.
4. Place the shift selector in fourth range (for a 2. An extremely low stall speed (such as 33 per-
pushbutton selector use D (Drive) and the ar- cent of the specified engine stall rpm), during
row keys to select fourth). which the engine does not smoke, may indicate
a freewheeling torque converter stator.
5. Once fourth range is attained, slowly acceler-
ate to full throttle. 3. If the fluid does not cool during the two minute
cool-down check, a stuck stator may be the
6. When the Pro-Link® tachometer levels off, source of the problem.
record maximum rpm attained.
4. If the engine stall speed meets the specification
7. Slowly release the throttle.
and the cool-down check shows that transmis-
8. Place the shift selector in N (Neutral). sion fluid cools properly, refer to the Allison
Transmission Electronic Control Trouble-
e. Neutral Cool-Down Check Procedure shooting Manual TS2470EN.
1. The neutral cool-down check determines if the
transmission fluid cools properly following an
engine load condition. Perform this check im- 2–17. FLUID LEAK DIAGNOSIS
mediately after the engine speed has been re-
corded in the stall test. Most fluid leaks can be located and repaired by visu-
ally finding the leak and replacing or repairing the nec-
2. Record the converter-out fluid temperature. essary parts. On some occasions, a fluid leak may be
difficult to locate or repair. The following procedure
3. With the transmission remaining in N (Neu-
may help in locating and repairing most leaks.
tral), run the engine at 1200–1500 rpm for two
minutes to cool the fluid.
a. Finding the Leak
4. At the end of two minutes, record the con-
verter-out fluid temperature. Converter-out 1. Identify the fluid. Determine whether it is en-
fluid temperature should return to within the gine oil, automatic transmission fluid, or hy-
normal operating temperature range. draulic fluid from a specific vehicle system.

2. Operate the vehicle to reach normal operating d. Possible Points of Fluid Leaks
temperature and park the vehicle. After a few and Their Causes
minutes look for dripping fluid to identify the 1. Transmission mating surfaces:
approximate location of the leak.
• Attaching bolts not correctly tightened
3. Visually check around the suspected area. In-
• Improperly installed or damaged gasket
spect all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that • Mounting face damaged
are hard to reach.
2. Housing leak:
4. If the leak still cannot be found, it may be neces- • Filler pipe or plug seal damaged or missing
sary to clean the suspected area with a degreaser, • Filler pipe bracket dislocated
steam, or spray solvent. Completely clean and
dry the area. Operate the vehicle for several miles • Oil cooler connector fittings loose or
damaged
at normal operating temperature and varying
speeds. After operating, visually check the sus- • Output shaft seals worn or damaged
pected leak area. If the leak is not located, use the • Pressure port plugs loose
powder or black light and dye methods.
• Porous casting
b. Powder Method 3. Leak at converter end:
1. Clean the suspected area. • Converter seal damaged
• Seal lip cut (check converter hub for damage)
2. Apply an aerosol-type white powder, such as
• Garter spring missing from seal
foot powder, to the suspected area.
• Converter leak in weld area or O-ring seal
3. Operate the vehicle under normal operating • Porous casting
conditions.
4. Fluid comes out vent or fill tube:
4. Visually inspect the suspected area and trace • Over-filled — incorrect dipstick
the leak path over the white powder surface to
• Plugged vent
the source.
• Water or coolant in fluid — fluid will
c. Black Light and Dye Method appear milky
• Incorrect electronic fluid level indication
• Drain-back holes plugged
NOTE:
5. Gaskets:
A dye and black light kit is available for finding
leaks. Refer to the manufacturer’s directions when • Fluid level/pressure is too high
using the kit. See kit directions for the color of the
• Plugged vent or drain-back holes
fluid and dye mix.
• Improperly tightened fasteners or dirty/
damaged threads
1. Pour the specified amount of dye into the trans-
• Warped flanges or sealing surface
mission fill tube.
• Scratches, burrs, or other damage to a
2. Operate the vehicle under normal operating sealing surface
conditions as directed in the kit.
• Damaged or worn gasket
3. Direct the black light toward the suspected
• Cracked or porous casting
area. The dyed fluid will appear as a brightly
colored path leading to the source. • Improper sealant used (where applicable)

6. Seals: 2–18. OUTPUT FLANGE/YOKE AND
• Fluid level/pressure is too high
OIL SEAL MAINTENANCE
(All, Except MD 3070PT)
• Plugged vent or drain-back holes
a. Disassembly (Figure 2–5)
• Damaged seal bore
1. If installed, remove eight washers 12 and eight
• Damaged or worn seal
bolts 13 and brake drum 11.
• Improper seal installation 2. Bend down tabs of locktab 6, if present.
• Cracks in component 3. Remove two bolts 7 and locktab 6 or two bolts
18 and two washers 19 or one bolt 16. Discard
• Output shaft surface scratched, nicked or
locktab 6 and bolts 7.
damaged
4. Remove flange 2 or yoke 8. Remove two
• Loose or worn bearing causing excess seal O-rings 4, retainer plug 5, and O-ring 3 or one
wear O-ring 14 and retainer plug 15.
• Improper driveline installation 5. If present, remove four bolts 10 and parking
brake assembly 9.
e. Repairing the Leak. Once the leak has been lo-
cated and traced back to its source, repair the leaking 6. Inspect the journal sealing area. Minimum
components. If a gasket is replaced, but the sealing allowable diameter is 89.78 mm (3.535 inch).
flange is bent, the new gasket will not repair the leak. 7. Remove oil seal 1 using tool J 24171 or
The bent flange must be repaired also. equivalent.
1
2
2
9
3 4
5 10
6
8 7
11
14 15 17 12
13
16 18
V05558
Figure 2–5. Output Flange and Oil Seal — MD 3000/B 300/B 400

b. Assembly (Figure 2–5) 6. Install retainer plug 5 or 15 into the yoke or
flange. Tighten bolts 18 to 30–35 N·m (22–26
1. For all models, except those with parking lb ft). Tighten bolt 16 to 70–80 N·m (51–60 lb ft.)
brake, install the output seal using installer
J 39928 and drive sleeve J 35921-1. If 7. If used, bend one tab of locktab 6 against each
equipped with a parking brake, install the rear bolt.
seal using installer J 35921-4 and drive sleeve
J 35921-1. Place the seal on the installer tool 8. If used, install parking brake 9 and retain with
so that the seal P/N will face outward after the four bolts 10. Tighten bolts to 228–266 N·m
seal is installed. Drive the seal into its bore un- (168–196 lb ft). Install brake drum 11 and
til the installer tool bottoms out squarely eight bolts 13 and eight washers 12. Tighten
against its locating surface. bolts 13 to 51–61 N·m (38–45 lb ft).
2. Install flange 2 or yoke 8.
3. Install O-ring 3 on retainer plug 5 or 15. Lubri-

2–19. YOKE AND OIL SEAL
cate the O-ring. MAINTENANCE (MD 3070PT)
a. Disassembly (Figure 2–7)

NOTE:
1. Remove output nuts 1 and washers 2 to remove
Bolts 18 and washers 17 are available in Service rear output yoke 5 and front output yoke 3.
Bolt Kit P/N 29535910 as described in
SIL 15-WT-98. Coned end of belleville washer 17 2. Remove yoke 5 and yoke 3 by using a slide
MUST contact the head of bolt 18 as shown in Fig- hammer or a similar tool.
ure 2–6. DO NOT use locktab 6 with washer 17 and
bolt 18. 3. Remove oil seals 4 using tool J 24171-A.
4. Inspect the front and rear output yokes and

4. Insert two bolts 18 through belleville front and rear oil seals for wear and damage.
washers 17 and retainer plug 5 or bolt 16
through retainer plug 15.
5. Install an O-ring 4 over the threaded end of

each bolt 18 or O-ring 14 over bolt 16 so that
the O-ring seats against the retainer plug.
1 2
BELLEVILLE 3
WASHER SERVICE BOLT 4
P/N 29535692 4 5
P/N 29535634
2
1
V05151.01
V05639
Figure 2–6. Installing Redesigned Two-Bolt

Flange Retention Kit Figure 2–7. Output Flange and Oil Seal — MD 3070PT

b. Assembly (Figure 2–7) 2–20. ON-VEHICLE MAINTENANCE
1. Inspect front output yoke 3 and rear output
The following may be serviced or removed with the
yoke 5 for wear on the output seal journal. No
transmission mounted in the vehicle. Refer to the indi-
scoring is permitted and should be removed by
cated paragraph for removal instructions.
using a soft stone or crocus cloth. Minimum al-
lowable seal journal diameter is 76.20 mm
(3.000 inch). Item Paragraph
2. Install oil seals 4 using J 38547 and J 35921-1. PTO(s) 4–2e
3. Install rear output yoke 5 and front output yoke 3 Oil Cooler Manifold 4–2d
by using a slide hammer or a similar tool.
Input and Output Speed Sensors 4–2c
4. Apply sealant on both sides of flat washers 2.
Install flat washers 2. Scavenge Pump 4–2f(1)
5. Install output nuts 1; tighten the nuts to Control Valve Module 4–2g
610–815 N·m (450–600 lb ft).

SECTION 3 — GENERAL OVERHAUL INFORMATION
3–1. SCOPE 3–2. TOOLS AND EQUIPMENT
This section provides general information for trans- a. Improvised Tools and Equipment
mission overhaul. The information provided includes:
The following items may be improvised.
• Tools and equipment required for overhaul
• Work Table — 500 kg (1000 lb) capacity
• Replacement parts information (Figure 3–1)
• Overhaul Stand — J 29109 or equivalent
• Cleanliness and careful handling (Figure 3–2)
• Cleaning and inspection
b. Special Tools. Special tools are illustrated in Fig-
ure 3–3. They are identified in Table 3–1, following
• Assembly procedures
the special tool illustrations.
• Transmission removal and installation
c. Mechanic’s Tools and Shop Equipment. The
• Locating wear data following tools, in addition to the common tools ordi-
narily required, should be available.
• Locating spring specifications
• Common hand tools, metric where required
• Locating torque specifications for plugs, • Metric wrench set (sockets, box-end
bolts, and nuts wrenches, and Allen wrenches)
120 cm
(48 in.)
200 cm
(78 in.) OIL DRAIN STEEL TOP
TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 in.) 35 mm (11⁄ 2 in.) DEEP
35 mm (11⁄ 2 in.) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
10x10 cm AND LEG BRACKETS
(4x4 in. LEGS)
V00660.02
Figure 3–1. Work Table

• Snapring pliers • Clean, lint-free shop cloths (do not use
waste cloths)
• Micrometer (metric preferred)
• Containers for parts
• Depth micrometer (metric preferred)
• Supply of wood blocks
• Dial indicator set (metric preferred)
• Petrolatum
• Metric headless guide bolts set
• Container of mineral spirits for cleaning
• M10 eye bolt
parts
• M16 eye bolt
CAUTION:
• Suitable hoist — 500 kg (1000 lb) capacity
Caustic cleaning compounds will damage some
• A 12 N·m (100 lb in.) torque wrench transmission parts. Use only mineral spirits to
clean transmission parts.
• A 350 N·m (250 lb ft) torque wrench
WARNING!
• A press for disassembly and assembly of
spring-loaded clutches and interference-fit Use appropriate safety equipment such as safety
parts glasses, safety shoes, and gloves.
J 35926 J 29109
V05613
Figure 3–2. Overhaul Stand

GENERAL OVERHAUL INFORMATION
MAIN TRANSMISSION TOOLS

1 5
2 3
6A 6 9
7 10
6C 8
7C
7B 8E 8A
6B 8B
11 13 7A 19
13B 13C 8C
8D
13A
15 16
14 18
17
12
x
–
9 +
–
8 6 =
5 3
7 2 R
4 TE
EN
1
0
20
TRANSFER CASE TOOLS
24
21
22 26
27
23
25
23B
28
23C
25B
23A
25A
NOTE: Objects are not shown to scale V05559.01
Figure 3–3. Special Tools

Table 3–1. Special Tools*
Kent-Moore Reference
Tool No.** Figure Item Description Paragraph
J 3940 3–3 1 Bearing Race Remover 5–12c, e, l, n; 5–13a, c;
5–15l, n, o
J 8092 3–3 2 Drive Handle 5–3b; 5–5e; 5–6b, c; 5–7b;
5–11b; 5–12g, p; 5–13e;
5–14b; 5–15a, c, e
J 24171-A 3–3 3 Slide Hammer and Jaw Set 2–18a; 2–19a; 5–5b; 5–6a;
5–12c, l; 5–13a; 5–15l, n
J 26417-A 3–3 16 Pressure Gauge Set 2–15a
J 28467-34 3–3 8E Handle 5–7a
J 29109 3–3 4 Repair Stand 3–2a; 4–2a; 6–2a
J 33163 3–3 5 Valve Body Parts Tray Set 5–16a
J 35921 3–3 6 Bearing and Seal Installers
J 35921-1 3–3 6A Output Bearing Installer/Drive Sleeve 2–18b; 2–19b; 5–5e; 5–6b, c;
5–12h, q; 5–13e, f;
5–15a, m, o
J 35921-3 3–3 6B Oil Pump (Input) Seal Installer 5–5e; 5–6c
J 35921-4 3–3 6C Output Seal Installer Adapter (Models 2–18b; 5–13f
With Parking Brake)
J 35922 3–3 7 Bearing/Bushing Installers
J 35922-1 3-3 7A Turbine Shaft/Output Shaft/P2 Planetary Bushing 5–7b; 5–11b;
Installer 5–12g, p; 5–13d, e
J 35922-2 3–3 7B Oil Pump Body Bushing/Ground Sleeve Bearing/ 5–5e; 5–6b, c; 5–7b
P1 Sun Gear Bushing Installer
J 35922-3 3–3 7C Output Bearing Cup Installer 5–12f, h, o, q; 5–13f
J 35923 3–3 8 Spring Compressor Set C1, C2, and C5
J 35923-1 3–3 8A Piston Spring Compressor (C1) 5–7a, b
J 35923-2 3–3 8B Piston Spring Compressor (C5) 5–7a, b; 5–12e, f, n, o;
5–13c, d; 5–14a, b
J 35923-3 3–3 8C Piston Spring Compressor (C2), Use With 5–7a, b
J 35926-2
J 35923-4 3–3 8D Compressor Base 5–7a, b; 5–14a, b
J 35924 3–3 9 Main Pressure Spring Remover/Installer 5–16f, i
J 35925 3–3 10 Spanner Nut Torque Tool Set 5–12c, h, l, q; 5–13a, f
J 35926 3–3 11 Main Case Holding Fixture 4–2a, f; 6–2a
J 38538 3–3 18 Diagnostic Data Reader 2–15b; 2–16b
J 38547 3–3 27 Front And Rear Output Seal Installer (MD 3070) 2–19b; 5–15m, o
J 38548 3–3 12 Torque Converter End Play Gauge 5–3b; 6–2q
J 38564A,B,C 3–3 13 Torque Converter Bolt Tool 4–2h; 6–2q
J 38565 3–3 14 PTO Bearing/Sleeve Installer 5–5d; 5–6b
J 38566 3–3 15 Pump Gear, Torque Converter Cover Bushing 5–3b
Installer
J 38568 3–3 23 Bearing Cup Installers

Table 3–1. Special Tools* (cont’d)
Kent-Moore Reference
Tool No.** Figure Item Description Paragraph
J 38568-1 3–3 23A Drive/Driven Bearing Cup Installer 5–15a
J 38568-2 3–3 23B Idler Bearing Cup Installer 5–15a
J 38568-3 3–3 23C Fwd/Rear Output Bearing Cup Installer 5–15m
J 38569 3–3 22 P3 Carrier/C6/C7 Housing Bushing Installer 5–14b; 5–15c, e
J 38572 3–3 24 Transfer Case Holding Fixture 4–2a, f; 5–15a; 6–2o
J 38573 3–3 26 C6 Spring Compressor 5–15b, c
J 38579 3–3 25 Bearing Installers
J 38579-1 3–3 25A Drive/Driven Bearing Installer 5–15k
J 38579-2 3–3 25B Fwd/Rear Output and Idler Bearing Installer 5–15k, m, o
J 39354 3–3 19 Rivet Installer 5–8b
J 39623 3–3 28 Bearing End Play Checker 5–15s
J 39928 3–3 21 Output Seal Installer 2–18b; 5–13f; 6–2k, l
J 41462 3–3 20 Main Pressure Relief Spring Compressor 5–6a; 5–6c
J 42048 3–3 17 Retarder Flow Valve Spring Compressor 5–12c, h, l, q
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or tools from these firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066
3–3. REPLACEMENT PARTS

WARNING!
Do not burn discarded Teflon® seals; toxic gases
a. Ordering Information. Refer to the latest ver-
are produced by burning Teflon®.
sion of Parts Catalog PC2150EN for parts informa-
tion. Do not order replacement parts using the refer-
ence numbers in this service manual.
3–4. CAREFUL HANDLING
b. Parts Normally Replaced at Overhaul. The Handle parts and subassemblies carefully to prevent
following parts are normally replaced at each nicking, scratching, and denting. Parts that fit together
transmission overhaul: closely and have a specific operating clearance can
bind if damaged. Parts that depend upon smooth sur-
• Gaskets faces for sealing may leak if scratched. Control valve
body assembly parts are especially susceptible to leak-
• Lockstrips
ing if scratched. Valves, when dry, must move freely
by their own weight. Handle these parts carefully and
• Washers or retaining rings damaged by re-
protect them during removal, cleaning, inspection, and
moval or abnormal wear
installation. Keep control valve body assembly parts in
clean containers until installation.
• Oil seals and piston sealrings
• Spiral retaining ring 4 (Foldout 10,B)

3–5. CLEANING AND INSPECTION
• Suction filter 3 (Foldout 17,A)
a. Dirt Causes Malfunction. All parts must be
• Suction filter 6 (Foldouts 17,B and 17,C) clean to permit effective inspection. Do not allow dirt

or foreign material to enter the transmission during as- • Do not remove the grease in which new
sembly. Even minute particles can cause close-fit bearings are packed until they are to be in-
parts, such as valves, to malfunction. stalled.
b. Cleaning Parts • Do not lay bearings on a dirty bench. Place

bearings on clean, lint-free paper.
1. Clean all metallic transmission parts, except
bearings and friction-faced clutch plates, by • If a bearing is not installed immediately,
steam-cleaning or with volatile mineral spirits. wrap or cover the lubricated bearing with
Do not use caustic soda solution for steam- clean paper or lint-free cloth to keep out
cleaning. Clean friction-faced clutch plates and dust.
bearings with mineral spirits only. e. Inspecting Bearings
2. Dry all parts, except bearing assemblies, with 1. Inspect bearings for rough rotation. Replace a
compressed air. To prevent rust, lubricate bearing if its rotation is still rough after clean-
steam-cleaned parts as soon as they are dry. ing and lubrication.
2. Inspect bearings for scored, pitted, scratched,

3. Clean fluid passages by working a piece of soft
cracked, or chipped races, and for excessive
wire through the passages and flushing them
roller or ball wear. Replace the bearing if any
with mineral spirits. Dry the passages with
defects are found.
compressed air.
3. Inspect a defective bearing’s bore and mating
4. Examine parts, especially fluid passages, after shaft for grooved, burred, or galled conditions
cleaning to make certain they are entirely that indicate the bearing has been turning in the
clean. Re-clean parts if necessary. bore or on the shaft. If the damage cannot be
repaired with crocus cloth, replace the defec-
c. Cleaning Bearings
tive part.
1. Bearings that have been in service should be
4. When removing a bearing, do not apply pres-
thoroughly cleaned in volatile mineral spirits.
sure across the balls. This can cause brinelling
2. Soak particularly dirty bearings or ones filled and bearing failure.
with hardened grease in mineral spirits before 5. If a bearing must be removed or installed with-
trying to clean them. out the proper tool, press only on the race
which is adjacent to the mounting surface. If a
WARNING! press is not available, carefully seat the bearing
with a drift and hammer.
Never dry bearings by spinning them with com-
pressed air. A spinning bearing can disintegrate, f. Inspecting Cast Parts
allowing balls or rollers to become lethal flying and Machined Surfaces
projectiles. Also, spinning a bearing without lu-
brication can damage the bearing. 1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
3. Before inspection, lubricate the bearings with deeply scratched or grooved.
transmission fluid.
2. Inspect all fluid passages for obstructions. If an
d. Keeping Bearings Clean. Ball or roller bearing obstruction is found, remove it with com-
failures are usually caused by dirt or grit in the bear- pressed air, or by working a soft wire back and
ing. Keep bearings clean during removal and installa- forth through the passage and flushing it out
tion. Observe the following rules to ensure maximum with mineral spirits.
bearing life:
3. Inspect mounting faces for nicks, burrs,
• Do not unwrap new bearings until they are scratches, and foreign matter. Remove any de-
to be installed. fects with crocus cloth or a soft stone. Clean

the part. If scratches are deep, replace the de- reinstalling, carefully check bushings for signs
fective part. of distress.
4. Inspect threaded openings for damaged

CAUTION:
threads. Clean damaged threads with the cor-
rect size tap. When removing a defective bushing do not dam-
age the bushing bore.
CAUTION:
2. Replace bushings that are out-of-round, deeply
Some parts have Spiralock threaded holes. A re- scored, or excessively worn. Inspect parts
pairable threaded hole can only be repaired us- mated to bushings to ensure they are not dam-
ing a Spiralock tap. A standard tap will
aged or worn beyond use.
eliminate the locking feature and require that the
part be replaced. Spiralock taps are available 3. Inspect thrust washers for distortion, scores,
from: Detroit Tool Industries, Madison Tech
burrs, and wear. Replace a thrust washer if de-
Center, 25219 DeQuindre, Madison Heights, MI,
48071; Phone: (800) 521-2688. fective or worn.
h. Inspecting Sealrings and Gaskets

As of this printing, the following parts have 1. Inspect piston sealrings and lip-type seals for
Spiralock threaded holes: nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
• Torque converter cover — flexplate adapter edges in piston grooves or on a mating surface
bolt holes and lockup clutch backplate bolt that could damage a new seal.
holes — starting with S/N 6510024410).
• Output shaft with single-bolt flange 2. Replace all composition gaskets.
retention — starting with S/N 6510184819. 3. Inspect hook-type sealrings for wear, broken
hooks, and distortion.
5. Inspect the ribs inside the main housing for
reaction plate wear grooves in the side of the 4. Install a new hook-type sealring if the old ring
ribs. Replace housings that have splines worn shows any wear on its outside diameter, or if
beyond wear limits. (Refer to Wear Limits, there is excessive side wear.
Table 7–1 in Section 7.)
5. Measure sealring end gap by inserting the seal-
6. Replace housings or other cast parts that are ring into its respective sealing bore. Use a
cracked. feeler gauge to measure end gap. Discard seal-
rings having excessive end gap. (Refer to Wear
7. Inspect all machined surfaces for damage that Limits, Section 7.)
could cause fluid leakage or other malfunction.
Rework or replace defective parts. 6. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
8. Inspect the oil tracks of the control module and could interfere with mating parts or damage
main housing for porosity, broken lands, the piston seal. Remove raised metal, sharp
cracks, dirt, and land surface imperfections. edges, burrs, or nicks with a soft stone and cro-
These imperfections will cause severe fluid cus cloth. Thoroughly clean all residue from
leakage leading to transmission failure. the housing before assembly.
g. Inspecting Bushings and Thrust Washers 7. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
1. Inspect bushings for scores, burrs, sharp edges, the seal. Remove raised metal, sharp edges,
and evidence of overheating. Remove scores burrs, or nicks with a soft stone and crocus
with crocus cloth. Remove burrs and sharp cloth. Thoroughly clean all residue from the
edges with a scraper or knife blade. Before piston before assembly.

i. Inspecting Gears m. Inspecting Springs. Inspect springs for signs of
overheating, permanent set, or wear due to rubbing ad-
1. Inspect gears for scuffed, nicked, burred, or
jacent parts. Replace the spring if any one of these de-
broken teeth. If a defect cannot be removed
fects are found. (Refer to Spring Data, Table 7–2 in
with a soft stone, replace the gear.
Section 7.)
2. Inspect gear teeth for wear that has changed n. Inspecting Clutch Plates (Figure 3–4)
the original tooth shape. If this condition is
found, replace the gear. 1. Inspect friction-faced clutch plates (internal-
splined plates) for burrs, embedded metal par-
3. Inspect the thrust face of gears for scores, ticles, severely pitted faces, loose faces, exces-
scratches, and burrs. Remove such defects with sive wear, cone, cracks, distortion, shallow oil
a soft stone. If scratches and scores cannot be groove depth, or damaged spline teeth. Re-
removed with a soft stone, replace the gear. move burrs using a soft honing stone. Replace
plates which have any defects.
4. Inspect gears for load pattern and signs of dis-
tress. Any sign of distress indicates that a gear 2. Inspect steel plates (external-tanged plates) for
failure during operation is possible. Reusing burrs, scoring, excessive wear, excessive cone,
distressed gears is an individual customer deci- distortion, imbedded metal, galling, cracks,
sion based on experience. Backlash cannot be breaks, or damaged tangs. Remove burrs and
used to establish critical gear wear. Backlash minor surface irregularities using a soft stone.
tolerances are of such nature that a gear usually Replace plates which have any defects.
pits, scuffs, scores, or galls long before gear
wear becomes critical. 3. The amount of clutch plate cone is determined
by measuring the distance between the inside
j. Inspecting Splined Parts diameter of the plate and a level surface (Fig-
ure 3–4). Discard plates having excessive cone.
1. Inspect splined parts for stripped, twisted,
(Refer to Wear Limits, Section 7).
chipped, or burred splines. Remove burrs with
a soft stone. Replace the part if other defects 4. Determine oil groove depth with a depth mi-
are found. Spline wear is not considered harm- crometer or by measuring the smooth surface
ful except where it affects the fit of the splined (total) thickness of the plate, measuring the
parts. thickness of the steel part of the plate at the oil
groove, and subtracting this measurement from
2. Spline wear is determined by comparing feeler the total thickness. Replace plates not having
gauge thickness with the thickness of the worn the minimum oil groove depth. (Refer to Wear
area on the spline. Replace parts having Limits, Section 7).
excessive spline wear. (Refer to Wear Limits,
Section 7.) o. Inspecting Swaged and Interference-Fit Parts.
If there is evidence of looseness, the assembly should
3. Backlash cannot be used to establish critical be replaced.
spline wear. Accurate backlash measurement
requires the mating parts to be concentrically
located.
CLUTCH PLATE
k. Inspecting Threaded Parts. Inspect threaded LEVEL SURFACE
parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
l. Inspecting Retaining Rings. Inspect all retaining Measure here for cone
rings for nicks, distortion, or excessive wear. Replace V00493.01
the retaining ring if any defects are found. The retain-
ing ring must snap tightly into its groove to function
properly. Figure 3–4. Method of Measuring Clutch Plate Cone

p. Inspecting Retainer and Ball Assembly in Re- 3. Assemble clutch plates so that the cone of each
tarder Stator. Inspect balls in the retarder stator for plate faces the same direction.
free movement. Inspect the staking that retains the
balls. Any restriction could prevent the ball from seat- e. Threaded Plugs and Hydraulic Fittings
ing during retarder application.
CAUTION:
q. Inspecting Sealing Surfaces • Do not use Teflon® tape on threaded parts. Sliv-
1. Inspect surfaces in contact with hook-type, ers can cause the transmission to malfunction.
scarf-cut, and butt-joint sealrings for step- • Improperly installed plugs or fittings can
wear, nicks, scratches, and scoring. Use a soft cause leakage and cracked housings.
stone or crocus cloth to remove only the raised
metal portion of these defects. Polishing the Threaded plugs in MD Product Line transmissions are
area to remove a defect is neither necessary nor straight-thread O-ring type plugs. Be sure that the
desirable. If the defects are too severe to cor- O-ring is in like-new condition and tighten all plugs to
rect, replace the defective part. the torque values specified in the assembly procedure
or in exploded views. Tighten other fittings sufficiently
2. Inspect surfaces in contact with spring-loaded, to prevent leakage.
lip-type seals for nicks, scratches, roughness,
or other surface irregularities. Inspect for em- f. Lip-Type Seals
bedded particles, step-wear, and dirt on flanges
or other components exposed to external con- 1. When replacing lip-type seals, make sure the
tamination. Remove the defects and restore the spring-loaded lip is toward the fluid to be
finish. Replace the part if scores or scratches sealed (toward the inside of the unit). Coat the
permit fluid leakage. inside of the seal with high temperature grease
(MIL-G-3545A or equivalent) to protect the
seal during shaft installation and to provide
3–6. ASSEMBLY PROCEDURES lubrication during initial operation.
2. The circumference of some seals is precoated

a. Parts Lubrication. During final assembly, with a dry sealant. The sealant is usually
lubricate all moving parts with transmission fluid. The colored for easy identification. Precoated seals
fluid will help protect friction surfaces and ferrous do not require any additional sealant before
metals until the unit is in service. installation.
b. Grease Used for Assembly. During assembly use g. Butt-Joint Sealrings
oil-soluble grease with a low melting point (petrola-
tum) to temporarily retain parts, butt-joint sealrings,
scarf-cut sealrings, and hook-type sealrings. CAUTION:
If humidity is allowed to penetrate and expand a
c. Sealing Compounds and Nonsoluble Greases. butt-joint sealring, the sealring can be damaged
Do not use gasket-type sealing compounds, fibrous during installation. A damaged sealring will leak
greases, or nonsoluble vegetable-base cooking com- fluid from the clutch piston cavity and cause
pounds inside the transmission or where they could be clutch slippage. Do not open the sealed package
flushed into the transmission hydraulic system. until you are ready to install the sealring.
d. Clutches and Pistons 1. Butt-joint sealrings require special handling

1. Soak each friction-faced clutch plate (two- during assembly. The sealrings contain materi-
minute minimum) in transmission fluid before als that absorb moisture from the atmosphere
final assembly. causing the sealring to expand. The sealrings
are shipped in airtight packages. Do not open
2. Apply a generous amount of transmission fluid the sealed package until the butt-joint sealring
to the piston cavity before final assembly. is ready to be installed into the transmission.

Check sealring end clearance before installa-
tion to ensure the sealring has not expanded. CAUTION:
Whenever a transmission is overhauled,
2. Remove the sealring from its package and exchanged, or has undergone repairs, the
place it in its operational position inside the Electronic Control Unit (ECU) must be “RESET
bore that it will be sealing. TO UNADAPTED SHIFTS”. This will cause the
ECU to erase previous adaptive information and
3. Using a feeler gauge, check the end clearance begin to adapt in Fast Adaptive Mode from the
of the sealring. The end clearance must not be base calibration. Use the Allison DOCTM (refer to
the Allison DOC™ User’s Guide for instructions)
less than specifications allow.
or Pro-Link® 9000 and select “RESET TO
UNADAPTED SHIFTS” from the “ACTION
4. If the end clearance is less than minimum specifi- REQUESTS” menu. Be sure that YES is
cations, bake the sealring in an oven at 93–149°C bracketed and press ENTER to finish the reset.
(200–300°F) for 24 hours or get a new seal-
ring. Repeat Steps (2) and (3). a. Drain Fluid. Drain the transmission fluid before
removing the transmission from the vehicle. The trans-
5. Pack the sealring and its groove with a liberal mission should be warm and the fluid allowed to drain
amount of oil-soluble grease. overnight.
6. Roll up the sealring to about half its free diam- 1. Remove the drain plug from the control mod-
eter and hold it for about 10 seconds. Being ule. Examine the drained fluid and magnetic
careful not to spread the sealring more than drain plug for evidence of contamination (refer
necessary, slide it onto the hub. Place one end to Paragraph 2–11). Reinstall the drain plug
of the sealring into the groove and gradually when fluid draining is completed.
work the seal into the groove.
2. Remove the transmission fill tube if it inter-
h. Bearings. If a bearing must be removed or feres with transmission removal.
installed without an installation sleeve, drive or press
only on the race which is adjacent to the mounting
surface. If a press is not available, carefully seat the NOTE:
bearing with a drift and a hammer, driving against the
A significant amount of fluid may drain from a
supported race.
hydraulic hose when it is disconnected from the
transmission.
i. Electrical Components. For inspection and re-
pair of electrical components, refer to the Allison
Transmission Electronic Troubleshooting Manual 3. Disconnect all hydraulic hoses from the trans-
TS2470EN (WTEC II Controls) or TS2973EN mission. Remove the hoses from the vehicle if
(WTEC III Controls). they interfere with the transmission removal.
Plug all openings to keep dirt from entering the
hydraulic system.
3–7. REMOVING (OR INSTALLING)
TRANSMISSION (Figures 3–5, 4. If an integral cooler is used, drain coolant from
3–6, 3–7, 3–8) the cooler and disconnect coolant hoses.
Remove the hoses from the vehicle if they
interfere with transmission removal. Plug all
openings to keep dirt from entering the cooling
WARNING! system.
Avoid contact with the hot fluid or the sump
when draining transmission fluid. Direct contact b. Disconnecting Controls. Disconnect or com-
with the hot fluid or the hot sump may result in pletely remove controls. If controls are not removed
bodily injury. from the transmission, position them so that they do
not interfere with transmission removal.

1. For non-retarder models, disconnect the trans- 4. For transfer case models, disconnect the trans-
mission external harness from the feedthrough mission external harness from the feedthrough
harness connector, the input speed sensor, the harness connector, the input speed sensor, the
output speed sensor, and the PTO connector, if transfer case connector, and the PTO connector,
present (see Figure 3–5). Disconnect the ta- if present (see Figure 3–8). Cover the harness
chograph drive, if used. connectors to keep out dirt.
)
2. For retarder models prior to 1/98, disconnect FEEDTHROUGH

HARNESS CONNECTOR
the transmission external harness from the RETARDER
TEMPERATURE
feedthrough harness connector, the input speed SENSOR
sensor, the retarder connector, and the PTO
connector, if present (see Figure 3–5). Cover
the harness connectors to keep out dirt.
3. For current retarder models, disconnect the OUTPUT

SPEED
transmission external harness from the SENSOR
transmission feedthrough harness, the input
speed sensor, the output speed sensor, the
retarder temperature sensor, the retarder valve
body connector, and the PTO connector, if
present (see Figure 3–6). If used, disconnect RETARDER
the tachograph drive. Cover the harness VALVE BODY
connectors to keep out dirt. SPEEDOMETER PROVISION CONNECTOR
(INCH SERIES THREADS)
(METRIC THREADS) V05561.00.01.eps
Figure 3–6. Disconnect Locations

(Retarder Models Beginning 1/98)
OUTPUT SPEED
SENSOR (INSIDE)
OUTPUT SPEED
SENSOR
RETARDER
TEMPERATURE
SENSOR
INPUT
SPEED
SENSOR
NAMEPLATE
FEEDTHROUGH
HARNESS
COOLER PORTS CONNECTOR
RETARDER
MAIN PRESSURE TAP CONNECTOR
NOTE: Inch Series Threads (ON SIDE) REMOTE SUMP
V05560 TACHOGRAPH PROVISION MANIFOLD
V07394
Figure 3–5. Disconnect Locations Figure 3–7. Disconnect Locations (Retarder Equipped
(Retarder Models Prior To 1/98) Models Starting with S/N 6510262246)

MOUNTING
2. PTOs, if present, must either have the output
PADS FEEDTHROUGH driveline disconnected or be removed from the
HARNESS
ASSEMBLY PADS transmission.
BREATHER
3. Securely support the transmission with a hoist,
jack, or other suitable removal equipment.
4. Remove all bolts, nuts, washers, spacers, and

supports that attach the transmission to the
Wo
rld
Tra
Manunsmi
factur
vehicle and to the engine.
SERIA
L NO.
Divisio
n of ssion
Genera
ed
By
Indiana
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XXX polis,
Corpor
XXX Indiana
ation
O B I L E A E R O S P A CE
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PART
L T UR A L I M P L E M ENT
933
UTOM
MODE
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XX XXX
XXXX XXX
X
d. Removing the Transmission
TRANSFER 1. Move the transmission away from the engine

CASE ENGINE SPEED approximately 110 mm (4.33 inch) until it is
CONNECTOR COOLER SENSOR
PORTS completely clear of the engine. Remove the
SCAVENGE PUMP
adapter ring (if used).
NAMEPLATE
2. Raise or lower the transmission as necessary to

remove it from the vehicle.
3–8. WEAR LIMITS

Refer to Wear Limits Data Table 7–1, for information
PTO
MOUNT covering parts fits, clearances, and wear limits.
3–9. SPRING SPECIFICATIONS

Refer to Spring Data Table 7–2 for spring identifica-
tion and specifications.
MD 3070PT V05562
Figure 3–8. Disconnect Locations (MD 3070PT) 3–10. TORQUE SPECIFICATIONS
c. Uncoupling From Driveline, Vehicle, Assembly procedures in Sections 5 and 6 specify the
And Engine torque requirements for all plugs, bolts, and nuts.
Torque values are also presented with the foldout
1. Disconnect the vehicle drive shaft from the illustrations in the back of this manual. Torque values
transmission output flange or yoke. Position specified are for dry assembly, except when otherwise
the disconnected shaft to avoid interference noted. Bolts and washers should be washed and dried
with removing the transmission. before assembly.

SECTION 4 — TRANSMISSION DISASSEMBLY
4–1. SCOPE balanced, and raise the transmission to the
mounting face of the repair stand.
a. Section. This section covers disassembly of MD
Product Line transmissions. Disassembly procedures 3. Secure the transmission holding fixture to re-
include PTO provisions and retarders. The disassem- pair stand J 29109.
bly sequence is continuous and includes all models. 4. For the MD 3070PT transmission model, fol-
b. Procedures. When a procedure does not apply to low Step (1). In addition, install fixture J 38572
your specific model, go to the next applicable proce- on the transfer case. Connect fixtures J 35926
dure. and J 38572 by installing four bolts 1
(Figure 4–1). Secure the transmission holding
c. Illustrations. Illustrations will not always show fixtures to the repair stand.
your model, but when an operation is identical for all
models, the correct procedure is shown. b. Removal of Common Externally-Mounted
Parts (Figure 4–2)
d. General Information. Refer to Sections 3 and 7
1. Inspect transmission breather 1 for damage or
for general information as follows:
obstruction. Remove if necessary for replace-
Paragraph Title ment or cleaning.
3–2 Tools and Equipment
3–3 Replacement Parts 2. Remove screw 22 retaining fill tube bracket 23
3–4 Careful Handling to the main housing module. Remove
bracket 23, fill tube 21, seal 20, and
3–5 Cleaning and Inspection
dipstick 24.
3–7 Removing Transmission
7–1 Wear Limits Data 3. Remove expander plug 2 from the other fill
7–2 Spring Data tube location on the opposite side of the
main housing module. For transmissions af-
e. Foldouts. Refer to Foldouts 7 through 19 for ex- ter S/N 6510107518, pry under the head of
ploded views. plug 3 and remove plug 3 and seal 4.
4. Remove six bolts 16 retaining remote cooler
4–2. DISASSEMBLY OF manifold 18, or cover 17, to the main housing
TRANSMISSION module. Remove cooler manifold 18, or
cover 17, and gasket 19.
a. Mounting Transmission on Repair Stand
WARNING! J 35926 1
J 38572
MD Product Line transmission dry weights are
as follows:
• Base Transmission 245 kg (535 lb)
• With PTO Provision 260 kg (575 lb)
• With Retarder 275 kg (610 lb)
• With PTO and Retarder 300 kg (655 lb)
• MD 3070PT 530 kg (1170 lb)
Use proper tools and lifting equipment when in-
stalling or removing a transmission from the re-
pair stand.
1. Mount holding fixture J 35926 onto the main

housing module.
2. Attach a hoist, making sure lifting attachments V05563
are placed so transmission is properly Figure 4–1. MD 3070PT Repair Stand Brackets

3
1
25
26 4
2
5
6
14
7
8
14
24
14
13 12
22 23 11
19 10
21 9
18
17 15
20
16 27 28
30
29 31
V07379
Figure 4–2. Common Externally-Mounted Parts Removal
5. If present, remove bolts 8 and brake drum 7. c. Removal of Speed Sensors
NOTE: NOTE:
For MD 3070PT transmission models, do not re- • For models without PTO, proceed to Step (1).
move yokes now. Removal is covered in Section 5–14 • For models with PTO, skip Step (1) and proceed
as part of transfer case disassembly. to Step (2).
6. Bend down edges of locktab 10, if present. Re- 1. Remove bolt 6 (Foldout 8,A), retainer 5, input
move two bolts 9 and locktab 10 or two speed sensor assembly 3, and O-ring 4 from the
bolts 31 and two washers 30, retainer plug 11, converter housing module. Skip to next NOTE.
O-ring 13, and two O-rings 12 or one bolt 29, 2. Remove bolt 22 (Foldout 8,B), retainer 21,
retainer plug 28, and O-ring 27. Discard lock- input speed sensor assembly 19, and O-ring 20
tab 10 and bolts 9. from the converter housing module.
7. Remove flange 14 or yoke 15.
NOTE:
8. Inspect the journal sealing area. Minimum di- • For models without retarder, proceed to Step (3).
ameter allowable is 89.78 mm (3.535 inch).
• For models with retarder (built prior to 1/98),
9. If present, remove four bolts 6 and parking skip Step (3) and proceed to Step (4).
brake assembly 5. • For models with retarder (built starting 1/98),
skip Steps (3) and (4) and proceed to Step (5).
10. If present, remove bolt 25 and harness • For MD 3070PT, proceed to f.
bracket 26.

TRANSMISSION DISASSEMBLY
3. Remove bolt 32 (Foldout 13,D), retainer 31, 3. Remove nine bolts 15 and nine washers 16.
output speed sensor assembly 29, and Remove cooler housing 7 and gasket 5.
O-ring 30 from the rear cover module.
4. Remove plate assembly 27 and four
4. Remove four bolts 7 (Figure 4–3) and cover 6. O-rings 28.
Remove bolt 5, retainer 2, output speed sensor
assembly 3, and O-ring 4. 5. Remove three bolts 13, three washers 14,
bolt 12, washer 11, six bolts 15 and six wash-
5. Remove bolt 43 (Foldout 13,B), retainer 42, ers 16. Remove cooler housing 7 and gasket 6.
output speed sensor assembly 40, and
O-ring 41 from the retarder housing. e. Removal of Power Takeoff(s)
(Foldout 19,B)
d. Removal of Integral Oil Cooler
(Foldout 19,A)
NOTE:
NOTE: Each PTO has eight mounting bolts, two studs, and
a gasket. Removal instructions are for a transmis-
• For models without retarder, proceed to Step (1).
sion with a single right-side mounted PTO. If your
• For models with retarder, skip Steps (1)–(3) and
transmission has more than one PTO or the PTO is
proceed to Step (4). mounted in a different location, use the same proce-
dure to remove the PTO(s).
1. Remove two bolts 24 and seventeen bolts 25.
Remove cover 23, gasket 22, and two
O-rings 26. 1. Remove eight PTO mounting bolts 7 or 11.
Carefully remove PTO assembly 8 or 12 and
2. Remove plate assembly 27 and four O-rings 28. gasket 6 or 10.
2. Inspect two PTO studs 5 or 9 for damage and

remove them if necessary.
f. Removal of Transfer Case
Module — MD 3070PT (Figures 4–4 and 4–5)
1. Remove hose 1 (Figure 4–4), fittings 2 and 3,
O-rings 4 and 5, and screen 6. Remove
scavenge pump 7 by removing nine bolts 8.
Remove gasket 9.
2. Separate fixture J 35926 and the transfer case

lifting fixture J 38572 by removing four
bolts 6.
WARNING:
The transfer case module assembly weighs
approximately 270 kg (595 lb).
4
3
3. Attach a hoist, making sure that lifting attach-
7 ments are placed so that the transfer case is
2
5 6 properly balanced. Remove nineteen bolts 2
1 and one bolt 7 to disconnect the transfer case
V01522
from the main transmission.
Figure 4–3. Output Speed Sensor 4. Raise the transfer case to the mounting face of
(Retarder Models Prior To 1/98 the repair stand.

g. Removal of Control Module (Figure 4–6)
7
4 12
3
8
NOTE:
The control module or filters may contain residual
1
9 transmission fluid.
10
11
12 WARNING!
2 The control module assembly weighs approxi-
5
mately 25 kg (56 lb). Handle carefully to avoid
6 personnel injury or control module damage. The
10 control module assembly used in an MD 3070PT
11 weighs approximately 29 kg (65 lb).
1. For a two-inch or seven-inch sump, remove

thirty-two bolts 3 retaining control module 1 to
the main housing module, including the bolts
retaining the filter covers.
V07378
2. For a four-inch sump, remove seven bolts 3

Figure 4–4. MD 3070PT Scavenge Pump Removal and twenty-five bolts 4 retaining control mod-
ule 1 to the main housing module, including
the bolts retaining the filter covers.
3. Loosen control module 1 by applying pressure
J 35926 at the reinforced tabs or use jack bolts. Insert
6
J 38572
jack bolts into the control module bolt holes
that bottom against the main housing module.
4. Remove control module assembly 1 and
gasket 2.
h. Removal of Torque Converter Module
(Figure 4–7)
1
5 1. Remove any brackets installed to prevent
4
2
torque converter movement.
7
NOTE:
• For units prior to S/N 6510165560, proceed to
3
Step (2).
V07368
• For units beginning with S/N 6510165560, skip
Steps (2) and (3) and proceed to Step (4).
Figure 4–5. Transfer Case Module Removal
2. Remove retaining ring 1 using snapring pliers

5. Secure the transfer case holding fixture to the (Figure 4–7, View A).
repair stand.
3. Thread an M6 bolt into converter end plug 2
6. Remove gasket 4 and selective shim 1. The se- and remove plug 2 and O-ring 3. Skip Steps (4)
lective shim is located inside shaft adapter 5. and (5) and proceed to Step (6).

flexplate adapter bolt holes. Then place a
screwdriver at an angle to prevent converter
rotation (Figure 4–7, View C).
7. Remove bolt 4 using converter bolt tool

J 38564.
8. Remove shim 5 located under bolt 4 (Figure 4–6,

View A).
9. Attach a sling to the flexplate adapter by posi-

tioning the adapter connections an equal dis-
tance from each other. Using a chain hoist,
carefully lift torque converter module 6 out of
the converter housing (Figure 4–7, View A).
2
10. Place two wooden blocks on the workbench,
spaced to support the torque converter module
and high enough for the converter hub to clear
1 1 the workbench. Lower the converter module,
converter hub down, onto the blocks.
i. Removal of Converter Housing Module

(Figure 4–8)
3 3
NOTE:
4
V07364 Three converter housing retaining bolts 3 are re-
moved from inside converter housing 1. After loos-
ening the bolts, use mechanical fingers or a similar
Figure 4–6. Control Module Removal
tool to remove these bolts.
4. Keep the torque converter cover from turning
by using a heel bar, two bolts and a screwdriver
(Figure 4–7, View C). 1. Remove twenty bolts 3 that retain converter
housing 1 to main housing module 4.
5. Remove threaded plug 7 and O-ring 8 using a
3⁄4 inch Allen wrench.
2. Lift straight up on converter housing module 1,
6. Hold the turbine and turbine shaft stationary by or remove it using the same sling used for re-
using one of the methods listed below: moving the converter module.
• Insert a screwdriver into the vanes on the
3. Remove main housing gasket 2 from converter
rotating clutch module (Figure 4–7,
housing 1, or from main housing module 4.
View B).
• If the control module is in place, remove the
plug(s), if present, from the fill tube hole or NOTE:
from cooler ports before applying lockup
air pressure. Apply air pressure through the • Proceed to Step j. for units with retarder built
lockup pressure tap (Figure 4–7, View D) prior to 1/98.
and use a heel bar, screwdriver, and bolts. • Proceed to Step k. for units with retarder built
Insert the heel bar into a torque converter starting 1/98.
housing bolt hole. Insert two bolts into the

Cupped end down

2 3 Use hoist and sling
4 6 ROTATING
1 5 CLUTCH
MODULE
7
8
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
BOTTOM VIEW
VIEW C VIEW D E05568.01
Figure 4–7. Torque Converter Module Removal
3
2
4 1
3 2
V07375
Figure 4–8. Converter Housing Module Removal V07370
j. Removal of Retarder Module (Units Built

Prior To 1/98) (Foldout 13,A and Figure 4–9) Figure 4–9. Retarder Module Removal
NOTE: 1. Remove twelve bolts 2 (Foldout 13,A), six

Do not remove bolt 56 or two bolts 57 which fasten bolts 3, and seven bolts 4, that secure retarder
the retarder housing to the retarder stator. module 2 (Figure 4–9) to main housing 3. If
used, remove rear support bracket.

3. Attach a suitable sling and lift upward, remov-
WARNING! ing rear cover module 2.
The retarder module assembly weighs approxi-
mately 64 kg (141 lb). Use care to prevent injury 4. Remove rear cover gasket 1 from main housing
to personnel while handling the retarder module 4 or rear cover module 2.
assembly.
n. Removal of Main Shaft Module
2. Thread an M10 eye bolt into the retarder out- (Figure 4–12)
put shaft and lift the retarder module 2 from 1. Remove shim 2 and thrust bearing 3 from the
main housing 3. main shaft module.
3. Remove retarder gasket 1 from main housing 3
or retarder module 2. 2. Lift main shaft module 1 out of the
transmission.
k. Removal of Retarder Module (Units Built
Beginning 1/98; Foldout 13,B and Figure 4–9
and Units Starting With S/N 6510262246; 1
Foldout 13,C)
1. Remove fourteen bolts 2 (Foldout 13,B), two
2
bolts 34, four bolts 3, seven bolts 4, and one
bolt 59 that secure retarder module 2 (Figure
3
4–9) to main housing 3.
WARNING!
mately 64 kg (141 lb). Use care to prevent injury 4
to personnel while handling the retarder module
assembly. 5
8 7 6 V05569
2. Thread an M10 eye bolt into the retarder out-
put shaft and lift the retarder module 2 from Figure 4–10. Transfer Case Adapter Housing Removal
main housing 3.
3. Remove retarder gasket 1 from main housing 3
or retarder module 2. 4
l. Removal of Transfer Case Adapter

Housing Module (Figure 4–10) 1
1. Remove adapter housing 3 by removing fifteen
2
bolts 8, three bolts 6, three bolts 5, four bolts 4,
and two bolts 7.
2. Remove gasket 2. 5
3. Remove P3 carrier assembly 1 (Foldout 18) by

sliding it up over the main shaft.
m. Removal of Rear Cover Module
3
(Figure 4–11)
V05616.01
1. Remove nineteen bolts 3.
2. If used, remove the rear support bracket. Figure 4–11. Rear Cover Module Removal

1 (MD PRODUCT LINE) 1
C5
2
3
2
3
1 (MD 3560)
1 (MD 3070PT)
V05617
V05565.01 Figure 4–13. P2 Module and C5 Clutch Pack Removal
Figure 4–12. Main Shaft Module Removal
o. Removal of P2 Module, C5 Clutch Plates,

and P1 Module (Figures 4–13, 4–14)
1. Lift P2 planetary module 1 (Figure 4–13) from

the main housing module. 1
2. Lift C5 clutch pack from the main housing

module — seven friction plates 3 and eight
steel reaction plates 2.
V05618
3. Measure the thickness of each friction plate 3.
Minimum thickness is 2.90 mm (0.114 inch).
Measure the oil groove depth of each friction Figure 4–14. P1 Module Removal
plate. Minimum groove depth is 0.20 mm
(0.008 inch).
2
3
4. Measure thickness of each steel reaction plate
2. Minimum thickness is 2.41 mm (0.095 inch).
5. Measure the cone of each plate. Maximum

cone is 0.41 mm (0.016 inch).
1
6. Lift P1 planetary module 1 (Figure 4–14) from
the main housing module.
p. Removal of Front Support/Charging Pump

Module and Rotating Clutch Module
(Figures 4–15, 4–16)
V05619
1. Remove eleven bolts 1 and 2 (Figure 4–15)

that retain front support and charging pump Figure 4–15. Front Support/Oil Pump
module 3 to the main housing. Module Removal

2. Lift front support and charging pump module 3 q. Removal of C3/C4 Clutch Assembly From
away from the turbine shaft. Main Housing Module (Figure 4–17)
CAUTION:
CAUTION: Ensure that the main housing assembly is horizon-
Carefully place rotating clutch module 1 (Figure tal when removing the C3/C4 clutch assembly.
4–15) on the workbench and prevent it from roll-
ing off the bench. 1. Remove twelve bolts 3 retaining C3/C4 clutch
assembly 1 in main housing module 2.
2. Remove C3/C4 clutch assembly 1 by sliding it
3. Using a hoist and an M16 eye bolt, lift turbine out of the input end of main housing module 2.
shaft and rotating clutch module 1 (Figure 4–16)
3. Remove the main housing from the repair
from the main housing module.
stand for cleaning.
4. Inspect the main housing clutch plate splines.
Maximum wear allowed is 1.15 mm
1 (0.045 inch).
V05620
V05621
Figure 4–16. Rotating Clutch Module Removal Figure 4–17. C3/C4 Clutch Module Removal

NOTES

SECTION 5 — MODULE REBUILD
5–1. SCOPE 5. Remove large seal 31 used between the cover
assembly and pump assembly.
a. Section. This section describes the disassembly
and assembly of the modules removed in Section 4. 6. Remove turbine assembly 18. Remove
sealring 16 from the hub of the turbine
b. Procedures. During rebuild procedures, refer to assembly. Measure the OD of the turbine hub.
the exploded views (Foldouts 7 through 19) in the Minimum diameter allowed is 61.34 mm
back of this manual. (2.415 inch). Place sealring 16 into the bore of
cover 8 where it is located during operation.
Measure the sealring ID. Replace the sealring
5–2. GENERAL INFORMATION FOR when the maximum allowable ID of 56.75 mm
MODULE REBUILD (2.234 inch) is exceeded.
Refer to Sections 3 and 7 for general overhaul infor- 7. Remove bearing assembly 19, if replacement is
mation as follows: necessary, and star washer 20.
Paragraph Description 8. Remove stator assembly 21.

3–2 Tools, Equipment
9. Remove bearing 30 and selective shim 29 from
3–3 Replacement Parts the back of the stator.
3–4 Careful Handling
3–5 Cleaning, Inspection 10. Remove retaining ring 22.
3–6 Assembly Procedures 11. Remove thrust plate 23 and measure its thick-
7–1 Wear Limits Data ness adjacent to the stator race. Minimum
7–2 Spring Data thickness allowed is 11.68 mm (0.460 inch).
12. Remove thrust washer 24.

5–3. TORQUE CONVERTER MODULE 13. Remove and inspect stator race 25, thirteen
springs 26, and rollers 27.
a. Disassembly (Foldout 7)
14. From converter cover assembly 7, remove
1. Before disassembling the torque converter, twenty (or thirty) bolts 15 retaining lockup
note balance marks or mark a line across the clutch backplate 14 to converter cover 8.
converter cover to the pump assembly with a
scribe. These marks will ensure correct assem- 15. Remove lockup clutch backplate 14. Measure
bly of the torque converter and reduce balance the thickness of the backplate wear surface.
problems. Minimum thickness allowed is 8.58 mm
(0.338 inch).
2. Place converter assembly 4 on a flat surface
with the oil pump drive tangs downward. Sup-
16. Remove lockup clutch/damper 13 from con-
port the converter assembly on wooden blocks
verter cover 8. Measure the thickness across
that keep the oil pump drive tangs from con-
the lockup clutch friction surfaces. Minimum
tacting the workbench.
thickness allowed is 8.05 mm (0.317 inch).
3. Remove thirty-six nuts 5 from the OD of Check for distortion of the lockup clutch fric-
torque converter cover assembly 6. tion surfaces. Maximum distortion allowed is
0.51 mm (0.020 inch). Check spline wear be-
4. Carefully separate cover assembly 6 from tween the turbine and the lockup clutch
pump assembly 32, avoiding damage to their damper. Maximum movement allowed is
sealing surfaces. 0.38 mm (0.015 inch).

NOTE: Roller to be installed in

small end of cam pocket
When the lockup clutch and damper assembly must
be replaced, be sure to obtain the correct part for SPRING (End of spring
may be up or down)
your S/N transmission. All transmissions starting
STATOR CAM
with S/N 6510141464 contain new damper hard-
ware and lockup clutch friction material. This lock-
up clutch and damper assembly is not
interchangeable with parts in units prior to the
above S/N.
17. Remove lockup clutch piston 11 by using air

V01360.01
pressure or by lightly striking the converter
cover against a flat surface. Remove OD seal-
Figure 5–1. Stator Roller/Spring Installation
ring 12 from the lockup clutch piston. Measure
the thickness of the lockup clutch piston. Mini- 6. If removed, press a new bushing 9 into the bore
mum thickness allowed is 5.71 mm of cover 8 using J 38566 bushing installer and
(0.225 inch). J 8092 drive handle. Insert turbine assembly 18
into the new bushing and check for freedom of
18. Remove thrust bearing 17.
rotation. After the trial fit, remove the turbine
19. Inspect the ID of converter cover bushing 9. from the front cover.
Maximum allowable bushing ID is 61.51 mm
7. Install thrust bearing 17 in converter cover
(2.422 inch). If replacement is necessary, re-
assembly 7.
move the bushing using a hammer and a chisel.
8. Install lockup clutch seal 10 on the hub of con-
20. Remove inner sealring 10 from the converter
verter cover 8 and seal 12 on the OD of lockup
cover.
clutch piston 11. Install the lockup clutch pis-
21. If replacement is necessary, remove thrust ton.
washer 33 from the pump.
9. Install lockup clutch/damper 13 into cover 8.
22. If bolt replacement is necessary, remove dam-
aged bolt(s) 35 from the OD of torque con- 10. Install lockup clutch backplate 14.
verter pump 34. 11. Install twenty (or thirty) bolts 15. Tighten bolts
23. Examine torque converter pump assembly 32 to 30–35 N·m (22–26 lb ft).
for cracks, missing vanes, or a loose torus ring. 12. Install thrust bearing 19 onto turbine 18, if it
b. Assembly (Foldout 7) was removed.
1. Install stator race 25 into stator and cam as- 13. Install sealring 16 onto turbine 18 and install
sembly 28. turbine 18 into converter cover assembly 6,
aligning the balance marks, if present.
2. Install thirteen springs 26 and rollers 27 into
14. Install stator assembly 21 onto turbine 18.
stator and cam assembly 28. Be sure springs
and rollers are installed in the cam pockets as 15. Install selective shim 29, removed in Paragraph
shown in Figure 5–1. Lube the rollers. 5–3a(9), and thrust bearing 30 onto the stator.
3. Install thrust washer 24 (Foldout 7) and thrust 16. Be sure all thirty-six bolts 35 are installed into
plate 23 onto stator 28. converter pump 34 flange. If removed, install
4. Install retaining ring 22. thrust washer 33 into converter pump assembly
32. Stake thrust washer 33 into the converter.
5. Lube star washer 20, and install it on the stator. Stake at six equally-spaced locations.

MODULE REBUILD
Figure 5–2. Torque Converter Selective Shim Procedure
Table 5–1. Torque Converter Selective Shims
Dimension C Use P/N Shim Thickness
0.08–0.35 mm (0.003–0.014 inch) — 0.000 mm NO STEP
0.36–0.60 mm (0.014–0.024 inch) 29502277 0.23–0.28 mm (0.009–0.011 inch)
0.61–0.83 mm (0.024–0.033 inch) 29502276 0.46–0.51 mm (0.018–0.020 inch)
0.84–1.06 mm (0.033–0.042 inch) 29502275 0.69–0.74 mm (0.027–0.029 inch)
17. Install sealring 31 onto converter cover 8. With go back to Paragraph 5–3a and disassemble the
balance marks or scribe mark aligned, place converter and install the correct shim at
converter pump assembly 32 over the top of Step b(15). Repeat Steps b(16)–b(23). If
converter cover assembly 6. dimension C equals the “NO STEP”
dimension, clearance is correct, go on to
18. Install four nuts 5, evenly spaced, onto four bolts Step (24).
35. Tighten the nuts to 30–35 N·m (22–26 lb ft).
19. Using a depth micrometer, measure from the 24. Install the remaining thirty-two nuts 5 onto
top of the converter hub to the thrust surface of converter pump bolts 34. Tighten all the nuts to
turbine assembly 18. This is dimension A (Fig- 30–35 N·m (22–26 lb ft).
ure 5–2).
20. Insert tool J 38548 into the converter cover and 5–4. TORQUE CONVERTER
place on a flat surface. Repeat the same mea-
HOUSING MODULE
surement as in Step (19). This is dimension B.
(Models Without PTO Provision)
21. Subtract dimension B from dimension A to get
dimension C. a. Disassembly (Foldout 8,A)
22. Refer to Table 5–1 for correct shim selection.
1. If not previously removed, remove input
23. If dimension C does not equal the “NO STEP” speed sensor retaining bolt 6, sensor retaining
dimension of 0.08–0.35 mm (0.003–0.014 inch), bracket 5, input speed sensor assembly 3, and

O-ring 4. The input speed sensor should have 5. Remove bearing retainer assembly 3 and PTO
a resistance of 300 ± 30 Ohms. gear assembly 9. If necessary, use jack bolts to
loosen the bearing retainer assembly.
CAUTION: 6. Inspect the bearing bore of converter housing
Use the correct wrench size to avoid crushing the 23 for damage. Measure the bearing bore —
breather. maximum ID permitted is 140.03 mm
(5.513 inch).
2. Remove breather assembly 9.
b. Disassembly of the Bearing Retainer
b. Assembly (Foldout 8,A)
1. Be sure O-ring 4 is in place and install input 1. Remove sealring 8 from bearing retainer 7. Re-
speed sensor assembly 3. Hold bracket 5 in move oil seal 4 using tool J 24171-A.
place and install retaining bolt 6. Tighten the
bolt to 24–29 N·m (18–21 lb ft). 2. Inspect bushing 6 for damage or wear and re-
move if replacement is necessary. Maximum
bushing ID permitted is 75.23 mm (2.962 inch).
CAUTION:
Use the correct wrench size to avoid crushing the 3. Inspect the bearing bore of bearing retainer 7
breather. for damage. Measure the bearing bore — max-
imum ID permitted is 140.06 mm (5.514 inch).
2. Install breather 9. Tighten the breather to 12–
c. Disassembly of the PTO Gear Assembly
16 N·m (9–12 lb ft).
1. Remove retaining ring 16. Remove oil pump
drive hub 14 from PTO gear 13. For units prior
5–5. TORQUE CONVERTER to S/N 24410, remove retaining ring 12 only if
HOUSING MODULE replacement is required.
(Models With PTO Provision)
2. Inspect oil pump drive hub for excessive wear
a. Module Disassembly (Foldout 8,B) on drive tangs. Maximum allowable tang wear
is 0.38 mm (0.015 inch).
1. If not previously removed, remove input
speed sensor retaining bolt 22, sensor re- 3. Remove sealrings 10 and 17. If replacement is
taining bracket 21, input speed sensor as- required, remove bearings 11 and 15 from PTO
sembly 19, and O-ring 20. The input speed gear 13.
sensor should have a resistance of 300
± 30 Ohms. d. Assembly of the PTO Gear Assembly
CAUTION: 1. If removed, press bearings 11 and 15 onto PTO

gear 13, using tool J 38565.
Use the correct wrench size to avoid crushing the
breather.
CAUTION:
2. Remove breather assembly 29 or breather On transmissions prior to S/N 6510005901, be
adapter 30. sure to assemble oil pump drive hub 14 with the
longer unsplined side toward the oil pump (see
3. If present, remove PTO cover(s) 26 by remov- Figure 5–3). A drive hub assembled backwards
ing ten bolts 27 for each cover. Remove PTO will cause transmission damage.
cover(s) 26 and gasket(s) 25.
4. Remove ten bolts 2 holding bearing retainer 2. If removed, install retaining ring 12 and then
assembly 3 and PTO gear assembly 9 into install oil pump drive hub 14 into PTO gear 13.
converter housing 23. Install retaining ring 16 onto hub 14.

MODULE REBUILD
3. Refer to Paragraph 3–6g. Insert two butt-joint 5. Be sure O-ring 20 is in place and install input
sealrings 10 and 17 into the sealing bore of speed sensor assembly 19. Hold bracket 21 in
converter housing 23 and measure the end gap place and install retaining bolt 22. Tighten the
with feeler gauges. Maximum allowable seal- bolt to 24–29 N·m (18–21 lb ft).
ring end gap is 1.15 mm (0.045 inch).
4. Remove the two sealrings 10 and 17 from the CAUTION:
converter housing and install them onto PTO Use the correct wrench size to avoid crushing the
gear 13. breather.
e. Assembly of the Bearing Retainer Assembly
6. Install breather 29 or breather adapter 30.
1. If removed, install bushing 6 using a press and Tighten the breather or breather adapter to
tools J 35922-2 and J 8092. 12–16 N·m (9–12 lb ft).
2. Install sealring 8. Install oil seal 4 using a press
and tools J 35921-3 and J 35921-1.
5–6. FRONT SUPPORT AND
f. Module Assembly CHARGING OIL PUMP MODULE
1. With a mallet, lightly tap PTO gear assembly 9
into converter housing 23 until the gear assem- a. Module Disassembly
bly is seated.
1. Remove three seals 23 (Foldout 9,A) from the
2. Use guide bolts to install bearing retainer as- front support hub.
sembly 3, rocking the retainer while installing.
3. Install ten bolts 2 holding bearing retainer as-
sembly 3 and PTO gear assembly 9 to 3. Remove eight bolts 6 that retain pump housing
housing 23. Tighten the bolts to 51–61 N·m assembly 7 to front support assembly 15.
(38–45 lb ft).
4. Compress pressure relief spring 26 using tool
4. If used, install PTO cover(s) 26 and gasket(s) J 41462. Remove pin 25. Slowly release pres-
25 using ten bolts 27 in each cover. Tighten the sure on the spring and remove spring 26 and
bolts to 51–61 N·m (38–45 lb ft). ball 27.
5. Remove pump housing assembly 7 and gear

set 10.
Longer side to
be toward the 6. On models without PTO, remove O-ring 4 and
oil pump oil seal 5 using tool J 24171-A.
7. Measure gear-cavity depth in the pump hous-

ing (Figure 5–4a). Maximum allowable depth
TRANSMISSIONS is 17.93 mm (0.706 inch).
PRIOR TO
S/N 6510005902
8. Measure gear-cavity diameter in the pump
housing (Figure 5–4b). Maximum ID permit-
TRANSMISSIONS
S/N 6510005902 ted is 127.30 mm (5.012 inch).
THRU
S/N 6510024409 9. On non-PTO models only, inspect bushing 8
TRANSMISSIONS inside pump housing 9 (Foldout 9,A) for wear
AFTER
S/N 6510024409, AND or damage. Measure the ID of the pump bush-
ALL 3000MH/T 200/T 300 ing. Maximum allowable ID is 75.23 mm
V01654.02
(2.962 inch). If worn or damaged, remove
Figure 5–3. Oil Pump Drive Hubs bushing 8 from pump housing 9.

10. If pump housing 9 is worn or damaged, replace 16. Install gear set 10 into pump housing 9. Mea-
the pump housing. sure pump gear side clearance (Figure 5–5).
Maximum clearance permitted is 0.13 mm
11. Measure the OD of the driven (outer) pump (0.005 inch).
gear. Minimum allowable OD is 126.95 mm
(4.998 inch). 17. Measure gear tooth tip clearance (Figure 5–6).
Maximum allowable clearance is 0.20 mm
12. Measure the width of the driven pump gear.
(0.008 inch).
Minimum width permitted is 17.81 mm
(0.701 inch). 18. Measure driven gear-to-pump housing (diame-
13. Inspect the bushing inside the drive (inner) tral) clearance (Figure 5–7). Maximum clear-
gear for wear or damage. Measure the ID of ance permitted is 0.36 mm (0.014 inch).
the drive gear bushing. Maximum ID allowed
is 57.30 mm (2.256 inch). If worn or damaged, 19. If any measurement is out of specification, re-
remove the bushing from the drive gear. place the pump housing and/or gear set 10 and
repeat Steps (11) through (18).
NOTE:
PUMP HOUSING
For MD Product Line transmissions starting with
S/N 6510024410, a NEW staked bushing is used with
a NEW gear set. You must use a NEW bushing with
the NEW gear set. The later bushing cannot be used
with the earlier gear set. Refer to Figure 5–5.
14. Measure the width of the drive and driven

pump gears. Minimum width allowed is
17.81 mm (0.701 inch).
MAX ID OF GEAR
15. For models with PTO, examine the tang slots CAVITY PERMITTED
127.30 mm (5.012 in.) V01661.01
in the drive pump gear. Replace the gear if the
slots have been battered.
Figure 5–4b. Measuring Gear-Cavity Diameter
In The Pump Housing
STAKED
BUSHING
PUMP
HOUSING
DRIVE
GEAR
PUMP
HOUSING MAX SIDE CLEARANCE DRIVEN GEAR
MAX ALLOWABLE
DEPTH OF GEAR CAVITY PERMITTED
17.93 mm (0.706 in.) V01660.01 0.13 mm (0.005 in.) V02518.02
Figure 5–4a. Measuring Gear-Cavity Depth Figure 5–5. Measuring Gear Side Clearance
In The Pump Housing In The Pump Housing

MODULE REBUILD
23. If damaged, remove dowel pin(s) 19 from front
support 21.
24. Measure the OD of ground sleeve 16 or 17 at
the journal for the oil pump gear set bushing.
The minimum allowable OD is 57.04 mm
(2.246 inch).
25. If worn or damaged, remove ground sleeve 16
or 17 by pressing ground sleeve from front
support 21.
b. Assembly of the Front Support
MAX ALLOWABLE
GEAR TOOTH TIP
CLEARANCE 0.20 mm (0.008 in.) V01663.01 NOTE:
Figure 5–6. Measuring Gear Tooth Tip Clearance Prior to S/N 6510024410, if turbine shaft 6 or 9
In The Pump Housing (Foldout 9,B) is being replaced, ground sleeve 16 or
17 must be replaced also.
1. If removed, install ground sleeve 16 or 17

(Foldout 9,A and Figure 5–8). Place front sup-
DRIVEN
GEAR port 21 on press bed. The machined flat at the
base of the ground sleeve must align with the
cast arrow on the front support (Figure 5–8,
View C). Press ground sleeve 16 or 17 into
front support 21 to the shoulder. After installa-
tion, total runout may not exceed 0.30 mm
(0.012 inch).
PUMP 2. If removed, install dowel pin(s) 19. Press the

HOUSING
MAX GEAR-TO-HOUSING pin(s) to a height of 14.5 mm (0.57 inch) from
CLEARANCE PERMITTED
0.36 mm (0.014 in.) V01664.01 the surface (Figure 5–8, View A).
Figure 5–7. Measuring Driven Gear Clearance 3. Install front support sleeve 20 using a press,
In The Pump Housing and tools J 38565 and J 35921-1.
20. Remove ten bolts 12 (Foldout 9,A) retaining

stiffening plate 13, if present, and wear plate
CAUTION:
14 to front support assembly 15. Remove stiff- Be sure to use the correct length bolts when in-
ening plate 13, if present, and wear plate 14. stalling the front support or transmission dam-
Inspect wear plate 14 for scoring, nicks, or age will occur. The ten bolts 12 used when the
grooving. Measure the thickness of the wear stiffening plate is present are 5 mm (0.197 inch)
plate. Minimum wear plate thickness allowed longer than the bolts used when the stiffening
plate is not present.
is 4.70 mm (0.185 inch).
21. If damaged, remove bearing 22 from front sup- 4. Install stiffening plate 13, if present, and wear
port assembly 15 using tool J 24171-A. plate 14 (Foldout 9,A). Secure with ten bolts 12.
Tighten the bolts to 51–61 N·m (38–45 lb ft).
22. Measure the OD of front support sleeve 20.
Minimum allowable OD is 98.83 mm 5. Install bearing 22 using a press and tools
(3.891 inch). If worn or damaged, remove J 35922-2 and J 8092. Press bearing 22 flush to
front support sleeve 20 from front support 21. 0.25 mm (0.010 inch) below the surface.

FRONT SUPPORT 21 FRONT

PIN 19 E TOP
TURBINE SHAFT
GROUND SLEEVE SEALRING BORE MAX ID PIN 17
16 or 17 51.10 mm (2.012 in.)
FRONT SUPPORT 21
INSTALL REMOVE
14.5 mm
(0.57 in.)
FRONT SUPPORT
T.I.R. MAX SLEEVE 20
0.30 mm (0.012 in.) MIN OD PIN 17
98.83 mm (3.891 in.)
PIN 17
E FRONT
SUPPORT
SECTION EE BOTTOM 21
VIEW A VIEW B
To install, align flat on
ground sleeve with arrow
on front support
GROUND SLEEVE
16 or 17
VIEW C
Numbers in this illustration coincide
with callout numbers on foldout 9,A V01367.01
Figure 5–8. Ground Sleeve Removal And Installation
c. Assembly of the Pump Housing 2. Install oil seal 5 using a press and tools
J 35921-3 and J 35921-1.
NOTE:
3. Install O-ring 4.
• For models without PTO, proceed with Step (1).
• For models with PTO, skip Steps (1), (2), and (3) 4. Install pressure relief ball 27 and pressure re-
and proceed to Step (4). lief spring 26 into pump housing. Using tool
J 41462, compress spring 26. Install pin 25 to
1. If old bushing was removed, install new bush- retain spring and ball.
ing 8 (Foldout 9,A) into pump housing 9 using
5. Lubricate pump gear set 10 to prevent damage
a press and tools J 35922-2 and J 8092.
and install the gear set in pump housing 9.
NOTE: 6. Retain the pump housing to the front support
For MD Product Line transmission starting with with eight bolts 6. Tighten the bolts to 51–61 N·m
S/N 6510024410, a NEW staked bushing is used with (38–45 lb ft).
a NEW gear set. You must use a NEW bushing with
7. Install thrust bearing 24 onto front support 21.
the NEW gear set. The later bushing cannot be used
with the earlier gear set. Refer to Figure 5–5. 8. Refer to Paragraph 3–6h. Insert three butt-joint
sealrings 23 into the sealing bore of the

MODULE REBUILD
rotating clutch hub and measure the end gap
with feeler gauges. Maximum sealring end gap NOTE:
allowed is 1.44 mm (0.057 inch). All MD 3066 and B 400 models starting with
S/N 6510142342 have C1 and C2 drive hubs with
9. Remove three sealrings 23 from the rotating
changed material for increased torque capacity.
clutch hub and install them onto the hub of
The improved part MUST be used when replacing
front support 21.
either of the hubs in MD 3066 or B 400 units with
the S/N shown and above. All other MD Product
5–7. ROTATING CLUTCH MODULE Line transmissions prior to the S/N shown may be
serviced with the standard hubs.
a. Disassembly (Foldout 9,B)
12. Remove C1 retaining ring 32 and C1 clutch
1. Remove retaining ring 43. pack — two backplates 29, six friction plates
30, and five steel reaction plates 31.
2. Remove P1 sun gear assembly 40.
13. Measure the thickness of each friction plate 30.
3. Inspect and measure the ID of sun gear Minimum thickness allowed is 2.21 mm
bushing 42. Maximum ID permitted is (0.087 inch). Measure the oil groove depth and
68.22 mm (2.685 inch). Remove the bushing if cone of each friction plate. Minimum allowable
replacement is necessary. groove depth is 0.20 mm (0.008 inch). Maxi-
mum cone permitted is 0.40 mm (0.016 inch).
4. Remove C2 retaining ring 39.
14. Measure the thickness and cone of each steel
5. Remove C2 backplate 38. reaction plate 31. Minimum thickness allowed
is 2.41 mm (0.095 inch). Maximum allowable
6. Measure the wear surface thickness of C2 cone is 0.40 mm (0.016 inch).
backplate 38. Minimum thickness allowed is
15. Measure the wear surface thickness of the C1
6.25 mm (0.246 inch). Check flatness of the
backplates 29. Minimum thickness permitted
backplate. Maximum allowable distortion is
is 6.25 mm (0.246 inch). Check flatness of the
0.45 mm (0.018 inch).
backplates. Maximum distortion allowed is
7. Remove C2 clutch pack — six friction plates 0.15 mm (0.006 inch).
37 and six steel reaction plates 36. 16. Remove thrust bearing 15 from hub assembly 12.
8. Measure the thickness of each friction plate 37. 17. Remove retaining ring 16 and turbine shaft as-
Minimum thickness permitted is 2.21 mm sembly 5 or 8.
(0.087 inch). Measure the oil groove depth and 18. Inspect bushing 7 inside the end of turbine
cone of each friction plate. Minimum groove shaft 5 or 8. Measure the ID of the turbine
depth permitted is 0.20 mm (0.008 inch). Max- shaft bushing. Maximum ID allowed is
imum cone allowed is 0.40 mm (0.016 inch). 20.19 mm (0.795 inch).
9. Measure the thickness and cone of each steel 19. Remove three rotating sealrings 10.
reaction plate 36. Minimum allowable thick- 20. Remove O-ring 4 from turbine shaft assembly
ness is 2.41 mm (0.095 inch). Maximum cone 5 or 8.
permitted is 0.40 mm (0.016 inch).
WARNING!
10. Remove C2 drive hub 35, including two thrust
bearings 34. Inspect the splines of the C2 drive Piston springs are highly compressed. Be ex-
hub. Maximum spline wear permitted is tremely careful during disassembly. Personal in-
jury can occur if the spring force is not controlled.
0.38 mm (0.015 inch).
11. Remove C1 drive hub 33. Inspect the splines of 21. Place rotating clutch on tool base J 35923-4 so
the C1 drive hub. Maximum allowable spline rotating drum is supported by tool tangs (Figure
wear is 0.38 mm (0.015 inch). 5–9, View C). Install J 35923-1 (Figure 5–9,

View A), bearing, washer and handle 24. Remove C2 spring assembly 21.
J 28467-34. Tighten tool, compressing C1 bal-
25. Lift rotating drum 11 free of hub assembly 12
ance piston 26 (Foldout 9,B) and C1 return
and C1/C2 pistons 20 and 24. Inspect the
spring 25. Remove retaining ring 28. Remove
clutch splines of the rotating drum. Maximum
tool J 35923-1.
allowable spline wear is 0.38 mm (0.015 inch).
22. Remove balance piston 26, sealring 27, and C1 26. Remove C1 and C2 pistons 20 and 24 from
spring assembly 25. hub assembly 12 — rocking the pistons from
side-to-side.
23. Install tools J 35923-3 and J 35923-2 (Figure 27. Inspect the ID of rotating clutch hub
5–9, View B), bearing, washer and handle bushing 13. Maximum allowable bushing ID is
J 28467-34. Tighten tool and remove retaining 99.25 mm (3.907 inch). Remove the bushing
ring 22 (Foldout 9,B). Remove tools J 35923-2 from hub assembly 12 if replacement is neces-
and J 35923-3. sary. Avoid damaging the bushing bore.
J 35923-4
J 35923-4
J 28467-34
J 28467-34
FLAT WASHER
FLAT WASHER
J 35923-1
BEARING J 35923-2
BEARING
J 35923-3
VIEW A VIEW B
J 35923-4
LUBE ORIFICE
VIEW C
VIEW D ALIGNMENT SLOTS
V00221.02
Figure 5–9. Rotating Clutch Assembly/Disassembly

MODULE REBUILD
28. Remove piston seals 17 and 18 from hub as- 5. Place the assembly on tool base J 35923-4. In-
sembly 12. stall C1 spring assembly 25.
6. Install a new sealring 27 on balance piston 26.
NOTE: Lube the sealring.
Beginning with MD 3060/3560 models S/N 6510184386 7. Place balance piston 26 on the assembly, align-
and MD 3066/B 300/B 400 models S/N 6510130438, ing the notch on the C1 piston with the cast
clutch hub assembly 12 was changed from a single bump in the balance piston.
weld design to a double weld design. All T 200 and
T 300 models contain the double weld design. 8. Install tool J 35923-1 over the assembly along
Inspect units prior to this S/N carefully for cracks in with bearing, washer, and handle. Thread the
the weld area and replace defective parts with the handle down and compress C1 spring assem-
new design. Use magnetic particle inspection or bly 25.
place solvent in the C2 piston bore to confirm that a 9. Install retaining ring 28 into the hub of the ro-
crack is present. tating clutch assembly.
10. Carefully release the C1 spring and remove all
29. Separate C1 piston 24 and seal 23 from C2 pis- tools from the assembly.
ton 20 and seal 19 by tapping lightly on the C1
11. Install C1/C2 assembly into rotating clutch
piston. Remove seals 23 and 19 from the pis-
drum 11.
tons.
12. Install C2 clutch spring assembly 21 with the
b. Assembly (Foldout 9,B) stepped end down. Make sure the spring as-
sembly properly aligns with the drum and hub
CAUTION: splines.
Beginning with S/N 661032320, C1 clutch 13. Place the assembly on tool base J 35923-4 so
piston 24 and balance piston 26 are a new design. that the rotating drum is supported by tool
In units prior to the S/N, if either part must be re- tangs (Figure 5–9, View C). Install tools
placed, BOTH the C1 clutch piston 24 and the bal- J 35923-3 and J 35923-2 (Figure 5–9,
ance piston 26 must be replaced with the new
View B), bearing, washer, and handle.
design parts. Intermixing new and old design
parts causes misalignment leading to damage to Compress C2 spring assembly 21 and install
C1 return spring assembly 25 and potential failure retaining ring 22 (Foldout 9,B). Remove tools
of C1 clutch piston 24 or C1 balance piston 26. J 35923-3 and J 35923-2.
1. If removed during disassembly, install NOTE:

bushing 13 into rotating clutch hub 14 using For units built prior to S/N 6510024410, when tur-
tools J 35922-2 and J 8092. bine shaft 6 or 9 must be replaced, ground sleeve 16
2. Install piston seals 17 and 18 into rotating or 17 (Foldout 9,A) must also be replaced.
clutch hub assembly 12. Lube sealrings.
3. Install a new OD sealring 19 in C2 piston 20. 14. If removed, install bushing 7 into turbine shaft
Lube C2 clutch piston inside bore and on OD 6 or 9 using tools J 35922-1 and J 8092.
sealring. Install C2 piston 20 into the rotating 15. Install O-ring 4 onto the forward end of the tur-
clutch hub assembly. Lightly tap until it is fully bine shaft.
seated. 16. Refer to Paragraph 3–6h for method and proce-
4. Install a new OD sealring 23 into C1 piston 24. dure. Insert three butt-joint sealrings 10 into
Lube the inside bore and OD sealring on the the sealing bore of ground sleeve 16 or 17
C1 piston. Aligning slot in C1 clutch piston (Figure 5–8) and measure the end gap with
with any lube orifice on the rotating clutch feeler gauges. Maximum sealring gap allowed
hub, install C1 clutch piston into the center of is 0.94 mm (0.037 inch). Remove sealrings
C2 piston 20. With a soft mallet, lightly tap C1 from the ground sleeve bore and install them
piston until it is fully seated. on turbine shaft assembly 5 or 8 (Foldout 9,B).

17. Install turbine shaft assembly 5 or 8. Retain the 23. Install C2 backplate 38. Install C2 retaining
turbine shaft with retaining ring 16. ring 39.
18. Install thrust bearing 15 onto the end of rotat- 24. If removed, install bushing 42 using tools
ing clutch hub assembly 12. Position the as- J 35922-2 and J 8092.
sembly with the turbine shaft downward.
25. Install P1 sun-gear drive hub assembly 40. In-
NOTE: stall retaining ring 43.
In MD Product Line units starting with S/N 6510164169,
the two identical C1 pressure plates have been re-
placed by two different plates. The pressure plate
5–8. C3/C4 AND MAIN HOUSING
29 which goes next to the C1 piston is 2 mm (0.157 MODULE
inch) thinner. The pressure plate 29 at the opposite
end of the C1 clutch pack is 2 mm (0.157 inch) thick- a. Disassembly (Foldout 10,A)
er and is reshaped. See Figure 5–10 for pictorial in-
formation.
NOTE:
When replacing a nameplate, keep the original
CAUTION: nameplate. Stamp the information recorded on the
The new design C1 pressure plates must be used original nameplate onto the replacement name-
together and cannot be intermixed with the older plate.
identical plates or C1 clutch will fail.
1. If nameplate 28 is damaged, remove nameplate
19. Install C1 clutch pack — two pressure plates retaining screw 29 and nameplate 28.
29, one pressure plate on each side of the
clutch pack, six friction plates 30, and five 2. If present, remove two bolts 30 and feed-
steel reaction plates 31. Install clutch plates al- through connector assembly 32.
ternately, starting with a friction plate 30. In-
stall C1 retaining ring 32. 3. Inspect the clutch splines in the interior of
main housing 27. Maximum spline wear al-
20. Install C1 drive hub 33. lowed is 1.15 mm (0.045 inch).
21. Install a thrust bearing 34 on each side of C2 4. Remove twelve bolts 2 retaining C3 clutch
drive hub 35, and install this assembly over C1 components to C4 clutch housing 24. Remove
drive hub 33. C3 backplate assembly 3.
CAUTION: 5. Inspect three wear plates 5 and six rivets 6 on

clutch backplate 4. Measure the wear plates at
B 400 models beginning with S/N 6510043834 the contact surface. Minimum thickness al-
were called “enhanced” B 400’s and have C2
lowed is 2.81 mm (0.111 inch). Check flatness
clutch plates with a different friction coefficient.
Also, most early B 400 units were updated to this of backplate 4 and the wear plates. Maximum
configuration. Be sure to replace C2 clutch friction allowable distortion is 0.15 mm (0.006 inch). If
plates with the correct plates. “Enhanced” plates replacement is necessary remove the wear
are identified with an orange mark (5–20 mm plates by drilling out the rivets.
wide) on the OD of the plate.
6. Remove P1 ring gear 7. Inspect the clutch
splines of the P1 ring gear. Maximum spline
22. Install C2 clutch plates — six friction plates 37 wear permitted is 0.38 mm (0.015 inch).
and six steel reaction plates 36. Install clutch
plates alternately, starting with a steel reaction 7. Remove C3 clutch pack — five friction
plate 36. plates 8 and four steel reaction plates 9.

MODULE REBUILD
C1 Pressure Plate Redesigned C1 Pressure Plate

2 mm thinner than 2 mm thicker than prior
prior pressure plate pressure plate
V05566
Figure 5–10. Redesigned C1 Pressure Plates
8. Measure the thickness of each friction plate 8. ness permitted is 3.41 mm (0.135 inch). Maxi-
Minimum thickness allowed is 2.21 mm mum cone allowed is 0.40 mm (0.016 inch).
(0.087 inch). Measure the oil groove depth of
each friction plate. Minimum allowable groove 11. Only if damaged and replacement is necessary,
depth is 0.20 mm (0.008 inch). Maximum cone remove the return spring assemblies. Remove
permitted is 0.40 mm (0.016 inch). spring retainer assembly 12 and piston 13.
12. Remove C3 housing assembly 14.
NOTE:
13. Inspect three wear plates 16 and six rivets 15
In MD Product Line units starting with S/N 6510076858, on C3 housing 17. Measure the wear plates at
C3 and C4 clutch friction plates had hardened in- the contact surface. Maximum allowable wear
ternal splines. The improved plates are identified by is 2.81 mm (0.111 inch). Check flatness of
either a missing spline tooth or by a blue stripe on clutch housing and the wear plates. Maximum
the OD. distortion permitted is 0.15 mm (0.006 inch). If
replacement is necessary, remove the wear
plates by drilling out the rivets.
CAUTION: 14. Remove C4 clutch pack — five friction plates
B 400 models beginning with S/N 6510043834 19 and five steel reaction plates 18.
were called “enhanced” B 400’s and have C3 and
C4 clutch plates with a different friction coeffi- 15. Measure the thickness of each friction plate 19.
cient. Also, most early B 400 units were updated Minimum thickness allowed is 2.21 mm
to this configuration. Be sure to replace C3 or C4 (0.087 inch). Measure the oil groove depth of
clutch friction plates with the correct plates. each friction plate. Minimum groove depth al-
B 400’s and MD 3066’s use different plates than lowable is 0.20 mm (0.008 inch). Maximum
B 300 and other MD Product Line models. cone permitted is 0.40 mm (0.016 inch).
9. Measure the thickness of each steel reaction

NOTE:
plate 9. Minimum thickness allowed is
2.41 mm (0.095 inch). Maximum cone allow- In MD Product Line units starting with S/N 6510076858,
able is 0.40 mm (0.016 inch). C3 and C4 clutch friction plates had hardened in-
ternal splines. The improved plates are identified by
10. Remove piston return plate 11 with four return either a missing spline tooth or by a blue stripe on
spring assemblies 10 attached. Measure the the OD.
thickness of return plate 11. Minimum thick-

attached to the housing. No movement of the
CAUTION: wear plate is allowed.
B 400 models beginning with S/N 6510043834
were called “enhanced” B 400’s and have C3 and 6. Lube seal surfaces of C3 clutch piston 13, and
C4 clutch plates with a different friction coeffi- install the C3 clutch piston into C3 clutch
cient. Also, most early B 400 units were updated housing 14.
to this configuration. Be sure to replace C3 or C4
clutch friction plates with the correct plates. 7. Install C3 clutch housing assembly 14 with
B 400’s and MD 3066’s use different plates than clutch piston 13 on top of the assembled C4
B 300 and other MD Product Line models. clutch housing (items 18–24). Ensure the index
tangs on the clutch housings are aligned. In-
16. Measure the thickness of each steel reaction stall spring retainer assembly 12.
plate 18. Minimum thickness allowed is
2.41 mm (0.095 inch). Maximum allowable 8. Install piston return plate 11 and four return
cone is 0.40 mm (0.016 inch). spring assemblies 10. If removed, install spring
assemblies and attach them securely.
17. Remove piston return plate 21 with four return
spring assemblies 20 attached. Measure the 9. Install P1 ring gear 7.
thickness of return plate 21. Minimum thick-
ness permitted is 3.41 mm (0.135 inch). Maxi- 10. Install C3 clutch pack. Starting with a friction
mum allowable cone is 0.40 mm (0.016 inch). plate, alternately install five friction plates 8,
and four steel plates 9.
18. Remove spring retainer assembly 22 and
piston 23 from the C4 housing 24. 11. To assemble the C3 backplate, when wear
plates must be replaced, use six rivets 6 to fas-
19. Inspect C4 clutch housing 24 for damage.
ten three wear plates 5 to C3 backplate 4. Use
tool J 39354 to cold-form the rivets. Insert the
b. Assembly (Foldout 10,A)
rivet so the pre-formed head is below the active
1. Install piston 23 into C4 housing 24. Install surface of the wear plate. Use the cold-forming
spring retainer assembly 22. tool to upset each rivet at the rear of the back-
plate to complete the attachment process. A
2. If removed, install spring assemblies 20 and correctly formed rivet upset will be 4.00 mm
attach them securely. (0.157 inch) in diameter and no more than
1.00 mm (0.039 inch) above the surface of the
3. Install piston return plate 21 with four return backplate. The wear plate must be tightly at-
spring assemblies 20. tached to the backplate. No movement of the
wear plate is allowed.
4. Install C4 clutch pack. Starting with a friction
plate, alternately install five friction plates 19 12. Install C3 backplate assembly 3. Backplate 3
and five steel reaction plates 18. must be indexed with C3 and C4 housings in
order to insert the assembly into main
5. To assemble the C3 housing, when wear plates
housing 27 correctly.
must be replaced, use six rivets 15 to fasten
three wear plates 16 to the C3 housing 17. Use 13. Install twelve retaining bolts 2 through the C3
tool J 39354 to cold-form the rivets. Insert the backplate assembly 3 and into the C4 clutch
rivet so the pre-formed head is below the active housing 24. Tighten the bolts to 51–61 N·m
surface of the wear plate. Use the cold-forming (38–45 lb ft).
tool to upset each rivet at the rear of the clutch
housing to complete the attachment process. A 14. If removed, install nameplate 28 and screw 29.
correctly formed rivet upset will be 4.00 mm
(0.157 inch) in diameter and no more than 15. If present and removed, install feedthrough
1.00 mm (0.039 inch) above the surface of the connector assembly 32 and two bolts 30.
clutch housing. The wear plate must be tightly Tighten the bolts to 5–8 N·m (4–5 lb ft).

MODULE REBUILD
5–9. MAIN SHAFT MODULE 5. Install spiral retaining ring 4. Compress the
spiral retaining ring to lock it into place.
NOTE: 6. Proceed to Paragraph 5–10.

• For MD Product Line models, except MD 3560 c. Module Disassembly (MD 3560 Transmission
and MD 3070PT models, proceed to Step a. Models) (Foldout 11,A)
• For MD 3560 models, skip Steps a. and b. and
proceed to c. 1. Remove spiral retaining ring 4.
• For MD 3070PT model, skip Steps a.–d. and
proceed to e. 2. Remove P2 sun gear 5 and thrust bearing 6.
3. Remove spacer 7.
a. Disassembly (MD Product Line Models, 4. Inspect and measure main shaft pilots.
Except MD 3560 and MD 3070PT Models) Minimum pilot OD permitted is 19.98 mm
(Foldout 10,B) (0.787 inch). Inspect and measure main shaft
1. Remove spiral retaining ring 4. journal OD for P2 planetary bushing.
Minimum allowable main shaft journal OD is
2. Remove P2 sun gear 6. 42.97 mm (1.692 inch).
3. Remove thrust bearing 5. d. Module Assembly (MD 3560 Transmission
Models) (Foldout 11,A)
4. Remove bearing spacer 7.
5. Remove selective shim 1, if not previously re-
NOTE:
moved.
Do not install thrust bearing 2 or selective shim 1
6. Remove thrust bearing 2, if not previously re- until final transmission assembly. Measurement for
moved. selective shim 1 is performed during final buildup.
7. Remove P3 sun gear 8 from main shaft 9.
8. Inspect and measure main shaft pilots. Mini- 1. Install spacer 7 and thrust bearing 6.
mum pilot OD allowed is 19.98 mm
2. Install P2 sun gear 5 and spiral retaining ring 4.
(0.787 inch). Inspect and measure main shaft
Compress the spiral retaining ring to lock it
journal OD for the P2 planetary bushing. Mini-
into place.
mum permissible main shaft journal OD is
42.97 mm (1.692 inch). 3. Proceed to Paragraph 5–10.
b. Assembly (MD Product Line Models, e. Module Disassembly (MD 3070PT
Except MD 3560 and MD 3070PT Models) Transmission Model) (Foldout 11,B)
(Foldout 10,B)
1. Remove spiral retaining ring 3.
NOTE: 2. Remove P2 sun gear 5 and thrust bearing 4.

Do not install thrust bearing 2 or selective shim 1
3. Remove spacer 6.
until final transmission assembly. Measurement for
selective shim 1 is performed during final buildup. 4. Remove P3 sun gear 7.
1. Install P3 sun gear 8 onto main shaft 9.
6. Inspect C6 bushing journal OD on main
2. Install bearing spacer 7. shaft 8. Minimum allowable OD is 35.92 mm
(1.414 inch). Inspect P3 bushing journal OD.
3. Install thrust bearing 5.
Minimum OD allowed is 52.98 mm
4. Install P2 sun gear 6. (2.086 inch).

7. Measure the front main shaft pilot. Minimum
INDEXING FLAT
pilot OD permitted is 19.98 mm (0.787 inch).
Inspect and measure main shaft journal OD for
P2 planetary bushing. Minimum journal OD
allowed is 42.97 mm (1.692 inch).
NO WEAR
f. Module Assembly (MD 3070PT Transmission
Model) (Foldout 11,B)
1. Install thrust bearing 1. ABNORMAL WEAR
INDEXING RING
2. Install P3 sun gear 7. V04322
3. Install spacer 6. Figure 5–11. Carrier Indexing Ring Wear
4. Install P2 sun gear 5 and thrust bearing 4. 7. Measure the thickness of all thrust washers 9
and 12. Minimum thrust washer thickness per-
5. Install spiral retaining ring 3. Compress the mitted is 1.39 mm (0.054 inch).
spiral retaining ring to lock it into place.
8. Remove thrust bearings 3 and 13 from each
side of P1 planetary carrier 8.
5–10. P1 PLANETARY MODULE 9. Check spline wear of P1 planetary carrier 8
and P2 planetary ring gear 14. Maximum
a. Disassembly (Foldout 12,A) spline wear allowed is 0.38 mm (0.015 inch).
1. Remove retaining ring 2 from P2 ring gear 14. b. Assembly (Foldout 12,A)
2. Remove P2 ring gear 14.
NOTE:
3. Check P1 planetary pinion end play in P1 car- MD Product Line units starting with S/N 6510142342,
rier assembly 4. Pinion end play should not ex- the P1 carrier was changed to include an oil groove
ceed 0.94 mm (0.037 inch). Check all six in the ID bore. This carrier is not interchangeable
pinion gears. with former carriers. The new carrier must be used
with the new P2 carrier which has eliminated two
4. Remove retaining ring 5 and indexing ring 6.
sealring grooves and sealrings. The former carriers
Inspect indexing ring 6 for abnormal wear
where the spindles 7 contact (Figure 5–11). If are still available for service.
abnormal wear is present, the planetary
spindle 7 probably has a sharp edge instead of CAUTION:
a radius edge (Figure 5–12).
When replacing a P1 carrier in a transmission
prior to S/N 6510142342, be sure to obtain the
NOTE: correct replacement part. If installing a new style
carrier with the inner oil groove, also install a
Planetary spindles on transmission S/Ns from new P2 carrier which eliminates two sealring
6510063169–6510114718 have sharp edges (Figure grooves and sealrings.
5–12). If index ring 6 is worn and the spindles have
a sharp edge and fall within the S/N range above, 1. Install two bearing sets 11 into the center of
replace the spindles. pinion gear 10. Install thrust washers 9 and 12
inside P1 planetary carrier 8. Align thrust
5. Remove six spindles 7 from P1 carrier 8. washer tangs with the slots in the carrier and
retain them with oil-soluble grease. Slide the
6. Slide pinion gear 10, thrust washers 9 and 12, pinion gear and bearing sets into the side of the
and two bearing sets 11 from the side of P1 P1 planetary carrier, between the thrust
planetary carrier 8. Repeat the procedure with washers. Repeat the procedure with the five
the five remaining pinion gears. remaining pinion gears.

MODULE REBUILD
SHARP FLAT EDGE (REF)

(Radius added on
edge 0.25–1.50 mm)
VIEW A
SHARP FLAT EDGE

(Radius added on
edge 0.25–1.50 mm)
VIEW A
PLANETARY SPINDLE V04323
Figure 5–12. Sharp Edge vs. Radius Edge On Planetary Spindles
2. Install six spindles 7 so the lower step is posi- 5–11. P2 PLANETARY MODULE
tioned for proper installation of indexing
ring 6. a. Disassembly (Foldout 12,B)
CAUTION: NOTE:
Be sure that the planetary spindles cannot rotate In MD Product Line units starting with S/N 6510142342,
after the indexing ring has been installed or lube the two sealrings 2 on P2 carrier assembly 4 have
flow to the pinion bearings may be blocked.
been eliminated. The new carrier is not inter-
When the indexing ring slots are worn on one
corner (Figure 5–11), flip the plate over to obtain changeable with former carriers. The new carrier
a new unworn contact surface. If both contact must be used with the new P1 carrier which has an
areas are worn, replace the indexing ring. oil groove in the ID bore. The former carriers are
still available for service.
3. Install indexing ring 6 and retaining ring 5.
4. If components were replaced, check pinion end CAUTION:

play. Pinion end play should not exceed When replacing a P2 carrier in a transmission
0.94 mm (0.037 inch). Check all six pinion prior to S/N 6510142342, be sure to obtain the
gears. correct replacement part. If installing a new style
carrier with the two eliminated sealring grooves
5. Install P1 planetary carrier assembly 4 into P2 and sealrings, also install a new P1 carrier which
ring gear 14. has an oil groove in the ID bore.
6. Install retaining ring 2 into P2 ring gear 14, re- 1. Remove two sealrings 2, if present, from P2
taining P1 planetary carrier assembly 4 in the carrier.
P2 planetary ring gear.
2. Remove retaining ring 3.
7. Install two thrust bearings 3 and 13 one on
each side of P1 planetary carrier assembly 4. 3. Remove P3 ring gear 15.

4. Check P2 planetary pinion end play. Pinion 3. Install four spindles 12 so the lower step is posi-
end play should not exceed 0.94 mm tioned for proper installation of indexing ring 13.
(0.037 inch). Check all four pinion gears.
5. Remove retaining ring 14. Remove indexing CAUTION:

ring 13. Remove four pinion spindles 12 from Be sure that the planetary spindles cannot rotate
P2 carrier 6. Inspect indexing ring 13 for ab- after the indexing ring has been installed or lube
normal wear where the spindles 12 contact flow to the pinion bearings may be blocked.
(Figure 5–11). If abnormal wear is present, the When the indexing ring slots are worn on one
planetary spindle 12 probably has a sharp edge corner (Figure 5–11), flip the plate over to obtain
instead of a radius edge (Figure 5–12). a new unworn contact surface. If both contact
areas are worn, replace the indexing ring.
NOTE: 4. Install indexing ring 13 and retaining ring 14.

Planetary spindles on transmission S/Ns from 5. If components were replaced, check pinion end
6510063169–6510114718 have sharp edges (Figure play. Pinion end play should not exceed 0.94 mm
5–12). If index ring 6 is worn and the spindles have (0.037 inch). Check all four pinion gears.
a sharp edge and fall within the S/N range above,
6. Install P2 carrier 4 into P3 ring gear 15.
replace the spindles.
7. Install retaining ring 3 into P3 ring gear 15, re-
taining P2 planetary carrier assembly 4.
6. Slide a pinion gear 10, thrust washers 8 and 11,
and two bearing sets 9 from the side of P2 8. Insert two sealrings 2 into the P1 planetary
planetary carrier 6. Repeat the procedure with carrier bore and measure their end gap with a
the three remaining pinion gears. feeler gauge. Maximum sealring end gap
allowed is 1.20 mm (0.047 inch). Refer to
7. Measure the thickness of all thrust washers 8 Section 3 if the sealring end gap is incorrect.
and 11. Minimum thickness allowed is
9. Install two sealrings 2 on P2 carrier assembly 4.
1.39 mm (0.054 inch).
8. Inspect bushing 7 inside P2 planetary carrier 6 NOTE:

for wear or damage. Maximum allowable
• For models without retarder and without trans-
bushing ID is 43.20 mm (1.701 inch).
fer case, skip Paragraph 5–12 and proceed to
9. Check spline wear between P2 planetary car- Paragraph 5–13, Rear Cover Module.
rier 6 and P3 planetary ring gear 15. Maximum • For models with transfer case, skip Paragraphs
movement permitted is 0.38 mm (0.015 inch). 5–12 and 5–13 and proceed to Paragraph 5–14,
Adapter Housing and P3 Overhaul.
b. Assembly (Foldout 12,B)
1. If replacement is necessary, press a new bush-

ing 7 into P2 carrier 6 using a press, installer 5–12. RETARDER MODULE
J 35922-1, and driver J 8092.
2. Install two bearing sets 9 into the center of NOTE:

pinion gear 10. Install thrust washers 8 and 11 • For transmissions with retarder built prior to
in P2 planetary carrier 6, align thrust washer January, 1998, proceed to Step a.
tangs with slots in the planetary, and retain • For transmissions with retarder built in
them with oil-soluble grease. Slide the pinion January, 1998 or later, skip Steps a.–j. and
gear and two bearing sets into the side of the proceed to Step k.
P2 planetary carrier between the thrust • For transmissions starting with S/N 6510262246,
washers. Repeat the procedure with the three proceed to Step (s).
remaining pinion gears.

MODULE REBUILD
a. Disassembly of Retarder Valve Body (Units 6. Check the resistance of retarder solenoid 82.
Built Prior To 1/98) (Foldout 13,A) Resistance must be within the range shown on
Figure 5–13.
1. If not done previously, remove four bolts 71 re-
taining wiring harness cover 70 to retarder
7. Remove solenoid 82 from harness 80.
housing assembly 35 and remove the cover.
2. Remove nine bolts 77 that retain retarder 8. If repair or replacement of solenoid wiring har-
control body assembly 78 to retarder housing ness 80 is necessary, remove the external nut
assembly 35 and remove control body retaining the harness connector to solenoid
assembly 78. cover 81.
3. Remove separator plate gasket 72, solenoid 9. Remove pressure tap plug 86 and O-ring 87
separator plate 73, separator plate gasket 74, from retarder control body 88.
channel plate 75, and channel plate gasket 76.
4. Remove four bolts 79, solenoid cover 81, and 10. Remove retaining ring 90, O-ring 91, valve
gasket 95. plug 89, and spring 92 from retarder control
body 88.
5. Remove fluted retaining pin 93 from the re-
tarder control body 88. Remove solenoid 82 11. Remove retarder control valve 94 from retarder
and O-rings 83 and 84. control body 88.
WT SOLENOID RESISTANCE
SPEC VALUE = 3.26 ± .2 OHMS AT 20°C
5.2
4.8
4.6
SOLENOID RESISTANCE IN OHMS
4.4
4.2
4
MAXIMUM OHMS
3.8
3.6
3.4
MINIMUM OHMS
3.2
2.8
2.6
2.4
2.2 SUMP TEMPERATURE IN °F

4 32 68 104 140 176 212 248 284
2
–20 0 20 40 60 80 100 120 140
SUMP TEMPERATURE IN °C V00719.01
Figure 5–13. Solenoid Resistance vs. Temperature

b. Removal of Wiring Harness housing 51. Output speed sensor resistance
and Temperature Sensor should be 300 ± 30 Ohms.
1. Remove temperature sensor retainer bolt 59 2. For transmissions prior to S/N 6510021203, re-
and temperature sensor retainer 58. Carefully move signal valve retaining ring 40, plug 41,
remove temperature sensor assembly 68 from signal valve 42, and O-ring 43. For transmis-
retarder housing assembly 35. sions between S/N 6510021203 and
6510064183, remove retaining ring 40 and
2. Check temperature sensor with an ohmmeter. plug 41.
See Figure 5–14 for proper sensor readings.
3. If repair or replacement of temperature sensor NOTE:

68 and wiring harness assembly 60 is necessary,
remove the external nut that retains harness con- • For units prior to S/N 6510064183, do Step (3),
nector 61 to retarder housing assembly 35. skip Step (4), and go to Step (5).
c. Disassembly of Retarder Housing Step (3) and go to Step (4).
1. If not already removed, remove output speed
sensor bolt 39, bracket 38, output speed sensor 3. Remove retaining ring 59, plug 58, O-ring 57,
assembly 36, and O-ring 37 from retarder spring 56, retarder valve 55, and pin 54.
TEMPERATURE SENSOR CHART

TEMPERATURE VS. RESISTANCE
TEMP °C TEMP °F OHMS
2900 -50 -58 525
-40 -40 577
2700 -30 -22 632 ±7.0°C
TEMPERATURE SENSOR RESISTANCE IN OHMS
-20 -4 691
2500 -10 14 754
0 32 820
10 50 889
2300 20 68 962 ±5.0°C
30 86 1039
2100 40 104 1118
50 122 1202
1900 60 140 1288 ±4.0°C
70 158 1379
80 176 1472
1700 90 194 1569
±3.0°C
100 212 1670
1500 110 230 1774
120 248 1882
±2.0°C
130 266 1993
1300
140 284 2107
150 302 2225
1100 183 361 2628
±1.6°C
900
700 LOW PT
±3.0°C
500 SUMP TEMPERATURE IN °F

4 32 68 104 140 176 212 248 284 320 356
-60 -40 --20 0 20 40 60 80 100 120 140 160 180

SUMP TEMPERATURE IN °C V01602.02
Figure 5–14. Temperature Sensor Chart (Units Built Prior To 1/98)

MODULE REBUILD
4. Thread the J 42048 spring compressor tool d. Disassembly of P3 Planetary
into the accumulator port as far as it will go Carrier Assembly
and still allow the handle to be aligned with
plug 48. Compress plug 48 to relieve the 1. Remove retaining ring 15 and spacer 14. Re-
spring load on retaining ring 49. Remove remove output shaft assembly 7. Inspect bushing
taining ring 49. Carefully release the spring 8 inside the end of output shaft 9 for wear or
load by turning the tool handle counterclock- damage. Measure the ID of the output shaft
wise. Remove the J 42048 tool, retaining bushing. Maximum ID allowed is 20.19 mm
ring 49, plug 48, O-ring 47, spring 46, re- (0.795 inch).
tarder valve 45, and pin 44.
5. If not previously removed, remove output 2. If replacement is necessary, remove bearing as-
seal 55, using seal removal tool J 24171-A. sembly 13.
6. Flatten the tang of locknut retainer 53 to allow 3. Check pinion end play. Pinion end play should
rotation and removal of bearing retainer nut 54. not exceed 0.94 mm (0.037 inch). Repeat the
Remove bearing retainer (spanner) nut 54 us- check on the three remaining pinion gears.
ing special tool J 35925. Remove locknut re-
tainer 53.
NOTE:
7. Support retarder housing 51 so that P3 The spindles and pinions do not need to be removed
planetary carrier assembly 6 can be removed before removing output shaft assembly 7.
from the retarder housing. Place special tool
J 35925-1 against the threaded shoulder of the
P3 planetary carrier. Drive on J 35925-1 with a 4. Remove retaining ring 10. Remove indexing
hydraulic press or a mallet until the P3 ring 11. Remove four pinion spindles 16. In-
planetary carrier is separated from the retarder spect indexing ring 11 for abnormal wear
housing. where the spindles 16 contact (Figure 5–11). If
abnormal wear is present, the planetary spindle
16 probably has a sharp edge instead of a ra-
NOTE: dius edge (Figure 5–12).
Perform Steps 8 and 11 only if roller bearing 52 and
cup 50 need to be replaced.
NOTE:
Planetary spindles on transmission S/Ns from
8. Remove roller bearing 52 from the retarder 6510063169–6510114718 have sharp edges (Figure
housing. 5–12). If index ring 11 is worn and the spindles have
a sharp edge and fall within the S/N range above, re-
9. Remove two bolts 57 and bolt 56 to allow
place the spindles.
removal of retarder stator assembly 21 from
retarder housing 51. Remove gasket 32 which
seals between stator 28 and the retarder housing.
CAUTION:
10. Remove rotor 33 and sealrings 31 and 34. In-
sert hook-type sealrings 31 and 34 into their Be sure that the planetary spindles cannot rotate
mating bores and measure the ID of each seal- after the indexing ring has been installed or lube
ring. Replace the sealrings if the ID exceeds flow to the pinion bearings may be blocked. When
95.67 mm (3.767 inch). the indexing ring slots are worn on one corner
(Figure 5–11), flip the plate over to obtain a new
11. Remove bearing cup 50 using bearing tool unworn contact surface. If both contact areas are
J 3940. worn, replace the indexing ring.

5. Slide pinion gear 18, thrust washers 17 and 20, 2. If removed, install bearing cup 27 using bear-
and two bearings 19 from the side of P3 plane- ing tool J 35922-3.
tary carrier 12. Repeat the procedure with three
remaining pinion gears. 3. Install inner sealring 26 onto C5 clutch piston 24.
6. Measure the thickness of eight thrust washers 4. Install outer sealring 25 onto C5 clutch piston
17 and 20. Minimum thickness permitted is 24. Lube sealrings on the piston and seal bore
1.39 mm (0.054 inch). areas in the retarder stator.
e. Disassembly of Retarder Stator Assembly

NOTE:
1. Remove O-ring 30 from stator assembly 21.
Align the tang on the back of the C5 clutch piston
with the notch for the piston tang in the retarder
WARNING! stator before installing C5 clutch piston 24 into re-
Piston springs are highly compressed. Be ex- tarder stator 28.
tremely careful during removal and installation.
Personal injury can occur if the spring force is
not controlled. 5. Install C5 clutch piston 24 into retarder
stator 28.
2. Compress retainer and spring assembly 23 us-
ing piston spring compressor J 35923-2. Re- WARNING!
move retaining ring 22 and slowly release the
spring tension. Remove C5 clutch piston 24 Piston springs are highly compressed. Be ex-
tremely careful during installation. Personal in-
from retarder stator 28.
jury can occur if the spring force is not
3. Remove outer sealring 25 from C5 clutch pis- controlled.
ton 24.
4. Remove inner sealring 26 from C5 clutch pis- CAUTION:
ton 24.
Use care when compressing spring assembly not
to allow the assembly to catch in the retaining
NOTE: ring groove.
Perform Step (5) only if roller bearing 13 and cup
27 need to be replaced.
6. Align the tab on spring retainer 23 with the
notch in stator housing 28. Compress retainer
5. Remove bearing cup 27 using bearing tool and spring assembly 23 using piston spring
J 3940. compressor J 35923-2. Install retaining ring 22
so that the ends clear the tab in the spring re-
CAUTION: tainer and slowly release the spring force. Re-
Use care not to damage the stator housing when move the compressor tool.
removing the check ball and retainer assembly.
7. Install O-ring seal 30 on retarder stator 28.
6. Inspect each check ball and retainer g. Assembly of P3 Planetary Carrier Assembly
assembly 29 for proper movement. The balls
should move a minimum of 0.50 mm 1. If removed, install bearing assembly 13.
(0.020 inch) in their respective retainer seats. If
ball movement is less than the specified 2. If removed, install bushing 8 inside the end of
amount, use a 1⁄4-20 UNF tap to remove the output shaft 9 using installer J 35922-1, drive
check ball and retainer assembly. handle J 8092, and a press.
f. Assembly of Retarder Stator (Foldout 13,A) 3. If removed, install output shaft assembly 7 into
P3 planetary carrier 12.
1. If removed, install check ball and retainer as-
semblies 29. 4. Install spacer 14 and retaining ring 15.

MODULE REBUILD
5. Install two bearings 19 into the center of pinion 6. Install and tighten bearing retainer nut 54 using
gear 18. Install thrust washers 17 and 20 in P3 special tools J 35925-1 and J35925-2. Place
planetary carrier 12. Align thrust washer tangs the torque wrench and a breaker bar as shown
with the slots in the carrier and retain them in Figure 5–15. Rotate the torque wrench in the
with oil-soluble grease. Slide the pinion gear counterclockwise direction and tighten the nut
and bearing sets into the side of the P3 plane- to 145–155 N·m (107–114 lb ft). If the retarder
tary carrier between the thrust washers. Repeat module is installed on a transmission, see Sec-
the procedure with the three remaining pinion tion 6 assembly instructions for correct torque
gears. specifications.
6. Install four pinion spindles 16 so the lower step
is positioned for proper installation of indexing NOTE:
ring 11.
• For units prior to S/N 6510064183, do Step (7),
7. Install indexing ring 11. Install retaining skip Steps (8–11), and go to Step (12).
ring 10.
8. If components were replaced, check pinion end Step (7) and go to Step (8).
play. Pinion end play should not exceed
0.942 mm (0.037 inch). Check all four pinion
7. Support retarder housing 51 so that turning
gears.
torque of P3 carrier assembly 6 can be checked
h. Assembly of Retarder Housing Assembly after installation of bearing retainer nut 54
(Figure 5–16). Maximum allowable drag is
1. Place P3 carrier assembly 6 on the work table 3 N·m (26 lb in.).
(output shaft up) and place stator assembly 21
over the output shaft.
NOTE:
2. Install sealrings 30 and 33 onto rotor 32. Install
the rotor assembly over the output shaft. Delay bending the retainer tangs on the retainer nut
and the installing of output oil seal 55 until final as-
3. Install gasket 31 between stator assembly 21 sembly of the transmission.
and retarder housing 51. Place the retarder
housing over the output shaft and align the
holes of the housing with the holes of the stator
assembly. Install two bolts 57. Tighten the NOTE:
bolts to 51–61 N·m (38–45 lb ft). Effective S/N 6510021203, a different valve plug is
4. Install roller bearing 52 using installer used which does not require a signal valve. The later
J 35921-1 and press into retarder housing 51 valve plug is not interchangeable with the earlier
while rotating the retarder housing. housing. Refer to SIL 31-WT-94.
5. Install locknut retainer 53.

8. For MD Product Line transmissions prior to
S/N 6510021203, install O-ring 43, signal
CAUTION: valve 42, plug 41, and retaining ring 40. For
Over-tightening bearing retainer nut 54 will transmissions after S/N 6510021203, install
damage bearing rollers and cone 13 and 52. If the valve plug 41 and retaining ring 40.
torque wrench and breaker bar positions in Fig-
ure 5–15 are reversed, the output spanner nut 9. Install pin 44 into retarder valve 45 and insert
will be overtorqued. Be sure wrenches are posi- into the valve bore. Install spring 46, O-ring
tioned ONLY as shown in Figure 5–15. 47, plug 48, and retaining ring 49.

SPANNER TOOL SPANNER TOOL

J 35925-1 (MD/B300, B400) J 35925-2 (MD/B300, B400)
BREAKER TORQUE WRENCH

BAR TOOL
COUNTER-
STATIONARY CLOCKWISE
FORCE ROTATION
TOP VIEW
V04620.01
Figure 5–15. Tightening Output Spanner Nut
uncompressed until tool J 42048 is used to

safely compress it.
12. Align tool J 42048 with the retarder valve bore

and rotate the tool handle clockwise to contact
J 35925 the center of plug 48. Continue turning the tool
handle clockwise to compress spring 46 until
plug 48 is below the groove for retaining ring
49. Install retaining ring 49.
13. Turn the tool handle counterclockwise to allow

plug 48 to contact retaining ring 49 and to al-
V00222
low removal of the tool. Remove the J 42048
Figure 5–16. P3 Carrier Turning Torque compressor tool from the accumulator bore by
Check — Retarder Equipped Models rotating it counterclockwise.
14. Be sure O-ring 37 is in place and install output

NOTE: speed sensor assembly 36. Hold bracket 38 in
Effective S/N 6510044372, a different retarder valve place and install retaining bolt 39. Tighten the
spring, separator plate, retarder housing, stator, bolt to 24–29 N·m (18–21 lb ft).
and rotor are used. The later parts are not inter-
changeable with the earlier parts. If the parts are i. Installation of Wiring Harness Assembly
interchanged, retarder capacity will be affected.
Refer to SIL 28-WT-94, Rev. A. 1. If temperature sensor 68 and/or wiring harness
assembly 60 were repaired or replaced, care-
10. Thread the J 42048 spring compressor tool into fully install the temperature sensor assembly
the accumulator port as far as it will go and into the retarder housing. Install a new
still allow the handle to be aligned with the re- O-ring 69 on the temperature sensor. Install the
tarder valve bore. Rotate the tool counterclock- nut retaining the harness connector to the re-
wise to provide clear access to the retarder tarder housing. Tighten the nut to 10–13 N·m
valve bore. (7–10 lb ft).
11. Install pin 44 into retarder valve 45 and insert 2. Install temperature sensor retainer 58 and
into the valve bore. Install spring 46, O-ring retainer bolt 59. Tighten bolt to 24–29 N·m
47, and plug 48. Spring 46 must remain (18–21 lb ft).

MODULE REBUILD
j. Assembly and Installation of Retarder
Control Body Assembly NOTE:
Proceed to Paragraph 5–16, Control Valve Module to
1. Install retarder control valve 94, spring 92, continue module rebuild.
valve plug 89, O-ring 91, and retaining ring 90
into retarder control body 88. k. Disassembly of Retarder Valve Body (Units
Built Starting 1/98) (Foldout 13,B)
2. Install O-ring 87 and pressure tap plug 86.
Tighten plug to 10–13 N·m (7–10 lb ft). 1. Remove three bolts 91 and six bolts 92 that re-
tain retarder control body assembly 67 to re-
3. If solenoid wiring harness 80 was repaired or tarder housing assembly 35 and remove con-
replaced, install the nut retaining the harness trol body assembly 67.
connector to solenoid cover 81. Tighten the nut
to 2.8–3.4 N·m (25–30 lb in.). 2. Remove separator plate gasket 64, solenoid
separator plate 65, and separator plate
4. If replaced, connect solenoid 82 to harness 80. gasket 66.
3. Remove plug 82, O-ring 83, valve 84, and

5. Lube O-rings and install gasket 95 and spring 85.
solenoid 82 into solenoid mounting bore of the
retarder control body 88. 4. Remove plug 80, O-ring 79, spring 78, and
valve 77.
CAUTION:
When inserting solenoid retaining pin 93, be cer- 5. Remove spring clip 90. Move connector 69
tain it is installed into the off-center hole in the partially out of the bore to allow space for sole-
solenoid bore. Installing the pin in the bore cen- noid removal.
terline hole will destroy the solenoid.
6. Remove retaining pin 81 from retarder control
body 86. Carefully rotate and wiggle
6. Install, smooth end first, solenoid retaining solenoid 74 while exerting force toward con-
pin 93 into retarder control body 88. nector 69. Remove solenoid 74 and O-rings 75
and 76.
7. Install solenoid cover 81 and four bolts 79.
Tighten bolts to 24–29 N·m (18–21 lb ft). 7. Disconnect connector assembly 71 from sole-
noid 74. Remove wiring harness 68 from con-
8. Install two guide pins into the retarder control trol body 86. For repair or replacement of
body mounting flange bolt holes on retarder terminals 73 or connector 72, see TS2973EN,
housing assembly 35. WTEC III Troubleshooting Manual.
9. Install gasket 76, channel plate 75, gasket 74, 8. Check the resistance of retarder solenoid 74.
solenoid separator plate 73, and gasket 72. Resistance must be within the range shown on
Figure 5–13.
10. Install wiring harness cover 70 and four bolts 71. 9. Remove pressure tap plug 89 and O-ring 88
Tighten bolts to 24–29 N·m (18–21 lb ft). from retarder control body 86.
11. Install retarder control body assembly 78 and l. Disassembly of Retarder Housing
nine bolts 77 that retain it to retarder housing
assembly 35. Tighten bolts to 24–29 N·m 1. If not already removed, remove output speed
(18–21 lb ft). sensor bolt 43, bracket 42, output speed sensor

assembly 40, and O-ring 41 from the retarder ring 57. Carefully release the spring load by
housing. Output speed sensor resistance should turning the tool handle counterclockwise. Re-
be 300 ± 30 Ohms. move the J 42048 tool, retaining ring 58,
plug 57, O-ring 56, spring 55, retarder valve
2. If not already removed, remove temperature
54, and pin 53.
sensor bolt 39, bracket 38, temperature sensor
assembly 36, and O-ring 37 from the retarder 7. If not previously removed, remove output seal
housing. Check the resistance of the tempera- 63, using seal removal tool J 24171-A.
ture sensor and replace the sensor if it is defec-
tive (Figure 5–17). 8. Flatten the tang(s) of locknut retainer 61 (Fold-
3. Remove plug 48, O-ring 49, plug 50, and out 13,A) to allow rotation and removal of
washer 51 from retarder housing 52. bearing retainer nut 62. Remove bearing re-
tainer (spanner) nut 62 using special tool
4. Remove retaining ring 49, plug 48, O-ring 47, J 35925. Remove locknut retainer 61.
spring 46, retarder valve 45, and pin 44.
9. Support retarder housing 52 so that P3
5. Remove retaining ring 44 and flow valve
planetary carrier assembly 6 can be removed
plug 45.
from the retarder housing. Place special tool
6. Thread the J 42048 spring compressor tool into J 35925-1 against the threaded shoulder of the
the accumulator port as far as it will go and P3 planetary carrier. Drive on J 35925-1 with a
still allow the handle to be aligned with hydraulic press or a mallet until the P3
plug 57. Compress plug 57 to relieve the spring planetary carrier is separated from the retarder
load on retaining ring 58. Remove retaining housing.
RESISTANCE-TEMPERATURE
CHARACTERISTIC CHART
1,000,000
100,000
SENSOR RESISTANCE (‰)
10,000
1,000
100
10
1
— 40 14 68 122 176 230 284 338 392 ¡F
— 40 —10 20 50 80 110 140 170 200 ¡C

TEMPERATURE
V04641
Figure 5–17. Retarder Temperature Sensor Resistance vs. Temperature (Units Built Starting 1/98)

MODULE REBUILD
6. Measure the thickness of all thrust washers 17
NOTE: and 20. Minimum thickness permitted is
Perform Steps (10) and (13) only if roller bearing 60 1.39 mm (0.054 inch).
and cup 46 need to be replaced.
n. Disassembly of Retarder Stator Assembly
10. Remove roller bearing 60 from the retarder 1. Remove O-ring 29 from stator assembly 21.
housing.
WARNING!
11. Remove two bolts 34 and bolt 59 to allow re-
moval of retarder stator assembly 21 from re- Piston springs are highly compressed. Be ex-
tarder housing 52. Remove gasket 31 which
Personal injury can occur if the spring force is
seals between stator 28 and the retarder hous- not controlled.
ing.
12. Remove rotor 32 and sealrings 30 and 33. In- 2. Compress retainer and spring assembly 23 us-
sert hook-type sealrings 30 and 33 into their ing piston spring compressor J 35923-2. Re-
mating bores and measure the ID of each seal- move retaining ring 22 and slowly release the
ring. Replace the sealrings if the ID exceeds spring tension. Remove C5 clutch piston 24
95.67 mm (3.767 inch). from retarder stator 28.
13. Remove bearing cup 46 using bearing tool 3. Remove outer sealring 25 from C5 clutch pis-
J 3940. ton 24.
m. Disassembly of P3 Planetary 4. Remove inner sealring 26 from C5 clutch pis-
Carrier Assembly ton 24.
1. Remove retaining ring 15 and spacer 14. Re-
move output shaft assembly 7. Inspect NOTE:
bushing 8 inside the end of output shaft 9 for Perform Step (5) only if roller bearing 13 and cup
wear or damage. Measure the ID of the output 27 need to be replaced.
shaft bushing. Maximum ID allowed is
20.19 mm (0.795 inch).
5. Remove bearing cup 27 using bearing tool
2. If replacement is necessary, remove bearing as- J 3940.
sembly 13. o. Assembly of Retarder Stator (Foldout 13,B)
3. Check pinion end play. Pinion end play should 1. If removed, install bearing cup 27 using bear-
not exceed 0.94 mm (0.037 inch). Repeat the ing tool J 35922-3.
check on the three remaining pinion gears.
2. Install inner sealring 26 onto C5 clutch
piston 24.
NOTE:
The spindles and pinions do not need to be removed 3. Install outer sealring 25 onto C5 clutch
before removing output shaft assembly 7. piston 24. Lube sealrings on the piston and
seal bore areas in the retarder stator.
4. Remove retaining ring 10. Remove indexing

NOTE:
ring 11. Remove four pinion spindles 16.
Align the tang on the back of the C5 clutch piston
5. Slide pinion gear 18, thrust washers 17 and 20, with the notch for the piston tang in the retarder
and two bearings 19 from the side of P3 plane- stator before installing C5 clutch piston 24 into re-
tary carrier 12. Repeat the procedure with three tarder stator 28.
remaining pinion gears.

4. Install C5 clutch piston 24 into retarder 8. If components were replaced, check pinion end
stator 28. play. Pinion end play should not exceed
WARNING! gears.
Piston springs are highly compressed. Be ex- q. Assembly of Retarder Housing Assembly
jury can occur if the spring force is not 1. If removed, install bearing cup 46 using bear-
controlled. ing tool J 35922-3.
2. Place P3 carrier assembly 6 on the work table

CAUTION: (output shaft up) and place stator assembly 21
Use care when compressing spring assembly not over the output shaft.
to allow the assembly to catch in the retaining
ring groove. 3. Install sealrings 30 and 33 onto rotor 32. Install
the rotor assembly over the output shaft.
5. Align the tab on spring retainer 23 with the 4. Install gasket 31 between stator assembly 21
notch in stator housing 28. Compress retainer and retarder housing 52. Place the retarder
and spring assembly 23 using piston spring housing over the output shaft and align the
compressor J 35923-2. Install retaining ring 22 holes of the housing with the holes of the stator
so that the ends clear the tab in the spring reassembly. Install two bolts 34 and bolt 59.
tainer and slowly release the spring force. Re- Tighten the bolts to 51–61 N·m (38–45 lb ft).
move the compressor tool. 5. Install roller bearing 60 using installer
J 35921-1 and press into retarder housing 52
6. Install O-ring seal 29 on retarder stator 28. while rotating the retarder housing.
p. Assembly of P3 Planetary Carrier Assembly 6. Install locknut retainer 61.
1. If removed, install bearing assembly 13. CAUTION:

2. If removed, install bushing 8 inside the end of Over-tightening bearing retainer nut 62 will
damage bearing rollers and cone 13 and 60. If the
output shaft 9 using installer J 35922-1, drive
torque wrench and breaker bar positions in Fig-
handle J 8092, and a press. ure 5–15 are reversed, the output spanner nut
3. If removed, install output shaft assembly 7 into will be overtorqued. Be sure wrenches are posi-
tioned ONLY as shown in Figure 5–15.
4. Install spacer 14 and retaining ring 15. 7. Install and tighten bearing retainer nut 62 using
special tools J 35925-1 and J35925-2. Place
5. Install two bearings 19 into the center of pinion the torque wrench and a breaker bar as shown
gear 18. Install thrust washers 17 and 20 in P3 in Figure 5–15. Rotate the torque wrench in the
planetary carrier 12. Align thrust washer tangs counterclockwise direction and tighten the nut
with the slots in the carrier, and retain with them to 145–155 N·m (107–114 lb ft). If the retarder
oil-soluble grease. Slide the pinion gear and module is installed on a transmission, see Sec-
bearing sets into the side of the P3 planetary car- tion 6 assembly instructions for correct torque
rier between the thrust washers. Repeat the pro- specifications. If retarder module is installed
cedure with the three remaining pinion gears. onto transmission, see Section 6 assembly in-
structions for correct torque specifications.
is positioned for proper installation of indexing 8. Support retarder housing 52 so that turning
ring 11. torque of P3 carrier assembly 6 can be checked
after installation of bearing retainer nut 62
7. Install indexing ring 11. Install retaining (Figure 5–15). Maximum allowable drag is
ring 10. 3 N·m (26 lb in.).

MODULE REBUILD
(Foldout 13,C). Tighten bolts to 24–29 N•m
NOTE: (18–21 lb ft).
Delay bending the retainer tangs on the retainer nut
and the installing of output oil seal 63 until final as- 19. For units starting with S/N 6510262246, install
sembly of the transmission. jumper manifold gasket 94 and jumper
manifold 95 or remote manifold 97 and four
bolts 96 (Foldout 13,C). Tighten bolts to 51–61
9. Install flow valve plug 45 and retaining ring 44. N•m (38–45 lb ft).
10. Thread the J 42048 spring compressor tool into
the accumulator port as far as it will go and r. Assembly and Installation of Retarder
still allow the handle to be aligned with the re- Control Body Assembly
tarder valve bore. Rotate the tool counterclock-
wise to provide clear access to the retarder 1. Install and lube O-ring 70 on connector 69.
valve bore. Thread connector assembly 71, attached to
connector 69, through the bore at the top of
11. Install pin 53 into retarder valve 54 and insert valve body 86 and partially insert
into the valve bore. Install spring 55, O-ring connector 69, leaving room to install
56, and plug 57. Spring 55 must remain un- solenoid 74.
compressed until tool J 42048 is used to safely
compress it. 2. Install and lube O-rings 75 and 76 on
12. Align tool J 42048 with the retarder valve bore solenoid 74. Connect connector assembly 72 to
and rotate the tool handle clockwise to contact solenoid 74. Place solenoid 74 into position in
the center of plug 57. Continue turning the tool the valve bore just below connector 69. Rotate
handle clockwise to compress spring 55 until and wiggle the solenoid while pushing down to
plug 57 is below the groove for retaining ring seat the O-rings in their bores and to align the
58. Install retaining ring 58. solenoid groove with the hole for retaining
pin 81.
13. Turn the tool handle counterclockwise to allow
plug 57 to contact retaining ring 58 and to al- 3. Install retaining pin 81. Rotate the solenoid to
low removal of the tool. Remove the J 42048 be below the valve body mounting face. Be
compressor tool from the accumulator bore by sure the wires connecting to the solenoid are
rotating it counterclockwise. also below the valve body mounting face to
prevent damage during installation of the body.
speed sensor assembly 40. Hold bracket 42 in 4. Push connector 69 completely into the bore
place and install retaining bolt 39. Tighten the and install spring clip 90.
bolt to 24–29 N·m (18–21 lb ft).
15. If temperature sensor assembly 36 was re- 5. Install O-ring seal 88 and pressure tap plug 89.
placed, install a new O-ring 37 on the tempera- Tighten plug to 10–13 N·m (7–10 lb ft).
ture sensor and install the temperature sensor
assembly into the retarder housing. CAUTION:
16. Install temperature sensor bracket 38 and re- When inserting solenoid retaining pin 81, be cer-
tainer bolt 39. Tighten bolt to 24–29 N·m tain it is installed into the off-center hole in the
(18–21 lb ft). solenoid bore. Installing the pin in the bore cen-
terline hole will destroy the solenoid.
17. Install plug 48, O-ring 49, plug 50, and
washer 51. Tighten plug 48 to 60–67 N·m
(44–49 lb ft). Tighten plug 50 to 60–67 N·m 6. Install valve 77, spring 78, lubed O-ring 79, and
(44–49 lb ft). plug 80. Tighten plug to 24–29 N·m (18–21 lb ft).
18. For units starting with S/N 6510262246, install 7. Install spring 85, valve 84, lubed O-ring 83, and
gasket 51, cover 52, and nine bolts 53 plug 82. Tighten plug to 24–29 N·m (18–21 lb ft).

8. Install two guide pins into the retarder control 8. Check the resistance of retarder solenoid 74.
body mounting flange bolt holes on retarder Resistance must be within the range shown on
housing assembly 35. Figure 5–13.
9. Install gasket 64, solenoid separator plate 65, 9. Remove pressure tap plug 89 and O-ring 88
and gasket 66. from retarder control body 86.
10. Install retarder control body assembly 67, three t. Disassembly of Retarder Housing
bolts 91 and six bolts 92 that retain it to re-
tarder housing assembly 35. Tighten bolts to 1. Remove fours bolts 96 retaining either jumper
24–29 N·m (18–21 lb ft). manifold 95 or remote manifold 97 to retarder
housing 50.
s. Disassembly of Retarder Valve Body (Units
Built Starting with S/N 6510262246) 2. Remove either jumper manifold 95 or remote
(Foldout 13,C) manifold 97 and gasket 94.
NOTE: 3. If not already removed, remove output speed

sensor bolt 43, bracket 42, output speed sensor
Units before S/N 6510262246 contained two separa-
assembly 40, and O-ring 41 from the retarder
tor plate gaskets 64 and 66.
housing. Output speed sensor resistance should
be 300 ± 30 Ohms.
CAUTION: 4. If not already removed, remove temperature
Separator plate 65 and, if present, gaskets 64 and sensor bolt 39, bracket 38, temperature sensor
66 are not retained after removing bolts 91 and assembly 36, and O-ring 37 from the retarder
92. Avoid damaging the separator plate and gas- housing. Check the resistance of the tempera-
kets. ture sensor and replace the sensor if it is defec-
tive (Figure 5–18).
1. Remove three bolts 91 and six bolts 92 that re-
tain retarder control body assembly 67 to re- 5. Remove nine bolts 53, cover 52, and gasket 51
tarder housing 50 and remove control body as- from the bottom of retarder housing 50.
sembly 67.
6. Remove plug 48, O-ring 49 from retarder
2. Remove separator plate 65 and, if present, sep- housing 50.
arator plate gaskets 64 and 66. 7. Remove retaining ring 44 and flow valve
3. Remove plug 82, O-ring 83, valve 84, and plug 45.
spring 85. 8. Thread the J 42048 spring compressor tool into
4. Remove plug 80, O-ring 79, spring 78, and the accumulator port as far as it will go and
valve 77. still allow the handle to be aligned with
plug 58. Compress plug 58 to relieve the spring
5. Remove spring clip 90. Move connector 69
load on retaining ring 59. Remove retaining
partially out of the bore to allow space for sole-
ring 59. Carefully release the spring load by
noid removal.
turning the tool handle counterclockwise. Re-
6. Remove retaining pin 81 from retarder control move the J 42048 tool, plug 58, O-ring 57,
body 86. Carefully rotate and wiggle spring 56, retarder valve 55, and pin 54.
solenoid 74 while exerting force toward con-
nector 69. Remove solenoid 74 and O-rings 75 9. If not previously removed, remove output seal
and 76. 63, using seal removal tool J 24171-A.
7. Disconnect connector assembly 71 from sole- 10. Flatten the tang(s) of locknut retainer 61 to al-
noid 74. Remove wiring harness 68 from con- low rotation and removal of bearing retainer
trol body 86. For repair or replacement of nut 62. Remove bearing retainer (spanner) nut
terminals 73 or connector 72, see TS2973EN, 62 using special tool J 35925. Remove locknut
WTEC III Troubleshooting Manual. retainer 61.

MODULE REBUILD
RESISTANCE-TEMPERATURE
CHARACTERISTIC CHART
1,000,000
100,000
SENSOR RESISTANCE (‰) 10,000
1,000
100
10
1
— 40 14 68 122 176 230 284 338 392 ¡F
— 40 —10 20 50 80 110 140 170 200 ¡C

TEMPERATURE
V04641
Figure 5–18. Retarder Temperature Sensor Resistance vs. Temperature
11. Support retarder housing 50 so that P3 14. Remove rotor 32 and sealrings 30 and 33. In-
planetary carrier assembly 6 can be removed sert hook-type sealrings 30 and 33 into their
from the retarder housing. Place special tool mating bores and measure the ID of each seal-
J 35925-1 against the threaded shoulder of the ring. Replace the sealrings if the ID exceeds
P3 planetary carrier. Drive on J 35925-1 with a 95.67 mm (3.767 inch).
hydraulic press or a mallet until the P3
planetary carrier is separated from the retarder 15. Remove bearing cup 46 using bearing tool
housing. J 3940.
u. Disassembly of P3 Planetary
NOTE:
Carrier Assembly
Perform Steps (12) and (15) only if roller bearing 60
and cup 46 need to be replaced. 1. Remove retaining ring 15 and spacer 14. Re-
move output shaft assembly 7. Inspect
bushing 8 inside the end of output shaft 9 for
12. Remove roller bearing 60 from the retarder
wear or damage. Measure the ID of the output
housing.
shaft bushing. Maximum ID allowed is
13. Remove three bolts 34 to allow removal of re- 20.19 mm (0.795 inch).
tarder stator assembly 21 from retarder hous-
ing 52. Remove gasket 31 which seals between 2. If replacement is necessary, remove bearing as-
stator 28 and the retarder housing. sembly 13.

3. Check pinion end play. Pinion end play should w. Assembly of Retarder Stator (Foldout 13,B)
not exceed 0.94 mm (0.037 inch). Repeat the
check on the three remaining pinion gears. 1. If removed, install bearing cup 27 using bear-
ing tool J 35922-3.
NOTE: 2. Install inner sealring 26 onto C5 clutch

The spindles and pinions do not need to be removed piston 24.
before removing output shaft assembly 7. 3. Install outer sealring 25 onto C5 clutch
piston 24. Lube sealrings on the piston and
4. Remove retaining ring 10. Remove indexing seal bore areas in the retarder stator.
ring 11. Remove four pinion spindles 16.
NOTE:
5. Slide pinion gear 18, thrust washers 17 and 20,
and two bearings 19 from the side of P3 plane- Align the tang on the back of the C5 clutch piston
tary carrier 12. Repeat the procedure with three with the notch for the piston tang in the retarder
remaining pinion gears. stator before installing C5 clutch piston 24 into re-
tarder stator 28.
6. Measure the thickness of all thrust washers 17
and 20. Minimum thickness permitted is
4. Install C5 clutch piston 24 into retarder
1.39 mm (0.054 inch).
stator 28.
v. Disassembly of Retarder Stator Assembly
WARNING!
1. Remove O-ring 29 from stator assembly 21.
Piston springs are highly compressed. Be ex-
WARNING! jury can occur if the spring force is not controlled.
Personal injury can occur if the spring force is not CAUTION:
controlled. Use care when compressing spring assembly not
to allow the assembly to catch in the retaining ring
2. Compress retainer and spring assembly 23 us- groove.
ing piston spring compressor J 35923-2. Re-
move retaining ring 22 and slowly release the 5. Align the tab on spring assembly 23 with the
spring tension. Remove C5 clutch piston 24 notch in stator housing 28. Compress retainer
from retarder stator 28. and spring assembly 23 using piston spring
compressor J 35923-2. Install retaining ring 22
3. Remove outer sealring 25 from C5 clutch pis- so that the ends clear the tab in the spring re-
ton 24. tainer and slowly release the spring force. Re-
4. Remove inner sealring 26 from C5 clutch pis- move the compressor tool.
ton 24.
6. Install O-ring seal 29 on retarder stator 28.
NOTE: x. Assembly of P3 Planetary Carrier Assembly

Perform Step (5) only if roller bearing 13 and cup 1. If removed, install bearing assembly 13.
27 need to be replaced.
2. If removed, install bushing 8 inside the end of
5. Remove bearing cup 27 using bearing tool output shaft 9 using installer J 35922-1, drive
J 3940. handle J 8092, and a press.

MODULE REBUILD
3. If removed, install output shaft assembly 7 into
P3 planetary carrier 12. CAUTION:
Over-tightening bearing retainer nut 62 will dam-
4. Install spacer 14 and retaining ring 15. age bearing rollers and cone 13 and 60. If the
torque wrench and breaker bar positions in Figure
5. Install two bearings 19 into the center of pinion 5–15 are reversed, the output spanner nut will be
gear 18. Install thrust washers 17 and 20 in P3 overtorqued. Be sure wrenches are positioned
ONLY as shown in Figure 5–15.
planetary carrier 12. Align thrust washer tangs
with the slots in the carrier, and retain them
7. Install and tighten bearing retainer nut 62 using
with oil-soluble grease. Slide the pinion gear
special tools J 35925-1 and J35925-2. Place
and bearing sets into the side of the P3 plane-
the torque wrench and a breaker bar as shown
tary carrier between the thrust washers. Repeat
in Figure 5–15. Rotate the torque wrench in a
the procedure with the three remaining pinion
counterclockwise direction and tighten the nut
gears.
to 145–155 N·m (107–114 lb ft). If the retarder
module is installed on a transmission, see Sec-
tion 6 assembly instructions for correct torque
is positioned for proper installation of indexing
specifications.
ring 11.
8. Support retarder housing 50 so that turning
7. Install indexing ring 11. Install retaining torque of P3 carrier assembly 6 can be checked
ring 10. after installation of bearing retainer nut 62
(Figure 5–15). Maximum allowable drag is
8. If components were replaced, check pinion end 3 N·m (26 lb in.).
play. Pinion end play should not exceed
gears. NOTE:
Delay bending the retainer tangs on the retainer nut
y. Assembly of Retarder Housing Assembly and the installing of output oil seal 63 until final as-
sembly of the transmission.
1. If removed, install bearing cup 46 using bear-
ing tool J 35922-3.
9. Install flow valve plug 45 and retaining ring 44.
2. Place P3 carrier assembly 6 on the work table 10. Thread the J 42048 spring compressor tool into
(output shaft up) and place stator assembly 21 the accumulator port as far as it will go and
over the output shaft. still allow the handle to be aligned with the re-
tarder valve bore. Rotate the tool counterclock-
3. Install sealrings 30 and 33 onto rotor 32. Install wise to provide clear access to the retarder
the rotor assembly over the output shaft. valve bore.
4. Install gasket 31 between stator assembly 21 11. Install pin 54 into retarder valve 55 and insert
and retarder housing 50. Place the retarder the valve into it’s bore. Install spring 56,
housing over the output shaft and align the O-ring 57, and plug 58. Spring 56 must remain
holes of the housing with the holes of the stator uncompressed until tool J 42048 is used to
assembly. Install three bolts 34. Tighten the safely compress it.
bolts to 51–61 N·m (38–45 lb ft).
12. Align tool J 42048 with the retarder valve bore
5. Install roller bearing 60 using installer and rotate the tool handle clockwise to contact
J 35921-1 and press into retarder housing 50 the center of plug 58. Continue turning the tool
while rotating the retarder housing. handle clockwise to compress spring 56 until
plug 58 is below the groove for retaining
6. Install locknut retainer 61. ring 59. Install retaining ring 59.

13. Turn the tool handle counterclockwise to allow 3. Install retaining pin 81. Rotate the solenoid to
plug 58 to contact retaining ring 59 and to al- be below the valve body mounting face. Be
low removal of the tool. Remove the J 42048 sure the wires connecting to the solenoid are
compressor tool from the accumulator bore by also below the valve body mounting face to
rotating it counterclockwise. prevent damage during installation of the body.
14. Be sure O-ring 41 is in place and install output 4. Push connector 69 completely into the bore
speed sensor assembly 40. Hold bracket 42 in and install spring clip 90.
place and install retaining bolt 39. Tighten the
bolt to 24–29 N·m (18–21 lb ft). 5. Install O-ring seal 88 and pressure tap plug 89.
Tighten plug to 10–13 N·m (7–10 lb ft).
15. If temperature sensor assembly 36 was re-
placed, install a new O-ring 37 on the tempera- 6. Install valve 77, spring 78, lubed O-ring 79, and
ture sensor and install the temperature sensor plug 80. Tighten plug to 24–29 N·m (18–21 lb ft).
assembly into the retarder housing.
7. Install spring 85, valve 84, lubed O-ring 83, and
16. Install temperature sensor bracket 38 and re- plug 82. Tighten plug to 24–29 N·m (18–21 lb ft).
tainer bolt 39. Tighten bolt to 24–29 N·m
8. Install gasket 64, solenoid separator plate 65,
(18–21 lb ft).
and gasket 66 on retarder control body 86.
17. Install plug 48, O-ring 49. Tighten plug 48 to
9. Install retarder control body assembly 67, three
60–67 N·m (44–49 lb ft).
bolts 91 and six bolts 92 that retain it to re-
18. Install gasket 51, cover 52, and nine bolts 53. tarder housing assembly 35. Tighten bolts to
Tighten bolts to 24–29 N•m (18–21 lb ft). 24–29 N·m (18–21 lb ft).
19. Install jumper manifold gasket 94 and jumper
5–13. REAR COVER MODULE
manifold 95 or remote manifold 97 and four bolts
96. Tighten bolts to 51–61 N•m (38–45 lb ft).
a. Disassembly (Foldout 13,D)
z. Assembly and Installation of Retarder
Control Body Assembly 1. If not previously removed, remove retaining
bolt 32, bracket 31, output speed sensor assem-
1. Install and lube O-ring 70 on connector 69. bly 29, and O-ring 30. The output speed sensor
Thread connector assembly 71, attached to should have a resistance of 300 ± 30 Ohms.
connector 69, through the bore at the top of
valve body 86 and partially insert 2. If not previously removed, remove output
connector 69, leaving room to install seal 38 using seal removal tool J 24171-A. If
solenoid 74. present, remove plug 39 and washer 40.
2. Install and lube O-rings 75 and 76 on 3. Flatten the tang of locknut retainer 36 to allow
solenoid 74. Connect connector assembly 71 to rotation and removal of bearing retainer nut 37.
solenoid 74. Place solenoid 74 into position in 4. Remove bearing retainer (spanner) nut 37 us-
the valve bore just below connector 69. Rotate ing special tool J 35925.
and wiggle the solenoid while pushing down to
seat the O-rings in their bores and to align the 5. Remove locknut retainer 36.
solenoid groove with the hole for retaining
pin 81. 6. Place blocks under rear cover 28 or 41 so that
the P3 carrier assembly is above the work sur-
face far enough to allow disassembly from the
CAUTION: rear cover. Place special tool J 35925-1 against
When inserting solenoid retaining pin 81, be the threaded shoulder of the P3 carrier assem-
certain it is installed into the off-center hole in bly. Drive on special tool J 35925-1 with a
the solenoid bore. Installing the pin in the bore press or a mallet until the P3 carrier assembly
centerline hole will destroy the solenoid. is separated from the rear cover.

MODULE REBUILD
7. Remove roller bearing 35 and output speed 6. Measure the thickness of thrust washers 17 and
signal wheel 33 from rear cover 28 or 41. 20. Minimum thickness allowed is 1.39 mm
(0.054 inch).
NOTE: 7. Remove retaining ring 15 and spacer 14.

Perform Step (8) only if replacing roller bearing 35
and cup 34. 8. If not done previously, remove output shaft as-
sembly 6.
8. Remove bearing cup 34 using bearing tool 9. Inspect bushing 7 inside the end of output
J 3940. shaft 8 for replacement. Measure the ID of the
output shaft bushing. Maximum allowable ID
b. Disassembly of the P3 Planetary is 20.19 mm (0.795 inch).
Carrier Assembly
c. Disassembly of the Rear Cover Assembly
1. If damaged, or if removing bearing
assembly 13, or if replacing output speed sig-
nal wheel 33, remove pin 11. WARNING!
2. If replacement is necessary, remove bearing tremely careful during removal. Personal injury
assembly 13. can occur if the spring force is not controlled.
3. Check pinion end play. Pinion end play should

1. Remove C5 clutch piston 24 from rear cover
not exceed 0.94 mm (0.037 inch). Check all
28 or 41 by compressing retainer and spring
pinion gears.
assembly 23 using piston spring compressor
J 35923-2. Remove retaining ring 22 with
NOTE: snapring pliers and slowly release the spring
force.
Spindles and pinions do not need to be removed to
remove output shaft assembly 6. 2. Remove outer sealring 25 from C5 clutch
piston 24.
3. Remove inner sealring 26 from C5 clutch
ring 10. Remove four pinion spindles 16. In-
piston 24.
spect indexing ring 10 for abnormal wear
where the spindles 16 contact (Figure 5–11). If
abnormal wear is present, the planetary NOTE:
spindle 16 probably has a sharp edge instead of
a radius edge (Figure 5–12). Perform Step (4) only if replacing roller bearing 13
and cup 27.
NOTE:
Planetary spindles on transmission S/Ns from 4. Remove bearing cup 27 using bearing tool
6510063169–6510114718 have sharp edges (Figure J 3940.
5–12). If index ring 10 is worn and the spindles have
d. Assembly of Rear Cover (Foldout 13,D)
a sharp edge and fall within the S/N range above,
replace the spindles. 1. Install bearing cup 27 using bearing tool
J 35922-1.
5. Slide pinion gear 18, thrust washers 17 and 20,
and two bearings 19, from the side of P3 plane- 2. Install inner sealring 26 onto C5 clutch
tary carrier 12. Repeat the procedure with three piston 24. Install outer sealring 25 onto C5
remaining pinion gears. clutch piston 24.

3. Install 10 mm (0.39 inch) roll pin 11 (P/N 11512348)
NOTE: to a height of 2.20–2.80 mm (0.087–0.110 inch)
Before installing C5 clutch piston 24 into rear above the carrier shaft.
cover 28 or 41, align the tab on the back of the C5
clutch piston with the notch for the piston tab in the 4. If removed, press bushing 7 inside the end of
rear cover. output shaft 8 using installer J 35922-1 and
drive handle J 8092.
3. Install C5 clutch piston 24 into rear cover 28
or 41. 5. If removed, install output shaft assembly 6 into
WARNING!
6. Install spacer 14 and retaining ring 15.
jury can occur if the spring force is not 7. Install two bearings 19 into the center of pinion
controlled. gear 18. Install thrust washers 17 and 20 in P3
planetary carrier 12. Align the thrust washer
tangs with the slot in the carrier and retain
CAUTION: them with oil-soluble grease. Slide the pinion
Use care when compressing spring assembly not gear and bearing sets into the side of the P3
to allow the assembly to catch in the retaining planetary carrier between the thrust washers.
ring groove. Repeat the procedure with the three remaining
pinion gears.
4. Align the tab on the spring retainer with the 8. Install four pinion spindles 16 so the lower step
notch in the rear cover. Compress retainer and is positioned for proper installation of indexing
spring assembly 23 using piston spring com- ring 10.
pressor J 35923-2. Install retaining ring 22 so
that the ends clear the tab in the spring retainer
and slowly release the spring force. CAUTION:
Be sure that the planetary spindles cannot rotate
e. Assembly of the P3 Planetary after the indexing ring has been installed or lube
Carrier Assembly flow to the pinion bearings may be blocked.
When the indexing ring slots are worn on one
1. If removed, install bearing assembly 13. corner (Figure 5–11), flip the plate over to obtain
a new unworn contact surface. If both contact ar-
eas are worn, replace the indexing ring.
NOTE:
• If later model output speed signal wheel
P/N 29510781 is to be installed, proceed with 9. Install indexing ring 10. Install retaining
Step (2). This P/N is located on the side of the ring 9.
wheel in recessed characters.
• If earlier model output speed signal wheel 10. If components were replaced, check pinion end
P/N 29506608 is to be installed, skip Step (2) play. Pinion end play should not exceed
and go to Step (3). This P/N wheel does not have 0.942 mm (0.037 inch). Check all four pinion
a P/N located on the part. gears.
11. Align the slot in output speed signal wheel 33

2. Install 12 mm (0.47 inch) roll pin 11 (P/N 11512350) with spring pin 11. Using installer J 35921-1
to a height of 2.35–2.95 mm (0.093–0.116 inch) and not exceeding 10 230 N (2300 lbs) of
above the carrier shaft. Skip Step (3) and pro- force, press output speed signal wheel 33 to
ceed to Step (4). full depth on P3 carrier assembly 5.

MODULE REBUILD
f. Completion of the Rear Cover Module counterclockwise direction and tighten the nut
to 290–340 N·m (214–251 lb ft).
1. If removed, install bearing cup 34 using bear-
ing tool J 35922-3.
7. Support rear cover 28 or 41 so that turning
2. Place P3 carrier assembly 5 on the work table torque of P3 carrier assembly 5 can be checked
(with the output shaft up) and place rear cover after installation of bearing retainer nut 37 (Fig-
28 or 41 over the output shaft. ure 5–19). Maximum allowable drag is 3 N·m
(26 lb in.). Recheck the torque on bearing re-
3. Using installer J 35921-1 and not exceeding tainer nut 37 (Step 5 or 6 above). If torque is
10 230 N (2300 lbs) of force, press roller bear- correct, recheck drag torque. If both torque val-
ing 35 into rear cover 28 or 41, while rotating ues meet specification, proceed to Step 8.
the cover assembly.
8. Bend up two or more tangs of locknut
4. Install locknut retainer 36.
retainer 36 to prevent bearing retainer nut 37
from backing off. If only one tang is aligned with
CAUTION: a spanner nut slot, continue to torque the spanner
Over-tightening bearing retainer nut 37 will nut (but do not exceed the tightening torque or
damage bearing rollers and cone 13 and 35. If the drag torque limits) until two or more tangs can
torque wrench and breaker bar positions in Fig- be bent up into slots on the spanner nut.
ure 5–15 are reversed, the output spanner nut
will be overtorqued. Be sure wrenches are posi-
tioned ONLY as shown in Figure 5–15. NOTE:
DO NOT reuse a tang once it has been bent. Replace
locknut retainer 36, if necessary.
NOTE:
• If later model output speed signal wheel 9. Install output shaft oil seal 38 using J 39928
P/N 29510781 was installed in Paragraph 5–13e(11), (models with non-drum parking brake) or
proceed with Step (5). Part number will be J 35921-4 (models with drum parking brake).
shown on side of wheel in recessed numbers.
• If earlier model output speed signal wheel speed sensor assembly 29. Hold bracket 31 in
P/N 29506608 was installed in Paragraph 5–13e(11), place and install retaining bolt 32. Tighten the
skip Step (5) and go to Step (6). Part number is bolt to 24–29 N·m (18–21 lb ft).
not shown on this part but there is a 3.0 mm x
0.8 mm raised identification feature on one end
near the gear teeth.
J 35925
5. Install and tighten bearing retainer nut 37 using

special tools J 35925-1 and J 35925-2. Place
the torque wrench and a breaker bar as shown
in Figure 5–15. Rotate the torque wrench in the
counterclockwise direction and tighten the nut
to 74–88 N·m (55–65 lb ft). Skip Step (6) and
proceed to Step (7).
6. Install and tighten bearing retainer nut 37 using V00223

special tools J 35925-1 and J 35925-2. Place
the torque wrench and a breaker bar as shown Figure 5–19. P3 Carrier Turning Torque Check —
in Figure 5–15. Rotate the torque wrench in the Models Without Retarder

11. When rear cover 41 is used, be sure to install 12. Check pinion end play. Pinion end play should
plug 39 and washer 40. Torque plug 39 to not exceed 0.94 mm (0.037 inch). Check all
60–67 N·m (44–50 lb ft). pinion gears.

5–14. ADAPTER HOUSING AND ring 3. Remove four pinion spindles 7. Inspect
indexing ring 3 for abnormal wear where the
P3 OVERHAUL spindles 7 contact (Figure 5–11). If abnormal
a. Disassembly (Foldout 18,B) wear is present, the planetary spindle 7 proba-
bly has a sharp edge instead of a radius edge
1. Place the adapter housing assembly on tool (Figure 5–12).
base J 35923-4 with output end down.
2. Install tool J 35923-2 along with its washer, NOTE:

bearing, and handle. Planetary spindles on transmission S/Ns from
6510063169–6510114718 have sharp edges (Figure
3. Thread the handle down to compress spring re- 5–12). If index ring 3 is worn and the spindles have
tainer assembly 16. a sharp edge and fall within the S/N range above,
replace the spindles.
4. Remove retaining ring 15.
5. Remove tool J 35923-2, followed by C5 spring 14. Slide pinion gear 9, thrust washers 8 and 11,
retainer assembly 16. and two bearings 10, from the side of P3 plane-
tary carrier 5. Repeat the procedure with three
CAUTION: remaining pinion gears.
Make sure that the spring retainer does not catch 15. Measure the thickness of thrust washers 8 and
in the retaining ring groove.
11. Minimum thickness allowed is 1.39 mm
(0.054 inch).
6. Using a soft face mallet, loosen C5 clutch pis-
ton 17. Remove C5 piston from adapter hous- 16. Inspect bushing 6 inside the end of carrier 5
ing 20. for replacement. Measure the ID of bushing 6.
Maximum allowable ID is 53.22 mm
7. Remove square cut outer sealring 18 and inside (2.095 inch). Remove bushing 6 if replace-
lip-type sealring 19 from the piston. ment is needed. Be careful not to damage the
carrier bore during bushing removal.
8. Inspect seal bore areas in the housing for nicks
and wear. b. Assembly (Foldout 18,B)
9. Remove plug 22 from the lower left side of the 1. If removed, press bushing 7 inside carrier 5,
housing. using installer J 38569 and drive handle
J 8092.
10. Remove O-ring 23 from the plug.
2. Install two bearings 10 into the center of pinion
11. Remove filter screen 24 from housing 20. This
gear 9. Install thrust washers 8 and 11 in P3
screen filters main sump fluid before it enters
planetary carrier 5. Align the thrust washer
the transfer case lube pump.
tangs with the slot in the carrier and retain
them with oil-soluble grease. Slide the pinion
NOTE: gear and bearing sets into the side of the P3
P3 carrier disassembly is covered in Steps (12) planetary carrier between the thrust washers.
through (16). Repeat the procedure with the three remaining
pinion gears.

MODULE REBUILD
3. Install four pinion spindles 7 so the lower step 5–15. TRANSFER CASE MODULE
is positioned for proper installation of indexing (Foldouts 14, 15, 16)
ring 3.
a. Disassembly of Transfer Case Module
CAUTION:
Be sure that the planetary spindles cannot rotate WARNING!
after the indexing ring has been installed or lube The transfer case module assembly weighs ap-
flow to the pinion bearings may be blocked. proximately 170 kg (595 lb). Use proper lifting
When the indexing ring slots are worn on one and handling equipment to prevent injury.
corner (Figure 5–11), flip the plate over to obtain
a new unworn contact surface. If both contact ar-
eas are worn, replace the indexing ring.
NOTE:
Refer to Foldout 15 for Steps (1) through (4).
4. Install indexing ring 3. Install retaining ring 2.
5. If components were replaced, check pinion end 1. If not previously done, install transfer case as-
play. Pinion end play should not exceed sembly 1 on the transmission overhaul stand.
0.942 mm (0.037 inch). Check all four pinion Position the transfer case so that the front out-
gears. put is upward. Begin the transfer case disas-
6. Install a new filter screen 24. Make sure the sembly by loosening yoke nut 42 installed on
round metal boss properly indexes in the hous- front output housing 49. Loosen the nut by in-
ing. stalling a large reaction tool (for leverage) and
an impact wrench. Leave the nut installed on
7. Install a new O-ring 23 on plug 22, and then the front output shaft.
install the plug in the housing. Tighten the plug
to 34–47 N·m (25–35 lb ft). 2. Remove fifteen bolts 45. Remove front output
housing 49 by lifting with a chain hoist and eye
8. Install new inner lip-type sealring 19 and out- bolts in output yoke 44. Remove gasket 50.
side square-cut sealring 18 on the piston. Lube
3. Remove C7 clutch housing assembly 58.
the sealrings.
4. Rotate the fixture so that the rear output end is
9. Lube adapter housing seal bores. upward.
10. Install C5 piston17, aligning the cast tab on the
piston with the notch in the housing. Lightly NOTE:
seat the piston using a soft face mallet. Refer to Foldout 16 for Steps (5) through (11).
11. Install C5 spring retainer 16, aligning the notch
in the housing with the tab on the retainer. 5. Loosen rear output yoke nut 81 by following
the same procedure explained in Step (1).
12. Place adapter housing 20 on the base of tool
Leave the nut installed on the rear output shaft.
J 35923-4 with input side up.
6. Remove six bolts 75 and nine bolts 82. Re-
13. Install J 35923-2 along with its washer, bear- move rear output housing 74 by lifting with a
ing, and handle. Tighten the handle to com- chain hoist and eye bolts. Remove gasket 73.
press spring retainer assembly 16. Make sure
that spring retainer tab indexes with the notch 7. Remove P4 carrier assembly 57.
in the housing. 8. Remove fifteen bolts 23 and two bolts 24. Re-
14. Install retaining ring 15. move C6 clutch housing assembly 17. Remove
C6 housing gasket 22. Note where the different
15. Release spring force and remove tools length bolts were removed so that reassembly
J 35923-2 and J 35923-4. will be correct.

9. Remove five bolts 50, holding rear idler cover 22. Remove eight bolts 71 and manifold
49 on the transfer case. Remove rear idler assembly 72.
cover 49, gasket 47, and O-ring 48. Use small
pry bars at locations provided in order to re- 23. Remove shim pack C and keep it intact for as-
move the cover. sembly. Shim pack C is used to set up driven
gear end play.
10. Remove controls cover 43 after removing ten
bolts 44. Remove gasket 42. Removing the 24. Remove five bolts 22, then remove front idler
controls cover provides access to the control cover 23, O-ring 24, shim pack B (keeping it
valve body 29 and its wiring. intact), and gasket 28. Use pry bars as in
removal of rear idler cover.
11. Remove the bolts securing the rear transfer
case to transfer case holding fixture J 38572. 25. Remove nut 88, securing electrical harness
connector 31 to connector plate 29. Remove
NOTE: four bolts 32, holding connector plate 29 to the
Refer to Foldout 14,B for Steps (12) through (14). transfer case. Remove connector plate 29, fol-
lowed by the harness and gasket 30.
12. Remove fifteen bolts 17, fastening the rear 26. Remove the suction hose fitting (not shown)
transfer case 8 to the front transfer case 7. from the transfer case. The fitting is sealed
with an O-ring, and provides a pilot for the
13. Thread an eye bolt in the center of rear transfer screen which filters the fluid returning to the
case 8, to lift it. main transmission sump from the transfer case
14. Use a soft face mallet to separate the rear and sump. Replace the filter screen during the over-
front transfer cases. Pry points at opposite ends haul.
of the case halves are also provided to accom-
plish separation. 27. Inspect bearing races 17, 37, and 78 on front
transfer case 14 for wear and damage; like-
15. Lift and remove the rear transfer case; removal wise, inspect bearing races 21, 41, and 82 on
of the rear transfer case exposes drive gear 19 rear transfer case 2 (Foldout 16).
(Foldout 15), idler gear 39, driven gear 80, and
control valve body 29 (Foldout 16). Remove 28. If the bearing races must be replaced, drive
gasket 16 (Foldout 15) and replace it during as- them out by using a hammer and a drift.
sembly.
29. During the race installation, temporarily install
16. Remove the output speed sensor and solenoid the lube charging pump or the manifold with
wiring harness connectors. Remove two bolts the appropriate shim pack to locate the race in
46 and output speed sensor 45 (Foldout 16). the housing. Since the race does not have an
17. Remove control valve assembly 29 after re- actual seat in the housing, locating the race
moving six bolts 41 holding the control valve correctly is essential for proper gear end play.
body on the transfer case.
30. Reinstall the races in the housing. For the drive
18. Remove driven gear 80, idler gear 39, and and driven gear races, use special tools
drive gear 19 (Foldout 15). J 38568-1 and J 35921-1. For the idler gear
race, use J 38568-2 and J 8092.
19. Rotate the remaining assembly, front output
end upward. 31. Remove two lube passage plugs 33 (Foldout
20. Remove eight bolts 4, and then remove lube 15); removal of the lube plugs provides access
charging pump 5. to orifice plugs 34.
21. Remove shim pack A. Shim pack A is critical 32. Remove two orifice plugs 34. Inspect lube ori-
to drive gear end play; keep the shim pack in- fices for obstructions. Remove any obstruc-
tact for assembly. tions.

MODULE REBUILD
33. Install orifice plugs 34, and lube passage 8. Remove retaining ring 12 after using tool
plugs 33. Tighten the orifice plugs to 12–14 N·m J 38573 to compress the C6 piston return
(9–10 lb ft). Tighten lube passage plugs to spring assembly.
24–29 N·m (18–21 lb ft).
9. Release the piston spring force, remove the
34. Remove lube passage plug 25 (Foldout 16) and special tool and check sealring bores in
orifice plug 26. Inspect lube orifice for obstruc- housing 19 for wear, nicks, and other damage.
tions and remove any that are found. Remove spring retainer assembly 13.
35. Install orifice plug and tighten to 12–14 N·m 10. Remove piston 14 by firmly striking the hous-
(9–10 lb ft). Install lube passage plug and ing against a flat surface. Remove sealrings 15
tighten to 24–29 N·m (18–21 lb ft). and 16 from piston 14.
b. Disassembly of C6 Clutch (Foldout 16) 11. Inspect thrust bearing 8 for wear and damage.
If damaged, remove thrust bearing 8 from the
1. Remove retaining ring 6 holding C6 clutch C6 housing.
plates and C6 clutch hub in the C6 clutch hous-
ing.
NOTE:
2. Remove C6 clutch hub 7 by lifting it out along Bearing 8 must be replaced in any MD 3070 prior to
with five C6 clutch friction plates 10, four C6 S/N 6510072173. See SIL 29-WT-96.
clutch steel reaction plates 11, and backplate 9.
One steel reaction plate 11 will remain in C6
clutch housing 19. Inspect clutch hub splines 12. Measure the C6 clutch housing bushing 21 by
for wear and damage. Replace hub if it is dam- using a telescope gauge and an outside mi-
aged. crometer. The maximum allowable ID is
36.18 mm (1.424 inch). If bushing 21 is worn
3. Remove the remaining steel reaction plate 11 or damaged, remove it from the C6 housing.
from C6 clutch housing 19.
c. Assembly of C6 Clutch (Foldout 16)
4. Separate backplate 9, five friction plates 10,
and five reaction plates 11. 1. Inspect C6 clutch housing 19 for groove wear.
Maximum allowable groove wear is 2.29 mm
5. Inspect friction plates 10 for wear, damage, (0.090 inch).
and the following specifications: minimum
allowable thickness: 3.68 mm (0.145 inch), 2. If removed, install bushing 21 using tools
maximum cone permitted: 0.4 mm J 38569 and J 8092.
(0.016 inch), and minimum allowable oil
groove depth: 0.20 mm (0.008 inch); if any of
the above specifications are not met, replace NOTE:
the part. Bearing 8 must be replaced in any MD 3070 prior to
S/N 6510072173. See SIL 29-WT-96.
6. Inspect steel reaction plates 11 for wear,
damage, and the following specifications:
minimum thickness allowed: 2.41 mm 3. If removed, install thrust bearing 8 over C6
(0.095 inch), maximum allowable cone housing sleeve. Machined tangs on the thrust
0.40 mm (0.016 inch); if any of the above bearing help ensure that the bearing is installed
specifications is not met, replace the part. in the proper direction.
7. Inspect backplate 9 for burrs, wear, damage, 4. Inspect piston 14 for sealring groove damage.
flatness, and the following specifications: Correct the damage with crocus cloth or soft
minimum thickness 7.9 mm (0.311 inch), and stone. Replace the part if damage cannot be
maximum cone 0.40 mm (0.016 inch). corrected.

5. Inspect backplate 61 for minimum thickness
CAUTION: allowed — 8.67 mm (0.341 inch), wear, flat-
Incorrect lip-type sealring installation can cause ness, and damage.
improper transmission operation or failure.
6. Remove C7 piston 64. Remove internal and
5. Install new external sealring 15 and internal external sealrings 66 and 65 from piston 64.
sealring 16 in piston 14. For internal 7. Measure the C7 clutch housing bushing and
sealring 16, use proper lip position. Lube inter- replace bushing 68 if required. The maximum
nal and external sealring bores in the C6 clutch allowable bushing ID measurement is
housing, and also lube the sealrings on the pis- 47.26 mm (1.861 inch).
ton.
8. Inspect pressure-relief ball 69 and make sure
6. Install piston 14; use soft face mallet to seat the that the ball moves freely; minimum required
piston. movement is 1.00 mm (0.040 inch).
7. Inspect spring retainer assembly 13 for missing 9. Remove three sealrings 70 from C7 clutch
or broken springs. Refer to Section 7 for the housing 67.
spring specifications.
e. Assembly of C7 Clutch Housing (Foldout 15)
8. Install spring assembly 13.
1. Inspect C7 clutch housing 67 for damage to
9. Install retaining ring 12 after using tools sealring groove and piston seal surfaces, and
J 38573-1 and J 38573-3 to compress spring housing spline wear. Replace the C7 clutch
assembly 13. Remove special tools. housing if it is damaged.
10. Install C6 clutch hub 7 hub into the C6 2. Install three new sealrings 70 into C7 clutch
housing. housing 67.
11. Install five reaction plates 11, and five friction 3. If bushing 68 was removed, install the bushing
plates 10 alternately, starting with a reaction using tools J 38569 and J 8092.
plate 11, and finishing with a friction plate 10.
4. Install ball 69 if it was removed. Make sure
12. Install backplate 9. that it moves freely.
13. Install retaining ring 6. 5. Inspect piston 64 for sealring groove damage
and burrs.
d. Disassembly of C7 Clutch (Foldout 15)
1. Removing retaining ring 60. CAUTION:

Incorrect lip-type sealring installation can cause
2. Remove the C7 clutch hub 59 along with C7 improper transmission operation or failure.
clutch pack. The C7 clutch pack consists of
backplate 61, five friction plates 62, and five 6. Install new sealrings 65 and 66 into C7
steel reaction plates 63 stacked in an alternat- piston 64. Be sure that sealring lips are prop-
ing order. erly positioned. Lube the sealring areas on the
piston, and seal bore areas in C7 clutch hous-
3. Inspect C7 friction plates 62 for minimum al-
ing 67.
lowable thickness — 2.21 mm (0.087 inch),
minimum oil groove depth allowed — 0.20 mm 7. Install piston 64 into C7 clutch housing 67. Be
(0.008 inch), and maximum cone permitted — sure it is properly seated.
0.25 mm (0.010 inch).
8. Inspect C7 clutch hub 59 splines for wear and
4. Inspect C7 reaction plate 63 for minimum allow- damage. Replace hub if damage is not repair-
able thickness — 2.11 mm (0.083 inch), maxi- able. Install C7 clutch hub 59 into C7 clutch
mum cone permitted — 0.25 mm (0.010 inch). housing 67.

MODULE REBUILD
9. Install five friction plates 62 and five reaction 9. Install pressure relief valve 6, and spring 7 into
plates 63 into housing 67 in an alternating or- bore in the pump housing.
der, starting with a reaction plate 63 and finish-
10. Install a NEW washer onto plug 8, then install
ing with a friction plate 62.
the plug and tighten it to 12–14 N·m (9–10 lb ft).
10. Install backplate 61 into C7 clutch housing 67.
h. Disassembly of P4 Carrier (Foldout 16)
11. Install retaining ring 60 into C7 clutch
1. Remove P4 sun gear 63 by lifting it out of the
housing 67.
P4 carrier assembly 56.
f. Disassembly of Oil Pump (Foldout 15)
2. Remove one setscrew 58 by using an Allen
1. Remove pressure relief valve plug 8. wrench or socket.
2. Remove spring 7, and then remove pressure re- 3. Push spindle 59 out from the P4 carrier.
lief valve 6.
4. Remove pinion gears 61, along with upper and
3. Remove locating pins from front cover 83 by lower thrust washers 62, and uncaged needle
driving them out using a small punch and a bearings 60.
hammer. 5. Repeat Steps (2) through (4) to remove the re-
4. Separate front cover 83 from the rest of the maining two pinion gears 61.
pump assembly. i. Assembly of P4 Carrier (Foldout 16)
5. Remove drive gear 84 from the housing, then 1. Inspect thrust surfaces on each of three pinion
remove driven gear 85 and reversing ring 86. gears 61 for wear and damage. Also inspect in-
Note the orientation of drive and driven gears. side bore and gear tooth areas.
g. Assembly of Oil Pump (Foldout 15)
2. Inspect three upper and three lower thrust
1. Use a depth gauge to measure pump cavity washers 62 for wear and damage.
depth in pump rear cover 87.
3. Install three lower thrust washers 62 into each
2. Using an outside micrometer, measure the of three pinion slots in P4 carrier 57. Each
driven gear width and the drive gear width. washer has a machined tang which indexes
with the notch in the P4 carrier housing.
3. Determine each gear side clearance by sub-
tracting the gear width from the pump cavity 4. Apply a generous amount of lube to the inside
depth. The specified side clearance is bore of each pinion gear. Install needle bear-
0.125 mm (0.005 inch). ings 60 into each of three pinions 61. Use the
spindle to make sure that the needle bearings
4. If not within the specification, replace compo- are properly aligned.
nents as required.
5. Install pinion 61 and needle bearing 60 assem-
5. Install reversing gear 86. bly into P4 carrier 57 with bottom thrust
washer 62 already in place.
6. Install driven and drive gears 85 and 84 in the
same orientation as they were removed to 6. Install upper thrust washer 62, aligning the
match wear pattern in rear pump cover 87. washer indexing tab with the notch in P4 car-
rier 57.
7. The groove in reversing ring 86 indexes with
the notch in the pump front cover. 7. Inspect spindle 59 for wear and damage. Make
sure that the fluid holes are free of obstruc-
8. Install pump front cover 83, aligning the holes
tions.
with the locating pins in the housing. Drive the
locating pins into the cover from the back of 8. Install spindle 59 into P4 carrier 57, aligning
the pump housing. Use a small punch to the setscrew pilot on the spindle with the hole
slightly countersink the pins. in the housing.

9. Install one of three setscrews 58, and tighten to 3. Remove output seal 46 by using a hammer and
25–35 N·m (18–26 lb ft). Swage set screw a chisel or tool J 24171-A. Be careful not to
bore, using a chisel and a hammer. damage the seal bore area.
10. Repeat Steps (6) through (9) to install the re- 4. Remove output shaft bearing 47.
maining two pinion gears 61.
5. Inspect bearing races 48 and 55 for pitting,
11. Install sun gear 63 into P4 carrier assembly 57. scoring, and damage. If the bearing race(s)
needs replacement, remove it by using a ham-
j. Disassembly of Drive, Idler, and Driven Gears mer and a drift or a hammer and tool J 3940.
(Foldout 15)
6. Remove shims 51, 52, or 53, and output bear-
1. Inspect bearings 18, 20, 38, 40, 79, and 81 per ing spacer 54 from output shaft 57.
guidelines explained in Paragraph 3–5e. If any
of bearings 18 and 20 installed on drive 7. If bearing 56 on output shaft 57 is damaged,
gear 19, bearings 38 and 40 installed on idler remove bearing 56. To remove bearing 56, in-
gear 39, or bearings 79 and 81 installed on stall a split bearing puller on the bearing, and
driven gear 80 requires replacement, use the position the bearing and the puller on a press
procedure in the next step. table. Press the output shaft out using an ap-
propriate press.
2. To remove bearing 18 from drive gear 19, in- m. Assembly of the Front Output Housing
stall a large split bearing puller on the bearing. and Front Output Shaft (Foldout 15)
Using appropriate tool(s) and fixture(s), re-
move the bearing by pressing the gear out. 1. Inspect front output housing 49 for scoring and
burrs.
3. To remove bearings 20, 38, 40, 79, or 81, fol-
low the procedure in Step (2). 2. If removed, install new bearing races 48 and
55. To install the bearing races, use tool
k. Assembly of Drive, Idler, and Driven Gears J 38568-3 and a press. Press each bearing race
(Foldout 15) until it bottoms in the output housing.
1. Inspect drive gear 19, idler gear 39, and driven 3. Position bearing 47 in output housing 49.
gear 80 for tooth wear and damage. Refer to
Paragraph 3–5i for gear inspection guidelines. 4. Install output seal 46 in the output housing us-
ing tools J 38547 and J 35921-1.
2. If removed, install bearing 18 on drive gear 39
5. Inspect output yoke 44 for scoring of seal sur-
using tool J 38579-1 and press. Repeat the
face. Minimum seal surface diameter allowed
same procedure to install bearing 20 on drive
is 76.20 mm (3.00 inch). If the yoke does not
gear 39, or bearings 79 and 81 on driven
meet the required specification, replace the
gear 80.
yoke.
3. If removed, install bearing 38 on gear 39 using
6. Inspect output shaft 57 for spline damage and
tool J 38579-2 and appropriate press. Repeat
scoring. If necessary, replace the output shaft.
the same procedure to install bearing 40 on
gear 39. 7. If removed, install bearing 56 on output
shaft 57. To install the bearing, use tool
l. Disassembly of the Front Output Housing and J 38579-2. Position the bearing and tool
Front Output Shaft (Foldout 15) J 38579-2 on the press table, and then carefully
1. Remove front output yoke nut 42 and press the output shaft 57 into the bearing until
washer 43. it is fully seated.
8. Place output yoke 44 on a press table.
2. Press front output shaft 57 out of front output
housing 49, and remove front output yoke 44. 9. Position output housing 49 on the yoke.

MODULE REBUILD
10. Place bearing spacer 54 and shims 51, 52, or o. Assembly of the Rear Output Housing
53 on output shaft 57; the number of shims (Foldout 16)
could be one or more.
1. Inspect rear output housing 74 for scoring and
11. Install output shaft 57 into front output burrs.
housing 49 through bearing 47, output seal 46,
2. If removed, install bearing races 76 and 68 into
and into yoke 44. Once all the components are
rear output housing 74 by using tool J 3940 or
properly aligned, press shaft 57. Rotate hous-
a hammer and a drift.
ing 49 during this procedure to help the shaft
and its related components seat properly. 3. Position bearing 77 into the output housing.
12. Install output washer 43 and output nut 42. 4. Install output seal 78 into the output housing
by using tool J 38547 and J 35921-1.
13. Perform the bearing preload procedure as ex-
5. Inspect output yoke 79 seal area for nicks, burrs,
plained in Paragraph 5–15p which uses the
and damage. Measure yoke seal surface; mini-
rear output housing as an example.
mum allowable seal journal OD is 76.20 mm
n. Disassembly of the Rear Output Housing (3.00 inch). If the yoke does not meet the re-
(Foldout 16) quired specification, replace the yoke.
6. Place output yoke 79 on a press table.
1. Remove retaining ring 64 to remove P4 ring
gear 65. 7. Position output housing 74 on the yoke.
8. Inspect rear output shaft 66 for spline damage
2. Remove P4 ring gear 65 from rear output hous-
and scoring, and if required, replace the rear
ing 74.
output shaft.
3. Remove output nut 81 and washer 80. 9. If removed, install new bearing 67 on output
shaft 66. To install bearing 67, use tool
4. Remove rear output shaft 66 by pressing it out
J 38579-2. Position the bearing and tool
from rear output housing 74.
J 38579-2 on the press table, and then carefully
press output shaft 66 into the bearing until it is
5. Remove yoke 79. Check yoke sealing area for
fully seated.
nicks, burrs, or damage.
10. Install bearing spacer 69, and shims 70, 71, or
6. Remove output seal 78 by using tool 72 onto output shaft 66.
J 24171-A. Be careful not to damage the seal
bore areas. 11. Press rear output shaft 66 into the output hous-
ing passing through bearing 77, output seal 78,
7. Remove output shaft bearing 77 if it is dam- and yoke 79, making sure that the output hous-
aged. ing spins freely.
8. Inspect bearing races 76 and 68 for pitting, 12. Install washer 80 and output nut 81 but do not
scoring, and damage. If the bearing races need tighten.
replacement, remove each bearing race by us- 13. Place P4 ring gear 65 in housing 74.
ing tool J 3940 or a hammer and a drift.
14. Install retaining ring 64.
9. Remove shims 70, 71, or 72, and bearing
spacer 69 from output shaft 66. 15. Follow bearing preload procedure explained in
Paragraph 5–15p.
10. If bearing 67 on shaft 66 is damaged, replace it. p. Output Housing Bearing Preload Procedure
To remove bearing 67, position the bearing on
the press table and install split bearing puller. 1. Install rear output housing 74 (Foldout 16) on
Using a press, press rear output shaft 66 out. the rear transfer case half 2.

2. Remove output yoke nut 81. r. Assembly of C7 Control Valve
Body Assembly (Foldout 16)
3. Install washer 80 on the output shaft after coat-
ing both sides with sealant. 1. Insert solenoid regulator valve 38 in the bore
of body 30 and inspect for smooth movement.
4. Lube the threads on the output shaft.
5. Install output nut 81 and tighten it to 610–815 N·m 2. Inspect solenoid filter screen for damage or de-
(450–600 lb ft). bris.
6. Install a dial indicator to read up and down 3. Replace solenoid O-rings 36 and 37 during
shaft movements. overhaul.
7. You may need to place a shim or a smooth 4. Insert solenoid 35 into valve body 30.
washer on the output shaft to get true readings.
5. Insert valve 31, followed by spring 32 and
8. Bottom the output shaft by applying downward valve stop 33.
force while slightly rotating the output yoke.
6. Push in on stop 33 to compress spring 32 and
9. The shaft is bottomed when the dial indicator insert a small cylindrical punch through the top
shows no more down movement. Zero the dial hole in body 30 to hold these parts in position.
indicator at this point.
7. Install pin 34 by starting it in the hole opposite
10. Using a chain hoist and a scale, apply an up- where the punch has been inserted. Tap the pin
ward force of 734–778 N (165–175 lbs) on the into position. The punch will be displaced as
output shaft. While force is applied, slightly the pin is installed.
rotate the yoke.
8. Install pin 40 which retains solenoid 35. Insert
11. Check the dial indicator for movement. the smooth (not ridged) end of the pin into the
12. If the indicator readings are not within the spec- mating hole at the bottom face of body 30. Tap
ified limits, add or remove shims and check pre- the pin into position flush with the bottom of
load again. End play must be 0.025–0.127 mm body 30. Use a small diameter punch to
(0.001–0.005 inch). slightly countersink pin 40.
13. If the indicator readings are within the speci- s. Assembly of Transfer Case Module
fied limits, coat both sides of washer 80 with (Foldouts 14, 15, 16)
sealant and install the washer. Repeat Step (5)
1. Lube bearing races 17, 37, and 78 (Foldout
from above.
15), installed in front transfer case housing 14.
q. Disassembly of C7 Control Valve Body
(Foldout 16) 2. One side of drive gear 19 has a shorter shoul-
der than the other side. Install drive gear 19 so
1. Begin C7 valve body disassembly by removing that the side with the shorter shoulder is toward
pins 34 and 40 securing the C7 signal valve so- the front of the transmission.
lenoid 35 and C7 control valve 31 in body 30.
Remove the pins by driving them out from the 3. Install idler gear 39 with its threaded hole to-
top toward the bottom (machined face). ward the front of the transmission.
2. Remove stop 33, spring 32, and valve 31 from 4. Install driven gear 80 into front transfer case
body 30. 14 in the same orientation as it was removed.
3. Remove solenoid 35 and O-rings 36 and 37. 5. Install output speed sensor 45 (Foldout 16).
4. Remove solenoid regulator valve 38. 6. Install two bolts 46 and tighten them to
24–29 N·m (18–21 lb ft).
5. Check the valves and bores for wear, scoring,
and damage. 7. Install C7 control valve body assembly 29.

MODULE REBUILD
8. Install six bolts 41, and tighten them to 20. Install eight bolts 71 and tighten them to
24–29 N·m (18–21 lb ft). 60–75 N·m (44–55 lb ft) Two bolts will replace
guide pins.
9. Install new transfer case gasket 16
(Foldout 15). 21. Rotate the transfer case assembly so that the
rear side is up.
10. Install rear transfer case 2 (Foldout 16) onto
the front transfer case. If necessary, use soft 22. Install special tool J 39623 into drive gear as-
face mallet to seat the case half. sembly 19.
11. Install fifteen bolts 17 (Foldout 14). Tighten 23. Install a dial indicator, making sure that the
the bolts to 60–75 N·m (44–55 lb ft). end of the indicator rests squarely on the raised
center area of the tool.
24. Bottom the assembly by applying downward
NOTE:
force and rotating tool J 39623.
Follow Steps (12) through (27) for drive gear bear-
ing preload procedure. The procedure must be per- 25. Zero the dial indicator when there is no more
formed with all case-to-case bolts installed, but with downward movement.
the C6 housing and the rear output housing re- 26. Apply 734–778 N (165–175 lbs) of upward
moved. force using a hoist and a scale.
27. Record the dial indicator reading and add or re-
12. Install test fixtures where C6 housing and rear move shims if the reading is not within the
output housing would normally be installed. A specified limits; the allowable end play is
plate with the same diameter as C6 housing 0.025–0.127 mm (0.001–0.005 inch).
and the same hole pattern and size is to be used
as the test fixture and to be installed in the
place of C6 housing. Likewise, a plate with the NOTE:
same diameter and hole pattern and size as the Follow Steps (28) through (34) for driven gear bear-
rear output housing is to be used in place of the ing preload procedure.
rear output housing. When special fixture
plates are not available, use washers or spacers
28. Install special tool J 39623 into driven gear as-
under the bolt heads that retain the C6 housing
sembly 80 (Foldout 15).
and rear output housing.
29. Install a dial indicator, making sure that the
13. Rotate the assembly so that the front side of end of the indicator rests on the raised center
the transfer case is up. area of the tool.
14. Install guide pins to facilitate installation of 30. Bottom the assembly by applying downward
shims 10, 11, and 12 (Foldout 15). force and rotating tool J 39623.
15. Install shims 10, 11, and 12 (shim pack A); 31. Zero the dial indicator when there is no more
there may be more than or fewer than three downward movement.
shims.
32. Apply 734–778 N (165–175 lbs) of upward
16. Install lube charging pump 5. Install eight force using a hoist and a scale.
bolts 4 securing the pump to the case. Tighten
33. Record the dial indicator reading and add or re-
bolts 4 to 60–75 N·m (44–55 lb ft).
move shims if the reading is not within the
17. Install guide pins in two manifold bolt holes. specified limits; the allowable end play is
0.025–0.127 mm (0.001–0.005 inch).
18. Install manifold shims 75, 76, and 77 (shim
pack C). 34. If the preload reading is not within the speci-
fied limit, add or remove the shims, and re-
19. Install manifold 73. check the preload.

51. Use a chain hoist and apply 734–778 N
NOTE: (165–175 lbs) of upward force.
Follow Steps (35) through (53) for idler gear bear- 52. Read dial indicator to determine bearing pre-
ing preload procedure. load.
53. If preload is not within the specified limits, add
NOTE: or remove shims and repeat Steps (41)–(53).
The allowable end play is 0.025–0.127 mm
Both idler covers must be installed and tightened to
(0.001–0.005 inch).
establish the idler gear position before bearing pre-
load is checked. 54. When preload is within the specified limits, re-
move the special tools.
35. Install guide pins in two rear idler cover bolt 55. Install guide pins to ease installation of the
holes. front idler cover.
36. Install new gasket 47 (Foldout 16) over guide 56. Install a new gasket 28 over the guide pins, and
pins. Install new O-ring 48 on rear idler onto the transfer case.
cover 49.
57. Install shims 25, 26, and 27 (shim pack B).
37. Lube O-ring and install cover 49 over guide
pins. Install five bolts 50 and tighten them to 58. Install a new idler cover O-ring 24.
60–75 N·m (44–55 lb ft). Two bolts replace the 59. Lube the O-ring.
guide pins.
60. Install idler cover 23, and tap it lightly for in-
38. Rotate the transfer case assembly so that the stallation.
front side is up.
61. Install five bolts 22 and tighten them to 60–75 N·m
39. Install guide pins to ease installation of the (44–55 lb ft). Two bolts replace the guide pins.
front idler cover.
62. Install a new O-ring on main wiring harness
40. Install a new gasket 28 (Foldout 15) over the connector 31.
guide pins and onto the transfer case.
63. Install harness connector assembly 31 on connec-
41. Install shims 25, 26, and 27 (shim pack B) over
tor plate 29 and tighten nut 88 to 2.73–4.09 N·m
the guide pins.
(24–36 lb in.).
42. Install a new O-ring 24 on cover 23.
64. Place a new gasket 30 on the connector plate,
43. Lube the O-ring. carefully rotating wiring harness through the
44. Install idler cover 23 and tap it lightly with a gasket.
soft-faced mallet to seat it in position. 65. Position the harness connector through the
45. Install five bolts 22 and tighten them to 60–75 N·m transfer case, and the connector plate.
(44–55 lb ft). Two bolts replace the guide pins. 66. Install four bolts 32 and tighten them to 5–8 N·m
46. Remove front idler cover bolts 22, cover 23, (4–6 lb ft).
shim pack B, and gasket 28 to start the idler
67. Install a new O-ring 2 (Figure 5–20) on suction
gear bearing preload check.
hose fitting 3. Lube the O-ring.
47. Install the handle of tool J 39623 into the
threaded hole of idler gear 39. 68. Lube the metal boss of filter screen 1 and posi-
tion it in fitting 3
48. Mount the dial indicator.
49. Bottom the idler gear assembly by slightly ro- 69. Carefully thread the fitting into the transfer
tating tool J 39623 while applying downward case.
force. 70. Tighten the jam nut on fitting 3 to 100–120 N·m
50. Zero the dial indicator. (74–89 lb ft).

MODULE REBUILD
82. Position P4 carrier assembly 56 on the transfer
case.
83. Install two guide bolts to facilitate installation

of rear output housing 74.
84. Install a new gasket 73.
85. Carefully install rear output housing assembly

3 74 onto the transfer case.
2
1 86. Install six bolts 75 and nine bolts 82. Tighten

them to 60–75 N·m (44–55 lb ft) Two bolts
will replace guide bolts.
87. Install guide bolts in two C6 cover bolt holes.
88. Install a new gasket 22.
V05567 89. Position C6 clutch housing assembly 5 on the

.
transfer case.
Figure 5–20. Transfer Case Fitting And Screen
Installation
90. Install fifteen bolts 23 and two bolts 24.
71. Install C7 clutch assembly 58 (Foldout 15) into Tighten them to 60–75 N·m (44–55 lb ft).
the transfer case.
91. Perform selective shim measurement before
72. Install guide pins in two front output housing installing transfer case into the main transmis-
bolt holes. sion as explained in Paragraph 6–2l.
73. Install a new output housing gasket 50.
74. Position front output housing 49 on the trans- 5–16. CONTROL VALVE MODULE
fer case. (Foldouts 17,A; 17,B; and 17,C)
75. Install bolts 45 and tighten them to 60–75 N·m
(44–55 lb ft). CAUTION:
• Control valve module assembly springs and
76. Rotate the assembly so that the rear side is up.
other parts can be mistakenly interchanged.
77. Reconnect main wiring harness connector 31 Tag each part with its item number as it is re-
to speed sensor 45 (Foldout 16) and solenoid moved and use Valve Tray Set J 33163 to sim-
35, making sure that each connector locks in plify correct valve body reassembly.
place. • Control valve module parts fit together
closely and have specific operating clearances.
78. Install a new control cover gasket 42. They can bind if damaged. These parts de-
pend upon smooth sealing surfaces and may
79. Install control cover 43. leak if the sealing surface is scratched. Valves,
80. Install ten bolts 44, and tighten them to 24–29 N·m when dry, must move freely by their own
(18–21 lb ft). weight in their bores. Carefully handle all
such parts. Protect control module parts dur-
81. If not previously done, remove test fixtures ing removal, cleaning, inspection, and instal-
which were installed during drive and driven lation. Keep them in clean containers until
gear bearing preload. they are installed.

NOTE: NOTE:
The following SILs affect the control module and • For MD Product Line units prior to S/N 6510032369,
should be consulted for detail service and parts in- proceed to Step (1).
formation:
• For MD Product Line units with S/Ns between
27-WT-93—1991–1992 Controls Differences and
6510032369 and 6510096670, skip Steps (1)–(4)
Serviceability
and proceed to Step (5).
9-WT-96—Filter Cover Seal Change
7-WT-98—TransID • For MD Product Line units beginning with
19-WT-99 — Oil Level Sensor S/N 6510096671, skip Steps (1)–(8) and proceed
01-WT-00 — Suction Filter to Step (9).
1. Remove four bolts 9 (Foldout 17,A) and wiring

a. Removal of Filters
harness cover plate 8.
NOTE: 2. Disconnect all connectors. Remove three

bolts 10 and internal harness assembly 11.
• For MD Product Line units prior to S/N 6510069120,
proceed to Step (1). 3. Remove two bolts 104 and turbine speed sen-
• For MD Product Line units beginning with sor 105. The turbine speed sensor should have
S/N 6510069120, skip Steps (1) and (2) and pro- a resistance of 300 ± 30 Ohms.
ceed to Step (3).
4. If present, remove two bolts 147 and oil level
sensor assembly 148. Clean the oil level sensor
1. If not previously removed, remove two filter with a soft clean cloth. Refer to Troubleshoot-
covers 178 (Foldout 17,A), two square cut ing Manual TS2470EN for proper sensor oper-
seals 179, two O-rings 180, and two filters 181. ation. Proceed to Step c.
2. Remove bolt 5 and two bolts 7. Remove suc- 5. Remove four bolts 11 (Foldout 17,B) and wir-
tion housing 4, seal 6, suction filter assembly ing harness cover plate 12.
3, and gasket 2. Clean suction filter 3 and dis-
card it, if damaged. 6. Disconnect all connectors. Remove three
bolts 13 and feedthrough harness assembly 14.
3. If not previously removed, remove two filter
covers 183 (Foldout 17,B), two gaskets 184, 7. Remove two bolts 112 and turbine speed sen-
two O-rings 185, two O-rings 186, and two fil- sor 113. The turbine speed sensor should have
ters 187. a resistance of 300 ± 30 Ohms.
4. Remove three bolts 8 and face seal 7. Remove 8. If present, remove two bolts 156 (Foldout
suction housing/filter assembly 6 and gasket 5. 17,C) and oil level sensor assembly 157. Clean
Discard suction housing/filter 6, if damaged. the oil level sensor with a soft clean cloth.
Refer to Troubleshooting Manual TS2470EN
b. Removal of Electrical or TS2973EN for proper sensor operation.
Components and Sensors Proceed to Step c.
9. Disconnect all connectors. Remove three

NOTE: bolts 12 and feedthrough harness assembly 13.
Refer to Troubleshooting Manual TS2470EN
(WTEC II Controls) or TS2973EN (WTEC III 10. Remove two bolts 113 and turbine speed sen-
Controls) for inspection and repair procedures. sor 114. The turbine speed sensor should have
a resistance of 300 ± 30 Ohms.

MODULE REBUILD
11. If present, remove two bolts 156 and oil level resistance of each solenoid by using the chart
sensor assembly 157. Clean the oil level sensor in Figure 5–13.
with a soft clean cloth. Refer to Troubleshoot-
5. Remove valve retention pin 80.
ing Manual TS2470EN or TS2973EN for
proper sensor operation. 6. Remove stop 74, spring 73, and valve 72.
c. Disassembly of the Rotating Clutch 7. Remove solenoid separator plate 107.
Solenoid Body (Foldout 17,A)
8. If present, remove three screens 82 from
1. Remove seal 46. body 71.
2. Remove three bolts 45 and rotating clutch sole- e. Disassembly of C6 Control Valve Body
noid body assembly 47. (Foldout 17,A)
NOTE: NOTE:
Solenoid retention pins 61, 81, and 125 must be re- C6 control valve body is only in MD 3070PT trans-
moved from the BOTTOM of the solenoid bodies. mission models.
Note the grooved end of pin for positive retention.
1. Remove five bolts 84 to remove C6 valve body
3. Remove three solenoid retention pins 61 from cover plate 85.
bottom of solenoid body.
2. Remove C6 valve body cover plate 84.
4. Remove two solenoids 55, each with
O-rings 56 and 57. Remove one solenoid 58 3. Remove C6 valve body 87.
with O-rings 59 and 60. Remove three valves 4. Remove retaining pin 95, holding C6 regulator
54, and three springs 53. Check resistance of valve solenoid 90.
each solenoid by using chart in Figure 5–13.
5. Remove regulator valve solenoid 90 with
5. If present, remove valve retention pin 67, O-rings 91 and 92. Remove regulator valve 89
stop 66, spring 65, and valve 64. and spring 88. Check valve and bore for dam-
6. Remove two bolts 52 and pressure switch as- age.
sembly 48. Maximum resistance of pressure 6. Remove retaining pin 95, holding C6 interlock
switch assembly 48 (closed) must not exceed valve solenoid 99.
2 Ohms. Minimum resistance of pressure
switch assembly 48 (open) must be at least 7. Remove interlock valve solenoid 99 with
20,000 Ohms. The switch should close be- O-rings 100 and 101. Remove interlock valve
tween 159–255 kPa (23–37 psi). 102 and spring 103.
7. If present, remove three screens 62 from 8. Inspect interlock valve 102 and its bore for
body 63. nicks, wear, and damage.
d. Disassembly of the Stationary Clutch f. Disassembly of Main Valve Body
Solenoid Body (Foldout 17,A)
1. Remove two bolts 106 and main valve body as-
1. Remove eight bolts 68 and stationary clutch sembly 108.
solenoid body assembly 70.
2. If damaged, remove indexing pin 130.
2. Remove two seals 69.
3. Remove solenoid retention pin 125 from bot-
3. Remove three solenoid retention pins 81 from tom of solenoid body.
bottom of solenoid body 71.
4. Remove solenoid 126 with O-rings 127 and
4. Remove solenoids 75, small O-rings 77, large 128. Check resistance of the solenoid by using
O-rings 76, valves 78, and springs 79. Check the chart in Figure 5–13.

6. Remove stop 112, spring 111, and lockup relay
valve 110.
8. Remove stop 116, spring 115, and lube regula-
tor valve 114.
WARNING!
Springs 119 and 123 are highly compressed. Be
extremely careful during disassembly. Personal
injury can occur if the spring force is not con-
trolled.
9. Install spring compressor J 35924 (Figure 5–21). Figure 5–21. Use of Tool to Release Main-Pressure
Compress spring 119, remove valve retention Valve Spring Force
pin 117, and carefully remove compressor
J 35924 after turning handle counter-clockwise g. Disassembly of the Channel Plate
to release spring force. (Foldout 17,A)
10. Remove stop 120, spring 119, and main regu- 1. If damaged, remove two pins 161 or 169.
lator valve 118.
2. Remove drain plug 163 and O-ring 164 or
11. Remove valve retention pin 121. drain plug 174 and O-ring 175.
12. Remove stop 124, spring 123, and control 3. Remove eight pressure tap plug assemblies
main valve 122. 165 with O-ring 166 or nine plugs 171 with
13. Remove valve retention pin 130. O-ring 172.
14. Remove stop 134, spring 133, and C2 latch 4. Remove O-rings from all plugs.
valve 132. h. Assembly of the Channel Plate
1. Install new O-rings on all plugs.
16. Remove stop 138, spring 137, and exhaust
back valve 136. 2. Install eight pressure tap plugs 165 or nine plugs
171. Tighten plugs to 10–13 N·m (7–10 lb ft).
18. Remove stop 142, spring 141, and C1 latching NOTE:
valve 140.
A new, longer drain plug is available for improved
19. Remove valve retention pin 143. clamp load distribution and as a repair for channel
plates with damaged threads. See SIL 5-WT-98 for
20. Remove stop 146, spring 145, and converter
details.
regulator valve 144. Inspect stop 146 for bat-
tering. Replace the stop if it is battered. For
transmission S/Ns between 6510004324 and 3. Install drain plug 163 or 174. Tighten plug to
6510058500, also replace separator plate 157 25–32 N·m (18–24 lb ft).
and gasket 156 using part numbers specified in
SIL 24-WT-95. 4. If removed, install two pins 161 or 169.
21. Remove gasket 156, separator plate 157, and 5. Install gasket 158, separator plate 157, and
gasket 158. gasket 156.

MODULE REBUILD
i. Assembly of the Main Valve Body j. Assembly of C6 Control Valve Body
(Foldout 17,A) (Foldout 17,A)
1. Install converter regulator valve 144, 1. Insert interlock valve 102 in the bore and
spring 145, and stop 146. check it for free movement. After ensuring that
valve 102 moves freely, install spring 103.
2. Install valve retention pin 143.
2. Inspect solenoid filter screen 96, if present, for
3. Install C1 latching valve 140, spring 141, and
debris and damage. Replace it if necessary.
stop 142.
3. Install new O-rings 100 and 101 on interlock
valve solenoid 99, and install the solenoid.
5. Install exhaust-back valve 136, spring 137, and
4. Insert regulator valve 89 in the bore and check
stop 138.
it for free movement. After ensuring that
6. Install valve retention pin 135. valve 89 moves freely, install spring 88.
7. Install C2 latch valve 132, spring 133, and 5. Install new O-rings 91 and 92 on regulator
stop 134. valve solenoid 90.
8. Install valve retention pin 131. 6. Install regulator valve solenoid 90 in its bore.
9. Install control main valve 122, spring 123, and 7. Insert solenoid retention pins 95, smooth end
stop 124. first, from the bottom (separator plate side) of
body 87 into body 87. Seat pins using hammer
10. Install valve retention pin 121. and countersink the pins.
11. Install main regulator valve 118, spring 119, 8. Place the valve body on the control module.
and stop 120.
9. Install C6 valve body cover plate 85.
12. Install spring compressor J 35924 (Figure 5–21).
Compress spring 119, install valve retention 10. Install five bolts 84. Tighten the bolts to
pin 117, and remove J 35924 after turning han- 10–13 N·m (7–10 lb ft).
dle counter-clockwise until the tool clears pin
k. Assembly of the Stationary
117.
Clutch Solenoid Body (Foldout 17,A)
13. Install lube regulator valve 114, spring 115,
1. Install valve 72, spring 73, and stop 74. Install
and stop 116.
valve retention pin 80.
2. Install three each of springs 79, solenoid
15. Install lockup relay valve 110, spring 111, and regulator valve 78, small O-rings 76 and 77,
stop 112. and solenoids 75.
16. Install valve retention pin 109. 3. As valve bores are filled, install solenoid reten-
tion pins 81 from bottom of solenoid body.
17. Install O-rings 127 and 128 on solenoid 126
and install solenoid. 4. Install two seals 69.
18. Install solenoid retention pin 125 from bottom 5. Install stationary clutch solenoid body assem-
of main valve body assembly. bly 70 and eight bolts 68. Tighten bolts 68 to
10–13 N·m (7–10 lb ft).
19. Install indexing pin 130, if removed.
l. Assembly of the Rotating
20. Install main valve body assembly 108
Clutch Solenoid Body (Foldout 17,A)
21. Lubricate two bolts 106 with transmission
1. Install valve 64 with stem toward the outside.
fluid. Install bolts 106 finger tight.
Then install spring 65 and stop 66. Install valve
22. Install solenoid separator plate 107. retention pin 67.

2. Install three springs 53, three solenoid regula- 6. Install gasket 2, seal 6, suction filter 3, filter
tor valves 54, two solenoids 55 with O-rings 56 housing 4, bolt 5 and two bolts 7. Tighten bolts
and 57, and one solenoid 58 with O-rings 59 finger tight.
and 60.
7. Evenly tighten cover plate bolts 9, suction filter
3. Install solenoid retention pins 61 from bottom bolts 5 and 7, and main valve body bolts 106.
of rotating clutch solenoid body. Tighten all bolts to 10–13 N·m (7–10 lb ft).
4. Install pressure switch assembly 48 and two
8. Proceed to Section 6.
bolts 52. Tighten bolts to 5–8 N·m (4–6 lb ft).
5. Install seal 46. 9. Install feedthrough harness assembly 14 (Fold-
out 17,B) and three bolts 13. Tighten bolts to
6. Install rotating clutch solenoid body 2–3 N·m (18–27 lb in.).
assembly 47 and three bolts 45. Tighten bolts
45 to 10–13 N·m (7–10 lb ft). 10. If present, install oil level assembly 156 and
two bolts 155. Tighten bolts to 10–13 N·m
7. Install oil level sensor assembly 148 and (7–10 lb ft).
two bolts 147. Tighten bolts to 10–13 N·m
(7–10 lb ft). 11. Reconnect all connectors.
8. Install turbine speed sensor 105 and two bolts 12. Install wiring harness cover plate 12 and four
104. Tighten bolts to 10–13 N·m (7–10 lb ft). bolts 11. Tighten bolts finger tight.
m. Installation of the Wiring Harness
Assembly and Cover Plate (Foldout 17,A) 13. Install gasket 5, seal 9, suction filter 6, filter
housing 7, bolt 8 and two bolts 10. Tighten
bolts finger tight.
NOTE:
• For MD Product Line units prior to S/N 6510032369, 14. Evenly tighten cover plate bolts 11, suction fil-
proceed to Step (1). ter bolts 8 and 10, and main valve body bolts
• For MD Product Line units with S/Ns between 114. Tighten all bolts to 10–13 N·m (7–10 lb ft).
6510032369 and 6510096670, skip Steps (1)–(8)
and proceed to Step (9). 15. Proceed to Section 6.
• For units starting with S/N 6510096671, skip
Steps (1)–(15) and proceed to Step (16). 16. Install feedthrough harness assembly 13 (Fold-
out 17,C) and three bolts 12. Tighten bolts to
2–3 N·m (18–27 lb in.).
1. Install 24-way internal connector 16 (Fold-
out 17,A), two internal seals 15 and bolt 17 17. If present, install oil level assembly 157 and
onto standoff bracket 12. Tighten bolt 17 to two bolts 156. Tighten bolts to 10–13 N·m
1.3–2.7 N·m (12–24 lb in.). (7–10 lb ft).
2. Install wiring harness assembly 11 and three 18. Reconnect all connectors.
bolts 10. Tighten bolts to 2–3 N·m (18–27 lb in.).
19. Install four bolts 11. Tighten bolts finger tight.
3. If present, install oil level assembly 148 and
two bolts 147. Tighten bolts to 10–13 N·m 20. Install gasket 5, seal 7, filter housing 6, and
(7–10 lb ft). three bolts 8. Tighten bolts finger tight.
4. Reconnect all connectors.
21. Evenly tighten bolts 11, suction filter bolts 8,
5. Install wiring harness cover plate 8 and four and main valve body bolts 115. Tighten all
bolts 9. Tighten bolts finger tight. bolts to 10–13 N·m (7–10 lb ft).

SECTION 6 — TRANSMISSION ASSEMBLY
6–1. SCOPE 6. Rotate the repair stand so the transmission
housing output end is up and install the remain-
a. Section. This section covers the assembly of MD ing ten bolts 3. Tighten all bolts to 51–61 N·m
Product Line transmissions. Assembly procedures (38–45 lb ft).
include PTO provisions and retarders. The assembly
sequence is continuous and includes all models. b. Installation of the Rotating Clutch Module
(Figure 6–2)
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable proce- 1. Rotate the repair stand so the input end of the
dure. main housing is up.
c. Illustrations. Illustrations will not always show 2. Using a hoist and an M16 eye bolt, insert rotat-
your model, but when an operation is identical for all ing clutch module 1 in the front of the main
models, the correct procedure is shown. housing.
d. General Information. Refer to Section 3 for gen- c. Installation of the Front Support/Charging
eral information as follows: Pump Module (Figure 6–3)
Paragraph Description 1. Lower front support and charging pump mod-
3–2 Tools, Equipment ule 3 over the top of the turbine shaft.
3–3 Replacement Parts
1
3–4 Careful Handling
3–6 Assembly Procedures
2
e. Foldouts. Refer to Foldouts 7 through 19 for dis-

assembled views and torque specifications.
3
NOTE:
All parts must be cleaned and lubricated before
assembly.
6–2. ASSEMBLY OF TRANSMISSION V05621
Figure 6–1. C3/C4 Clutch Module Installation

a. Assembly of C3/C4 Clutch
1. Mount holding fixture J 35926 onto the main
1
housing.
2. Attach a hoist and lift the fixture and main
housing.
3. Mount the fixture and main housing on repair
stand J 29109. Make sure the main housing
centerline is horizontal.
4. Install C3/C4 clutch assembly 1 (Figure 6–1)
through the input end of main housing 2, align-
ing the tabs on the clutch assembly with the
slot in the main housing.
V05620
5. Install two bolts 3, 180 degrees from each
other, to hold clutch assembly 1 in place. Figure 6–2. Rotating Clutch Module Installation

2. Align bolt holes in front support 3 with the
threaded holes in the main housing.
3. Install six bolts 1 and five bolts 2. Tighten bolts
to 51–61 N·m (38–45 lb ft).
d. Installation of the P1 Planetary Module
1
(Figure 6–4)
1. Rotate the repair stand so the rear of the main
housing is up.
2. Install P1 planetary module 1 — consisting of

the P1 carrier and P2 ring gear. V05618
3. Mesh the P1 pinion gears with the P1 ring gear Figure 6–4. P1 Planetary Module Installation
inside the C3/C4 clutch assembly.
e. Installation of the P2 Planetary Module
(Figure 6–5)
1. Install P2 planetary module 1 — consisting of 1
the P2 carrier and the P3 ring gear.
C5
2. Mesh the P2 pinions with the P2 ring gear dur- 2
3
ing installation.
f. Installation of the C5 Clutch Pack (Figure 6–5).
Install the C5 clutch pack in the main housing — eight
steel reaction plates 2 and seven friction plates 3,
stacked alternately, starting with a steel reaction plate.
Stack all plates so plate cone faces the same direction.
Steel plates mesh with the main housing and reaction V05617
plates mesh with the P3 ring gear.
g. Installation of the Main Shaft (Figure 6–6). In- Figure 6–5. P2 Planetary Module and
stall main shaft 1 as assembled in Section 5, without C5 Clutch Pack Installation
selective shim 2 and thrust bearing 3 (does not apply to
MD 3070PT models).
2
3 1 (MD PRODUCT LINE)
2
3
1
1 (MD 3560)
1 (MD 3070PT)
V05619 V05565.01
Figure 6–3. Front Support/Oil Pump

Module Installation Figure 6–6. Main Shaft Installation

TRANSMISSION ASSEMBLY
h. Main Shaft Selective Shim Measurement For mounting surface and place a straight edge
Models With Retarder (Figure 6–7) across the P3 planetary carrier.
1. Place a straight edge across the retarder or rear 5. Measure dimension D, from top of the straight
cover mounting surface of the main housing. edge to the mounting gasket.
6. Measure dimension E from the top of the
2. Measure dimension A, from top of the straight straightedge to the thrust bearing contact sur-
edge to the selective shim thrust surface on the face on the P3 planetary carrier. Subtract di-
main shaft bearing spacer. mension E from dimension D — the remainder
is dimension F.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension A 7. Dimension G is the remainder of C minus F
— the remainder is dimension C. and determines the thickness of the selective
shim.
4. Place the retarder or rear cover module output
end down (facing the bench top). Install an 8. Install the proper thickness selective shim and
uncompressed gasket on the retarder the thrust bearing.
BEARING AND
STRAIGHT EDGE SHIM REMOVED STRAIGHT EDGE
DIM. E
GASKET
INSTALLED
DIM. A DIM. B
DIM. C DIM. F
DIM. D
NON-
RETARDER RETARDER
MODEL MODEL
MAIN SHAFT MODULE
PROCEDURE:
• FORMULA (C) – (F) = G
DIM. G USE P/N SHIM ID
4.574–4.843 mm
29503218 1 NOTCH
0.180–0.190 in.
4.844–5.113 mm
29503219 2 NOTCHES
0.192–0.201 in.
5.114–5.383 mm
29503220 3 NOTCHES
0.202–0.212 in.
5.384–5.653 mm
29503221 4 NOTCHES
0.213–0.223 in.
5.654–5.923 mm
29503222 5 NOTCHES
0.224–0.233 in.
5.924–6.193 mm
29503223 6 NOTCHES
0.234–0.244 in.
6.194–6.463 mm
29503224 7 NOTCHES
0.245–0.254 in. V06748
Figure 6–7. Main Shaft Selective Shim Measurement (Close Ratio Models) — MD Product Line Except MD 3070PT

i. Main Shaft Selective Shim Measurement surface and place a straight edge across the P3
(Wide Ratio Models) (Figure 6–8) planetary carrier.
1. Place a straight edge across the retarder or rear 5. Measure dimension D from top of the straight
cover mounting surface of the main housing. edge to the rear cover mounting gasket.
6. Measure dimension E from the top of the
2. Measure dimension A, from top of the straight straightedge to the thrust bearing contact sur-
edge to the selective shim thrust surface on the face on the P3 planetary carrier. Subtract di-
main shaft bearing spacer. mensions E from dimension D — the
3. Measure dimension B, thickness of straight remainder is dimension F.
edge. Subtract dimension B from dimension A 7. Dimension G is the remainder of C minus F
— the remainder is dimension C. and determines the thickness of the selective
4. Place retarder or rear cover output end down shim.
(facing the bench top). Install an uncompressed 8. Install the proper thickness selective shim and
gasket on the retarder or rear cover mounting the thrust bearing.
BEARING AND
STRAIGHT EDGE SHIM REMOVED STRAIGHT EDGE
DIM. E
GASKET
INSTALLED
DIM. A DIM. B
DIM. C DIM. F
DIM. D
NON-
RETARDER RETARDER
MODEL MODEL
MAIN SHAFT MODULE
PROCEDURE:
4.574–4.843 mm
29503226 1 NOTCH
0.180–0.190 in.
4.844–5.113 mm
29503227 2 NOTCHES
0.192–0.201 in.
5.114–5.383 mm
29503228 3 NOTCHES
0.202–0.212 in.
5.384–5.653 mm
29503229 4 NOTCHES
0.213–0.223 in.
5.654–5.923 mm
29503230 5 NOTCHES
0.224–0.233 in.
5.924–6.193 mm
29503231 6 NOTCHES
0.234–0.244 in.
6.194–6.463 mm
29503232 7 NOTCHES
0.245–0.254 in. V06747
Figure 6–8. Main Shaft Selective Shim Measurement (Wide Ratio) — MD 3560

j. Main Shaft Selective Shim Measurement For 4. Place transfer case rear output end down (fac-
MD 3070PT (Figure 6–9) ing the bench top). Install a NEW gasket on the
front main transfer case mounting surface and
1. Place a straight edge across the transfer case place straight edge across the transmission
mounting surface of the adapter housing (gas- shaft adapter.
ket removed). Also, be sure that there is no se-
5. Measure dimension D from the top of the
lective shim in place at this time.
straight edge to the transfer case mounting gas-
ket.
2. Measure dimension A from the top of the
straight edge to the shoulder where the selec- 6. Measure dimension E from the top of the
tive shim will rest. straight edge to the step inside the adapter cou-
pling. Subtract dimension E from dimension D
— the remainder is dimension F.
3. Measure dimension B, from the top of the
straight edge to the face where the gasket rests. 7. Dimension G is the remainder of C minus F,
Subtract dimension B from dimension A — the and determines the thickness of the selective
remainder is dimension C. shim.
STRAIGHT EDGE STRAIGHT EDGE

DIM. A
GASKET DIM. E
INSTALLED DIM. F
DIM. B
DIM. D
DIM. C
TRANSMISSION ASSEMBLY PROCEDURE: TRANSFER CASE MODULE

0.899–1.169 mm
29503226 1 NOTCH
0.035–0.046 in.
1.169–1.439 mm
29503227 2 NOTCHES
0.046–0.057 in.
1.439–1.709 mm
29503228 3 NOTCHES
0.057–0.067 in.
1.709–1.979 mm
29503229 4 NOTCHES
0.067–0.078 in.
1.979–2.249 mm
29503230 5 NOTCHES
0.078–0.089 in.
2.249–2.519 mm
29503231 6 NOTCHES
0.089–0.099 in.
2.519–2.874 mm
29503232 7 NOTCHES
0.099–0.113 in. LV01843.01.01.eps
Figure 6–9. Main Shaft Selective Shim Measurement For MD 3070PT

8. Coat the selected shim with a generous coating 5. Retighten spanner nut 54 (Foldout 13,A) to
of lube (petrolatum) and insert shim inside the 74–88 N·m (55–65 lb ft). If only one tang is
transmission shaft adapter. aligned with a bearing retainer nut slot, con-
tinue to torque the bearing retainer nut (but do
NOTE: not exceed the tightening torque or drag torque
• Proceed to Step k. for units with retarder built limits) until two or more tangs can be bent up
prior to 1/98. into slots on the bearing retainer nut.
• Proceed to Step l. for units with retarder built
starting 1/98. NOTE:
DO NOT reuse a tang once it has been bent. Replace
k. Installation of Retarder Module (Units Built locknut retainer 53, if necessary.
Prior To 1/98) (Foldout 13,A)
NOTE: 6. Install output shaft oil seal 55 using tool

Former transmission main case P/N 29535311 has been J 39928.
completely cancelled. Current transmission main case
now has an additional drilled and tapped bolt hole. If l. Installation of Retarder Module (MD Product
transmission is equipped with a non-sump cooling Line Units Built Starting 1/98) (Foldout 13,B)
integral cooler, re-work must be performed
when replacing a transmission main case prior to
S/N 6510262246 with main case P/N 29536861. Rework NOTE:
is required due to possible interference between Former transmission main case P/N 29535311 has been
stator bolt and threaded hole in main case. Refer to completely cancelled. Current transmission main case
SIL 13-WT-00 for re-work procedures. now has an additional drilled and tapped bolt hole. If
transmission is equipped with a non-sump cooling
1. Install a NEW retarder gasket 1 on the trans- integral cooler, re-work must be preformed
mission main housing. when replacing a transmission main case prior to
2. Install guide bolts to ease the installation of re- S/N 6510262246 with main case P/N 29536861. Rework
tarder module 5 and to keep gasket 1 in place. is required due to possible interference between
stator bolt and threaded hole in main case. Refer to
SIL 13-WT-00 for re-work procedures.
WARNING!
mately 64 kg (141 lb). Use care to prevent injury
to personnel while handling the retarder module BOLT (12), A
A
A
assembly. M12 x 1.75 x 165 mm A A

MARKED A
A A
3. Place retarder module 5 on the transmission

A
main housing using a hoist and sling as a lift- A
ing fixture. If used, install the rear support A A
bracket. BOLT (6),

M12 x 1.75 x 190 mm A C
4. Install twelve M12 x 1.75 x 165 mm bolts at MARKED C C C

locations marked A (Figure 6–10). Install six B C
C
C B
M12 x 1.75 x 190 mm bolts marked C. Tighten
BOLT (7),
the eighteen M12 bolts to 90–110 N·m M10 x 1.5 x 180 mm B B B B B
(66–81 lb ft). Install seven M10 x 1.5 x 180 mm MARKED B

bolts at locations marked B. Tighten the M10 V01644.01
bolts to 51–61 N·m (38–45 lb ft). Three bolts
not mentioned were installed and tightened in Figure 6–10. Retarder Module Bolts
Section 5. (Units Built Prior To 1/98)

NOTE: BOLT (14),

M12 x 1.75 x 130 mm A
A A
• For units prior to S/N 6510262246 proceed to MARKED A
A A
Step (1).
A A
• For units starting with S/N 6510262246 proceed A A
to Step (5).
A A
BOLT (4),
M12 x 1.75 x 190 mm
A
MARKED C A
1. Install a NEW retarder gasket 1 on the trans-
mission main housing. BOLT (7), A C
M10 x 1.5 x 180 mm B C

C
C B
MARKED B
2. Install guide bolts to ease the installation of re- B B B B B
tarder module 5 and to keep gasket 1 in place.
V05638
WARNING! Figure 6–11. Retarder Module Bolts

(Units Built Starting 1/98)
mately 64 kg (141 lb). Use care to prevent injury
to personnel while handling the retarder module BOLT (4),
assembly. M10 x 1.5 x 192 mm
BOLT (14), A MARKED D
A A
M12 x 1.75 x 130 mm
A A
MARKED A
3. Place retarder module 5 on the transmission A A
main housing using a hoist and sling as a lift-

A A
ing fixture. If used, install the rear support
bracket. BOLT (4),
A A
M12 x 1.75 x 190 mm A A

MARKED C
4. Install fourteen M12 x 1.75 x 130 mm bolts at A C
locations marked A (Figure 6–11). Install four B C

C
C D D
M12 x 1.75 x 190 mm bolts marked C. Tighten

B B B D D
the eighteen M12 bolts to 90–110 N·m

BOLT (7),
(66–81 lb ft). Install seven M10 x 1.5 x 180 mm M10 x 1.5 x 182 mm
bolts at locations marked B. Tighten the M10 MARKED B V07363
bolts to 51–61 N·m (38–45 lb ft). Three bolts

not mentioned were installed and tightened in Figure 6–12. Retarder Module Bolts
Section 5. (Starting With S/N 6510262246)
5. Install fourteen M12 x 1.75 x 130 mm bolts

NOTE:
marked A (Figure 6–12). Install four
M12 x 1.75 x 190 mm marked C. Tighten eigh- DO NOT reuse a tang once it has been bent. Replace
teen M12 bolts 90–110 N·m (66–81 lb ft). In- locknut retainer 61, if necessary.
stall four M10 x 1.5 x 182 mm bolts marked B.
Tighten M10 bolts to 51–61 N·m (38–45 lb ft).
7. Install output shaft oil seal 63 using tool
6. Retighten spanner nut 62 (Foldout 13,B) to J 39928.
74–88 N·m (55–65 lb ft). If only one tang is
aligned with a bearing retainer nut slot, con- m. Installation of Rear Cover Module
tinue to torque the bearing retainer nut (but do (Figure 6–13)
not exceed the tightening torque or drag torque
limits) until two or more tangs can be bent up 1. Install a NEW rear cover gasket 1 on main
into slots on the bearing retainer nut. housing 4.

2. Install guide bolts to ease rear cover 2 installa- o. Installation of Transfer Case Module
tion and keep gasket 1 in place. (Figure 6–15)
1. Install a NEW gasket 4.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture. In- 2. Be sure that selective shim 1 is located inside
stall rear support bracket, if used. shaft adapter 5.
3. Mount J 38572 on transfer case 3.
4. Install nineteen bolts 3. Tighten bolts to
90–110 N·m (66–81 lb ft). WARNING!
The transfer case module assembly weights ap-
5. Install output shaft oil seal 5. proximately 270 kg (595 lb).
4. Use hoist and J 38572 to lift transfer case 3.

n. Installation of Transfer Case Adapter Housing 5. Install transmission shaft adapter 5 into trans-
(Figure 6–14) fer case 3.
6. Install transfer case 3 into the main transmis-
1. Install a new adapter housing gasket 2. sion, and install bolts 2.
7. Beginning with S/N 6510205652 (Foldout 18,B)
2. Inspect adapter housing 3 for cracks, nicks, or
the transfer case housing, C6 housing and
burrs. Remove the burrs and nicks with crocus
gasket have been changed to use improved
cloth or light stone.
transfer case retaining bolt 27, a stepped and
knurled-shank bolt. Install bolt 27 passing
3. Install adapter housing 3 by installing fifteen through C6 housing into the adapter housing.
bolts 8 and three bolts 5. Torque to 90–110 N.m If reusing the former housings, install bulge-
(66–81 lb ft). bolt 28 passing through C6 housing into the
adapter housing (SIL 16-WT-00). Tighten bolts
4. Install three bolts 6, two bolts 7, and four bolts to 51–61 N . m (38–45 lb ft).
4. Tighten bolts to 51–61 N.m (38–45 lb ft). 8. Tighten bolts 2 and bolt 7 to 51–61 N . m
(38–45 lb ft).
4 1
1 2
2 3
5
3
8 7
V05616 6 V05569
Figure 6–14. Transfer Case Adapter Housing

Figure 6–13. Rear Cover Module Installation Installation

p. Installation of the Converter Housing Module • If the control module is in place, remove the
(Figure 6–16) plug(s), if present, from the fill tube hole or
1. Place transmission input end up. Install a new from cooler ports before applying lockup
converter housing gasket 2 on main housing air pressure. Apply air pressure through the
module 4. lockup pressure tap (Figure 4–7, View D)
and use a heel bar, screwdriver, and bolts.
2. Install guide bolts to ease converter housing 1 Insert the heel bar into a torque converter
installation and keep gasket 2 in place. housing bolt hole. Insert two bolts into the
3. Lower converter housing 1 onto main flexplate adapter bolt holes. Then place a
housing 4. If the transmission is PTO screwdriver at an angle to prevent converter
equipped, rotate the PTO drive gear to align rotation (Figure 6–17, View C).
the gear tangs with the charging pump.
6. Install converter end play gauge J 38548
4. Install three bolts 3 into the inside of converter and tighten the attaching bolt to 27–34 N·m
housing 1. Use mechanical fingers, or a similar (20–25 lb ft).
tool, when installing these bolts.
5. Remove the two guide bolts and install the re-
maining seventeen bolts 3. Tighten all bolts to J 35926
6
51–61 N·m (38–45 lb ft).
J 38572
q. Installation of the Torque Converter Module

(Figure 6–17)
1. The torque converter is installed over the tur-
bine shaft which rotates inside the stator shaft
or ground sleeve. The splines on the ground
1
sleeve engage the converter stator. The splines 5
on the turbine shaft engage the converter tur- 4
2
bine. The end of the turbine shaft is threaded
and machined to accept the converter retaining
bolt and lockup sealring. 7
2. The splines of the ground sleeve and turbine

shaft must engage with their respective splines 3 V07368
in the torque converter module. The tangs on
the converter-pump hub must engage the Figure 6–15. Transfer Case Module Installation
charging pump tangs or the PTO oil pump
drive hub. 1
3. Using hoist and sling, install torque converter

module 6 into the converter housing module 2
(Figure 6–17, View A).
4
4. Ensure the torque converter is properly seated.
If PTO equipped, rotate the PTO gear to en- 3
gage the pump hub with the charging pump.
Proceed with the selective shim measurement.
5. Hold the turbine and turbine shaft stationary by
using one of the methods listed below:
• Insert a screwdriver into the vanes on the
V07375
rotating clutch module (Figure 6–17,
View B). Figure 6–16. Converter Housing Module Installation

Cupped end down

2 3 Use hoist and sling ROTATING
4 6
5 CLUTCH
1 MODULE
7
8
J 38564
VIEW A VIEW B
J 38548
VIEW C VIEW D E05623.01
Figure 6–17. Torque Converter Module Installation and Selective Shim Measurement
Table 6–1. Torque Converter Selective Shims
Dimension “C” Use P/N Shim Step Dimension

0.4093–0.6597 mm (0.0161–0.0260 in.) 29505688 0.000 mm; NO STEP
0.6598–0.8377 mm (0.0261–0.0330 in.) 29505681 0.178–0.228 mm (0.007–0.009 in.)
0.8378–1.0157 mm (0.0331–0.0400 in.) 29505682 0.356–0.406 mm (0.014–0.016 in.)
1.0158–1.1937 mm (0.0401–0.0470 in.) 29505683 0.534–0.584 mm (0.021–0.023 in.)
1.1938–1.3707 mm (0.0471–0.0540 in.) 29505684 0.711–0.761 mm (0.028–0.030 in.)
1.3708–1.5487 mm (0.0541–0.0610 in.) 29505685 0.889–0.939 mm (0.035–0.037 in.)
1.5488–1.6823 mm (0.0611–0.0662 in.) 29505686 1.067–1.117 mm (0.042–0.044 in.)

r. Installation of the Control Module
NOTE: (Figure 6–18)
Dimension C shown in Table 6–1 includes a correction
due to internal deflection caused by the 27–34 N·m WARNING!
(20–25 lb ft) bolt torque applied to gauge J 38548.
Accurate torque value is critical to selection of the Transmissions installed in overhaul stands must
proper shim. be positioned vertically before installing control
module. Failure to do so could result in personal
injury.
7. Measure from top of tool J 38548 to face of
turbine shaft and record it as dimension B.
Subtract dimension B from dimension A — di- 1. Position transmission in overhaul stand verti-
mension A is the height of tool J 38548, cally.
100.00 mm (3.937 inch) to determine dimen-
sion C (Figure 6–17, View D). WARNING!
8. Use Dimension C and Table 6–1 to determine The control module assembly weighs approxi-
proper selective shim part number. Remove mately 25 kg (56 lb). The control module assem-
tool J 38548 and continue with installation of bly used in an MD 3070PT weighs approximately
the torque converter. 29 kg (65 lb).
NOTE: 2. Install a new control module gasket 2 over the

• For MD Product Line units prior to S/N 6510165560, dowel pins on control module 1.
• For MD Product Line units beginning with
S/N 6510165560, skip Steps (9–11) and proceed
to Step (12).
9. Install selective shim 5 with the shim step side

toward the turbine shaft. Install bolt 4, con-
verter bolt tightening tool J 38564, and retain-
ing ring 1 (Figure 6–17, View A).
10. Prevent turbine shaft rotation as in Step (5).
Tighten bolt 4 to 100–120 N·m (74–89 lb ft).
11. If present, remove retaining ring 1 and tool
J 38564. Install O-ring 3 on converter end
plug 2. Install the end plug. Aligning retaining
ring 1 so that the sharp edge faces outward, in-
stall the retaining ring. 2
12. Install selective shim 5 with the shim step side
toward the turbine shaft. Install bolt 4 and con-
verter bolt tightening tool J 38564 (Figure 6–17,
View A). 1 1
13. Prevent turbine shaft rotation as in Step (5).
Tighten bolt 4 to 100–120 N·m (74–89 lb ft).
14. Remove tool J 38564. Install O-ring 8 on
threaded converter end plug 7. Use a 3⁄4 inch
Allen socket to install end plug 7 and tighten it
to 50–60 N·m (37–44 lb ft).
15. Install converter shipping brackets (Foldout 3 3 4
10,A), or equivalent, to retain the torque con-
V07364
verter to the transmission. Tighten the shipping
bracket bolts to 51–61 N·m (38–45 lb ft). Figure 6–18. Control Module Installation

3. Guide control module 1 onto the main housing 2. Install nine bolts 15 and nine washers 16 (two
using the dowel pins. Install one bolt 176 will replace the guide bolts) which fasten the
(Foldout 17,A) in the top center bolt hole. cooler housing to the main housing. Tighten
the bolts to 51–61 N·m (38–45 lb ft).
NOTE: 3. Install plate assembly 27 with four lubed
Main and lube filters are interchangeable. However, O-rings 28 in place. Push the plate assembly in
until the O-rings are seated in their mating
the filters for a two inch sump are a different length
bores in the cooler housing.
than those for a four inch sump. The filters in the
seven inch sump are the same as in the two inch sump. 4. Install two O-rings 26. Install two guide bolts
at rear of cooler housing where cover 23 at-
taches. Slide gasket 22 and cover 23 into posi-
tion over the guide bolts.
NOTE:
5. Install two bolts 24 and seventeen bolts 25 (two
• For MD Product Line units prior to S/N 6510032369,
will replace the guide bolts). Tighten the two
bolts 24 to 90–110 N·m (66–81 lb ft) and the
• For MD Product Line units beginning with seventeen bolts 25 to 51–61 N·m (38–45 lb ft).
S/N 6510032369, and later, skip Step (4) and go
to Step (5). 6. Install two M10 guide bolts at rear of retarder
housing where cooler housing attaches. Slide
4. Install two square cut seals 179 (Foldout gasket 6 and cooler housing 7 onto the guide
bolts. Be sure the housing and gasket are prop-
17,A), two O-rings 180, two filters 181, and
erly aligned.
two filter covers 178. Install remaining
thirty-one bolts 176 and 177. Tighten all bolts 7. Install bolt 12, washer 11, six bolts 15 and six
to 51–61 N·m (38–45 lb ft). washers 16 which fasten the cooler housing to the
retarder housing. Tighten the bolts to 51–61 N·m
5. Install two filter covers 183 (Foldout 17,B), (38–45 lb ft). Install three bolts 13 and three
two gaskets 184, two O-rings 185, two washers 14. Tighten the three bolts 13 to
O-rings 186, and two filters 187. Install re- 100–120 N·m (74–88 lb ft).
maining thirty-one bolts 188 and 189. Tighten 8. Install plate assembly 27 with four lubed
all bolts to 51–61 N·m (38–45 lb ft). O-rings 28 in place. Push the plate assembly in
s. Installation of Power Takeoff(s) until the O-rings are seated in their mating
(Figure 6–19) bores in the cooler housing.
9. Install two O-rings 26. Install two guide bolts
1. If removed, install PTO studs 4. at rear of cooler housing where cover 23 at-
2. Install PTO gasket 3 and PTO assembly 2. In- taches. Slide gasket 22 and cover 23 into posi-
sert bolt 1 into each of the 6 o’clock and tion over the guide bolts.
12 o’clock positions. Install the remaining six 10. Install two bolts 24 and seventeen bolts 25 (two
bolts. Tighten bolts to 51–61 N·m (38–45 lb ft). will replace the guide bolts). Tighten the two
bolts 24 to 90–110 N·m (66–81 lb ft) and the
t. Installation of Integral Oil Cooler seventeen bolts 25 to 51–61 N·m (38–45 lb ft).
(Foldout 19,A)
u. Installation of Speed Sensors
NOTE:
NOTE:
• For units without retarder, proceed to Step 1.
• For MD Product Line units without retarder,
• For units with retarder, skip Steps 1–5 and pro-
ceed to Step 6.
• For MD Product Line units with retarder (built
prior to 1/98), skip Step (1) and proceed to Step (2).
1. Install two M10 guide bolts at rear of main hous-
• For MD Product Line units with retarder (built
ing where cooler housing attaches. Slide gasket 5
and cooler housing 7 onto the guide bolts. Be starting 1/98), skip Steps (1) and (2) and proceed
sure the housing and gasket are properly aligned. to Step (3).

3
1
4
3
1
V07369
Figure 6–19. Power Takeoff(s) Installation
1. Install output speed sensor assembly 29 (Fold-

out 13,C), O-ring 30, retainer 31, and bolt 32 NOTE:
into the rear cover assembly 21. Tighten • For models without PTO, proceed to Step (4).
bolt 32 to 24–29 N·m (18–21 lb ft). Skip to
next NOTE. • For models with PTO, skip Step (4) and proceed
to Step (5).
2. Install output speed sensor assembly 36 (Fold-
out 13,A), O-ring 37, retainer 38 and bolt 39.
Tighten bolt 39 to 24–29 N·m (18–21 lb ft). In- 4. Install input speed sensor assembly 3 (Foldout
stall cover 70 and four bolts 71. Tighten bolts 8,A), O-ring 4, retainer 5, and bolt 6 into the
71 to 39 to 24–29 N·m (18–21 lb ft). Skip to converter housing module. Tighten bolt 6 to
next NOTE. 24–29 N·m (18–21 lb ft).
3. Install output speed sensor assembly 40 (Fold- 5. Install input speed sensor assembly 19 (Fold-
out 13,B), O-ring 41, retainer 42, and bolt 43 out 8,B), O-ring 20, retainer 21, and bolt 22
into the retarder housing. Tighten bolt 43 to into the converter housing module. Tighten
24–29 N·m (18–21 lb ft). bolt 22 to 24–29 N·m (18–21 lb ft).

v. Installation of Common Externally-Mounted 5. For a transmission which uses front cooler
Parts (Figure 6–20) ports, install gasket 19, cover plate 17, and
six bolts 16. Tighten the bolts to 51–61 N·m
1. Install transmission breather 1, if not previ- (38–45 lb ft).
ously installed. Tighten breather to 12–16 N·m
(9–12 lb ft). CAUTION:
2. Install fill tube seal 20, fill tube 21, bracket 23, The bolts to be used with cooler port manifold 18
and screw 22. Tighten screw to 24–29 N·m are longer than those used with remote cooler
port cover 17. DO NOT use the short cover bolts
(18–21 lb ft). Install dipstick 24.
to install a cooler port manifold or the main
housing will be damaged.
3. If not previously removed, remove and discard
expander plug 2. Install seal 4 and plug 3. Plug
3 is fully seated when the underside of the plug 6. Install parking brake assembly 5. Install four
head contacts seal 4. bolts 6. Tighten the bolts to 228–266 N·m
(168–196 lb ft).
4. If transmission has rear cooler ports, install 7. Install output flange 14 or yoke 15.
new cooler port gasket 19. Install remote
cooler port manifold 18 and six bolts 16. 8. Install lubricated O-ring 13 on retainer
Tighten bolts to 51–61 N·m (38–45 lb ft). plug 11.
3
1
25
26 4
2
5
6
14
7
8
14
24
14
13 12
22 23 11
19 10
21 9
18
17 15 27 28
20
16
29
V05564.01
Figure 6–20. Externally-Mounted Parts Installation

13. Replace gasket 9 (thin coated metal type), and
NOTE: install scavenge pump 7. Install nine bolts 8.
A service kit is recommended which improves the Tighten bolts 8 to 51–61 N.m (38–45 lb ft).
clamp load on parts retained by the two output
flange bolts. The kit contains Allen-Head bolts, 14. Install O-ring 4 and fitting 3 into scavenge
belleville washers, O-rings and an instruction sheet. pump 7. Tighten jam nut to 100–120 N·m
(74–88 lb ft.)
9. Insert two bolts 9 through belleville washers 10
and retainer plug 11 or one bolt 29 through re- w. Removal of Transmission From Repair Stand
tainer plug 28. (Figure 6–22). Using a hoist, remove the transmission
and holding fixture from the repair stand and prepare
10. Install an O-ring 12 over the threaded end of for vehicle installation.
each bolt 9 or O-ring 27 over bolt 29, so that
the O-ring seats against the retainer plug.
NOTE:
11. Install retainer plug 11 or 28 into the yoke or
flange. Tighten bolts 9 to 30–35 N·m (22–26 lb ft). Refer to Mechanic’s Tips MT2159EN or
Tighten bolt 29 to 70–80 N·m (51–60 lb ft.) MT3004EN for preparing the transmission for in-
stallation and installing the transmission onto the
12. If used, install brake drum 7 and two bolts 8. vehicle.
Tighten bolts to 56–66 N·m (41–49 lb ft).
NOTE:
If you have an MD 3070PT transmission model, CAUTION:
complete Steps (13) and (14). Refer to Figure 6–21. Whenever a transmission is overhauled, ex-
changed, or has undergone repairs, the Elec-
tronic Control Unit (ECU) must be “RESET TO
UNADAPTED SHIFTS”. This will cause the
7 ECU to erase previous adaptive information and
4 12
3 begin to adapt in Fast Adaptive Mode from the
8 base calibration. Use either the Allison DOC™ or
the Pro-Link® 9000 DDR and select “RESET TO
9
1 UNADAPTED SHIFTS” from the “ACTION
10 REQUESTS” menu. Be sure that YES is brack-
eted and press ENTER to finish the reset.
11
12
2
5
WARNING!
6 Transmission dry weights are as follows:
10
• MD/B 300/B 400 245 kg (535 lb)
11
• MDR/B 300R/B 400R 275 kg (610 lb)
• MDP/B 300P/B 400P 260 kg (575 lb)
• MDPR/B 300PR/B 400PR 300 kg (655 lb)
• MD 3070PT 530 kg (1170 lb)
V07378
Use proper tools and lifting equipment when
installing or removing a transmission from the
Figure 6–21. MD 3070PT — Scavenge Pump Installation repair stand.

J 29109
J 35926
J 38572
J 35926
VIEWA VIEW B
MD PRODUCT LINE MD 3070PT
V07377
Figure 6–22. Removing Transmission From Repair Stand

SECTION 7 — WEAR LIMITS AND SPRING DATA
7–1. WEAR LIMITS DATA adjacent parts, or permanent set. Discard springs
which do not meet the load height specifications ac-
a. Maximum Variations. Wear limits information cording to Table 7–2, Spring Data.
in this Section shows the maximum wear at which
components are expected to function satisfactorily. Ta- b. Inspection. Inspection criteria (load vs. height)
ble 7–1 lists the Wear Limits Data and is referenced to and identification characteristics of the springs are pre-
the exploded views (Foldouts 7 through 19) in the sented in Table 7–2. The Spring Data are keyed to the
back of this manual. exploded views (Foldouts 7 through 19) in the back of
this manual.
b. Cleaning and Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Section 3.
NOTE:
When more than one spring part number is listed
7–2. SPRING DATA for the same location, refer to the latest edition of
Parts Catalog PC2150EN to determine which
a. Spring Replacement. Springs should be replaced spring is used in your specific assembly number.
if there are signs of overheating, wear due to rubbing
Table 7–1. Wear Limits Data
Wear Limit
Illustration Description mm (inches)
Foldout 7 TORQUE CONVERTER MODULE
9 Cover Bushing, Maximum ID 61.51 2.422
11 Piston, Minimum Thickness 5.71 0.225
13 Lockup Clutch Friction Plate Flatness, Maximum Distortion 0.51 0.020
13 Lockup Clutch Friction Plate, Minimum Thickness 8.05 0.317
13, 18 Turbine-To-Damper Spline Wear, Maximum Movement 0.38 0.015
14 Backing Plate Wear Surface, Minimum Thickness 8.58 0.338
16 Turbine Hub Hook-Type Sealring, Maximum ID When Installed In 56.75 1.441
Cover 7 Bore
18 Turbine Hub, Minimum OD 61.34 2.415
23 Stator Thrust Plate, Minimum Thickness 11.68 0.460
34 Converter Pump Hub, Minimum OD 74.999 2.9527
Foldout 8,B TORQUE CONVERTER HOUSING MODULE — WITH PTO
6 Bearing Retainer Bushing, Maximum ID 75.23 2.962
7 Bearing Retainer Bearing Bore, Maximum ID 140.06 5.514
10, 17 Oil Pump Drive Hub Seals, When Installed in Sealing Bore, 1.15 0.045
Maximum End Gap
14 Oil Pump Drive Hub, Maximum Tang Wear 0.38 0.015
23 Converter Housing Bearing Bore, Maximum ID 140.03 5.513

Table 7–1. Wear Limits Data (cont’d)
Wear Limit
Foldout 9,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 75.23 2.962
9 Pump Housing Gear Cavity, Maximum Depth 17.93 0.706
9 Pump Housing Gear Cavity, Maximum ID 127.30 5.012
9, 10 Driven Gear-To-Pump Housing, Maximum Diametrical Clearance 0.36 0.014
10 Drive/Driven Gear, Maximum Gear Tooth Tip Clearance 0.20 0.008
10 Driven Gear, Minimum OD 126.95 4.998
10 Drive/Driven Gear, Minimum Width 17.81 0.701
10, 14 Gear-To-Plate Maximum Side Clearance 0.13 0.005
11 Pump Drive Gear Bushing, Maximum ID 57.30 2.256
14 Wear Plate, Minimum Thickness 4.70 0.185
16, 17 Ground Sleeve Oil Pump Bushing Journal, Minimum OD 57.04 2.246
20 Front Support Sleeve, Minimum Dimension 98.83 3.891
23 Front Support Seal, Maximum End Gap 1.44 0.057
Foldout 9,B ROTATING CLUTCH MODULE
7 Turbine Shaft Bushing ID, Maximum 20.19 0.795
10 Turbine Shaft Seal, Maximum End Gap 0.94 0.037
11 Drum, Maximum Spline Wear 0.38 0.015
13 Rotating Clutch Hub Bushing, Maximum ID 99.25 3.907
29 C1 Clutch Pressure Plate Flatness, Maximum Distortion 0.15 0.006
29 C1 Clutch Pressure Plate, Minimum Wear Surface Thickness 6.25 0.246
30, 37 C1, C2 Friction Plate, Maximum Cone 0.40 0.016
30, 37 C1, C2 Friction Plate, Minimum Thickness 2.21 0.087
30, 37 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31, 36 C1, C2 Steel Reaction Plate, Maximum Cone 0.40 0.016
31, 36 C1, C2 Steel Reaction Plate, Minimum Thickness 2.41 0.095 *
33, 35 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
38 C2 Clutch Pressure Plate, Maximum Cone 0.45 0.018
38 C2 Clutch Pressure Plate, Minimum Thickness 6.25 0.246
42 P1 Sun Gear Drive Hub Bushing, Maximum ID 68.22 2.685
* 0.0965 For MD 3070PT Model

WEAR LIMITS AND SPRING DATA
Wear Limit
Foldout 10,A MAIN HOUSING MODULE
4 Backing Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate, Minimum Thickness At Wear Point 2.81 0.111
7 P1 Ring Gear, Maximum Spline Wear 0.38 0.015
8, 19, 38 C3, C4, C5 Friction Plate Cone, Maximum Distortion 0.40 0.016
8, 19 C3, C4 Friction Plate, Minimum Thickness 2.21 0.087
8, 19 C3, C4 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
9, 18, 37 C3, C4, C5 Reaction Steel Plate Cone, Maximum Distortion 0.40 0.016
9, 18, 37 C3, C4, C5 Reaction Steel Plate, Minimum Thickness 2.41 0.095
11, 21 C3, C4 Piston Return Plate Cone, Maximum Distortion 0.40 0.016
11, 21 C3, C4 Piston Return Plate, Minimum Thickness 3.41 0.135
17, 24 C3, C4 Clutch Housing Flatness, Maximum Distortion 0.15 0.006
27 Main Housing Clutch Plate Splines, Maximum Wear 1.15 0.045
38 C5 Friction Plate, Minimum Thickness 2.90 0.114
38 C5 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
Foldout 10,B
MAIN SHAFT MODULE (MD 3060 and MD 3560)
and 11,A
9, 8 Main Shaft Pilot, Minimum OD 19.98 0.787
9, 8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
Foldout 11, B MAIN SHAFT MODULE (MD 3070PT)
8 Main Shaft Pilot (Front), Minimum OD 19.98 0.787
8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
8 Main Shaft C6 Bushing Journal, Minimum OD 35.92 1.414
8 Main Shaft P3 Bushing Journal, Minimum OD 52.98 2.086
Foldout 12,A P1 PLANETARY MODULE
9, 12 P1 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
10 Pinion, Maximum End Play 0.94 0.037

Wear Limit
Foldout 12,B P2 PLANETARY MODULE
2 P2 Carrier Seal, Maximum End Gap 1.20 0.047
7 P2 Carrier Bushing, Maximum ID 43.20 1.701
Foldout 13,A;
RETARDER AND P3 PLANETARYMODULE
13,B; 13,C
8 Output Shaft Bushing, Maximum ID 20.19 0.795
29 Retainer Ball, Minimum Movement (N/A To Foldout 13,B and 13,C) 0.50 0.020
Foldout 13,D REAR COVER AND P3 PLANETARY MODULE
7 Output Shaft Bushing, Maximum ID 20.19 0.795
Foldout 15 C7 CLUTCH HOUSING
44 Yoke Journal Seal Wear, Minimum Diameter 76.20 3.000
61 C7 Backplate, Minimum Thickness 8.67 0.341
62 C7 Friction Plate, Maximum Cone 0.25 0.010
63 C7 Reaction Plate, Minimum Thickness 2.11 0.083
63 C7 Reaction Plate, Maximum Cone 0.25 0.010
68 Bushing, Maximum ID 47.26 1.861
69 Ball, Free Movement 1.00 0.040

Wear Limit
Foldout 16 C6 CLUTCH HOUSING
9 Backplate, Minimum Thickness 7.90 0.311
9 Backplate, Maximum Cone 0.40 0.016
11 C6 Reaction Plate, Minimum Thickness 2.41 0.095
11 C6 Reaction Plate, Maximum Cone 0.40 0.016
19 C6 Housing, Maximum Groove Wear 2.29 0.090
21 C6 Housing Bushing 36.18 1.424
Foldout 18,A OUTPUT FLANGE AND YOKE
1, 7 Journal Seal Wear, Minimum Diameter 89.78 3.535
Foldout 18,B TRANSFER CASE ADAPTER HOUSING AND P3 MODULE
6 P3 Carrier Bushing, Maximum ID 53.22 2.095

7–6
Table 7–2. Spring Data

Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length

Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
7 25 Stator 29500064 No Code N/A N/A N/A 17.8 3.3 0.7–1.6
Convoluted (0.70) (0.13) (0.16–0.36)
9,B 21 C2 Return 29503215 No Code 12* 2. 04* 13.00* 45.3** 37.0 4823–5379**
(0.080) (0.512) (1.78) (1.46) (1084–1209)
9,B 25 C1 Return 23045586 No Code 10* 2.19* 16.00* 45.2** 27.5 5763–6369**
(0.086) (0.630) (1.78) (1.08) (1296–1432)
10,A 10 C3 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)

10,A 12 C3 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
(0.102) (0.522) (0.50) (0.43) (2543–3284)
10,A 20 C4 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)
10,A 22 C4 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
(0.102) (0.522) (0.50) (0.43) (2543–3284)
13,A/13,B 23/23 C5 Retainer 29507780 No Code 9.5* 1.83* 14.35* 39.2** 25.0 3044–3364**
(0.072) (0.565) (1.54) (0.98) (684–756)
13,A 46 Retarder 6880775 Yellow/ 12 1.93 16.61 53.85 35.31 73–89
Red Stripe (0.076) (0.654) (2.12) (1.39) (16.5–20.1)
13,A 46 Retarder 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 177.5–196.3
(0.085) (0.75) (2.42) (1.02) (39.9–44.1)
13,A 46 Retarder 29515101 Green 16.0 3.78 36.6 106.7 73.66 120.1–146.7
(0.149) (1.44) (4.20) (2.90) (27.0–33.0)
13,A/13,B 46/55 Retarder 29515692 None 11.4 4.12 36.17 114.3 91.1 200.0–226.6
(0.162) (1.42) (4.50) (3.59) (44.96–50.94)
13,A 92 Retarder Control 29510494 Solid Orange 7 1.60 15.50 27.8 18.0 44–50.9
Low, 27 psi (0.063) (0.610) (1.09) (0.71) (9.9–11.4)
* Individual Springs
** For the complete Spring Assembly
Table 7–2. Spring Data (cont’d)
Spring Approx. Free
Length Under Load
13,A 92 Retarder Control 29510495 Solid Silver 7.5 1.40 15.09 30.8 18.0 32.5–35.9
Medium, 36 psi (0.055) (0.594) (1.21) (0.71) (7.3–8.05)
13,A 92 Retarder Control 29510496 Solid Blue 8 1.14 14.59 36.0 18.0 19.8–21.9
High, 45 psi (0.045) (0.574) (1.42) (0.71) (4.5–4.9)

13,B 78 Retarder Control 29529300 White/ 8.52 1.27 13.46 33.02 16.51 34.22–37.86
Low, 54 psi Black Stripe (0.050) (0.530) (1.30) (0.650) (7.69–8.51)
13,B 78 Retarder Control 29529299 Yellow/ 9.25 1.04 12.19 37.8 16.51 23.44–25.94
Medium, 64 psi Red Stripe (0.041) (0.480) (1.49) (0.650) (5.27–5.83)

13,B 78 Retarder Control 29529298 Pink/ 8.23 0.94 12.19 31.47 16.51 9.39–10.37
High, 76 psi White Ends (0.037) (0.480) (1.24) (0.650) (2.11–2.33)
13,D/18,B 23/16 C5 Retainer 29500867 No Code 11.5* 2.16* 16.00* 52.1** 33.0 3034–3498**
(0.085) (0.630) (2.05) (1.30) (682.1–786.4)
2109–
C6 Spring Retainer 1.84 12.70 35.10 26.20
16 13 29501191 No Code 10 2331**
Assembly (0.072) (0.500) (1.382) (1.032)
(474–524)
17,A 53, 79, Solenoid Regulator 29502195 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
88, 103 (0.026) (0.435) (0.26) (0.14) (0.72–0.94)
17,B 60, 75 Solenoid Regulator 29502195 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
84, 109 (0.026) (0.435) (0.26) (0.14) (0.72–0.94)
17,C 61, 76 Solenoid Regulator 29502195 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
89, 110 (0.026) (0.435) (0.26) (0.14) (0.72–0.94)
17,A/17,B 65/96 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 47.3–52.3
17,C 97 (0.050) (0.460) (1.72) (0.79) (10.6–11.8)
17,A/17,B 73/103 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.4–15.2
17,C 104 (0.030) (0.305) (1.05) (0.49) (2.79–3.42)
* Individual Springs
** For the complete Spring Assembly
7–7
† OD at larger end
Table 7–2. Spring Data (cont’d)
7–8
Spring Approx. Free

Length Under Load

17,A/17,B 111/119 Lockup Relay 23049326 No Code 10 1.37 14.10 42.1 17.0 49.2–60.2
17,C 120 (0.054) (0.555) (1.66) (0.67) (11.06–13.53)
17,A/17,B 115/123 Lube Regulator 23049327 Red 13 1.22 11.10 46.3 23.5 46.5–51.3
17,C 124 (0.048) (0.437) (1.82) (0.93) (10.5–11.5)
17,A/17,B 119/127 Main Regulator 29500963 Lt. Blue 15 2.87 22.0 98.5 54.6 305–337
17,C 128 (0.113) (0.866) (3.88) (2.15) (68.6–75.8)
17,A/17,B 123/131 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.2 131–145
17,C 132 (0.072) (0.583) (1.76) (0.95) (29.5–32.6)

17,A/17,B 133/141 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 64.1–78.3
17,C 142 (0.052) (0.450) (1.63) (0.75) (14.4–17.6)
17,A/17,B 137/145 Exhaust Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2.40–2.94
17,C 146 (0.024) (0.307) (1.15) (0.72) (0.54–0.66)
17,A/17,B 141/149 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 16.7–18.9
17,C 150 (0.054) (0.640) (1.82) (1.15) (3.75–4.25)
17,A/17,B 145/153 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 53.7–59.3
17,C 154 (0.060) (0.433) (1.19) (0.90) (12.1–13.3)
SECTION 8 — CUSTOMER SERVICE
8–1. OWNER ASSISTANCE Step Two — If your problem cannot be readily re-
solved at the distributor level without additional assis-
The satisfaction and goodwill of the owners of Allison tance, contact the Allison Transmission Regional
transmissions are of primary concern to Allison Trans- Office responsible for your local distributor (see
mission Division (ATD), its distributors, and their maps in Warranty Manual). You will be assisted by a
dealers. member of the Regional Service Manager’s staff.
As an owner of an Allison transmission, you have ser- For prompt assistance, please have the following infor-
vice locations throughout the world eager to meet your mation available.
parts and service needs with:
• Name and location of authorized distributor
• Expert service by trained personnel
or dealer
• Emergency service 24 hours a day in many
areas • Type and make of equipment
• Complete parts support • Transmission model number, serial number,

and assembly number — if equipped with
• Sales teams to help determine your trans-
electronic controls, also provide the ECU
mission requirements
assembly number
• Product information and literature
• Transmission delivery date and accumu-
Refer to a current North American Parts and Service lated miles and/or hours of operation
Directory SA2229EN or the International Parts and
Service Directory SA2338EN for a listing of Allison • Nature of problem
Transmission authorized distributors and service • Chronological summary of unit’s history
dealers.
Normally, any situation that arises in connection with Step Three — If you contacted a regional office and
the sale, operation, or service of your transmission will you are still not satisfied, present the entire matter in
be handled by the distributor or dealer in your area. writing or by phone to the Home Office:
(Check the telephone directory for the Allison Trans-
mission service outlet nearest you.) Manager Warranty Administration — PF9
Allison Transmission
We recognize, however, that despite the best intentions P. O. Box 894
of all concerned, misunderstandings may occur. To Indianapolis, Indiana 46206-0894
further assure your complete satisfaction, we have de- Phone: (800) 524-2303
veloped the following three-step procedure in the
event you have a problem that has not been handled The inclusion of all pertinent information will assist
satisfactorily. the Home Office in expediting the matter. If an addi-
tional review by the Home Office of all the facts in-
Step One — Discuss your problem with a member volved indicates that some further action can be taken,
of management from the distributorship or dealer- the Regional Office will be advised.
ship. Complaints are frequently the result of a break-
down in communication and can be quickly resolved When contacting the Regional or Home Office, please
by a member of management. If you have already dis- keep in mind that ultimately your problem will likely
cussed the problem with the Sales or Service Manager, be resolved at the distributorship or dealership — us-
contact the General Manager. All ATD dealers are as- ing their facilities, equipment, and personnel. There-
sociated with an ATD distributor. If your problems fore, we suggest you follow the above steps, in se-
originate with a dealer, explain the matter to a distribu- quence, when experiencing a problem.
torship member of management with whom the dealer
has his service agreement. The dealer will provide his Your purchase of an Allison Transmission product is
ATD distributor’s name, address, and telephone num- greatly appreciated, and it is our sincere desire to as-
ber on request. sure complete satisfaction.

8–2. SERVICE LITERATURE SGI, Inc.
Attn: Allison Literature Fulfillment Desk
Additional service literature is available. This service
literature provides fully illustrated instructions for 8350 Allison Avenue
operation, maintenance, service, overhaul, and parts Indianapolis, IN 46268
support for your transmission. To ensure that you get
maximum performance and service life from your Toll Free: 888-666-5799
transmission, you may order publications from: International: 317-471-4995
Table 8–1. Service Literature

Literature Type Base Transmission MD 3070PT
*Mechanic’s Tips (WTEC III Controls) MT3004EN —
*Mechanic’s Tips (WTEC II Controls) MT2159EN MT2923EN
*Operator’s Manual (WTEC III Controls) OM2995EN —
*Operator’s Manual (WTEC II Controls) OM2157EN OM2683EN
Parts Catalog PC2150EN PC2150EN
Parts Catalog on CD-ROM CD2150EN CD2150EN
Principles of Operation PO2454EN PO2454EN
Retail Literature Catalog GM2798EN GM2798EN
Service Manual SM2148EN SM2148EN
Troubleshooting Manual (WTEC III Controls) TS2973EN TS2973EN
Troubleshooting Manual (WTEC II Controls) TS2470EN TS2470EN
* Also Available On The Internet At www.allisontransmission.com

Legend For Foldout 1 Is On The Opposite Side Of This Page.
Copyright © 2001 General Motors Corp. Foldout 1

Legend For Foldout 1
1 — Lockup clutch and damper assembly
2 — Converter turbine
3 — Converter pump
4 — Converter housing
5 — Front Support
6 — Rotating clutch module
7 — C2 clutch
8 — Main case module
9 — C3 clutch
10 — P1 planetary module
11 — C4 clutch
13 — C5 clutch
15 — Rear cover module
16 — Output shaft
17 — Main shaft module
18 — Control valve module
19 — C1 clutch
20 — Oil pump
21 — Ground sleeve
22 — Converter stator
23 — Turbine shaft
Foldout 1 Copyright © 2001 General Motors Corp.

F OLDOUT 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16
V03348.01
Foldout 1. MD Product Line Transmission — Cross Section


5 — Front Support
6 — Oil pump
7 — Main housing module
8 — C3 clutch
9 — C4 clutch
10 — C5 clutch
11 — Retarder housing
12 — Retarder stator
13 — Retarder rotor
15 — P2 sun gear
16 — P3 sun gear
21 — Oil level sensor
22 — C2 clutch
23 — C1 clutch

F OLDOUT 2
5 6 7 8 9 10
11
12
2
13
4
14
15
16
17
18
19
20
25 24 23 22 21
V03134.01
Foldout 2. MD 3066 Transmission with Retarder (Prior To January 1, 1998) — Cross Section


5 — PTO gear assembly
6 — Front support
8 — C2 clutch
10 — C3 clutch
12 — C4 clutch
14 — C5 clutch
17 — Stator assembly
18 — Rotor assembly
19 — Speed sensor
20 — Rear output shaft
24 — C1 clutch
25 — Oil pump
26 — Oil pump drive hub

26 25 24 23 22 21 20
V04375
F OLDOUT 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
29 28 27 26 25 24 23 22 21 20
V04375.01.00.eps
Foldout 3. MD Product Line Transmission with PTO Provision and Retarder (Beginning January 1, 1998) — Cross Section


6 — Front support
8 — C2 clutch
10 — C3 clutch
12 — C4 clutch
14 — C5 clutch
17 — Stator assembly
18 — Rotor assembly
19 — Retarder temperature sensor
20 — Remote manifold
21 — Output shaft
25 — C1 clutch
26 — Oil pump

F OLDOUT 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
30 29 28 27 26 25 24 23 22 21 20
V07392.01.00.eps
Foldout 4. MD Product Line Transmission with PTO Provision and Retarder (Starting With S/N 6501262246) — Cross Section

5 — Front Support

7 — C2 clutch
9 — C3 clutch
11 — C4 clutch
13 — C5 clutch
15 — Rear cover module
16 — Output shaft

19 — C1 clutch
20 — Oil pump

F OLDOUT 5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16
V04635.02
Foldout 5. Model MD 3560 Transmission — Cross Section



6 — Front support
8 — C2 clutch
10 — C3 clutch
12 — C4 clutch
14 — C5 clutch
16 — Transfer case adapter housing
17 — Transfer case module
18 — C6 clutch
19 — Transfer case rear output shaft
20 — C7 clutch
21 — Transfer case front output shaft
24 — C1 clutch
25 — Oil pump

&F OLDOUT 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
29 28 27 26 25 24 23 22 21 20 19
V04637.01
Foldout 6. Model MD 3070PT Transmission — Cross Section

F OLDOUT 7
1
2
3
7
1 — Retaining ring 23 — Stator thrust plate assembly 8
2 — Converter end plug 24 — LH stator thrust washer 9

6
10
3 — O-ring 25 — Torque converter stator race 4
11
4 — Torque converter module 26 — Torque converter stator spring (13)
5 — Nut, M8 (36), A 27 — Torque converter stator roller (13) 5 12
6 — Torque converter cover assembly 28 — Stator and cam assembly

13
7 — Cover and bushing assembly 29 — Shim, converter, 0.2540 mm
(0.010 inch), selective
8 — Torque converter cover 18 14
29 — Shim, converter, 0.4826 mm
9 — Bushing
10 — Lockup piston sealring 19
29 — Shim, converter, 0.7112 mm 20 16
11 — Lockup piston assembly (0.028 inch), selective 22
12 — Lockup piston sealring 23 17
30 — Pump thrust bearing assembly 24
13 — Lockup clutch and damper assembly 25
31 — O-ring
27
14 — Lockup clutch backplate
32 — Torque converter pump assembly 28
15 — Bolt, M8 x 1.25 x 20 (**), A 15
33 — Pump thrust washer
29
16 — Hook-type sealring
34 — Torque converter pump assembly 30
17 — Thrust bearing assembly 26 31
35 — T-head bolt (36) 21
18 — Torque converter turbine assembly
** With 20 hole plate 13, use qty 20 bolts 14; with 30 hole
19 — Stator thrust bearing assembly plate 13, use qty 30 bolts 14.
33
20 — Star washer
Torque N·m lb ft
21 — Torque converter stator assembly
22 — Retaining ring A 30–35 22–26
34
32 35
V03940.02
Foldout 7. Torque Converter Module — Exploded View


A 9 — PTO gear assembly
1 — Torque converter housing module 10 — Sealring
2 — Torque converter housing 11 — Single row ball bearing
3 — Speed sensor assembly 12 — Internal retaining ring (only used prior to

S/N 6510024410)
4 — O-ring
13 — PTO gear
5 — Speed sensor retainer
14 — Oil pump drive hub (2-tang style used starting
6 — Bolt, M8 x 1.25 x 20, A with S/N 2510024410)
7 — Torque converter housing gasket 15 — Single row ball bearing
8 — Bolt, M10 x 1.5 x 35 (20), B 16 — Internal retaining ring
9 — Vent assembly, M10 x 1.5, C 17 — Sealring
10 — Sensor shipping cover 18 — Converter housing assembly
11 — Pressure tap plug assembly, D 19 — Speed sensor assembly
12 — O-ring 20 — O-ring
13 — Pressure tap plug 21 — Speed sensor retainer
22 — Bolt, M8 x 1.25 x 20, B
Torque N·m lb ft 23 — Converter housing
A 24–29 18–21 24 — Sensor shipping cover
B 51–61 38–45 25 — PTO cover gasket (2)

26 — PTO cover (2)
C 12–16 9–12
27 — Bolt, M10 x 1.5 x 25 (20), A
D 10–13 7–10
28 — Bolt, M10 x 1.5 x 35 (20), A
29 — Vent Assembly, M10 x 1.5, C
B 30 — Breather adapter, M10 x 1.5, C
1 — Converter housing module 31 — Torque converter housing gasket
2 — Bolt (10), M10 x 1.5 x 35 (10), A
3 — Bearing retainer assembly Torque N·m lb ft
4 — Oil seal assembly
A 51–61 38–45
5 — Bearing retainer assembly
B 24–29 18–21
6 — Bearing retainer bushing
C 12–16 9–12
7 — Bearing retainer
8 — Piston sealring

F OLDOUT 8
A B
2
4
9 3
29
1
5
27
6
26
30
25
2
7
8
10
11 1
12
13 9
3 18
14 19
5
4 20 21
15 22
7
8 6 16
17
23 24
31
10 28
11
13
12
11
13 12
25
26
27
V05570
V02001
Foldout 8,A. Converter Housing Module, Without PTO Provision — Exploded View Foldout 8,B. Converter Housing Module, With PTO Provision — Exploded View

A — Shim, torque converter turbine, 4.000 mm

1 — Bolt, M10 x 1.5 x 60 (6), A 3 — Rotating clutch module
2 — Bolt, M10 x 1.5 x 35 (5), A 4 — O-ring
3 — Front support module 5 — Turbine shaft assembly (without PTO)
4 — O-ring (without PTO only) 6 — Turbine shaft
5 — Oil seal assembly (without PTO only) 7 — Turbine shaft bushing
6 — Bolt, M10 x 1.5 x 60 (8), A 8 — Turbine shaft assembly (with PTO)
7 — Pump housing assembly 9 — Turbine shaft
8 — Bushing (without PTO only) 10 — Sealring (3)
9 — Pump housing 11 — Rotating clutch drum
10 — Gear set assembly 12 — Rotating clutch hub assembly
11 — Bushing 13 — Rotating clutch hub bushing
12 — Bolt, M10 x 1.5 x 25 (10), A 14 — Rotating clutch hub assembly
13 — Stiffening plate 15 — Thrust bearing
14 — Wear plate 16 — Turbine shaft retaining ring
15 — Front support assembly 17 — C2 piston sealring
16 — Ground sleeve (with PTO) 18 — C1 piston sealring
17 — Ground sleeve (without PTO) 19 — C2 piston sealring
18 — Front support assembly 20 — C2 piston
19 — Dowel pin, 10 x 32 (2) 21 — C2 spring assembly
20 — Front support sleeve 22 — Internal retaining ring
21 — Front support 23 — C1 piston sealring
22 — Roller bearing assembly 24 — C1 piston
23 — Sealring (3) 25 — C1 spring assembly
24 — Thrust bearing assembly 26 — Rotating clutch balance piston
25 — Dowel pin, 6 x 35 27 — Rotating clutch balance piston sealring
26 — Pressure relief spring 28 — External retaining ring
27 — Pressure relief ball 29 — C1 clutch backplate (2)
Torque N·m lb ft 30 — C1 friction plate (6)
A 51–61 38–45 31 — C1 reaction plate (5)
32 — External retaining ring
B 33 — C1 drive hub
1 — Bolt, M16 x 2.0 x 50, A 34 — Thrust bearing (2)
35 — C2 drive hub
2 — Torque converter turbine shim
36 — C2 reaction plate (6)
— Shim, torque converter turbine, 5.092 mm
(0.201 inch), selective 37 — C2 friction plate (6)
— Shim, torque converter turbine, 4.914 mm 38 — C2 clutch backplate
(0.194 inch), selective 39 — Internal retaining ring
— Shim, torque converter turbine, 4.736 mm 40 — Sun gear assembly
(0.187 inch), selective 41 — Sun gear
— Shim, torque converter turbine, 4.559 mm 42 — Sun gear bushing
(0.180 inch), selective 43 — Internal retaining ring
— Shim, torque converter turbine, 4.381 mm
(0.173 inch), selective Torque N·m lb ft
— Shim, torque converter turbine, 4.203 mm A 100–120 74–89
F OLDOUT 9
A B
1
2
4
5
2 6
10
7 11
9
12 3
21 8 13
14
22
15
23 16
4 17
3 24 18
5 7
19
8
25 20
9 10 12 26
27
11 32 28
6 13
15 29
14 16 33 30
31
34
27 35
1
26 17 18
19 34
25 21 36
37 29
20
24
23
22
38
39
41
42
40
43
V01975
V03941
Foldout 9,A. Front Support and Oil Pump Module — Exploded View Foldout 9,B. Rotating Clutch Module — Exploded View

A 31 — Connector shipping cover

32 — Feedthrough connector assembly
1 — C3/C4 clutch assembly
(earlier models)
2 — Bolt, M10 x 1.5 x 90 (12), A
33 — Orange 24-way internal seal
3 — C3 backplate assembly
34 — O-ring
4 — Clutch backplate
35 — Green 24-way internal seal
5 — Clutch wear plate (3)
36 — Bolt, M10 x 1.5 x 35 (12), A
6 — Rivet (3 OD x 6) (6)
37 — C5 clutch reaction plate (8)
7 — P1 ring gear
38 — C5 clutch friction plate (7)
8 — C3 clutch friction plate (5)
9 — C3 clutch reaction plate (4) Torque N·m lb ft
10 — Return spring assembly (4) A 51–61 38–45
11 — Piston return plate B 5–8 4–5
12 — Spring retainer assembly
13 — C3 clutch piston
14 — C3 clutch housing assembly
15 — Rivet (3 OD x 6) (6) B
16 — Clutch wear plate (3) 1 — Shim (selective), 0.27 mm (0.01 inch)
17 — C3 clutch housing 1 — Shim (selective), 0.54 mm (0.02 inch)
18 — C4 clutch reaction plate (5) 1 — Shim (selective), 0.81 mm (0.03 inch)
19 — C4 clutch friction plate (5) 1 — Shim (selective), 1.08 mm (0.04 inch)
20 — Return spring assembly (4) 1 — Shim (selective), 1.35 mm (0.05 inch)
21 — Piston return plate 1 — Shim (selective), 1.62 mm (0.06 inch)
22 — Spring retainer assembly 1 — Shim (selective), 1.89 mm (0.07 inch)
23 — C4 clutch piston 2 — Thrust bearing
24 — C4 clutch housing 3 — Main shaft module
25 — Bolt, M10 x 1.5 x 25 (3), A 4 — Spiral retaining ring
26 — Converter shipping bracket (3) 5 — Thrust bearing
27 — Main housing 6 — P2 sun gear
28 — Nameplate 7 — Bearing spacer
29 — Screw, #4 x 1⁄4 8 — P3 sun gear
30 — Bolt, M5 x 0.8 x 20 (2), B 9 — Main shaft

F OLDOUT 10
A B
2
3
4 10
5 7 4
1
5
8 14
9 1516
2
17
20
11
3
12
18
19 13
26
6
25
21 7
22
23
24
31 9
27
28 29
32
30 33
34
35 37 38
36
V05571
V05415
Foldout 10,A. Main Housing Module — Exploded View Foldout 10,B. MD Product Line Main Shaft Module (Except MD 3560, MD 3070PT) — Exploded View

MD 3560
1 — Selective shim
2 — Thrust bearing assembly
4 — Spiral retaining ring
5 — P2 sun gear
7 — Bearing spacer
8 — Main shaft
MD 3070PT
3 — Spiral retaining ring
4 — Thrust bearing
5 — P2 sun gear
6 — Bearing spacer
7 — P3 sun gear
8 — Main shaft

F OLDOUT 11
A B
3
4 2
4 5
1
1
6
2
3
5
6
V05572
V05573
Foldout 11,A. Main Shaft Module (MD 3560) — Exploded View Foldout 11,B. Main Shaft Module (MD 3070PT) — Exploded View

A B
1 — P1 planetary module 1 — P2 planetary module
2 — Internal retaining ring 2 — Sealring kit
3 — Thrust bearing assembly 3 — Internal retaining ring
4 — P1 planetary carrier assembly 4 — P2 planetary carrier assembly
5 — Retaining ring 5 — Carrier and bushing assembly
6 — P1 indexing ring 6 — P2 planetary carrier
7 — P1 planetary spindle (6) 7 — Bushing
8 — P1 planetary carrier 8 — Thrust washer (4)
9 — P1 thrust washer (6) 9 — Roller bearing (8)
10 — P1 pinion gear (6) 10 — P2 pinion gear (4)
11 — Roller bearing assembly (12) 11 — Thrust washer (4)
12 — P1 thrust washer (6) 12 — P2 planetary spindle (4)
13 — Thrust bearing assembly 13 — P2 indexing ring
14 — P2 planetary ring gear 14 — Internal retaining ring
15 — P3 planetary ring gear

F OLDOUT 12
A B
2 1
1
3
3
13
4
14
4
6 15
5
6
7
8
13
7
14
8
9
10 12
9 11
10
11
12
V03473
V04223
Foldout 12,A. P1 Planetary Module — Exploded View Foldout 12,B. P2 Planetary Module — Exploded View
F OLDOUT 13,A
1 — Adapter housing gasket 52 — Cone and roller bearing assembly
2 — Bolt, M12 x 1.75 x 165 (12), A 53 — Locknut retainer
3 — Bolt, M12 x 1.75 x 190 (6), A 54 — Bearing retainer nut, M70 x 20, D
4 — Bolt, M10 x 1.5 x 180 (7), B 55 — Oil seal assembly 5
5 — Retarder and P3 planetary module 56 — Bolt, M10 x 1.5 x 155, B 22
23 21
6 — P3 planetary carrier assembly 57 — Bolt, M10 x 1.5 x 130 (2), B
7 — Output shaft assembly 58 — Temperature sensor retainer 24
8 — Bushing 59 — Bolt, M8 x 1.25 x 20, C 6 25
9 — Output shaft 60 — Wiring harness assembly
10 — Internal retaining ring 61 — Bulkhead connector
26
11 — P3 indexing ring 62 — Pin terminal (6) 1
7 28
27
12 — P3 planetary carrier 63 — Cavity plug (2) 8 29
13 — Cone and roller bearing assembly 64 — Female terminal (2) 9 10
14 — Spacer 65 — Temperature sensor connector 30
11
15 — External retaining ring 66 — Teflon spiral wrap
16 — P3 planetary spindle (4) 67 — 2-pin connector 12
17 — P3 thrust washer (4) 68 — Temperature sensor assembly
18 — P3 pinion gear set 69 — O-ring 13
(set of four pinion gears) 70 — Wiring harness cover 2
19 — Roller bearing assembly (8) 16 14
71 — Bolt, M8 x 1.25 x 20 (4), C 15
20 — P3 thrust washer (4) 72 — Gasket 96
21 — Retarder stator assembly 73 — Solenoid separator plate
22 — External retaining ring 74 — Gasket 17 78
23 — Spring and retainer assembly 75 — Channel plate 18 60 79
24 — C5 clutch piston 76 — Channel plate gasket 19 62
63 80
25 — Piston sealring, 281 mm diameter 77 — Bolt, M8 x 1.25 x 90 (9), C 20 61
26 — Internal sealring, 140 mm diameter 78 — Retarder control body assembly 68 65 64 81
27 — Roller bearing cup 79 — Bolt, M8 x 1.25 x 55 (4), C 58 59 69 95
28 — Retarder stator 80 — Wiring harness 32 82
29 — Retainer and ball assembly (2) 83
81 — Solenoid cover 33 57 66 84 86
67
30 — O-ring 82 — Solenoid 94 87
31 — Hook-type sealring 83 — O-ring 70 93 85
32 — Gasket 84 — O-ring 34 36
33 — Rotor 85 — Pressure tap plug assembly, E 31 39 88
38 71
34 — Hook-type sealring 86 — Pressure tap plug 92
37 89
35 — Retarder housing assembly 87 — O-ring 91 90
36 — Speed sensor assembly 88 — Retarder control body
37 — O-ring 89 — Valve plug 40
38 — Speed sensor retainer 41
90 — Retaining ring 50 77
73 72
39 — Bolt, M8 x 1.25 x 20, C 91 — O-ring 75
40 — Retaining ring 51 76 74
92 — Spring 40
41
41 — Valve plug 93 — Retaining pin, 2.5 OD x 40 43
42
42 — Signal valve 94 — Retarder control valve 44
43 — O-ring 95 — Solenoid cover gasket 52
45
44 — Spring pin 96 — Shipping cover 53
35 56
45 — Retarder valve 46 54
47 55
46 — Valve spring Torque N·m lb ft 48
49
47 — O-ring A 90–110 66–81
48 — Valve plug B 51–61 38–45
49 — Retaining ring C 24–29 18–21 4 3 V05601
50 — Roller bearing cup D 74–88 55–65
51 — Retarder housing E 10–13 7–10
Foldout 13,A. Retarder and P3 Planetary Module (Prior To 1/98) — Exploded View
F OLDOUT 13,B
1 — Retarder housing gasket 51 — Plug washer
2 — Bolt, M12 x 1.75 x 130 (14), A 52 — Retarder housing
3 — Bolt, M12 x 1.75 x 190 (4), A 53 — Spring pin, 5 x 45 5
4 — Bolt, M10 x 1.5 x 180 (7), B 54 — Retarder valve 22
23 21
5 — Retarder and P3 planetary module 55 — Retarder valve spring
24
6 — P3 planetary carrier assembly 56 — O-ring
7 — Output shaft assembly 57 — Valve plug 6 25
8 — Bushing 58 — Internal retaining ring
9 — Output shaft 59 — Bolt, M10 x 1.5 x 155, B 26
10 — Internal retaining ring 60 — Cone and roller bearing assembly 7 28
1 27
11 — P3 indexing ring 61 — Locknut retainer 8
12 — P3 planetary carrier 62 — Bearing retainer nut, M70 x 20, E 9 10
13 — Cone and roller bearing assembly 63 — Oil seal assembly 11
29
14 — Spacer 64 — Gasket
12
15 — External retaining ring 65 — Solenoid separator plate
16 — P3 planetary spindle (4) 66 — Gasket
17 — P3 thrust washer (4) 67 — Retarder control body assembly 13
18 — P3 pinion gear set 68 — Wiring harness
16 14
(set of four pinion gears) 69 — Connector 15
2
19 — Roller bearing assembly (8) 70 — O-ring
20 — P3 thrust washer (4) 71 — Connector assembly
21 — Retarder stator assembly 72 — Connector 17 67
22 — External retaining ring 73 — Terminal 18
68
23 — Spring and retainer assembly 74 — Solenoid 19
24 — C5 clutch piston 75 — O-ring 20 93 69
25 — Piston sealring, 281 mm diameter 76 — O-ring 70
26 — Internal sealring, 140 mm diameter 77 — Retarder control valve 31 73 71
27 — Roller bearing cup 72
78 — Spring
28 — Retarder stator 82
79 — O-ring 32 34 74
39 75 83 92
29 — O-ring 80 — Plug, C 36 84
76
30 — Hook-type sealring 81 — Retainer pin 90 85
37 81
31 — Gasket 82 — Plug, C 30 33 38 91
32 — Rotor 83 — O-ring 86
33 — Hook-type sealring 84 — Relay valve 40 43
77 89
34 — Bolt, M10 x 1.5 x 90 (2), B 85 — Relay spring 42 78 88
41 79
35 — Retarder housing assembly 86 — Retarder control body 80
44 87
36 — Temperature sensor assembly 87 — Pressure tap plug assembly, F 45
64 65 66
38 — Temperature sensor bracket 89 — Pressure tap plug 52 46
39 — Bolt, M8 x 1.25 x 20, C 90 — Spring clip 47
49
40 — Speed sensor assembly 48
91 — Bolt, M8 x 1.25 x 40 (3), C 51 59
41 — O-ring 92 — Bolt, M8 x 1.25 x 60 (6), C 50
53 60
42 — Speed sensor retainer 93 — Shipping cover
54 61
43 — Bolt, M8 x 1.25 x 20, C Torque N·m lb ft 35
62
44 — Retaining ring A 90–110 66–81 56
55 63
45 — Flow valve plug 57
B 51–61 38–45 58
46 — Roller bearing cup C 24–29 18–21
47 — Retarder housing subassembly D 60–67 44–50 3
48 — Straight thread plug, D E 74–88 55–65
4 V05602
49 — O-ring F 10–13 7–10

50 — Tachograph plug, D Foldout 13,B. Retarder and P3 Planetary Module (Beginning 1/98) — Exploded View
F OLDOUT 13,C
1 — Retarder housing gasket 35 — Retarder housing assembly 68 — Wiring harness

2 — Bolt, M12 x 1.75 x 130 (14), A 36 — Temperature sensor assembly 69 — Connector 5
3 — Bolt, M12 x 1.75 x 190 (4), A 37 — O-ring 70 — O-ring 22
23 21
4 — Bolt, M10 x 1.5 x 182 (4), B 38 — Temperature sensor bracket 71 — Connector assembly
24
5 — Retarder and P3 planetary 39 — Bolt, M8 x 1.25 x 20, C 72 — Connector
module 40 — Speed sensor assembly 73 — Terminal 6 25
6 — P3 planetary carrier assembly 41 — O-ring 74 — Solenoid
7 — Output shaft assembly 42 — Speed sensor retainer 75 — O-ring 26
7 28
8 — Bushing 43 — Bolt, M8 x 1.25 x 20, C 76 — O-ring 1 27
9 — Output shaft 8
44 — Retaining ring 77 — Retarder control valve
9 10
10 — Internal retaining ring 45 — Flow valve plug 78 — Spring 29
11 — P3 indexing ring 46 — Roller bearing cup 79 — O-ring 11
12 — P3 planetary carrier 47 — Retarder housing 80 — Plug, C 12
13 — Cone and roller bearing subassembly 81 — Retainer pin
assembly 48 — Tachograph plug, D 82 — Plug, C 13
14 — Spacer 49 — Plug washer 83 — O-ring
15 — External retaining ring 16 14
50 — Retarder housing 84 — Relay valve 15
16 — P3 planetary spindle (4) 51 — Gasket 85 — Relay spring
17 — P3 thrust washer (4) 52 — Cover 86 — Retarder control body
18 — P3 pinion gear set 53 — Bolt, M8 x 1.25 x 25 (9) C 87 — Pressure tap plug assembly, F 17 67
(set of four pinion gears) 54 — Spring pin, 5 x 45 88 — O-ring 18
68
19 — Roller bearing assembly (8) 55 — Retarder valve 89 — Pressure tap plug 19
20 — P3 thrust washer (4) 56 — Retarder valve spring 20 93 69
90 — Spring clip
21 — Retarder stator assembly 57 — O-ring 2 70
91 — Bolt, M8 x 1.25 x 40 (3), C 31 73 71
22 — External retaining ring 58 — Valve plug 92 — Bolt, M8 x 1.25 x 60 (6), C 72
23 — Spring and retainer assembly 59 — Internal retaining ring 93 — Shipping Cover 34 82
32 74
24 — C5 clutch piston 60 — Cone and roller bearing 94 — Gasket 39 75 83 92
36 84
25 — Piston sealring, 281 mm Dia assembly 76
95 — Jumper manifold 90
81 85
26 — Internal sealring, 140 mm Dia 61 — Locknut retainer 37
96 — Bolt, M10 x 1.5 x 30 (4) B 30 33 38 91
27 — Roller bearing cup 62 — Bearing retainer nut, 97 — Remote manifold 86
28 — Retarder stator M70 x 20, E
Torque N·m lb ft 40 77 89
29 — O-ring 63 — Oil seal assembly 43 78 88
A 90–110 66–81 41 42 79
30 — Hook-type sealring 64 — Gasket* B 51–61 38–45 80 87
31 — Gasket 65 — Solenoid separator plate 50
C 24–29 18–21 64 65 66
32 — Rotor 66 — Gasket* 47
D 60–67 44–50 45 44 60
35 49
33 — Hook-type sealring 67 — Retarder control body E 74–88 55–65 48 61
34 — Bolt, M8 x 1.25 x 90 (3), B assembly F 10–13 7–10 62
63
46
* Units before S/N 6510262246. 54
55
56 51 97
57 94
58 52
59 95
53 3
96
4
V07372
Foldout 13,C. Retarder and P3 Planetary Module (Starting With S/N 6510262246) — Exploded View
F OLDOUT 13,D
3
1 — Rear cover gasket 23 — Spring and retainer assembly
2 — Bolt, M12 x 1.7 x 45 (19), A 24 — C5 clutch piston
3 — Rear support bracket 25 — Piston sealring, 281 mm diameter
4 — Rear cover and P3 planetary module 26 — Internal sealring, 140 mm diameter 5
5 — P3 planetary carrier assembly 27 — Roller bearing cup 1
6 — Output shaft assembly 28 — Rear cover
22
7 — Bushing 29 — Speed sensor assembly 23
8 — Output shaft 30 — O-ring 4
24
9 — Internal retaining ring 31 — Speed sensor retainer 21 2
10 — Indexing ring 32 — Bolt, M8 x 1.25 x 20, B
25
11 — Spring pin, 5 x 12 33 — Output speed signal wheel
12 — P3 planetary carrier 34 — Roller bearing cup
13 — Cone and roller bearing assembly 35 — Cone and roller bearing assembly 26
14 — Output spacer 36 — Locknut retainer 27
15 — External retaining ring 37 — Bearing retainer nut, M70 x 20, C 28
6
16 — P3 planetary spindle (4) 38 — Oil seal assembly 7 31 32
17 — Thrust washer (4) 39 — Tachograph plug 8 9 30
18 — P3 pinion gear set (set of four gears) 40 — Washer 10
19 — Roller bearing assembly (8) 41 — Rear cover 11 29
20 — P3 thrust washer (4) 12
Torque N·m lb ft 42
21 — Rear cover assembly
A 90–110 66–81 16
22 — External retaining ring 13
B 24–29 18–21
C 74–88 55–65 14
41
15
17
18
40
19 39
20
33
34
35
36
37
38
V03946.01
Foldout 13,D. Rear Cover and P3 Planetary Module — Exploded View


A 15 — OD sealring
16 — ID sealring
Kent-Moore Tools
17 — Bolt, M10 x 1.5 x 100 (15), A
1 — J 38547
Forward/rear output seal installer
18 — Bolt, M10 x 1.5 x 40 (5), A
2 — J 38568
Bearing cup installers
19 — Idler cover
3 — J 38568-1
Drive/driven bearing cup installer
20 — Idler cover o-ring
4 — J 38568-2
Idler bearing cup installer
21 — Idler bearing retainer shim,
5 — J 38568-3
Forward/rear output bearing cup
0.254 mm (0.010 inch)
installer
6 — J 38569 P3 carrier/C6/C7 housing bushing
0.127 mm (0.005 inch)
installer
7 — J 38572 Transfer case holding fixture
0.076 mm (0.003 inch)
8 — J 38573 C6 spring compressor
24 — Idler cover gasket
9 — J 38579 Bearing installers
25 — Tapered roller bearing cup
10 — J 38579-1 Drive/driven bearing installer
11 — J 38579-2 Forward/rear output and idler
27 — Output oil seal
bearing installer
12 — J 38547 Front and rear output seal installer
29 — Output housing
13 — J 39263 Bearing end play checker
31 — Bolt, M10 x 1.5 x 35 (8), A
B 32 — Manifold assembly
1 — Bolt, M10 x 1.5 x 55 (8), A 33 — Output bearing retainer shim,
2 — Oil pump assembly 0.254 mm (0.010 inch)
3 — Input bearing retainer shim, 34 — Output bearing retainer shim,
0.254 mm (0.010 inch) 0.127 mm (0.005 inch)
4 — Input bearing retainer shim, 35 — Output bearing retainer shim,
0.127 mm (0.005 inch) 0.076 mm (0.003 inch)
5 — Input bearing retainer shim, 36 — Tapered roller bearing cup
0.076 mm (0.003 inch) 37 — Tapered roller bearing cup
6 — Transfer case housing assembly 38 — Tapered roller bearing cup
7 — Transfer case housing 39 — Output housing
8 — Transfer case cover 40 — Tapered roller bearing cup
9 — Tapered roller bearing cup 41 — Output oil seal
10 — Tapered roller bearing cup 42 — Bolt, M10 x 1.5 x 100 (15), A
11 — C6 clutch housing assembly
12 — Internal retaining ring Torque N·m lb ft
13 — Spring retainer assembly A 60–75 44–55

14 — C6 piston

F OLDOUT 14
A B
J 35921-1
J 38568-1
J 8092
1
31
J 38568-2 18
9 2 19 32
25
MD TRANSFER CASE TOOLS

1 8 A(3,4,5) B(21,22,23)
6 6 20 C(33,34,35)
36 10
8 12
2 J 3940 7
38
4 26
5 40 D D
7 9 37 24
10 41
J 8092
39
3 J 24171 J 38568-3
13 J 38573 28
11 17
27 D
42
29 30 “D” FIFTEEN BOLTS (17) AND FIFTEEN

NOTE: Objects are not shown to scale V05600 BOLTS (42). TORQUE FOR EVEN CLAMP.
12
J 35921-1
14 13 PART OF J 38547
15 11 16 J 38573
E01845.02
Foldout 14,A. Transfer Case Special Tools — Exploded View Foldout 14,B. Transfer Case, Special Disassembly/Assembly Instructions — Exploded View
F OLDOUT 15
3
83 5
84
1 — Transfer case module 34 — Orificed plug (lube hole) (2), D 70 — Manifold sealring 85
86 A
87
2 — Bolt, M10 x 1.5 x 40 (15), A 35 — Plug assembly (2), D 71 — Bolt, M10 x 1.5 x 35 (8), A 11
4 10
3 — Transmission shaft adapter 36 — O-ring (9.25 ID) 72 — Manifold assembly 12
4 — Bolt, M10 x 1.5 x 55 (8), A 37 — Tapered roller bearing cup 73 — Manifold 6
7 9
5 — Oil pump assembly 38 — Tapered roller bearing cone 74 — Ball, 0.218 dia. 22 8
6 — Pressure relief valve 39 — Idler gear (37T) 75 — Output bearing retainer shim 23
0. 254 mm (0. 010 in.) 24 B
7 — Spring 40 — Tapered roller bearing cone
25
8 — Plug, D 41 — Tapered roller bearing cup 76 — Output bearing retainer shim 26 2
9 — Spring pin 42 — Front output shaft nut, E 0.127 mm (0.005 inch) 27 32 88 13
77 — Output bearing retainer shim 29 14
10 — Input bearing retainer shim, 43 — Flat washer 30
31 1
0.254 mm (0.010 inch) 44 — Front yoke assembly (16 TYS) 0.076 mm (0.003 inch) 28
78 — Tapered roller bearing cup 33 15
11 — Input bearing retainer shim, 45 — Bolt, M10 x 1.5 x 40 (15), A 72
34
0.127 mm (0.005 inch) 46 — Output oil seal 79 — Tapered roller bearing cone 73 16 18
17
12 — Input bearing retainer shim, 47 — Tapered roller bearing cone 80 — Driven gear 74 C
19
0.076 mm (0.003 inch) 81 — Tapered roller bearing cone 75 33
48 — Tapered roller bearing cup 71 76 34 20
13 — Transfer case housing assembly 82 — Tapered roller bearing cup 77 36 21
49 — Output housing
14 — Transfer case housing 50 — Output housing gasket 83 — Lube charging pump front
15 — Dowel 51 — Idler bearing retainer shim cover
35
16 — Splitline gasket (front and rear 0.254 mm (0.010 inch) 84 — Lube charging pump drive gear
37
cases) 52 — Idler bearing retainer shim 85 — Lube charging pump driven 36 38
17 — Tapered roller bearing cup gear 39
0.127 mm (0.005 inch) 54
18 — Tapered roller bearing cone 86 — Lube charging pump reversing 55 40
53 — Idler bearing retainer shim 35
19 — Drive gear (30T) ring 56 41
0.076 mm (0.003 inch)
20 — Tapered roller bearing cone 54 — Output bearings spacer 87 — Lube charging pump rear cover 57 78
88 — Connector nut, F 79
21 — Tapered roller bearing cup 55 — Tapered roller bearing cup 80
22 — Bolt, M10 x 1.5 x 40 (5), A 56 — Tapered roller bearing cone 59
Torque N·m lb ft 60 81
23 — Idler cover 57 — Front output shaft A 60–75 44–55 61 82
24 — Idler cover o-ring 58 — C7 clutch housing assembly B 5–8 4–6 42 62
25 — Idler bearing retainer shim, 59 — C7 clutch hub C 24–29 18–21 43 44
63 58
0.254 mm (0.010 inch) 60 — Internal retaining ring D 12–14 9–10 46 45
26 — Idler bearing retainer shim, 61 — C7 clutch backplate E 610–815 450–600 47 64
0.127 mm (0.005 inch) 62 — C7 friction plate 24–36 lb 48 65
27 — Idler bearing retainer shim, F 2.73–4.09 49 66
63 — C7 reaction plate in. 50
0.076 mm (0.003 inch) 67
64 — C7 piston 51 68
28 — Idler cover gasket 65 — External sealring 52
29 — Electrical connector plate 66 — Internal sealring 53 70
30 — Electrical connector gasket 67 — C7 clutch housing
31 — Electrical connector assembly 68 — Bushing, 53.105 69
32 — Bolt, M8 x 1.25 x 25 (4), B 69 — Ball, 0.250 dia.
33 — Lube hole plug (2), C
E01846.01
Foldout 15. Front Main Transfer Case — Exploded View

F OLDOUT 16
1 — Transfer case housing assembly 47 — Idler cover gasket
2 — Transfer case cover 48 — Idler cover o-ring
3 — Bearing retainer 49 — Idler cover 3
4 — Bolt, M10 x 1.5 x 35 (8), A 50 — Bolt, M10 x 1.5 x 40 (5), A 4
5 — C6 clutch housing assembly 51 — Orifice plug, 5 mm (0.197 inch) 6
7 22
6 — Internal retaining ring 52 — Drain plug assembly, D
8
7 — C6 hub 53 — O-ring 9 5
8 — Thrust bearing 54 — Bearing retainer 10
9 — C6 backplate 55 — Bolt, M10 x 1.5 x 35 (8), A 11
10 — C6 friction plate 56 — P4 carrier assembly
11 — C6 reaction plate 57 — P4 carrier 12
12 — External retaining ring 58 — Planetary pinion shaft setscrew (3), D 13
14
13 — Spring retainer assembly 59 — P4 spindle 17
15
14 — C6 piston 60 — Roller bearings
16 21
15 — C6 OD sealring 61 — Pinion gear (17T) 18
16 — C6 ID sealring 62 — Thrust washer 20
1 19
17 — C6 housing assembly with bushing 63 — Sun gear
18 — C6 housing assembly 64 — External retaining ring 40 23
19 — C6 housing 65 — Ring gear (59T) 2 35
25
20 — C6 sleeve 66 — Rear output shaft 36
26 37
21 — Bushing 67 — Tapered roller bearing cone 38 41
22 — C6 housing gasket 68 — Tapered roller bearing cup 39
34
23 — Bolt, M10 x 1.5 x 100 (15), A 69 — Output bearings spacer 27 33 24
24 — Bolt, M10 x 1.5 x 40 (2), A 70 — Output bearing retainer shim 28 45 32 42
31
25 — Lube hole plug, B 0.254 mm (0.010 inch) 46 29 43
30
26 — Orificed plug (lube hole), C 71 — Output bearing retainer shim 47
27 — Plug assembly, C 0.127 mm (0.005 inch) 48 49 44
28 — O-ring (9.25 ID) 72 — Output bearing retainer shim
29 — Control valve body assembly 0.076 mm (0.003 inch) 50
30 — Control body 73 — Output housing gasket
31 — Valve 74 — Output housing 53 52 56
32 — Spring 75 — Bolt, M10 x 1.5 x 40 (6), A 51
33 — Stop 76 — Tapered roller bearing cup 58 57
34 — Pin 77 — Tapered roller bearing cone 54
55 59
35 — Solenoid, N/C modulating 78 — Output oil seal
36 — O-ring, 0.551 ID 79 — Rear yoke assembly (16 TYS)
63
37 — O-ring, 0.364 ID 80 — Flat washer 70
60
64 65
38 — Valve 81 — Rear output shaft nut, E 72 74 61
82 — Bolt, M10 x 1.5 x 100 (9), A 62 66
39 — Solenoid spring 75
40 — Pin 68
Torque N·m lb ft 67
41 — Bolt, M8 x 1.25 x 50 (6), B 77
42 — Control cover gasket A 60–75 44–55 71 76 69
78
43 — Control cover B 24–29 18–21 79
44 — Bolt, M8 x 1.25 x 30 (10), B C 12–14 9–10 73
45 — Speed sensor D 25–35 18–26 80
81
82
46 — Bolt, M8 x 1.25 x 25 (2), B E 610–815 450–600
E05574.01
Foldout 16. Rear Main Transfer Case — Exploded View

Legend For Foldout 17,A
1 — Control valve assembly 49 — Socket terminal (2)

2 — Suction filter gasket 50 — Solenoid connector
3 — Suction filter 51 — O-ring
4 — Scavenge sump suction filter housing 52 — Allen-head bolt, M5 x 0.8 x 12 (2), D
5 — Bolt, M6 x 1.0 x 60, A 53 — Solenoid regulator spring (3)
6 — Face seal 54 — Solenoid regulator valve (3)
7 — Bolt, M6 x 1.0 x 95 (2), A
55 — Solenoid, N/O (2)
8 — Wiring harness cover plate
9 — Bolt, M6 x 1.0 x 95 (4), A 56 — O-ring
10 — Electronic connector shoulder bolt (3), B 57 — O-ring
11 — Internal harness assembly 58 — Solenoid, N/C
12 — Standoff 59 — O-ring
13 — Socket terminal (19) 60 — O-ring
14 — Cavity plug 61 — Retention pin (3)
15 — 12-Way internal seal (2) 62 — Solenoid filter screen
16 — 24-Way internal connector 63 — Rotating clutch solenoid body
17 — Standoff bolt, C 64 — A/R valve
18 — Temperature sensor 65 — A/R valve spring
19 — High temperature cable tie 66 — A/R valve stop
20 — Socket terminal 67 — Retention pin, 2.5 OD x 25
21 — Socket terminal 68 — Bolt, M6 x 1.0 x 95 (8), A
22 — 2-Way solenoid connector 69 — Face seal (2)
23 — Spiral Teflon wrap 70 — Stationary clutch solenoid body assembly
24 — 2-Way connector (C3 pressure switch) 71 — Stationary clutch solenoid body
25 — Pin terminal (2) 72 — Overdrive valve
26 — Socket terminal 73 — Overdrive valve spring
27 — Socket terminal 74 — Valve stop
28 — 2-Way solenoid connector 75 — Solenoid, N/C (3)
30 — 2-Way solenoid connector 77 — O-ring
31 — 2-Way solenoid connector 78 — Solenoid regulator valve (3)
32 — Socket terminal 79 — Solenoid regulator spring (3)
33 — Socket terminal 80 — Retention pin
34 — Socket terminal (2) 81 — Retaining pin (3)
35 — 2-Way solenoid connector 82 — Solenoid filter screen
36 — 2-Way solenoid connector 83 — C6 clutch body assembly
37 — Socket terminal (2) 84 — Bolt, M6 x 1.0 x 60 (5), A
38 — Secondary lock (2) 85 — C6 body cover plate
39 — Socket terminal (3) 86 — Solenoid filter screen
40 — 4-Way oil level sensor connector 87 — C6 clutch body
41 — Socket terminal (2) 88 — Spring
42 — 2-Way solenoid connector 89 — Solenoid regulator valve
43 — Socket terminal (2) 90 — Regulator valve solenoid assembly
44 — Turbine speed sensor connector 91 — O-ring
45 — Bolt, M6 x 1.0 x 95 (3), A 92 — O-ring
46 — Face seal 93 — Solenoid protective plate
47 — Rotating clutch solenoid body assembly 94 — Push-on speed nut
48 — Pressure switch 95 — Retaining pin, 2.5 OD x 25
Copyright © 2001 General Motors Corp. Foldout 17,A

Legend For Foldout 17, A (cont’d)
96 — Solenoid filter screen 146 — Converter regulator stop

97 — Push-on speed nut 147 — Bolt, M6 x 1.0 x 45 (2), A
98 — Solenoid protective plate 148 — Oil level sensor assembly
99 — C6 interlock solenoid assembly 149 — Sensor bracket
101 — O-ring 151 — Oil level sensor
102 — C6 interlock valve 152 — 4-pin plug
103 — Spring 153 — Pin terminal
104 — Bolt, M6 x 1.0 x 20 (2), A 154 — Spacer
105 — Turbine speed sensor 155 — Base plate
106 — Bolt, M6 x 1.0 x 95 (2), A 156 — Case gasket
107 — Solenoid separator plate 157 — Separator plate
108 — Main valve body assembly 158 — Channel plate gasket
109 — Retaining pin, 5 OD x 43 159 — Channel plate assembly
110 — Lockup relay valve 160 — Shipping plug (2), E
111 — Lockup relay valve spring 161 — Dowel pin, 10 x 50 (2
112 — Lockup relay valve stop 162 — Channel plate
113 — Retaining pin, 3 OD x 43 163 — Oil drain plug assembly, F
114 — Lube regulator valve 164 — O-ring
115 — Lube regulator spring 165 — Pressure tap plug assembly (8), A
116 — Lube regulator stop 166 — O-ring
117 — Retaining pin, 5 OD x 43 167 — Pressure tap plug
118 — Main regulator valve 168 — Channel plate assembly
119 — Main regulator spring 169 — Dowel pin
120 — Main regulator stop 170 — Channel plate
121 — Retaining pin, 3 OD x 43 171 — Pressure tap plug assembly (8), A
122 — Control main valve 172 — O-ring
123 — Control main spring 173 — Pressure tap plug
124 — Control main stop 174 — Oil drain plug assembly, F
125 — Retaining pin, 2.5 OD x 40 175 — O-ring
126 — Solenoid assembly 176 — Bolt, M10 x 1.5 x 55 (7) or (32), G
127 — O-ring 177 — Bolt, M10 x 1.5 x 100 (25, 4 in. sump only), G
128 — O-ring 178 — Filter cover (2)
129 — Control valve body 179 — Square cut seal (2)
130 — Spring pin, 5 x 55 180 — O-ring (2)
131 — Retaining pin, 5 OD x 43 181 — Oil filter (2)
132 — C2 latch valve
133 — C2 latch spring
134 — C2 latch stop Torque N·m lb ft
135 — Retaining pin, 3 OD x 43 A 10–13 7–10
136 — Exhaust back valve B 2–3 18–27*
137 — Exhaust back spring C 1.3–2.7 12–24*
138 — Exhaust back stop
139 — Retaining pin, 5 OD x 43 D 5–8 4–6
140 — C1 latching valve E 2.5–3.5 22–31*
141 — C1 latching spring F 25–32 18–24
142 — C1 latching stop G 51–61 38–45
143 — Retaining pin, 3 OD x 43
144 — Converter regulator valve
145 — Converter regulator spring * lb in.
Foldout 17,A Copyright © 2001 General Motors Corp.

F OLDOUT 17,A
7 6 1 (Cont'd)
5
147
148
1 112
107 108
111 149
109 110
4 113 116
139 115
143 135 117 151
1 150
114 120
106 121
131 119
125 152 153
29
50
36 3 11
70
104 118 124

9
17 123
105
8 122 154
16
2 15 126
10 155
14
12 13 144 128
127
145
43 156
40 146 140
39 41 44
69 38 141 129
68 42 23 18 142 136
37 19
70 20 137 130
23
138 132 157
36 28 22
71 21 133
35 24
134 158
72 34 30 25
26 168
73 33 32 31 27
81 29
74 169
79 159
78
84 45
77 80 161
170 160
76 46 162
85
75
82
47
52 181
86 83 50 49 48
87 55 180
51 171 172
57 175
56 179
67 173
88 54 58 174 163
90 66 164
89 65 53 178 165 166
96 91 60
92 59 167
95
54 176
53 61
97 64
98 176
176
100 93 94 or 177
101 63 177
99 102 103 62
V05603.01 V05604
Foldout 17,A. Control Valve Module (Prior To S/N 6510032369) — Exploded View
Legend For Foldout 17, B
1 — Spring clip 51 — 2-Way solenoid connector

2 — Feedthrough tag 52 — Socket terminal
3 — Cable tie 53 — Socket terminal
4 — Control valve assembly 54 — 2-Way solenoid connector
5 — Suction filter gasket 55 — Bolt, M6 x 1.0 x 60 (5), A
6 — Suction filter 56 — C6 body cover plate
7 — Scavenge sump suction filter housing
57 — C6 clutch body assembly
8 — Bolt, M6 x 1.0 x 60, A
9 — Face seal 58 — Solenoid filter screen
10 — Bolt, M6 x 1.0 x 95 (2), A 59 — C6 clutch body
11 — Bolt, M6 x 1.0 x 95 (4), A 60 — Spring
12 — Wiring harness cover plate 61 — Solenoid regulator valve
13 — Electronic connector shoulder bolt (3), B 62 — Regulator valve solenoid assembly
14 — Internal control harness assembly 63 — O-ring
15 — Standoff 64 — O-ring
16 — O-ring 65 — Solenoid protective plate
17 — Feedthrough standoff seal 66 — Push-on speed nut
18 — Standoff grommet assembly 67 — Retaining pin, 2.5 OD x 25
19 — Cavity plug 68 — Solenoid filter screen
20 — Backshell grommet 69 — Push-on speed nut
21 — Backshell follower 70 — Solenoid protective plate
22 — Backshell housing 71 — C6 interlock solenoid assembly
23 — Pin terminal (17) 72 — O-ring
24 — 31-Way receptacle connector 73 — O-ring
25 — Socket terminal (2) 74 — C6 interlock valve
26 — Turbine speed sensor connector 75 — Spring
27 — Temperature sensor 76 — Bolt, M6 x 1.0 x 95 (3), A
28 — 2-Way solenoid connector 77 — Face seal
29 — Socket terminal 78 — Rotating clutch solenoid body assembly
30 — Socket terminal 79 — Pressure switch
31 — Pin terminal (2) 80 — Socket terminal (2)
32 — 2-Way connector (C3 pressure switch) 81 — Solenoid connector
34 — Socket terminal 83 — Allen-head bolt, M5 x 0.8 x 12 (2), C
35 — Socket terminal 84 — Solenoid regulator spring (3)
36 — Socket terminal (2) 85 — Solenoid regulator valve (3)
37 — 2-Way solenoid connector 86 — Solenoid, N/O (2)
39 — Socket terminal 88 — O-ring
40 — Socket terminal 89 — Solenoid, N/C
43 — Socket terminal (2) 92 — Retention pin (3)
44 — 2-Way solenoid connector 93 — Rotating clutch solenoid body
45 — 4-Way oil level sensor connector 94 — Retention pin, 2.5 OD x 25
46 — Socket terminal (3) 95 — A/R valve
47 — Secondary lock (2) 96 — A/R valve spring
48 — 2-Way solenoid connector 97 — A/R valve stop
50 — Socket terminal (2) 99 — Face seal (2)
100 — Stationary clutch solenoid body assembly
Copyright © 2001 General Motors Corp. Foldout 17,B
Legend For Foldout 17, B (cont’d)
101 — Stationary clutch solenoid body 154 — Converter regulator stop

102 — Overdrive valve 155 — Bolt, M6 x 1.0 x 45 (2), A
103 — Overdrive valve spring 156 — Oil level sensor assembly
104 — Valve stop 157 — Sensor bracket
105 — Solenoid, N/C (3) 158 — O-ring
106 — O-ring 159 — Oil level sensor
107 — O-ring 160 — 4-Pin plug
108 — Solenoid regulator valve (3) 161 — Pin terminal
109 — Solenoid regulator spring (3) 162 — Spacer
110 — Retention pin 163 — Base plate
111 — Retaining pin (3) 164 — Separator plate
112 — Bolt, M6 x 1.0 x 20 (2), A 165 — Channel plate gasket
113 — Turbine speed sensor 166 — Channel plate assembly
114 — Bolt, M6 x 1.0 x 95 (2), A 167 — Shipping plug (2), D
115 — Solenoid separator plate 168 — Dowel pin, 10 x 50 (2
116 — Main valve body assembly 169 — Channel plate
117 — Retaining pin, 5 OD x 43 170 — Oil drain plug assembly, E
118 — Lockup relay valve 171 — O-ring
119 — Lockup relay valve spring 172 — Pressure tap plug assembly (8), A
120 — Lockup relay valve stop 173 — O-ring
121 — Retaining pin, 3 OD x 43 174 — Pressure tap plug
122 — Lube regulator valve 175 — Channel plate assembly
123 — Lube regulator spring 176 — Dowel pin
124 — Lube regulator stop 177 — Channel plate
125 — Retaining pin, 5 OD x 43 178 — Pressure tap plug assembly (8), A
126 — Main regulator valve 179 — O-ring
127 — Main regulator spring 180 — Pressure tap plug
128 — Main regulator stop 181 — Oil drain plug assembly, E
129 — Retaining pin, 3 OD x 43 182 — O-ring
130 — Control main valve 183 — Filter cover (2)
131 — Control main spring 184 — Filter cover gasket (2)
132 — Control main stop 185 — O-ring (2)
133 — Retaining pin, 2.5 OD x 40 186 — O-ring (2)
134 — Solenoid assembly 187 — Oil filter (2)
135 — O-ring 188 — Bolt, M10 x 1.5 x 55 (7) or (32), F
136 — O-ring 189 — Bolt, M10 x 1.5 x 100 (25, 4 in. sump only), F
137 — Control valve body 190 — Case gasket
138 — Spring pin, 5 x 55 191 — Panel nut
139 — Retaining pin, 5 OD x 43 192 — Feedthrough lockwasher
140 — C2 latch valve
141 — C2 latch spring Torque N·m lb ft
142 — C2 latch stop A 10–13 7–10
143 — Retaining pin, 3 OD or 5 OD x 43
144 — Exhaust back valve B 2–3 18–27*
145 — Exhaust back spring C 5–8 4–6
146 — Exhaust back stop D 2.5–3.5 22–31*
147 — Retaining pin, 5 OD x 43 E 25–32 18–24
148 — C1 latching valve
149 — C1 latching spring F 51–61 38–45
150 — C1 latching stop
151 — Retaining pin, 3 OD x 43 * lb in.
152 — Converter regulator valve
153 — Converter regulator spring
Foldout 17,B Copyright © 2001 General Motors Corp.

F OLDOUT 17,B
4 (Cont’d)
10 9 191
8 155
192 14 11
156
12
116 120
24 22 115 157
7 4 119
19 21
20 3 117 118
20 121 124
23 19 1 147 159
29
50 6 18 2 123 158
36
70
21 DE
TA
BE CH
FO CO
CO RE NNEC
NT DR
RO OP TOR
151 143 125
122
L MO PING
17
DU
LE
128
4 114 129
22 160 161
139 127
5 133
16 126
112 132
55 131
113 162
15 56 130
49 50 13 57 163
134
48
51 58
59 152 136
135
45 153
43 4647 52 53 154 148 190
25 60
62 149 137
44 54 26 61
68 63 150 144
42 64
41 67
145 138
146 140 164
27 28 69
40
39 70 141
38 33 142 165
37 29
32 72 65 66
30 73
35 31 71 74 75 175
36 34 166
176 167 168
99 76 169
77 177
98
78
187
83
79 186
100 81 80
86
82 185
88
87 178 179
101 182 172 173 170
85 89 184 180 171
97 84 174
102 96 181
91
103 90
111 183
104 85
109 84 92
108 95
107 110
106
94
105 93
188 188 V05606
V05605.01 189
Foldout 17,B. Control Valve Module (S/N 6510032369 to S/N 6510096670) — Exploded View
Legend For Foldout 17,C
1 — Spring clip 51 — 2-Way solenoid connector

2 — Feedthrough tag 52 — Socket terminal
3 — Cable tie 53 — Socket terminal
4 — Control valve assembly 54 — 2-Way solenoid connector
5 — Suction filter gasket 55 — U-channel
6 — Suction filter 56 — Bolt, M6 x 1.0 x 60 (5), A
7 — Scavenge sump suction filter housing
57 — C6 body cover plate
8 — Bolt, M6 x 1.0 x 60, A
9 — Face seal 58 — C6 clutch body assembly
10 — Bolt, M6 x 1.0 x 95 (2), A 59 — Solenoid filter screen
11 — Bolt, M6 x 1.0 x 95 (4), A 60 — C6 clutch body
12 — Electronic connector shoulder bolt (3), B 61 — Spring
13 — Feedthrough harness assembly 62 — Solenoid regulator valve
14 — Standoff 63 — Regulator valve solenoid assembly
16 — Feedthrough standoff seal 65 — O-ring
17 — Standoff grommet assembly 66 — Solenoid protective plate
18 — Cavity plug 67 — Push-on speed nut
19 — Backshell grommet 68 — Retaining pin, 2.5 OD x 25
20 — Backshell follower 69 — Solenoid filter screen
21 — Backshell housing 70 — Push-on speed nut
22 — Backshell housing 71 — Solenoid protective plate
23 — Pin terminal (17) 72 — C6 interlock solenoid assembly
24 — 31-Way receptacle connector 73 — O-ring
26 — Turbine speed sensor connector 75 — C6 interlock valve
27 — Temperature sensor 76 — Spring
28 — 2-Way solenoid connector 77 — Bolt, M6 x 1.0 x 95 (3), A
29 — Socket terminal 78 — Face seal
30 — Socket terminal 79 — Rotating clutch solenoid body assembly
31 — Pin terminal (2) 80 — Pressure switch
32 — 2-Way connector (C3 pressure switch) 81 — Socket terminal (2)
33 — 2-Way solenoid connector 82 — Solenoid connector
35 — Socket terminal 84 — Allen-head bolt, M5 x 0.8 x 12 (2), C
36 — Socket terminal (2) 85 — Solenoid regulator spring (3)
37 — 2-Way solenoid connector 86 — Solenoid regulator valve (3)
38 — 2-Way solenoid connector 87 — Solenoid, N/O (2)
41 — Socket terminal (2) 90 — Solenoid, N/C
44 — 2-Way solenoid connector 93 — Retention Pin (3)
45 — 4-Way oil level sensor connector 94 — Rotating clutch solenoid body
46 — Socket terminal (3) 95 — Retention pin, 2.5 OD x 25
47 — Secondary lock (2) 96 — A/R valve
48 — 2-Way solenoid connector 97 — A/R valve spring
49 — Socket terminal (2) 98 — A/R valve stop
Copyright © 2001 General Motors Corp. Foldout 17,C

Legend For Foldout 17, C (cont’d)
100 — Face seal (2) 152 — Retaining pin, 3 OD x 43

101 — Stationary clutch solenoid body assembly 153 — Converter regulator valve
102 — Stationary clutch solenoid body 154 — Converter regulator spring
103 — Overdrive valve 155 — Converter regulator stop
104 — Overdrive valve spring 156 — Bolt, M6 x 1.0 x 45 (2), A
105 — Valve stop 157 — Oil level sensor
106 — Solenoid, N/C (3) 158 — Viton® Ferule (4)
107 — O-ring 159 — Internal harness OLS adapter assembly
108 — O-ring 160 — 3-way connector plug
109 — Solenoid regulator valve (3) 161 — Secondary lock, TPA
110 — Solenoid regulator spring (3) 162 — Pin terminal (6)
111 — Retention pin 163 — Secondary lock, TPA
112 — Retaining pin (3) 164 — 4-way receptacle connector
113 — Bolt, M6 x 1.0 x 20 (2), A 165 — Separator plate
114 — Turbine speed sensor 166 — Channel plate gasket
115 — Bolt, M6 x 1.0 x 95 (2), A 167 — Channel plate assembly
116 — Solenoid separator plate 168 — Shipping plug (2), D
117 — Main valve body assembly 169 — Dowel pin, 10 x 50 (2
118 — Retaining Pin, 5 OD x 43 170 — Channel plate
119 — Lockup relay valve 171 — Oil drain plug assembly, E
120 — Lockup relay valve spring 172 — O-ring
121 — Lockup relay valve stop 173 — Pressure tap plug assembly (8), A
122 — Retaining pin, 3 OD x 43 174 — O-ring
123 — Lube regulator valve 175 — Pressure tap plug
124 — Lube regulator spring 176 — Channel plate assembly
125 — Lube regulator stop 177 — Dowel pin
178 — Channel plate
179 — Pressure tap plug assembly (8), A
127 — Main regulator valve
180 — O-ring
128 — Main regulator spring
181 — Pressure tap plug
129 — Main regulator stop
182 — Oil drain plug assembly, E
130 — Retaining Pin, 3 OD x 43
183 — O-ring
131 — Control main valve
184 — Filter cover (2)
132 — Control main spring
185 — Filter cover gasket (2)
133 — Control main stop
186 — O-ring (2)
134 — Retaining pin, 2.5 OD x 40
187 — O-ring (2)
135 — Solenoid assembly
188 — Oil filter (2)
136 — O-ring 189 — Bolt, M10 x 1.5 x 55 (7) or (32), F
137 — O-ring 190 — Bolt, M10 x 1.5 x 100 (25, 4 in. sump only), F
138 — Control valve body 191 — Case gasket
139 — Spring pin, 5 x 55 192 — Panel nut
141 — C2 latch valve Torque N·m lb ft
142 — C2 latch spring
A 10–13 7–10
143 — C2 latch stop
144 — Retaining pin, 3 OD or 5 OD x 43 B 2–3 18–27*
145 — Exhaust back valve C 5–8 4–6
146 — Exhaust back spring D 2.5–3.5 22–31*
147 — Exhaust back stop E 25–32 18–24
149 — C1 latching valve F 51–61 38–45
150 — C1 latching spring
151 — C1 latching stop * lb in.
Foldout 17,C Copyright © 2001 General Motors Corp.

F OLDOUT 17,C
4 (Cont’d)
7 192 13
8
8
24 11
21
157
18 20
19 117 121
19 116
6 18 4
23 120 158
20 17 1 119
2 118 166
DE
TA
BE CH
FO CO
CO RE NNEC
122 125
16
NT DR
RO OP TOR
L MO PING
148
DU
22
LE
3 124
5 152 144 126
15 123 129
4 130 159
115 160
140 128
134 161
14 58 113 127 133 162
12
50 56
49 132 163
51 59 57 114 164
48 60 131 165
25 135
45 52 53
46 26
54 61 153 136
43 47 62 63 137
27 28 154
69 64
65 149 191
44 29 68 155
42 138
30 150
41
70 151
33 32 145
31 71
40 146 139
39 38 37 35
73 66 67 147 141 165
34 74
36 72 75 76 142
55 143 166
176 167
177 168 169
77 170
178
78
79
188
99 100 80
81 187
83 82
85
84 186
86 179
87 180
102 183 173 174 171
101 88 90 185 172
98 181
89 182 175
103 97 91
104 92
112 184
105 88
110 89 93
109 96
108 111
107
95
106 94
189 V07373
V07374
190
Foldout 17,C. Control Valve Module (Beginning With S/N 6510096671) — Exploded View

A 11 — P3 thrust washer (4)

12 — Selective shim
1 — Output flange
13 — Adapter housing gasket
2 — Blank flange
14 — Adapter housing assembly
3 — O-ring (2)
15 — External retaining ring
4 — O-ring
16 — Spring retainer assembly
5 — Retainer plug
17 — C5 clutch piston
6 — Locktab
18 — C5 outer piston sealring
7 — Bolt, M10 x 1.5 x 30 (2), A
19 — C5 inner piston sealring
8 — Output shipping cover
20 — Adapter housing
9 — Output yoke
21 — Plug assembly
10 — Output yoke
22 — Plug, A
11 — Bolt
23 — O-ring
12 — O-ring
24 — Screen
13 — Retainer plug
25 — Bolt, M10 x 1.5 x 70 (4), B
14 — Bolt, M14 x 2.0 x 70, B
26 — Transfer case housing gasket
Torque N·m lb ft 27 — Bolt, M10 x 1.5 x 205, (stepped and
A 30–35 22–26 knurled shank) B
B 70–80 51–60 28 — Bolt, M10 x 1.5 x 205, (bulged shank) B
29 — Bolt, M12 x 1.75 x 60 (3), C
B 30 — Bolt, M10 x 1.5 x 100 (3), B
31 — Bolt, M10 x 1.5 x 40 (2), B
1 — P3 carrier assembly 32 — Bolt, M12 x 1.7 x 45 (15), C
2 — Internal retaining ring 33 — Bolt, M10 x 1.5 x 40 (19), B
3 — P3 indexing ring
Torque N·m lb ft
4 — Carrier and bushing assembly
A 34–47 25–35
5 — P3 planetary carrier B 51–61 38–45
6 — Bushing C 90–110 66–81
7 — P3 planetary spindle (4)
8 — P3 thrust washer (4)
9 — P3 pinion gear set (contains 4 pinions)
10 — Roller bearing assembly (8)

F OLDOUT 18
A B
11
12
15
16 14
17
18 13
8 19
20
26
3
3 4
4 33
5
6 6
10 32
7 27
7
12
13 24
23 25 28
21 22 29
31 30
14
8
9
10
V05924
11 V07362
Foldout 18,A. Output Flange and Yoke — Exploded View Foldout 18,B. Transfer Case Adapter Housing — Exploded View

A B
1 — Gasket 1 — Parking brake, 12 x 4
2 — Cover 2 — M16 x 2.0 x 40 (4), A
3 — Cooler port manifold 3 — Brake drum
4 — Bolt, M10 x 1.5 x 28 (6), A 4 — Bolt, 3⁄8-24 x 3⁄4 (2), B
5 — Gasket (without retarder) 5 — Stud (2)
6 — Gasket (retarder) 6 — PTO gasket
7 — Cooler housing 7 — Bolt, M10 x 1.5 x 35 (8), C
8 — Gasket (2) 8 — PTO assembly
9 — Connector (2) 9 — Stud (2)
10 — Bolt, M10 x 1.5 x 35 (8), A 10 — PTO gasket
11 — Washer 11 — Bolt, M10 x 1.5 x 35 (8), C
12 — Bolt, M10 x 1.5 x 205 (used with retarder), A 12 — PTO assembly
13 — Bolt, M12 x 1.75 x 230 (3, with retarder), B Torque N·m lb ft
14 — Washer (3) A 228–266 168–196
15 — Bolt, M10 x 1.5 x 70 (9, without retarder), A B 56–66 41–49
Bolt, M10 x 1.5 x 225 (6, with retarder), A C 51–61 38–45
16 — Washer (9, or 6)
17 — Pressure tap plug assembly (2), C
18 — Pressure tap plug
19 — O-ring
20 — Plug, 1⁄2-14, D
21 — Elbow (2)
22 — Gasket
23 — Cover
24 — Bolt, M12 x 1.75 x 25 (2), E
25 — Bolt, M10 x 1.5 x 35 (17), A
26 — O-ring (2)
27 — Plate assembly
28 — O-ring (4)
Torque N·m lb ft
A 51–61 38–45
B 100–120 74–88
C 10–13 7–10
D 22–27 16–20
E 90–110 66–81

F OLDOUT 19
A B
1
1 2
2
3
3
9 4
8
5
7
6 10
11
8 28
27 5
9
14 7
13 12
26
19 28
18
17 6
40 16 15
10 19 24 8
18 17
26
9
25
21
22
11
23 24
12
10
V05576 V05577
Foldout 19,A. Oil Cooler — Exploded View Foldout 19,B. Support Equipment — Exploded View
F OLDOUT 20
Foldout 20. MD Product Line Hydraulic Schematic — Neutral

SM2148EN 200112 www.allisontransmission.com Printed in U.S.A. 200206

SM2148EN

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Service Manual

Allison Transmission MD Product Line Service Manual SM2148EN

Allison Transmission MD Product Line Service Manual SM2148EN

Allison Transmission MD Product Line Service Manual SM2148EN

Division of General Motors Corporation

Printed in the U.S.A. Copyright © 2001 General Motors Corp.

ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL

The following trademarks are the property of the companies indicated:

ii Copyright © 2001 General Motors Corp.

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cau-

WARNINGS, CAUTIONS, AND NOTES

Copyright © 2001 General Motors Corp. iii

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

iv Copyright © 2001 General Motors Corp.

1–3. ORDERING PARTS 1–10. OPERATING INSTRUCTIONS . . . . . . . . . 1–9

Copyright © 2001 General Motors Corp. v

vi Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. vii

viii Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. ix

x Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. xi

xii Copyright © 2001 General Motors Corp.

FEEDTHROUGH HARNESS CONNECTOR

OIL FILL TUBE AND

OUTPUT SPEED SENSOR

INPUT SPEED SENSOR

FEEDTHROUGH HARNESS CONNECTOR

OIL FILL TUBE AND DIPSTICK

1–2 Copyright © 2001 General Motors Corp.

BREATHER ASSEMBLY PADS

OIL FILL TUBE AND

INPUT SPEED SENSOR

FEEDTHROUGH HARNESS CONNECTOR

Copyright © 2001 General Motors Corp. 1–3

MAIN PRESSURE TAP

OUTPUT SPEED SENSOR

MAIN PRESSURE TAP

1–4 Copyright © 2001 General Motors Corp.

TRANSFER CASE FEEDTHROUGH HARNESS CONNECTOR

OIL FILL TUBE AND DIPSTICK

Figure 1–7. Model MD 3070PT Transmission — Right Front-View

OIL FILL TUBE

Figure 1–8. Model MD 3070PT Transmission — Left-Rear View

Copyright © 2001 General Motors Corp. 1–5

Indianapolis, Indiana transmission model is a six speed transmission.

Indianapolis, Indiana, USA

1–4. GENERAL DESCRIPTION TC 411

1–6 Copyright © 2001 General Motors Corp.

j. Output Configuration. The output module in- c. Entering Diagnostic Mode

Copyright © 2001 General Motors Corp. 1–7

1–8 Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. 1–9

MD Product Line With PTO

* All data and specifications are subject to change without notice.

1–10 Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. 1–11

2–2. PERIODIC INSPECTION NOTE:

2. Inspect the transmission for: c. Electronic Controls and Protection Circuits.

a. Transmission Fluid. Transmission fluid cools, a. Fluid Level Check Procedure

Copyright © 2001 General Motors Corp. 2–1

2–2 Copyright © 2001 General Motors Corp.

Copyright © 2001 General Motors Corp. 2–3

b. Consistency of Readings. Always check the fluid b. Cold Check Procedure