Transmission: Service Manual

TRANSMISSION
T2180A JUNE 1998

(NEW ISSUE)
10-112
SERVICE MANUAL
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-ii
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PLEASE LET US KNOW!

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

Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)
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FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE
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IN THE
UNITED STATES
BUSINESS REPLY MAIL

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

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WORLD HEADQUARTERS
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ALLENTOWN PA 18105-9972
FOLD ALONG THIS LINE

TRANSMISSION
T2180A
SERVICE MANUAL
JUNE 1998 © MACK TRUCKS, INC. 1998

(NEW ISSUE) 10-112
front.fr5 Page ii Monday, June 22, 1998 11:19 AM
ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including electronic, mechanical, photocopying,
recording, or otherwise without prior written permission
of Mack Trucks, Inc.
ii
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SAFETY INFORMATION
SAFETY INFORMATION
iii
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SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of per-
sonal injury to service personnel, or the possibility of improper service methods which may damage the
vehicle or render it unsafe. Additional Notes and Service Hints are utilized to emphasize areas of proce-
dural importance and provide suggestions for ease of repair. The following definitions indicate the use of
these advisory labels as they appear throughout the manual:
Directs attention to unsafe practices which could result in damage to equipment and
possible subsequent personal injury or death if proper precautions are not taken.
Directs attention to unsafe practices which could result in personal injury or

death if proper precautions are not taken.
Directs attention to unsafe practices and/or existing hazards which will result
in personal injury or death if proper precautions are not taken.
An operating procedure, practice, condition, etc., which is essential to emphasize.
A helpful suggestion which will make it quicker and/or easier to perform a certain
procedure, while possibly reducing overhaul cost.
000001a
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SAFETY INFORMATION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle, always be seated in the driver’s seat, place the
transmission in neutral, be sure that parking brakes are set, and disengage
the clutch.
2. Before working on a vehicle, place the transmission in neutral, set the

parking brakes, and block the wheels.
3. Before towing the vehicle, place the transmission in neutral and lift the rear
wheels off the ground, or disconnect the driveline to avoid damage to the
transmission during towing.
REMEMBER,
SAFETY . . . IS NO ACCIDENT!
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NOTES
vi
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EXPLANATION OF NUMERICAL CODE
vii
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EXPLANATION OF 3-DIGIT GROUP 500 — BRAKES, AUXILIARY
SYSTEMS
NUMERICAL CODE GROUP 600 — CAB, TRUCK BODY
The organization of MACK service manuals has GROUP 700 — ELECTRICAL
been upgraded to standardize manual content
according to a reference system based on The second two digits of the 3-digit code
component identification. The new reference are used to identify the system, assembly or
system will help to link the information contained subassembly, as appropriate, within each of
in this publication with related information the groupings. The codes applicable to this
included in other MACK service-warranty publication are shown at the TOP OF EACH
publications, such as associated service bulletins, PAGE and at SECTION HEADINGS as
warranty manuals, and the TS477 Labor Time necessary, and may also appear in the TABLE
Standards Manual. OF CONTENTS, to guide you to specific
component information.
The system is based on a numerical code, the
first digit of which identifies the general Additionally, a two-character alpha code (i.e.,
component grouping as listed here: [GA] CASE, MAIN) may be shown with each
operation. This alpha code, in combination with
GROUP 000 — INSPECTIONS the three-digit Group number, identifies the
GROUP 100 — CHASSIS specific assembly, subassembly or part, and
GROUP 200 — ENGINE directly relates to the first five positions of the
operation code listed in the Service Labor Time
GROUP 300 — CLUTCH, TRANSMISSION, Standards Manual, TS477.
TRANSFER CASE AND PTO
GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
EXAMPLES:
321 GA 3N 45
BASE OPERATION
TRANSMISSION HOUSING
CASE, MAIN
MACK TRANSMISSION, T2180A
REPLACE
302279a
viii
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TABLE OF CONTENTS
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
EXPLANATION OF 3-DIGIT NUMERICAL CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
300 TRANSMISSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT IDENTIFICATION STAMPING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
300 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
T2180A TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Splash Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Magnetic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GEAR RATIOS AND SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
300 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EXPLODED VIEW OF MAIN CASE SHIFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EXPLODED VIEW OF REAR CASE SHIFT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CUTAWAY VIEW OF RANGE SHIFT CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EXPLODED VIEW OF MAIN DRIVE PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VIEW OF MAINSHAFT AND GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EXPLODED VIEW OF FRONT MAINSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EXPLODED VIEW OF REAR MAINSHAFT (OUTPUT SHAFT) AND SYNCHRONIZER ASSEMBLY . . . . . . 20
EXPLODED VIEW OF REAR OUTPUT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED VIEW OF FRONT COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED VIEW OF FRONT COUNTERSHAFT REAR BEARING COVER . . . . . . . . . . . . . . . . . . . . . . . . 21
EXPLODED VIEW OF REAR COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EXPLODED VIEW OF REAR COUNTERSHAFT BEARING COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EXPLODED VIEW OF REVERSE IDLER GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
300 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
300 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Magnetic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
300 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
[320] TRANSMISSION DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
300 BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
[320] TRANSMISSION COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
[323] Main Case Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
[323] Main Case Shift Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
[324] Rear Case Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
[323] Range Shift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
[322] Main Drive Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
[322] Front Mainshaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
[322] Rear Mainshaft (Output Shaft) and Synchronizer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ix
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TABLE OF CONTENTS
300 BENCH PROCEDURES (Cont.)
[322] Rear Output Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
[322] Front Countershaft Front Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
[322] Front Countershaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
[322] Front Countershaft Rear Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
[322] Rear Countershaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
[322] Rear Countershaft Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
[322] Reverse Idler Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
300 INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
[300] Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
[322] Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
[322] Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
[323] Shifter Forks, Sliding Clutches and Shift Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
[321] Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
300 BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
[320] TRANSMISSION COMPONENT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
[322] Reverse Idler Gear Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
[322] Rear Countershaft Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
[322] Rear Countershaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
[322] Front Countershaft Rear Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
[322] Front Countershaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
[322] Front Countershaft Front Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
[322] Rear Output Housing Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
[322] Rear Mainshaft (Output Shaft) and Synchronizer Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
[322] Front Mainshaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
[322] Main Drive Pinion Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
[323] Range Shift Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Rear Case Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
[323] Main Case Shift Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
300 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
[320] TRANSMISSION REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
300 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
GEAR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
All Forks and Sliding Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
GENERAL TOLERANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
TRANSMISSION SPECIFICATIONS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
300 SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
[543] T2180A AIR CONTROL WITH COMPOUND NEUTRALIZING FOR PTO . . . . . . . . . . . . . . . . . . . . . . 172
[543] T2180A AIR CONTROL WITH COMPOUND NEUTRALIZING FOR PTO . . . . . . . . . . . . . . . . . . . . . . 173
[543] T2180A AIR CONTROL WITHOUT COMPOUND NEUTRALIZING FOR PTO . . . . . . . . . . . . . . . . . . 174
[543] T2180A AIR CONTROL WITHOUT COMPOUND NEUTRALIZING FOR PTO . . . . . . . . . . . . . . . . . . 175
300 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
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10-112a.fm Page 1 Monday, June 22, 1998 11:39 AM
300 TRANSMISSION IDENTIFICATION
TRANSMISSION IDENTIFICATION
Page 1
Figure 1 — Location of Identification Stamping on Left Side of Main Case
UNIT IDENTIFICATION
STAMPING LOCATION
The following model code information is stamped
on the left side of the transmission, toward the
rear of the main case. Refer to inset above.
1. Unit Symbol Identification
T = transmission
2 = 200 series
18 = usable forward speeds
0 = overdrive
A = heavy duty application
2. Transmission Serial No.
3. Transmission Assembly (Part) No.
* = digits may vary
4. Assembly No. Revision Level
Page 2
Figure 2 — Differences Between T2180 and T2180A Transmissions
Page 3
NOTES
Page 4
300 DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION
Page 5

T2180A TRANSMISSION The T2180A rear compound case has openings
that allow for additional Power Take-Off (PTO)
units. The speed of the rear compound gears
Description depends on engine speed and on the selected
main case gear. This allows multiple speeds
The T2180A transmission is a triple countershaft
available at the rear compound PTO openings.
unit. It consists of a compact main box which
houses five non-synchronized forward-speed The main case and the bell housing are
gearsets plus a reverse gear set. The rear combined into a one-piece aluminum casting.
compound case of the T2180A is also a triple The case is heat-treated for strength.
countershaft unit. It consists of Lo-range and
Hi-range gearsets plus a splitter section. The bearings are housed in cast-iron bearing
retainers (covers). Tapered roller bearings are
A single gear shift lever is used to shift through a used at each end of all transmission
“progressive-H” shift pattern. In addition, an air- countershafts.
operated valve, mounted on the shift lever, is
used to shift both the range gears and splitter All gears are of the spur-type design and are in
gears in the rear compound. constant mesh with mating gears. All shifting is
done by forks and sliding clutches. The shift rails
Operating the range selector causes a plate-type and forks are integral with the shift cover for the
synchronizer to be shifted by an air-operated shift main case. The rear case shift cover incorporates
cylinder between the Hi-range/Hi-split gearset an air-operated shift fork and piston assembly for
and the Lo-range gearset. Operating the split shift gear split shifting and a range shift cylinder
selector causes a shift between the compound mounted at the rear of the case for Hi-range and
Lo-split gearset and the Hi-range/Hi-split gearset. Lo-range shifting.
This unit also provides four reverse speeds The six countershafts, three in the main case and
produced from a gearset in the main case and by three in the rear compound case, are equally
means of the Lo-range, Hi-range and splitter spaced around the two mainshafts. This design
gearing in the compound case. Refer to T2180A distributes the load equally among the
SHIFTING INSTRUCTIONS for complete shifting countershafts, thus keeping normal deflection
procedure information. and gear tooth loading to a minimum.
The T2180A has 18 forward speeds and 4
reverse speeds. The range selector is shifted into
Lo-range and the split shift selector is toggled
between Hi-split and Lo-split to obtain the first 10
forward speeds of Lo-Lo-Lo, Lo-Hi-Lo, first-Lo,
first-Hi, second-Lo, second-Hi, third-Lo, third-Hi,
fourth-Lo and fourth-Hi. This is done in
conjunction with the gear shift lever positions of
Lo through fourth. The rear compound is then
shifted into Hi-range and the main box repeats
shift positions fifth (first) through eighth (fourth) to
obtain the forward speeds of fifth-Lo, fifth-Hi,
sixth-Lo, sixth-Hi, seventh-Lo, seventh-Hi,
eighth-Lo and eighth-Hi (a total of 18 forward
speeds). Reverse is used in Lo range to obtain
reverse Lo-Lo and reverse Hi-Lo. When Hi-range
is selected, the additional two reverse gear INPUT
speeds of reverse Lo-Hi and reverse Hi-Hi are SHAFT
obtained (a total of four reverse speeds).
300618a
Figure 3 — Equal Torque Distribution
Page 6

LUBRICATION Magnetic Oil Filter
A magnetic oil filter assembly is built into the right
Splash Lubrication side of the transmission case (see Figure 5). It
consists of a trough arrangement cast into the
All parts inside the transmission are lubricated
inside wall of the case and a removable cover
by a splash-and-gravity system. To minimize
plate (1). The trough is open at the top to collect
churning, only the lower countershaft dips into the
oil. The oil is then channelled past a magnetic
lubrication oil. As the gears on the lower
plug (2), which removes ferrous metallic particles
countershaft spin, a constant spray of oil is
from the passing oil. After passing the magnetic
directed to all internal parts of the transmission.
plug, the oil is channelled upward to an outlet,
The oil cools as it circulates over the aluminum
where it returns (by gravity) down into the
case. Troughs and passages, cast into the inside
transmission case sump. The magnetic plug is
of the case, capture and direct oil to the bearings.
removable from the outside of the transmission.
The drain plug at the bottom of the case is also
magnetic.
Figure 4 — Splash Lubrication
Figure 5 — Magnetic Oil Filter Viewed from Inside Case
Page 7

GEAR RATIOS AND SHIFT PATTERN
Main Box Rear Compound
T2180A T2180A
T2180A
Gear (Main Box) Splitter Range Ratio
LO LO LO 13.91
LO HI LO 11.80
1 LO LO 8.78
1 HI LO 7.45
2 LO LO 6.28
2 HI LO 5.33
3 LO LO 4.52
3 HI LO 3.83
4 LO LO 3.22
4 HI LO 2.73
5 LO HI 2.29
5 HI HI 1.94
6 LO HI 1.64
6 HI HI 1.39
7 LO HI 1.18
7 HI HI 1.00
8 LO HI 0.84
8 HI HI 0.71
R LO LO 28.98
R HI LO 24.58
R LO HI 7.56
R HI HI 6.41
Page 8

SHIFTING INSTRUCTIONS Upshifting
The T2180A main box portion of this transmission To upshift the T2180A, begin in Lo gear with
is non-synchronized. There is a Lo and Hi air-shift range selector in LO and air-shift splitter
auxiliary compound section controlled by an air selector in LO (shown on shift pattern diagram).
shift selector on the shifter. This compound Apply the accelerator and engage the clutch and
section is equipped with a synchronizer to accelerate to governed speed. Select HI on the
facilitate Lo-Hi range shifting. The T2180A splitter selector (preselect) and release the
transmission also provides four reverse speeds accelerator pedal long enough for the split shift to
by means of the reverse position of the shift lever complete. Reapply the accelerator. Shift through
and the air-shift range selector and air-shift 1/5 Lo-split, 1/5 Hi-split, 2/6 Lo-split, 2/6 Hi-split
splitter selector on the lever. To utilize the four and so on until 4/8 Hi-split is reached.
reverse speeds, the gear shift lever must be
moved to the “R” position and the range selector To continue while in 4/8 Hi-split, move the range
and splitter selector must be toggled to LO or HI. selector to the HI position (preselect), move the
splitter selector to the LO position (preselect) and
The rear compound Lo-range provides ten low then move the gear shift lever through neutral
ratios for the five forward main case gear back to the 1/5 position. As the lever moves
positions. In rear compound Hi-range, there are through neutral, the range shift to Hi, and the split
eight additional forward gears that can be shift to Lo is completed. The transmission is now
achieved. Remember, however, to double-clutch in fifth Lo-split Hi-range. Continue upshifting
whether moving up or down through the gears. through 1/5 (fifth) Hi-split, 2/6 (sixth) Lo-split, 2/6
For normal highway use, start in Lo-range Lo-split (sixth) Hi-split, 3/7 (seventh) Lo-split and so on
with shift lever in 1/5 position and shift through until 4/8 (eighth) Hi-split is reached.
2/6, 3/7 and 4/8. The LO position in Lo-range
Lo-split for this transmission is designed for use in To upshift the transmission from Lo-split to
off-highway and slow-moving operations (e.g., Hi-split (in the same gear lever position),
curb pouring, material spreading, heavy load/ accelerate the engine to governed speed, move
steep grade). Reverse is used in Lo-range and the splitter selector to HI (preselect), release the
Hi-range with Lo-split and Hi-split for four reverse clutch and back off of the accelerator pedal.
speeds. Reapply the accelerator and engage the clutch
after the audible shift is heard (or when engine
speed drops approximately 200 rpm). Depressing
the clutch pedal may not be needed to break
r Make sure that air pressure is at least 100 psi driveline torque. The need to release the clutch
before making range shifts. Warm up the varies with road and load conditions.
transmission before making range shifts.
Always start in Lo-range. This also applies to To upshift from one gear position Hi-split to the
dynamometer testing. Do not select Hi-range next higher gear Lo-split, accelerate the engine to
and attempt to move a stationary vehicle. governed speed, move the splitter selector to LO
(preselect) and then move the gear shift lever to
r If a gear is preselected, especially under the next higher gear range. As the lever is moved
heavy load, the splitter will not shift until the through neutral, the split shift is completed.
driveline torque is relieved. To do this,
depress the clutch pedal and then release it,
or back off the throttle and then reapply it.
r It is important to preselect the range shift.
This means that the range shift must be Continued on next page.
moved to its next position (up or down) before
the gear shift lever is moved. Then, move the
gear shift lever through neutral to the next
desired gear position. As the lever passes
through neutral, the range shift is completed.
Page 9

Continued from previous page. To downshift from a Lo-split to the next lower gear
position Hi-split, as engine speed falls, move the
Downshifting splitter selector to HI (preselect). Then, move the
gear shift lever to the next lower gear position. As
To downshift the T2180A, shift from 4/8 (eighth the lever passes through neutral, the split shift is
Hi-range) Hi-split to 4/8 Lo-split, 3/7 (seventh) completed.
Hi-split, 3/7 (seventh) Lo-split and so on, double-
clutching between the gears until 1/5 (fifth)
Lo-split is reached.
r Be careful not to overspeed the engine during
While in 1/5 (fifth) Lo-split, move the range downshifting. Damage to powertrain
selector to LO (preselect), select HI on the splitter components may result.
selector (preselect) and then move the gear shift
lever over to 4/8 (fourth) position (double- r When the truck is stationary, do NOT shift to
clutching and manipulating the throttle in the Hi-range and then start moving the truck.
normal manner between gears). As the gear shift Damage to the sychronizer can result.
lever passes through neutral, the range shift to Lo r Do not shift the synchronizer while moving in
and the split shift to Hi is completed. Continue reverse.
downshifting using the shift lever and the splitter
selector in the normal manner until LO gear Lo-
split is reached.
To downshift from Hi-split to Lo-split in the same

gear, as engine speed falls, move the splitter
selector to LO (preselect), release and reapply
the accelerator pedal. An audible shift completion
should be heard.
Page 10

POWER FLOW DIAGRAMS
The following illustrations show power flow
through the T2180A transmission in each gear
range. Gear designations are listed in order of
gear shift lever position, splitter selector position
and range selector position.
Figure 8 — First Speed (Lo-Split, Lo-Range)
Figure 6 — Lo Speed (Lo-Split, Lo-Range)
Figure 9 — First Speed (Hi-Split, Lo-Range)
Figure 7 — Lo Speed (Hi-Split, Lo-Range)
Figure 10 — Second Speed (Lo-Split, Lo-Range)
Page 11
Figure 11 — Second Speed (Hi-Split, Lo-Range) Figure 14 — Fourth Speed (Lo-Split, Lo-Range)
Figure 12 — Third Speed (Lo-Split, Lo-Range) Figure 15 — Fourth Speed (Hi-Split, Lo-Range)
Figure 13 — Third Speed (Hi-Split, Lo-Range) Figure 16 — Fifth Speed (Lo-Split, Hi-Range)
Page 12
Figure 17 — Fifth Speed (Hi-Split, Hi-Range) Figure 20 — Seventh Speed (Lo-Split, Hi-Range)
Figure 18 — Sixth Speed (Lo-Split, Hi-Range) Figure 21 — Seventh Speed (Hi-Split, Hi-Range)
Figure 19 — Sixth Speed (Hi-Split, Hi-Range) Figure 22 — Eighth Speed (Lo-Split, Hi-Range)
Page 13
Figure 23 — Eighth Speed (Hi-Split, Hi-Range) Figure 26 — Reverse Speed (Lo-Split, Hi-Range)
Figure 24 — Reverse Speed (Lo-Split, Lo-Range) Figure 27 — Reverse Speed (Hi-Split, Hi-Range)
Figure 25 — Reverse Speed (Hi-Split, Lo-Range)
Page 14
300 EXPLODED VIEWS
EXPLODED VIEWS
Page 15
300 EXPLODED VIEWS
1. 3rd/4th Shift Fork 12. Washer 23. Breather

2. 1st/2nd Shift Fork 13. Interlock Valve Pin 24. Interlock Pin
3. Lo/Reverse Shifter 14. Poppet Ball 25. Interlock Ball
4. Shifter Body Spring (Interlock) 15. Poppet Ball Spring 26. Lo/Reverse Shift Rail
5. Shifter Body Plunger (Interlock) 16. Interlock Rocker Hardware 27. 1st/2nd Shift Rail
6. Lo/Reverse Shift Fork 17. Interlock Valve O-Ring and Sleeve 28. Interlock Ball
7. 3rd/4th Shifter 18. Interlock Valve Spring 29. Interlock Pin
8. 3rd/4th Rocker Pin 19. 3rd/4th Rocker Pin Hardware 30. Interlock Ball
9. Washer 20. Interlock Rocker 31. 3rd/4th Shift Rail
10. 3rd/4th Rocker Arm 21. Interlock Rocker Bolt 32. Lo/Reverse Shifter Ball
11. Bushing 22. Pipe Plug 33. Lo/Reverse Shifter Spring
Exploded View of Main Case Shift Cover
Page 16
300 EXPLODED VIEWS
1. Shift Fork 9. Shift Cylinder Cover

2. Rail 10. Piston/Rail Nut
3. O-Ring 11. O-Ring
1. Cover O-Ring 7. Shift Fork Setscrew 4. Shift Piston 12. Cover Capscrew
2. Piston O-Ring 8. Splitter Shift Fork 5. O-Ring 13. O-Ring
3. Splitter Shift Piston 9. Capscrew (4) 6. Piston Sleeve 14. Breather Vent
4. Capscrew (10) 10. Piston Cover 7. Shift Cylinder 15. O-Ring
5. Rear Case Shift Cover 11. Shaft O-Ring 8. O-Ring 16. O-Ring
6. Gasket
Cutaway View of Range Shift Cylinder
Exploded View of Rear Case Shift Cover
Page 17
300 EXPLODED VIEWS
5
4
6
7
8
9 1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear

Gear 5. Lo Speed Gear
10 2. Second (Sixth) Speed 6. Reverse Speed Gear
11 Gear 7. Mainshaft
3. Sliding Clutch
300743a
View of Mainshaft and Gears
1. Main Drive Pinion Shaft 7. Bearing
2. Spigot Bearing 8. Spiral Snap Ring
3. Snap Ring 9. Gasket
4. Main Drive Pinion Gear 10. Pinion Bearing Cover
5. Spiral Snap Ring 11. Oil Seal
6. Snap Ring
Exploded View of Main Drive Pinion
Page 18
300 EXPLODED VIEWS
1. Spigot Bearing Inner Race Snap Ring 14. Mainshaft Snap Ring 27. Reverse Speed Gear
2. Spigot Bearing Inner Race 15. Internal-Toothed Thrust Washer 28. External-Toothed Thrust Washer
3. Mainshaft Snap Ring 16. External-Toothed Thrust Washer 29. Gear Snap Ring
4. Internal-Toothed Thrust Washer 17. Gear Snap Ring 30. Front Mainshaft
5. Fourth (Eighth) Speed Gear 18. First (Fifth) Speed Gear 31. Mainshaft Snap Ring
6. External-Toothed Thrust Washer 19. Gear Snap Ring 32. Spacer
7. Gear Snap Ring 20. External-Toothed Thrust Washer 33. Mainshaft Rear Bearing
8. Gear Snap Ring 21. Internal-Toothed Thrust Washer 34. Mainshaft Rear Bearing Sleeve
9. External-Toothed Thrust Washer 22. Mainshaft Snap Ring 35. Mainshaft Snap Ring
10. Internal-Toothed Thrust Washer 23. Lo Speed Gear 36. Main Drive Gear
11. Second (Sixth) Speed Gear 24. Sliding Clutch 37. Internal-Toothed Thrust Washer
12. Mainshaft Snap Ring 25. Mainshaft Snap Ring 38. Mainshaft Snap Ring
13. Sliding Clutch 26. Internal-Toothed Thrust Washer 39. Sliding Clutch
Exploded View of Front Mainshaft
Page 19
300 EXPLODED VIEWS
1. Output Shaft Snap Ring 14. Clutch Housing 27. Lo-Range Gear Hub
2. Internal-Toothed Thrust Washer 15. Synchronizer Pin 28. Output Shaft
3. External-Toothed Thrust Washer 16. Sliding Clutch 29. Lo-Range Gear
4. Hi Range/Hi Split Gear Snap Ring 17. Support Tube 30. Bearing Cone
5. Hi Range/Hi Split Gear 18. Preload Spring 31. Bearing Cup
6. External-Toothed Thrust Washer 19. Synchronizer Pin 32. Gasket
7. Internal-Toothed Thrust Washer 20. Clutch Housing 33. Output Housing
8. Output Shaft Snap Ring 21. Threaded Insert (3) 34. Output Housing Capscrew
9. Spacer (Front Synchronizer Pack) 22. Reaction Disc (4) 35. Collapsible or Ground Spacer
10. Reaction Disc (4) 23. Friction Disc (4) 36. Bearing Cup
11. Friction Disc (4) 24. Output Shaft Snap Ring 37. Bearing Cone
12. Twelve-Point Capscrew (3) 25. Internal-Toothed Thrust Washer 38. Output Housing Oil Seal
13. Non-Threaded Insert (3) 26. Lo-Range Gear Snap Ring
Exploded View of Rear Mainshaft (Output Shaft) and Synchronizer Assembly
Page 20
300 EXPLODED VIEWS
1. Rear Output Housing 3. Gasket

2. Outer Bearing Cup 4. Inner Bearing Cup
Exploded View of Rear Output Housing
1. Bearing Cup 7. Lo Speed Gear

2. Main Drive Gear 8. Spacer (Rear)
3. Fourth Speed Gear 9. Key
4. Second Speed Gear 10. Countershaft (Reverse
5. Spacer (Front) Speed Gear)
6. First Speed Gear 11. Bearing Cone
Exploded View of Front Countershaft
300674a
1. Front Bearing Cup 3. Rear Bearing Cup

2. Bearing Cover
Exploded View of Front Countershaft Rear Bearing
Cover
Page 21
300 EXPLODED VIEWS
3
2
4
1
5
300668a
1. Thrust Washer 4. Expansion Plug

2. Reverse Idler Gear 5. Reverse Idler Shaft
3. Bearing
Exploded View of Reverse Idler Gear
1. Bearing Cone 5. Key

2. Lo-Split Gear 6. Rear Countershaft
3. Spacer (Lo-Range Gear)
4. Hi Range/Hi Split Gear 7. Bearing Cone
Exploded View of Rear Countershaft
1. Bearing Cup 3. Shim

2. O-Ring
Exploded View of Rear Countershaft Bearing Cover
Page 22
300 TROUBLESHOOTING
TROUBLESHOOTING
Page 23
300 TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom Probable Cause Remedy
NOISE a. Low oil level. a. Fill to correct level.
b. Wrong oil used. b. Drain and refill with correct oil.
c. Side-mounted PTO installed too tight c. Reinstall PTO correctly.
or too loose.
d. Loose bell housing-to-flywheel housing d. Install new capscrews, using Loctite.
capscrews.
e. Incorrect clutch-driven discs used. e. Install correct clutch-driven discs.
f. Gears worn, chipped, rough, cracked. f. Replace gears.
g. Bearings worn, cracked, corroded, g. Replace bearings.
galled, etc.
h. Mismatched carrier ratios. h. Install correct matched gearing.
i. Resonating (ringing) driveshaft. i. Install suitable dampening material,
high-speed balance driveshaft.
HARD SHIFTING a. Incorrect driving practices. a. Educate driver.
b. Low oil level. b. Fill to correct level.
c. Improperly adjusted clutch, clutch c. Adjust properly.
linkage, clutch brake or shift linkage.
d. Wrong oil used. d. Drain and refill with correct oil.
e. Remote shift linkage not lubricated. e. Clean and lubricate.
f. Shift lever binding or has interference. f. Relieve binding or interference.
g. Poppet balls binding in their holes. g. Clean holes and balls.
h. Loose setscrews in shifters or shift h. Tighten to correct torque.
forks.
i. Improperly adjusted fourth/ninth-fifth/ i. Adjust properly.
tenth eccentric pin (if applicable).
j. Worn spigot bearing. j. Replace bearing.
k. Clutch brake ears broken. k. Replace clutch brake.
l. Clutch discs worn into main drive l. Replace clutch discs and main drive
pinion. pinion.
m. Mainshaft snap ring or thrust washer m. Replace snap rings or thrust washers.
failure.
GEAR DISENGAGEMENT a. Excessive length and/or weight of gear a. Replace with standard lever and/or
(JUMPING OUT OF GEAR) shift lever and/or knob. knob.
b. Shift lever interference. b. Remove interference.
c. Improperly adjusted remote control c. Adjust properly.
linkage.
d. Worn or loose mounting insulators. d. Replace insulators.
e. Loose, broken or missing capscrews e. Replace capscrews, check threads in
between clutch housing and flywheel case.
housing.
f. Weak or broken shift rail poppet f. Replace springs.
springs.
g. Bent or worn shift forks. g. Replace forks.
h. Broken snap rings. h. Replace snap rings.
Page 24
300 TROUBLESHOOTING
Symptom Probable Cause Remedy
GEAR DISENGAGEMENT i. Shift rail bent or poppet notches worn. i. Replace shift rail.
(JUMPING OUT OF GEAR)
Continued j. Worn taper or chipped teeth on sliding j. Replace both the sliding clutch and
clutch teeth. mating gear if clutch teeth are
damaged.
k. Worn or damaged spigot bearing. k. Replace bearing.
l. Misaligned engine flywheel housing. l. Realign properly.
m. Chassis resonant ride. m. Correct resonance.
OIL LEAKS a. Oil level too high. a. Drain to correct level.
b. Drain plug, fill plug or magnetic plug b. Tighten plug.
loose.
c. Loose or missing capscrews. c. Tighten or replace.
d. Improper lubricant used. d. Drain and refill with correct oil.
e. Clogged breather. e. Clean or replace.
f. Gaskets or O-rings broken, shifted or f. Replace gaskets or O-rings.
squeezed out of position.
g. Worn oil seals. g. Replace seals.
h. O-rings in air shift cover/cylinder h. Replace O-rings.
leaking air pressure into transmission.
BEARING FAILURE a. Dirt in system. a. Clean system, replace bearings as
needed, flush and refill with clean oil.
b. Wrong grade of oil or contaminated oil. b. Clean system, replace bearings as
needed, flush and refill with clean oil.
c. Excessive vibrations. c. Eliminate vibrations, replace bearings.
d. Binding or seized propeller shaft slip d. Clean and replace as needed.
yoke.
e. Improper bearing clamping. e. Replace bearings and reclamp, using
correct procedures.
f. Improper bearing installation f. Replace, using correct procedures.
(preloads, etc.).
AIR SHIFT MALFUNCTIONS a. Low system air pressure. a. Wait for pressure to build up to normal.
b. Restricted air line (bent, squeezed, b. Reroute and/or replace air lines.
twisted, etc.).
c. Air lines too small. c. Replace with correct size air lines.
d. Defective pressure-reducing valve. d. Replace valve.
e. Defective O-rings in air shift cylinders. e. Replace O-rings.
f. Scored air shift cylinders or pistons. f. Repair or replace cylinders/pistons.
g. Defective range shift valve and/or air g. Repair or replace as needed.
shift selector valve (on shift lever).
h. Defective synchronizer. h. Repair or replace as necessary.
i. Hi-range sychronizer friction discs worn i. Replace sychronizer discs as needed.
or burned.
j. Intermixed synchronizer parts. j. Install matched parts.
Page 25
NOTES
Page 26
300 MAINTENANCE
MAINTENANCE
Page 27
300 MAINTENANCE
MAINTENANCE
Checking Oil Check the oil when it is at normal operating
temperature. The vehicle should be in a level
position, both front-to-rear and side-to-side.
Check the level of the oil at the intervals specified
Be careful not to burn your finger in hot gear in the Maintenance and Lubrication Manual
oil when checking oil level in transmission. (TS494). Add oil, if needed, until the oil begins to
run out of the filler plug hole. Use only specified
To check the transmission oil, remove the filler oil. Refer to Transmission Specifications and
plug on the right-hand side of the case. The oil Capacities found in the SPECIFICATIONS
should be level with the bottom of the filler plug section.
hole (Figure 28).
Changing Oil
Current production T2180A transmissions are

now built with a 1/2-inch internal square-drive
drain plug. The original external square-drive
drain plug is completely interchangeable with the
new internal drive plug. Tightening torque range
for both remains the same at 25–30 lb-ft
Figure 28 — Correct Oil Level (34–41 NNm).
If oil can only be felt by reaching your finger down

into the unit, the oil level is too low (Figure 29). When changing the oil in the transmission, the oil
should be at normal operating temperature.
Remove the magnetic drain plug from the bottom
of the transmission case. Drain the hot oil from
the unit into an industry-approved recovery
OK container. Clean and reinstall the magnetic drain

plug. Then tighten plug to 25–30 lb-ft
(34–41 NNm) torque.
Remove the filler plug and fill the transmission

with oil of the proper specification to the level of
the filler plug hole. (For proper oil specification,
refer to Transmission Specifications and
Capacities found in the SPECIFICATIONS
301259a section.)
Figure 29 — Incorrect Oil Level
Page 28
300 MAINTENANCE
NEW-STYLE
1/2-INCH INTERNAL
SQUARE DRIVE Be sure to add oil to the transmission through the
OIL DRAIN PLUG filler hole, NOT the magnetic filter plug hole. The
OIL FILLER
baffles of the magnetic filter will prevent proper
AND CHECK filling, and the resulting low oil level may cause
PLUG severe damage.
MAGNETIC
FILTER PLUG
Reinstall and snug the filler plug by hand only.
Then wrench-tighten the plug an additional 3/4 to
one turn, not exceeding 55 lb-ft (75 NNm) of
torque. Change the oil at the intervals specified in
the Maintenance and Lubrication Manual
(TS494).
Magnetic Oil Filter

Remove the magnetic oil filter plug and clean the
magnet in the plug every time the oil is changed.
Also clean the trough inside and then reinstall the
magnetic plug. Tighten the plug to 25–30 lb-ft
OLD-STYLE EXTERNAL (34–41 NNm) torque.
WRENCH DRIVE OIL
DRAIN PLUG 302278a
Air Breathers
Figure 30 — Plug Locations
The T2180A has one air breather located on the
main case top cover. The air breather should be
removed every time the oil is changed and
cleaned with a suitable solvent. Also check to be
sure that airflow through the breather is
unobstructed. Reinstall breather into case top
cover and tighten until snug.
The T2180A also has a small breather located on
the bottom side of the range shift cylinder. Clean
or replace the breather as necessary.
Page 29
NOTES
Page 30
10-112b.fm Page 31 Monday, June 22, 1998 11:34 AM
300 DISASSEMBLY
DISASSEMBLY
Page 31
300 DISASSEMBLY
[320] TRANSMISSION DISASSEMBLY PROCEDURES
Unless a complete overhaul is necessary, remove Lift and move the transmission with a hoist, using
only those parts required to gain access to faulty the two lifting brackets provided.
parts. Do not disturb parts with a heavy press fit
(interference fit) unless replacement is necessary.
2. Disconnect the air lines attached to the
When replacement is necessary, use proper
range shift cylinder and the rear case shift
press setups and pullers so that usable parts are
cover. Label the air lines for proper
not damaged.
reassembly.
3. Remove the range shift valve, dual-double
check valve, inversion valve, air directional
valve and associated brackets from the
External inspection of the unit before cleaning transmission.
and disassembly often reveals information about 4. Leave all air lines and valves connected and
existing operating conditions. This may help when then remove the valves and air lines as an
diagnosing problems. assembly.
During disassembly, remember the sequence

in which components and individual parts are
removed from the transmission. It is good
practice to keep related parts together in groups
when removed. Small parts such as shims and
spacers can be wired to the larger pieces they go
with. Groups of parts can be kept together in
boxes.
Figure 31 — Removing Air Lines and Valves
Keep parts such as shim packs, bearings, 5. Remove the interlock valve sleeve, spring,
bearing retainers (covers), bearing races and pin and O-ring from the main case top cover.
gears with the original countershaft from which Refer to Figure 80 on page 47.
they are removed. Mark each countershaft and
bearing cover before removal. Mark the upper left 6. Remove the clutch release bearing
front and rear countershafts and bearing covers assembly, shafts, yoke and clutch brake (if
(viewed from rear) as number 1. Mark the upper equipped).
right front and rear countershafts and bearing
covers (viewed from rear) as number 2. Mark the
lower front and rear countershafts and bearing
covers as number 3.
1. Clean the transmission externally and mount

it in an overhaul stand. Drain the lubricant
and plug any air line openings to prevent dirt
from entering. Label air lines so they can be
installed correctly during reassembly.
Page 32
300 DISASSEMBLY
7. Remove the main case shift cover
capscrews.
Figure 34 — Removing Rear Compound Case

Shift Cover Capscrews
Figure 32 — Removing Main Case Cover Capscrews 10. Remove the rear case shift cover.
8. Remove the main case shift cover assembly.
To remove the drive yoke nut of the T2180A

transmission, place at least two gears in both the
main case and rear case into engagement. This
is done to lock the gearing and prevent it from
rotating while removing the yoke nut.
11. Reach through the rear case top opening

and verify that the splitter sliding clutch and
the synchronizer assembly sliding clutch are
both engaged.
300446a
Figure 33 — Removing Main Case Shift Cover
9. Remove the rear compound case shift cover

capscrews.
Page 33
300 DISASSEMBLY
12. Reach into the main case top opening and
move at least two sliding clutches into
engagement. This locks two different gears
to the mainshaft and prevents the gears and
shaft of the transmission from rotating.
13. Remove the drive yoke nut.
Figure 37 — Removing Shift Fork Setscrew

Figure 35 — Removing Drive Yoke Nut
16. Remove the range shift cylinder capscrews.
14. Remove the drive yoke, using a suitable
puller.
Figure 38 — Removing Cylinder Capscrews
Figure 36 — Removing Drive Yoke
15. Reaching inside the rear case opening,

remove the range shift fork setscrew.
Page 34
300 DISASSEMBLY
17. Remove the range shift cylinder cover and
O-ring, and set aside.
18. Remove the shift cylinder from the rear case.
Note offset of the range shift fork. Straight
side of fork faces the front; angled side of
fork faces the rear.
Figure 41 — Removing Output Housing Oil Seal
21. Remove the rear output housing capscrews.

Remove the jackscrew plugs from the
housing.
Figure 39 — Removing Range Shift Cylinder
Figure 42 — Removing Output Housing Capscrews
22. Using jackscrews, separate the output

housing from the rear case.
Figure 40 — Shift Fork Offset
19. Shift the transmission gears into neutral.

Verify that the transmission is in neutral.
20. Remove the rear output housing oil seal.
Figure 43 — Separating Output Housing from Case
Page 35
300 DISASSEMBLY
23. Remove the output housing along with the
outer bearing cone and bearing preload
spacer (collapsible or ground).
Figure 46 — Mark Rear Countershaft Bearing

Covers for Placement
Figure 44 — Removing Output Housing, Bearing

Cone and Spacer
Position the transmission vertically, rear end up.
24. Remove the output housing gasket from
either the housing or case as needed.
26. Remove all of the rear compound
25. Number the front countershaft front bearing countershaft bearing cover capscrews.
covers and the rear compound countershaft
bearing covers, using a grease pencil. Write
the number 1 on the upper right front cover
(viewed from front), the number 2 on the
upper left front cover (viewed from front) and
the number 3 on the lower front cover. Write
the number 1 on the upper left rear cover
(viewed from rear), the number 2 on the
upper right rear cover (viewed from rear) and
the number 3 on the lower rear cover.
Figure 47 — Removing Rear Countershaft Bearing

Cover Capscrews
27. Remove the jackscrew plugs from the

covers.
300480a
Figure 45 — Mark Front Countershaft Front Bearing

Covers for Placement
Page 36
300 DISASSEMBLY
28. Using jackscrews, remove the rear
compound countershaft bearing covers.
Figure 50 — Removing Outer Case-to-Case Capscrews
Figure 48 — Removing Bearing Cover
29. Mark the rear compound countershafts so

they can be installed in the same position
during reassembly.
300489a
Figure 51 — Removing Dowel Bolts
Figure 49 — Marking Rear Countershafts
When separating the rear case from the front

case, make sure the transmission is in the
vertical position. The rear countershafts are
not supported when the case is removed.
They can fall out and cause damage or
Figure 52 — Removing Inner Case-to-Case Capscrews
personal injury.
30. Remove the capscrews and dowel bolts

holding the rear case to the main case (two
capscrews are located inside the rear case
opening).
Page 37
300 DISASSEMBLY
31. Lift the rear case from the front case. Lift
only the case, not the compound gearset or
output shaft and synchronizer assembly.
32. Using a hoist and suitable output yoke
retaining nut with welded strap, lift and
remove the synchronizer and output shaft
assembly.
Figure 54 — Removing the Compound Countershafts
34. Remove the splitter sliding clutch from the

mainshaft.
Figure 53 — Lifting Synchronizer and Output Shaft
33. Remove the three rear compound

countershafts from the rear of the
transmission.
Figure 55 — Remove Splitter Sliding Clutch
Remember to mark the countershafts so they

can be installed in the same position during
reassembly. Also, notice the gear timing marks.
Countershaft gear timing should be marked in
alignment with the countershaft keyway.
Page 38
300 DISASSEMBLY
35. Remove the rear compound Lo-split gear 38. Remove the capscrews from the front
snap ring, internal-toothed thrust washer mainshaft rear bearing cover and then
and Lo-split gear from the mainshaft. remove the cover.
Figure 58 — Removing Rear Bearing Cover Capscrews
39. Remove the front mainshaft snap ring next

to the rear bearing.
Figure 56 — Removing Snap Ring, Thrust

Washer and Lo-Split Gear
36. Remove the No. 2 (upper right) front

countershaft rear bearing cover capscrews.
37. Using jackscrews, remove the No. 2 (upper
right) front countershaft rear bearing cover.
Figure 59 — Removing Rear Bearing Snap Ring
Figure 57 — Removing No. 2 Front Countershaft Rear

Bearing Cover
Page 39
300 DISASSEMBLY
40. Remove the front mainshaft rear bearing. 42. Using suitable snap ring pliers, remove the
snap ring from inside the reverse speed
gear.
Figure 62 — Removing Reverse Speed Gear Snap Ring
43. Position the transmission horizontally.

Remove the main drive pinion bearing cover
capscrews.
Figure 60 — Removing Front Mainshaft Rear Bearing
41. Remove the front mainshaft rear bearing

spacer and spacer snap ring from the
mainshaft.
300447a
Figure 63 — Removing Pinion Bearing Cover Capscrews
Figure 61 — Removing Front Mainshaft Bearing Spacer

and Snap Ring
Page 40
300 DISASSEMBLY
44. Using jackscrews, free the main drive pinion 47. Using a soft mallet, drive the mainshaft
assembly from the case. rearward in the case to free the mainshaft
gears from the countershaft gears.
48. Position the transmission vertically with the
rear end up.
49. Remove the No. 2 (upper right) countershaft
from the case by lifting the front end off of
the front bearing cone and then sliding the
countershaft through the opening.
300448a
Figure 64 — Use Jackscrews to Free Main Drive Pinion
45. Remove main drive pinion assembly from

the case.
Figure 67 — Removing No. 2 Countershaft from Case

2 1
If not already done, use a grease pencil to

number the front countershaft rear bearing
3
covers. Write the number 1 on the upper left rear
cover (viewed from rear) and the number 3 on the
300449a
lower rear cover. Also, mark the front
countershafts (use same numbers and locations
Figure 65 — Removing Main Drive Pinion Assembly indicated above) so that they can be installed in
the same position during reassembly.
46. Remove the third/fourth (7th/8th) sliding
clutch.
Figure 66 — Removing Third/Fourth Sliding Clutch
Page 41
300 DISASSEMBLY
50. Place the transmission in a horizontal 52. Place the transmission in a vertical position.
position. Remove the No. 2 (upper left) front Remove the upper right reverse idler shaft
countershaft front bearing cover capscrews. expansion plug (next to No. 2 countershaft),
using a hammer and sharp punch.
This action destroys the expansion plug. Make

sure replacement expansion plugs are available.
300452a
Figure 68 — Removing No. 2 Front Countershaft Front

Bearing Cover Capscrews

left) front countershaft front bearing cover.
Figure 71 — Removing Upper Right Reverse Idler Shaft

Expansion Plug
53. Using tool J 34630 or a slide hammer,

remove the upper right reverse idler shaft
(next to No. 2 countershaft). To prevent
damage to the reverse idler gear, catch the
gear as it separates from the shaft.
Figure 69 — Removing No. 2 Front Countershaft Front

Bearing Cover Using Jackscrews
Figure 72 — Using Tool J 34630 to Remove Reverse

Idler Shaft
Figure 70 — No. 2 Front Countershaft Front Bearing

Cover Removed
Page 42
300 DISASSEMBLY
Figure 73 — Removing Reverse Idler Gear and Shaft Figure 74 — Moving and Blocking No. 1 (Upper Left)
Countershaft Away from Mainshaft
54. Remove the No. 1 (upper left) front
countershaft rear bearing cover capscrews. 60. Tip the front end of the mainshaft outward
and remove it from the case.
left) front countershaft rear bearing cover.
56. Using a hammer and sharp punch, remove
the upper left reverse idler shaft expansion The reverse gear is free on the mainshaft and
plug (next to No. 1 countershaft). can fall off when handling the mainshaft
assembly.


remove the upper left reverse idler shaft
(next to No. 1 countershaft). To prevent
damage to the reverse idler gear, catch the
gear as it separates from the shaft.
58. From top of case, slide the mainshaft
reverse gear and Lo/reverse sliding clutch
forward toward the front of the transmission.
59. Using a pry bar, move the rear end of the
No. 1 (upper left) countershaft away from Figure 75 — Removing the Mainshaft
the mainshaft as far as possible without
damage. Block the countershaft in this 61. Remove the capscrews from the No. 3
position, using wadding made from rags. (lower) front countershaft rear bearing cover.
62. Using jackscrews, remove the No. 3 (lower)
front countershaft rear bearing cover.
63. Using a hammer and sharp punch, remove
the lower reverse idler shaft expansion plug
(next to No. 3 countershaft).
Continued on next page.
Page 43
300 DISASSEMBLY
63. ...continued


remove the lower reverse idler shaft (next to
No. 3 countershaft). To prevent damage to
the reverse idler gear, catch the gear as it
separates from the shaft.
65. Remove the No. 1 (upper left) front Figure 77 — Removing No. 3 Lower Countershaft
countershaft by pulling and tilting the front
end upward. 67. Remove the remaining No. 1 (upper right)
and No. 3 (lower) front countershaft front
bearing cover capscrews and bearing
covers. Use jackscrews to remove the
covers.
300478a
Figure 78 — Removing No. 1 and No. 3 Front

Countershaft Bearing Covers
Figure 76 — Removing No. 1 Upper Left Countershaft
66. Remove the No. 3 (lower) countershaft by

pulling and tilting the front end upward.
Page 44
10-112c1.fm Page 45 Monday, June 22, 1998 11:32 AM
300 BENCH PROCEDURES
BENCH PROCEDURES
(DISASSEMBLY)
Page 45

[320] TRANSMISSION COMPONENT DISASSEMBLY
Unless a complete overhaul is necessary, remove

only the parts that are required to repair the
assembly. Do not disturb parts that have a heavy
press fit (interference fit) unless the part must be
replaced. When replacement is necessary, use
proper pullers and press setups to prevent
damage to usable parts.
[323] Main Case Shift Cover
300767a
Figure 79 — Shift Cover Assembly
Page 46

Figure 80 — Exploded View of Main Case Shift Cover
Page 47

[323] Main Case Shift Cover Disassembly
1. Remove the nut and washers from the 3. Remove the interlock ball from the cover.
interlock rocker bolt.
Figure 83 — Remove Interlock Ball from Cover

Figure 81 — Remove Nut and Washers
2. Remove the interlock rocker and bolt from

the cover.
Figure 82 — Remove Interlock Rocker and Bolt
Page 48

4. Remove the setscrew from the Lo/reverse 5. Remove the setscrew from the Lo/reverse
shift fork. shifter.
300764a
Figure 85 — Removing Setscrew from

300766a
Lo/Reverse Shifter
Figure 84 — Removing Setscrew from Lo/Reverse
Shift Fork
Page 49

6. Slide the Lo/reverse shift rail to the left and 7. Remove the Lo/reverse shift fork from the
remove the interlock pin. cover.
300765a
Figure 86 — Sliding Lo/Reverse Shift Rail Figure 87 — Removing Lo/Reverse Shift Fork
Page 50

8. Push the Lo/reverse shift rail forward, using 9. Remove the poppet ball and spring from the
a metal bar or large screwdriver. Hold a shop Lo/reverse shift rail vertical pocket in line
towel over the top opening. The shop towel with the rail.
prevents the spring and ball under the rail
from popping out and becoming lost.
A magnet is helpful in removing the poppet ball

and spring.
Poppet balls are spring-loaded and may cause
injury when released.
300755a
300763a
Figure 89 — Removing Poppet Ball and Spring
Figure 88 — Pushing Lo/Reverse Shift Rail Forward
Page 51

10. Remove the interlock ball from the horizontal 11. Continue sliding the Lo/reverse shift rail
pocket between the Lo/reverse shift rail and forward to remove the Lo/reverse shifter.
the first/second shift rail.
300762a
Figure 90 — Removing Interlock Ball Figure 91 — Removing Lo/Reverse Shifter
Page 52

12. Slide the Lo/reverse shift rail from the shift 13. Remove the setscrew from the first/second
cover and at the same time, remove the shift fork.
third/fourth shift fork.
300758a
Figure 93 — Removing Setscrew from First/Second

300756a Shift Fork
Figure 92 — Removing Third/Fourth Shift Fork
Page 53

14. Push the first/second shift rail forward, using 15. Remove the poppet ball and spring from the
a metal bar or large screwdriver. Hold a shop first/second shift rail vertical pocket in line
towel over the top opening. The shop towel with the rail.

and spring.
Poppet balls are spring-loaded and can cause
injury when they are released.
300759a
300752a Figure 95 — Removing Poppet Ball and Spring
Figure 94 — Pushing First/Second Shift Rail Forward
Page 54

16. Remove the interlock ball from the horizontal 17. Remove the interlock pin from the
pocket between the first/second shift rail and first/second shift rail.
the third/fourth shift rail.
300754a 300760a
Figure 96 — Removing Interlock Ball

Figure 97 — Removing Pin from First/Second
Shift Rail
Page 55

18. Slide the first/second shift rail further forward 20. Remove the setscrew from the third/fourth
and remove the first/second shift fork. shifter.
300751a
Figure 100 — Removing Setscrew from Third/Fourth

Shifter
Figure 98 — Removing First/Second Shift Fork
19. Continue sliding the first/second shift rail

until it clears the cover.
300750a
Figure 99 — Removing First/Second Shift Rail
Page 56

21. Push the third/fourth shift rail forward using a 22. Continue sliding the third/fourth shift rail
metal bar or large screwdriver. Hold a shop forward out of the shift cover. At the same
towel over the top opening. The shop towel time, remove the third/fourth shifter.
Poppet balls are spring-loaded and can cause

injury when they are released.
Figure 102 — Removing Third/Fourth Shifter
300749a
Figure 101 — Pushing Third/Fourth Rail Forward
Page 57

23. Remove the poppet ball and spring from 25. Remove the nut and washers from the
under the third/fourth shift rail. third/fourth rocker pin.

and spring.
300619a
Figure 105 — Loosening Third/Fourth Rocker Pin Nut
26. Remove the third/fourth rocker pin and

rocker arm.
300747a
Figure 103 — Removing Poppet Ball and Spring
24. Remove the poppet ball and spring and

interlock plunger and spring from the
Lo/reverse shifter.
300745a
Figure 106 — Removing Third/Fourth Rocker Pin and

Rocker Arm
300746a
Figure 104 — Lo/Reverse Shifter Disassembled
Page 58

27. Remove the reverse light switch from the 28. Remove the reverse light switch rod from the
shift cover. cover.
300735a 300734a
Figure 107 — Removing Reverse Light Switch Figure 108 — Removing Reverse Light Switch Rod
29. Remove the shift cover breather vent.
300744a
Figure 109 — Removing Breather Vent
Page 59

[324] Rear Case Shift Cover
1. Remove the setscrew securing the shift fork
to the shift piston.
Figure 111 — Removing Setscrew
2. Remove the piston cover capscrews and

shift piston cover.
1. Cover O-Ring 7. Shift Fork Setscrew

2. Piston O-Ring 8. Splitter Shift Fork
3. Splitter Shift Piston 9. Capscrew (4)
4. Capscrew (10) 10. Piston Cover
5. Rear Case Shift Cover 11. Shaft O-Ring
6. Gasket
Figure 110 — Exploded View of Rear Case Shift Cover
Figure 112 — Removing Piston Cover
Page 60

3. Slide the shift piston out of the housing and 5. Remove the O-ring (that seals shaft of
at the same time, remove the shift fork. Note piston) from the rear of the shift piston
the orientation of the shift fork; the offset housing.
faces forward.
Figure 115 — Removing O-Ring from Rear of Housing
6. Remove the O-ring located on the shift

piston.
Figure 113 — Removing Piston and Shift Fork
4. Remove the piston cover O-ring from the

housing of the shift cover.
Figure 116 — Removing Piston O-Ring
Figure 114 — Removing O-Ring from Cover
Page 61

[323] Range Shift Cylinder Disassembly
1. With the range shift cylinder in hand, tap the
end of the piston shift rail on a firm surface
to remove the piston assembly.
300644a
Figure 118 — Piston Assembly Partially Removed
2. Remove the sleeve from the shift piston.
1. Shift Fork 9. Shift Cylinder Cover 300643a

4. Shift Piston 12. Cover Capscrew Figure 119 — Removing Sleeve from Piston
6. Piston Sleeve 14. Breather Vent 3. Remove the shift piston and rail assembly
7. Shift Cylinder 15. O-Ring from the range shift cylinder.
Figure 117 — Cutaway View of Range Shift Cylinder
The nut securing the piston to the rail in the

piston/rail assembly is tightened to a torque of
75–105 lb-ft (102–142 NNm).
Page 62

4. Remove the O-ring from the outside front 6. Remove the front O-ring at the shift rail end
end of the shift cylinder. Also remove the of the piston.
shift rail O-ring located inside the cylinder,
using a pick or suitable tool.
Figure 123 — Removing O-Ring from Front of Piston
7. Remove the nut securing the shift piston to

Figure 120 — Removing Shift Cylinder Outside O-Ring the shift rail. Then separate rail and piston.
Do not clamp the shift piston or shift rail in a vise.

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

removing the nut, temporarily install the shift fork
and tighten the setscrew. This gives a leverage
advantage for loosening the nut.
Figure 121 — Removing Shift Cylinder Inside O-Ring
5. Remove the O-ring from the rear of the shift

piston.
Figure 124 — Removing Shift Piston Retaining Nut
Figure 122 — Removing O-Ring from Rear of Piston
Page 63

8. Remove the O-ring located on the shift rail. 10. The following figure shows the breather vent
removed (No. 1) and installed (No. 2). Check
the breather vent for free airflow. Clean or
replace, if necessary.
Figure 125 — Removing Shift Rail O-Ring
9. Remove the O-ring from the piston sleeve.
300739a
Figure 126 — Removing O-Ring from Sleeve
Figure 127 — Shift Cylinder Breather Vent Shown

Removed (1) and Installed (2)
Page 64

[322] Main Drive Pinion Disassembly
1. Remove the gasket from the main drive
pinion bearing cover.
300663a
5
4
Figure 129 — Removing Gasket from Main Drive Pinion
3 Bearing Cover
2 2. Remove the spiral snap ring from the end of

the main drive pinion shaft, inside the main
1 drive pinion gear. Using a flat-blade
screwdriver, roll the snap ring out of the
groove and over the shoulder of the main
drive pinion.
6
7
8
9
10
11
300558a
300743a
Figure 130 — Removing Snap Ring from Main

1. Main Drive Pinion Shaft 7. Bearing Drive Pinion
6. Snap Ring
The action of removing the snap ring may destroy
Figure 128 — Exploded View of Main Drive Pinion the snap ring. Make sure a replacement snap ring
is available.
Page 65

3. Remove the main drive pinion gear by lifting
it straight up.
300573a
Figure 133 — Spigot Bearing Removed from Main Drive

Pinion Shaft
300559a
6. Remove the snap ring from the main drive

Figure 131 — Main Drive Pinion Gear Removed pinion cover bearing, using suitable snap
from Shaft ring pliers.
4. Remove the spigot bearing snap ring from
the main drive pinion, using suitable snap
ring pliers.
The large snap ring is very difficult to
compress and remove, and may fly off the
snap ring pliers, causing injury.
300572a
Figure 132 — Removing Spigot Bearing Snap Ring

300574a
5. Remove the spigot bearing from inside the
end of the main drive pinion shaft.
Figure 134 — Removing Main Drive Pinion Cover
Bearing Snap Ring
Page 66

7. Separate the main drive pinion shaft and
bearing assembly from the main drive pinion
bearing cover.
300571a
Figure 135 — Separating Main Drive Pinion

Shaft and Cover
8. Remove the spiral snap ring securing the

bearing to the main drive pinion shaft. Using
a small flat-blade screwdriver, roll the spiral
snap ring out of the groove until released.
300620a
Figure 137 — Pressing Bearing from Main Drive

Pinion Shaft
10. Remove the oil seal from the main drive

pinion bearing cover, using a hammer and a
blunt punch.
Removing the oil seal destroys the seal. Make

sure a replacement oil seal is available.
300567a
Figure 136 — Removing Spiral Snap Ring from Main

Drive Pinion
The action of removing the spiral snap ring may

destroy the snap ring. Make sure a replacement
snap ring is available.
9. Place the main drive pinion shaft and

bearing into a suitable press and remove the
bearing. 300560a
Figure 138 — Removing Main Drive Pinion Bearing

Cover Oil Seal
Page 67
10-112c3.fm Page 68 Tuesday, June 23, 1998 8:02 AM

[322] Front Mainshaft Disassembly
The splines on the mainshaft are usually not

aligned for the whole length of the shaft (see Figure 140 — Removing Reverse Gear Snap Ring
Figure 139). The recommended procedure is to from Mainshaft
remove the fourth and second speed gears, gear
thrust washers and snap rings, and first/second 2. Working at the rear of the mainshaft, slide
sliding clutch from the front of the shaft (parts the reverse gear from the shaft.
shown to the left of the arrows). Remove the
remaining reverse, Lo and first speed gears and
components from the rear of the shaft (parts
shown to the right of the arrows).
Figure 141 — Removing Reverse Gear from Mainshaft
3. Remove the Lo/reverse sliding clutch from

the mainshaft.
1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear

2. Second (Sixth) Speed 6. Reverse Speed Gear
Gear 7. Mainshaft
3. Sliding Clutch
Figure 139 — View of Mainshaft and Gears
1. If not already done, remove the external-
toothed and internal-toothed thrust washers.
Then remove the snap ring retaining the
reverse gear to the mainshaft, using suitable Figure 142 — Removing Lo/Reverse Sliding Clutch
from Mainshaft
snap ring pliers.
Page 68
1. Spigot Bearing Inner Race Snap 14. Mainshaft Snap Ring 27. Reverse Speed Gear
Ring 15. Internal-Toothed Thrust Washer 28. External-Toothed Thrust Washer
2. Spigot Bearing Inner Race 16. External-Toothed Thrust Washer 29. Gear Snap Ring
3. Mainshaft Snap Ring 17. Gear Snap Ring 30. Front Mainshaft
4. Internal-Toothed Thrust Washer 18. First (Fifth) Speed Gear 31. Mainshaft Snap Ring
5. Fourth (Eighth) Speed Gear 19. Gear Snap Ring 32. Spacer
6. External-Toothed Thrust Washer 20. External-Toothed Thrust Washer 33. Mainshaft Rear Bearing
8. Gear Snap Ring 22. Mainshaft Snap Ring 35. Mainshaft Snap Ring
9. External-Toothed Thrust Washer 23. Lo Speed Gear 36. Main Drive Gear
10. Internal-Toothed Thrust Washer 24. Sliding Clutch 37. Internal-Toothed Thrust Washer
11. Second (Sixth) Speed Gear 25. Mainshaft Snap Ring 38. Mainshaft Snap Ring
12. Mainshaft Snap Ring 26. Internal-Toothed Thrust Washer 39. Sliding Clutch
13. Sliding Clutch
Figure 143 — Exploded View of Front Mainshaft
Page 69

4. Remove the snap ring on the mainshaft 6. Slide Lo speed gear from the mainshaft.
retaining the Lo speed gear, using suitable
snap ring pliers.
Figure 146 — Removing Lo Speed Gear

300827a
7. Remove the snap ring inside the Lo speed

Figure 144 — Removing Lo Speed Gear Snap Ring
gear.
5. Remove the internal-toothed and external-
toothed thrust washers from inside the Lo
speed gear.
Figure 147 — Removing Snap Ring from Inside Lo

Speed Gear
Figure 145 — Removing Internal-Toothed and External-

Toothed Thrust Washers
Page 70

8. Remove the first (fifth) speed gear from the
mainshaft. Slide the gear straight off the rear
of the shaft.
Figure 150 — Removing Internal-Toothed and External-

Toothed Thrust Washers
11. Remove the first (fifth) speed gear mainshaft

Figure 148 — Removing First Speed Gear snap ring, using suitable snap ring pliers.
from Mainshaft
12. Working at the front of the mainshaft and
9. Remove the first (fifth) speed gear snap ring, using suitable snap ring pliers, remove the
using suitable snap ring pliers. snap ring retaining the fourth (eighth) speed
gear from the shaft.
Figure 149 — Removing First Speed Gear Snap Ring 300811a
10. Remove the first (fifth) speed gear Figure 151 — Removing Fourth Speed Gear Snap Ring
internal-toothed and external-toothed thrust
washers.
Page 71

13. Remove the internal-toothed and external- 15. Remove the snap ring from inside the fourth
toothed thrust washers from inside the fourth (eighth) speed gear.
(eighth) speed gear.
Figure 154 — Removing Snap Ring Inside Fourth

Speed Gear
Figure 152 — Removing Fourth Speed Gear Internal-
Toothed and External-Toothed Thrust Washers 16. Slide the second (sixth) speed gear from the
mainshaft.
14. Remove the fourth (eighth) speed gear from
the mainshaft.
300817a
Figure 155 — Removing Second Speed Gear
Figure 153 — Removing Fourth Speed Gear 17. Remove the snap ring from inside the
second (sixth) speed gear.
Figure 156 — Removing Second Speed Gear Snap Ring
Page 72

18. Remove the second (sixth) speed gear
external-toothed and internal-toothed thrust
washers from the mainshaft.
300808a
Figure 159 — Removing First/Second Sliding Clutch
21. Remove the snap ring that retains the

spigot-bearing inner race on the front of the
Figure 157 — Removing Third Speed Gear External- mainshaft. Use suitable snap ring pliers.
Toothed and Internal-Toothed Thrust Washers
19. Remove the second (sixth) speed gear

mainshaft snap ring, using suitable snap ring
pliers.
Figure 160 — Removing Front Spigot-Bearing Inner

Race Snap Ring
22. Remove the front spigot-bearing inner race,

using a suitable puller such as J 39477-1.
Figure 158 — Removing Second Speed Gear Snap Ring
20. Remove the first/second sliding clutch from

the mainshaft. Slide straight off the splines.
300822a
Figure 161 — Removing Front Spigot-Bearing

Inner Race
Page 73

[322] Rear Mainshaft (Output Shaft) and Synchronizer Disassembly
1. Remove the snap ring from the front end of Figure 163 — Removing Thrust Washers
the output shaft, using suitable snap ring
pliers. 3. Remove the Hi range/Hi split gear.
Figure 162 — Removing Snap Ring from Front of Shaft Figure 164 — Removing Hi Range/Hi Split Gear
2. Remove the internal-toothed and

external-toothed thrust washers from the
front end of the output shaft. Note that the oil
grooves of the external-toothed thrust
washer, face the front of the shaft toward the
internal-toothed thrust washer.
Page 74
13. Non-Threaded Insert (3) 26. Lo-Range Gear Snap Ring
Figure 165 — Exploded View of Rear Mainshaft (Output Shaft) and Synchronizer Assembly
Page 75

4. Remove the snap ring from inside the
Hi range/Hi split gear, using suitable snap
ring pliers.
Figure 166 — Removing Snap Ring from Gear
5. Remove the external-toothed thrust washer

from the front of the synchronizer assembly. Figure 168 — Remove Internal-Toothed Thrust
Note that the oil grooves of the external- Washer and Snap Ring
toothed thrust washer face rearward toward
the internal-toothed thrust washer. 7. Remove the front synchronizer disc pack
spacer from the synchronizer.
Figure 167 — Removing External-Toothed

Thrust Washer Figure 169 — Removing Spacer from the Synchronizer
Disc Pack
6. Remove the internal-toothed thrust washer
and snap ring from the front of the
synchronizer assembly.
Page 76

8. Remove the first internal-toothed friction disc 11. Remove the synchronizer assembly from the
from the front synchronizer disc pack. output shaft. Set the assembly aside for later
disassembly.
Figure 170 — Removing Friction Disc

Figure 172 — Removing Synchronizer Assembly
9. Remove the first external-toothed steel
reaction disc from the front synchronizer disc 12. Remove the first external-toothed steel
pack. reaction disc from the rear synchronizer disc
pack.
Figure 171 — Removing Reaction Disc

Figure 173 — Removing Reaction Disc
10. Continue removing the remaining friction
and steel reaction discs until all are
removed.
Page 77

13. Remove the first internal-toothed friction disc
from the rear synchronizer disc pack.
Figure 176 — Removing Lo-Range Gear and Hub

from Shaft
17. Remove the snap ring securing the Lo-range

gear to the hub of the gear, using suitable
snap ring pliers.
Figure 174 — Removing Friction Disc
14. Continue removing the remaining friction

and steel reaction discs until all are
removed.
15. Remove the output shaft snap ring located
inside the Lo-range gear hub, using suitable
snap ring pliers. Also remove the internal-
toothed thrust washer.
Figure 177 — Removing Snap Ring from Hub
18. Separate the Lo-range gear from the gear

hub. Note that the machined synchronizer
disc pack surface of the Lo-range gear faces
the front of the transmission.
Figure 175 — Removing Snap Ring from Output Shaft
16. Remove the Lo-range gear and hub from the

output shaft.
Figure 178 — Separating Lo-Range Gear from Hub
Page 78

19. Position the output shaft in a suitable press.
Separate the tapered roller bearing cone
from the shaft, using bearing separator
J 8176 or equivalent.
Figure 181 — Remove Synchronizer Support Tubes and

Preload Springs from Sliding Clutch
23. Remove the sliding clutch from the

remaining housing.
24. Remove the synchronizer pins from the
remaining synchronizer housing.
Figure 179 — Separating Bearing Cone from

Output Shaft
SYNCHRONIZER DISASSEMBLY
20. Remove the 12-point screws and threaded
and nonthreaded inserts from the
Figure 182 — Removing Synchronizer Pins
As you remove the pins, notice that the pins and

the sliding clutch are marked with the letter “R,”
which stands for “Rear.” All the R marks on either
end of the pins are placed on the same side of
the sliding clutch marked with the letter R. During
reassembly, make sure to coordinate all R marks
Figure 180 — Removing 12-Point Screws on both the pins and sliding clutch of the
synchronizer assembly. All R marks must face the
21. Lift the synchronizer housing from the rear of the transmission when installed.
assembly.
22. Remove the three support tubes and
preload springs from the synchronizer
assembly.
Page 79

[322] Rear Output Housing Disassembly
1. Using a blunt punch and hammer, remove
the outer bearing cup from the output
housing.
Figure 184 — Removing Bearing Cup from Housing
2. In the same manner, remove the inner

bearing cup from the output housing.

Figure 183 — Exploded View of Rear Output Housing
Page 80

[322] Front Countershaft Front Bearing Cover Disassembly
1. Remove the O-ring from the shoulder of the
front countershaft front bearing cover.
1
300565a
Figure 186 — Removing O-Ring from Shoulder of Front

Countershaft Front Bearing Cover
2. Remove the bearing cone from the front

2
countershaft front bearing cover, using a
suitable puller such as J 39477-1 with
bearing separator J 8176 or equivalent.
3
300742a
J 39477-1
1. O-Ring 3. Front Bearing Cover
PULLER
2. Bearing Cone
Figure 185 — Exploded View of Front Countershaft
Front Bearing Cover
The following disassembly procedure applies to

J 8176
all three front countershaft front bearing covers. BEARING
SEPARATOR
300564a
Figure 187 — Removing Bearing Cone from Front

Countershaft Front Bearing Cover
3. Thoroughly clean the bearing cover and

inspect for damage.
Page 81

[322] Front Countershaft Disassembly
The following countershaft disassembly
procedure applies to all three front countershafts.
1. Press the front countershaft main drive gear
off the countershaft. Note that the hub of the
gear faces rearward.
300721a
Figure 189 — Pressing Main Drive Gear

Off Shaft

2. Main Drive Gear 8. Spacer (Rear)
3. Fourth Speed Gear 9. Key
Page 82

2. Press the front countershaft fourth (eighth) 3. Press the front countershaft second (sixth)
speed gear off the countershaft. speed gear off the countershaft.
300719a
Figure 190 — Pressing Fourth Speed Gear Off Shaft Figure 191 — Pressing Second Speed Gear Off Shaft
Page 83

4. Remove the “front” spacer located between 6. Press the Lo-speed gear off the
the second (sixth) and first (fifth) speed countershaft.
gears from the countershaft.
300672a
Figure 194 — Pressing Lo Speed Gear Off Shaft
7. Remove the “rear” spacer from the

countershaft.
8. Remove the key from the keyway of the
countershaft.
9. Press the rear bearing cone off the rear of
the countershaft, using suitable press tools.
300718a
Figure 192 — Removing Spacer
5. Press the first (fifth) speed gear from the

countershaft.
J 8176 BEARING
300672a SEPARATOR
300717a
Figure 193 — Pressing First Speed Gear Off Shaft
Figure 195 — Removing Bearing Cone
Page 84

10. Remove the bearing cup from the front
countershaft main drive gear, using a
suitable puller.
OEM-4052
300716a
Figure 196 — Removing Bearing Cup from Main

Drive Gear
Page 85

[322] Front Countershaft Rear Bearing Cover Disassembly
300714a
2 Figure 199 — Removing Rear Bearing Cup

inspect for damage.
1
300674a

2. Bearing Cover
Figure 197 — Exploded View of Front Countershaft Rear
Bearing Cover
1. Remove the front and rear bearing cups

from the front countershaft rear bearing
cover.
300715a
Figure 198 — Removing Front Bearing Cup
Page 86

[322] Rear Countershaft Disassembly
1. Press the rear bearing cone off the rear
countershaft, using a bearing separator such
as J 8176 or equivalent.
J 8176
BEARING
SEPARATOR
300555a
Figure 201 — Pressing Off Rear Bearing Cone
2. Press the rear countershaft Lo-split gear and

the front bearing cone off the countershaft.
Note that the hub of the gear faces rearward.

Figure 200 — Exploded View of Rear Countershaft Figure 202 — Pressing Off Gear and Bearing Cone
3. Remove the spacer located between the

Lo-split gear and Hi range/Hi split gear.
Page 87

4. Press the Hi range/Hi split gear from the
countershaft. Note that the hub of the gear
faces forward.
Figure 203 — Pressing Off Hi Range/Hi Split Gear
5. Remove the key from the keyway of the rear

countershaft.
Page 88

[322] Rear Countershaft Bearing Cover Disassembly
1. Remove the shims and O-ring from the
shoulder of the rear countershaft bearing
cover. Tag the shims and record the
markings for use during assembly.
300577a
Figure 205 — Removing Cover Shims and O-Ring
2. Remove the bearing cup from the bearing

cover, using a suitable puller.

2. O-Ring 4. Bearing Cover
Figure 204 — Exploded View of Rear Countershaft
Bearing Cover
The following disassembly procedure applies to

all three rear countershaft bearing covers.
300576a
Figure 206 — Removing Bearing Cup from Cover

inspect for damage.
Page 89

[322] Reverse Idler Gear Disassembly
1. Press the bearing out of the reverse idler
gear, using a suitable driver.
3
2
4
1
5
300668a
300776a
3. Bearing Figure 208 — Pressing Out Reverse Idler Gear Bearing
Figure 207 — Exploded View of Reverse Idler Gear 2. Thoroughly clean the reverse idler gear and
inspect for damage.
Reverse idler gear disassembly applies to all
three reverse idler gears.
Page 90
10-112d.fm Page 91 Monday, June 22, 1998 11:28 AM
300 INSPECTION OF PARTS
INSPECTION OF PARTS
Page 91

[300] Inspection and Cleaning [322] Gears
Thoroughly clean the cases, covers and all other Replace all gears with teeth that show signs of
parts of the transmission. Remove all grease, oil abrasive wear, scratching (except normal
and foreign matter, using a suitable safe solvent. manufacturing tool marks), ridging, scoring,
Dry the parts with filtered, moisture-free surface fatigue, pitting, spalling, corrosive wear,
compressed air. digging in or cracking. Use magnaflux (or a
similar system) to inspect gears for cracks that
[322] Bearings otherwise would not be detected.
Soak bearings in fresh, clean solvent to loosen all [323] Shifter Forks, Sliding Clutches
hardened grease and foreign matter, until the
bearings are clean. Blow them dry with filtered,
and Shift Rails
moisture-free compressed air. Replace forks and/or sliding clutches when the
side clearance between the fork (2) and sliding
clutch (1) groove exceeds the specified limit
found in the Fits and Limits table in the
Do not spin the bearings with compressed air. SPECIFICATIONS section.
Damage to the bearings can occur.
Inspect each bearing for flaking, cracks, fractures,

2
cavities, indentations, measurable wear,
brinelling, fretting, corrosion, nicking, cage wear
(or deformation) and other damage. If any of
these conditions are present, replace the bearing.
Apply a light coat of fresh, clean, specified gear 1

oil to the bearings. (Refer to recommended SAE
grade gear oil in the TRANSMISSION
SPECIFICATIONS section.) Turn the races and
bearings slowly by hand to be sure they move
freely and are smooth. If there is resistance to
movement or the bearings or races feel rough,
replace the bearings and races.
A
If a bearing cone or cup needs replacement, a

complete new assembly, including cup and
mating cone, is required.
Do not remove a new bearing from its packing
before time of installation. Never clean protective 300783a
grease from new bearings.
Do not handle bearings with dirty hands. Rags Figure 209 — Fork and Clutch Detail
must be clean and lint free.
Clean bearings which are satisfactory for

installation. Wrap the bearings in a clean, lint-free
cloth and store for assembly.
Page 92

Replace shift rails if they are cracked in either Be careful when installing a shaft through a new
the poppet or setscrew holes. If the clearance seal (or seal over shaft). Lubricate the shaft
between the shift rail and housing (cover) bore before inserting it through the seal. Splines,
exceeds 0.010 inch (0.254 mm) maximum, keyways and holes in a shaft can damage seals
determine which part is worn before replacing. unless care is taken. Lubricate the seal to prevent
Shift rail wear can be checked by measuring the damage during the initial start-up period, before
shift rail at an unworn location. Then measure normal lubrication begins. Keep anti-seize and
the rail at the worn area and compare sealing compounds away from oil seals.
measurements. When measuring a shift rail, the
reading should be an average of diameter If an oil seal does not have a preapplied sealant
measurements taken at four locations. Compare on its outer diameter, apply an appropriate sealer
one side of the rail to the other, AB–CD as shown around the outside diameter to prevent leaks.
in the following figure.
Lip-type oil seals are precision made and require
close attention and care during installation. The
quality of the installation method and the tools
used directly affect the life of the seal. Do not use
a block of wood or discarded bearing as a
substitute for the proper seal driver. However,
with some seal applications, a seal driver may not
be available. In these situations, light tapping in a
circular motion using a light, broad-faced hammer
is acceptable.
For the seal to function properly, install it squarely

with respect to the shaft centerline. The seal
should be kept square within 0.010 inch
Figure 210 — Measuring Shift Rail
(0.254 mm) total indicated runout (TIR).
Squareness of the seal to the shaft is controlled
by using the proper seal installation tools as
[321] Oil Seals shown in the following figure.
When an overhaul is required, replace all oil
seals. Be careful to ensure that the sealing
surface of any seal is not damaged, turned back
or cut. A nick on a shaft sealing surface can cut
the seal. Remove sharp edges that could
damage the seal (chamfer edges if possible).
Be careful when using any abrasive polishing

methods such as emery or crocus cloth on a
sealing surface. It is possible to leave micro-
grooves on the sealing surface. This can cause
oil to leak past the sealing lip(s) of the oil seal.
With this condition, a new seal will not stop the oil
leak.
Page 93

Press seals into housings with smooth, even General Inspection
pressure to prevent cocking or distorting the seal.
Gently press the seal into place. Correct A cracked transmission case should be replaced.
installation depth is achieved as the driver tool Check all components for wear or damage.
bottoms against the positioning tool as shown in Replace all parts as required. Replace all
the following figure. gaskets, O-rings and any part that shows
mutilation or damage. Repair all stripped threads
J 8092 using a thread repair insert that is compatible with
DRIVER HANDLE J 36053 epoxy-coated fasteners.
SEAL DRIVER
MAIN DRIVING
(PIN MOUNTED General Reassembly Instructions
IN SEAL DRIVER)
PINION BEARING
COVER Refer to Torque Specifications and Fits and Limits
found in the SPECIFICATIONS section.
SEAL
All working metal parts, especially the bearings,
should be coated with fresh, clean, specified gear
oil while the transmission is being reassembled.
This ensures immediate lubrication and helps
prevent parts from seizing during initial start-up.
(Refer to recommended SAE grade gear oil in
TRANSMISSION SPECIFICATIONS section.)
J 36052
When installing bearings, use proper bearing
POSITIONING drivers. When pressing a bearing onto a shaft,
TOOL 301059a apply force only to the inner race of the bearing.
When pressing a bearing into a housing (bearing
Figure 211 — Main Drive Pinion Oil Seal Tools cover), apply force only to the outer race. Do not
apply force that is transmitted through the bearing
rollers, balls or cage. Damage and premature
bearing failure can result. Always apply even
pressure to the bearing to prevent it from cocking
or distorting during installation.
As moving parts are installed, check the parts

frequently to see that they are moving freely.
Page 94
10-112e1.fm Page 95 Monday, June 22, 1998 11:25 AM
BENCH PROCEDURES
(REASSEMBLY)
Page 95

[320] TRANSMISSION COMPONENT REASSEMBLY
[322] Reverse Idler Gear Reassembly
2. Press the bearing until flush with the gear
surface. The bearing must not protrude on
either side of the gear surface. Verify that the
bearing is flush or slightly below flush by
using a straightedge across the gear
surface.
3
2
4
1
5
300668a

3. Bearing
Figure 212 — Exploded View of Reverse Idler Gear
300790a
The following reassembly procedure applies to all Figure 213 — Pressing Bearing into Gear
three reverse idler gears.
1. Install a new bearing into the reverse idler 3. Verify correct fit of idler gear shaft to idler
gear, using a suitable driver. gear bearing. The gear should rotate freely
on the shaft, with no binding or excessive
looseness.
Page 96

[322] Rear Countershaft Bearing Cover Reassembly
1. Press the bearing cup into the cover, using a
suitable driver.
300789a
2. O-Ring 4. Bearing Cover
Figure 215 — Pressing Bearing Cup into Cover
Bearing Cover 2. Keep the original shims and a new O-ring
with each cover for reassembly. Bearing
The following reassembly procedure applies to all preload adjustments must be made before
three rear countershaft bearing covers. installing shim pack and O-ring.
Page 97

[322] Rear Countershaft Reassembly
1. Install the key into the keyway of the rear
countershaft, using a soft-faced mallet.
Figure 217 — Installing Key
2. Press the rear countershaft Hi-range/Hi-split

gear onto the shaft. Position the gear so that
the protruding hub faces the front of the
shaft.

The following reassembly procedure applies to all

three rear countershafts.
Figure 218 — Pressing On Hi Range/Hi Split Gear
Page 98

3. Install the spacer onto the shaft. 5. Press the front bearing cone onto the rear
countershaft, using a suitable driver. Apply
force to the inner race of the bearing cone
only.
Figure 219 — Installing Spacer
4. Press the rear countershaft Lo-split gear

onto the shaft. Position the gear so that the
protruding hub faces the rear of the shaft.
Figure 221 — Pressing On Front Bearing Cone
6. Press the rear bearing cone onto the rear

countershaft, using a suitable driver. Apply
force to the inner race of the bearing cone
only.
Figure 222 — Pressing On Rear Bearing Cone
Figure 220 — Pressing On Lo-Split Gear
Page 99

[322] Front Countershaft Rear Bearing Cover Reassembly
300724a
Figure 224 — Pressing Front Bearing Cup into Cover

300674a

2. Bearing Cover
Figure 223 — Exploded View of Front Countershaft Rear
Bearing Cover

three front countershaft rear bearing covers.
1. Press the front and rear bearing cups into
the front countershaft rear bearing cover,
using a suitable driver.
2. Set the front countershaft rear bearing cover
300677a
aside for later installation.
Figure 225 — Pressing Rear Bearing Cup into Cover
Page 100

[322] Front Countershaft Reassembly
Remember to apply the recommended oil to all

shaft and gear surfaces before pressing parts
together.
1. Using a suitable driver, press the bearing

cup into the front countershaft main drive
gear.
300785a
Figure 227 — Pressing Bearing Cup into Main

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

countershaft, using a soft-faced mallet.
2. Main Drive Gear 8. Spacer (Rear) 3. Install the rear spacer onto the shaft next to
3. Fourth Speed Gear 9. Key the reverse speed gear (part of shaft).

three front countershafts.
Page 101
During all pressing operations involving a key and

keyway, watch the key to make sure that no
material is shaved off as each gear is being
pressed on. This material can collect between the
gears and prevent proper seating.
4. With spacer in place, press the Lo speed

gear onto the front countershaft.
Figure 229 — Pressing First Speed Gear onto Shaft
6. Install the front spacer onto the shaft next to

the first (fifth) speed gear.
7. With spacer in place, press the second
(sixth) speed gear onto the shaft.
Figure 228 — Pressing Lo Speed Gear onto Shaft
5. Press the first (fifth) speed gear onto the

shaft.
Figure 230 — Pressing Second Speed Gear onto Shaft
Page 102

8. Press the fourth (eighth) speed gear onto 10. Press a new bearing cone onto the rear end
the shaft. of the shaft, using a suitable driver. Apply
force only to the inner race of the bearing
cone. Press the bearing until seated against
the surface of the reverse speed gear (part
of shaft).
Figure 231 — Pressing Fourth Speed Gear onto Shaft
9. Press the main drive gear onto the shaft until

seated against the fourth (eighth) speed
gear. The protruding hub of the gear faces Figure 233 — Pressing Rear Bearing Cone onto Shaft
the rear of the shaft.
Figure 232 — Pressing Main Drive Gear onto Shaft
Page 103

[322] Front Countershaft Front Bearing Cover Reassembly
1. Press a new bearing cone onto the front
countershaft front bearing cover, using a
suitable driver. Apply force to the inner race
of the bearing cone only.
300667a
Figure 235 — Pressing Bearing Cone onto Cover
2 2. Install the large O-ring onto the shoulder of

the front bearing cover.
3
300742a
1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Front Bearing Cover

three front countershaft front bearing covers.
300565a
Figure 236 — Installing O-Ring onto Front Cover
Page 104

[322] Rear Output Housing Reassembly
1. Drive a new inner bearing cup into the
output housing, using a suitable driver.
Figure 238 — Driving Bearing Cup into Output Housing
2. In a similar manner, install a new outer

bearing cup into the housing.
3. Obtain the output shaft. Using a suitable
driver, press a new inner bearing cone onto
the shaft until seated against the shoulder of
the shaft. Apply force to the inner race only.

Figure 237 — Exploded View of Rear Output Housing
Figure 239 — Pressing Bearing onto Output Shaft
Page 105

4. Position the output housing over the output
shaft until the inner bearing cup is seated on
the inner bearing cone.
Figure 241 — Installing Spacer
6. Position the outer bearing cone over the

output shaft as far as it will go without
Figure 240 — Positioning Output Housing Over Shaft
pressing.
5. Install either a new collapsible or
ground-type spacer onto the output shaft.
Some early production transmissions were built

with a non-collapsible spacer (ground). These
spacers require a different bearing preload setup
than the current production collapsible type
spacer.
Figure 242 — Positioning Bearing Cone
7. Lubricate all bearing cups and cones with

the recommended gear oil, in preparation for
the following procedure.
8. Position the output housing assembly in a
hydraulic press.
Page 106

SETTING REAR OUTPUT HOUSING BEARING 12. Increase crush load slowly until rolling
PRELOAD WITH COLLAPSIBLE SPACER torque of 1.5–5 pounds of resistance is
achieved, then stop! If rolling torque exceeds
five pounds of resistance, the collapsible
spacer has been crushed too far and must
The following procedure may require more than be removed. Replace with a new spacer and
one attempt to achieve the required bearing repeat the procedure until desired rolling
preload. Make sure to have extra new collapsible torque is achieved.
spacers on hand.
SETTING REAR OUTPUT HOUSING BEARING
PRELOAD WITH GROUND-TYPE SPACER
9. For the collapsible-type spacer, wrap several
turns of cord around the pilot area of the 13. For the ground-type spacer, use a dial
output housing and attach a spring tension indicator set up to read end play or vertical
scale, such as J 8129 or equivalent, to the movement of the output housing as shown in
cord. Refer to the following figure. the following figure.
Figure 243 — Setup for Bearing Preload Adjustment Figure 244 — Adjusting Bearing Preload Using
Using Collapsible Spacer Ground-Type Spacer
10. Begin pressing the bearing cone over the 14. Apply two tons of load to the outer bearing
shaft while moving the housing up and cone inner race while rotating the housing to
down. Watch press gauge pressure during seat the bearings. Attach the dial indicator.
this procedure. Stop pressing immediately 15. Move the output housing up and down to
when all end play is removed. Gauge measure end play of the bearings. Record
pressure will begin to climb when this the amount of end play measured on the dial
occurs. indicator.
11. While maintaining crush load, use the spring
tension scale and test for the amount of
bearing preload resistance required to rotate
the housing. Maintain a steady pull on the
housing while reading the scale.
Page 107

16. To obtain the correct amount of preload on
the output shaft bearings, the measured end
play plus the additional required preload
amount of 0.001–0.004 inch must be
removed from the ground-type spacer.
Example: If 0.037 inch end play is measured
on the dial indicator, add 0.001–0.004 inch
(required preload) to this measurement.
Then, subtract this sum (0.038–0.041 inch)
from the length of the spacer.
0.037 inch (measured end play)
0.001–0.004 inch (required preload)
0.038–0.041 inch (end play plus preload)
0.038–0.041 inch (remove from spacer)
17. Press the output shaft out of the housing.
See Figure 245.
18. Remove the spacer and measure its length.
Record this measurement. Example: A Figure 245 — Pressing Output Shaft from Housing
typical measurement would be 2.050 inches.
20. Grind the end of the spacer to achieve the
19. Starting with a typical spacer length of calculated spacer length required for proper
2.050 inches: output shaft bearing preload.
2.050 inches, minus measured end play plus 21. Set the output shaft aside with the
preload, equals 2.012–2.009 inches of associated synchronizer assembly
desired spacer length. components for later reassembly.
22. Place the output housing, spacer and outer
bearing on a clean work surface for later
transmission reassembly.
Preload is negative end play or “crush.” It cannot

be measured directly. Determining spacer length
must be done carefully as described, to obtain
the correct preload on the bearings.
Page 108

[322] Rear Mainshaft (Output Shaft) and Synchronizer Reassembly
2. The three synchronizer preload springs are

made up of two pieces. Make sure that the
preload springs are assembled with
smooth-sided inner portion of the spring
inside the notched (detent) outer portion of
the spring.
SYNCHRONIZER REASSEMBLY
1. Install the synchronizer pins into one of the
two identical synchronizer clutch housings.
Install the pins with the marked letter “R”
facing up. Alternate pin heads as shown.
Figure 247 — Assembling Preload Springs
3. Position the synchronizer sliding clutch on

As you install the pins, notice that the pins and
the bench with the marked letter R facing up.
the sliding clutch are marked with the letter R,
Install the three preload springs into the
which stands for “Rear.” All the R marks on either
sliding clutch holes provided. The smaller
end of the pins are placed on the same side of
holes are ramped and found halfway
the sliding clutch marked with the letter R. During
between the three largest holes.
reassembly, make sure to coordinate all R marks
on both the pins and sliding clutch of the
synchronizer assembly. All R marks must face the
rear of the transmission when installed.
Figure 248 — Installing Preload Springs into

Sliding Clutch
Figure 246 — Installing Synchronizer Pins
Page 109
13. Nonthreaded Insert (3) 26. Lo-Range Gear Snap Ring
Figure 249 — Exploded View of Rear Output Shaft and Synchronizer Assembly
Page 110
10-112e1.fm Page 111 Friday, June 26, 1998 9:32 AM

4. Install the sliding clutch (with preload 7. Install the three 12-point screws and
springs) over the synchronizer clutch threaded and nonthreaded inserts into the
housing and pins. Make sure the marked largest holes of the synchronizer assembly.
letter R on the clutch is facing in the same
direction as the R marked on the pins.
With this sliding clutch design it is very important

to make sure that the clutch is facing in the
correct direction when installed. This is due to the
differing number of clutch teeth on the front and
rear sides of the range clutch. Incorrectly
installing the sliding clutch prevents proper
shifting.
5. Install the three support tubes into the

Figure 251 — Installing Twelve-Point Screws and Inserts
8. Tighten the three 12-point screws to
specification, using a suitable hex wrench to
hold the threaded inserts.
Figure 250 — Install Support Tubes into Assembly
6. Install the remaining synchronizer housing

over the pins, tubes and springs. Align the
Figure 252 — Tightening 12-Point Screws
housing with the pin heads.
Page 111
10-112e1.fm Page 112 Friday, June 26, 1998 9:32 AM

9. If not previously done, press a new inner 11. Install the snap ring to secure the Lo-range
bearing cone onto the output shaft. Seat the gear to the hub of the gear, using suitable
bearing against the shoulder of the shaft, snap ring pliers.
using a suitable driver. Apply force to the
inner race only.
Figure 255 — Installing Hub Snap Ring
12. Install the Lo-range gear and hub over the

output shaft.
Figure 253 — Pressing Bearing onto Output Shaft
10. Install the Lo-range gear over the gear hub.

Note that the machined synchronizer disc
pack surface of the Lo-range gear faces the
front of the transmission.
Make sure that the oil holes in the Lo-range gear

Figure 256 — Installing Lo-Range Gear and Hub
hub are open and free to channel oil to the onto Output Shaft
synchronizer discs.
Figure 254 — Placing Lo-Range Gear Over Hub
Page 112

13. Install the internal-toothed thrust washer and 16. Install an external-toothed steel reaction disc
output shaft snap ring inside the Lo-range onto the friction disc just installed.
gear hub, using suitable snap ring pliers.
Figure 257 — Installing Thrust Washer and Snap Ring
14. Apply specified gear oil to both sides of a

synchronizer friction disc.
15. Install the internal-toothed friction disc onto

Figure 259 — Installing Reaction Disc
the machined surface of the Lo-range gear.
17. Continue alternately installing the remaining
friction and steel reaction discs until four of
each have been installed. Make sure to
lubricate each friction and reaction disc with
specified gear oil during installation. The last
disc installed should be an external-toothed
steel reaction disc.
Figure 258 — Installing Friction Disc
Page 113

18. Align all external teeth of the steel reaction 19. Install an external-toothed steel reaction disc
discs and then install the synchronizer onto the front synchronizer disc housing,
assembly over the output shaft. The side of aligning the external teeth. Lubricate the
the synchronizer sliding clutch marked R disc with the specified gear oil during
must face down (toward the rear of the installation.
output shaft) when installed.
Rotating the synchronizer assembly back and

forth during installation helps the assembly to
align with the external teeth of the steel reaction
discs.
Figure 261 — Installing Reaction Disc
20. Install an internal-toothed friction disc onto

the steel reaction disc just installed. Make
sure to lubricate both sides of the disc with
the specified gear oil during installation.
Figure 260 — Installing Synchronizer Assembly
Figure 262 — Installing Friction Disc
Page 114

21. Continue alternately installing the remaining
friction and steel reaction discs until four of
each have been installed. Make sure to
lubricate each friction and reaction disc with
the specified gear oil during installation. The
last disc installed should be an internal-
toothed friction disc.
22. Install the synchronizer disc pack spacer
onto the synchronizer friction disc just
installed. Lubricate the spacer with the
specified gear oil during installation
Figure 264 — Installing Internal-Toothed Thrust Washer
24. Install the external-toothed thrust washer

onto the front of the output shaft. Note that
the oil grooves of the external-toothed thrust
washer face rearward toward the
Figure 263 — Installing Spacer onto Disc Pack
23. Install the snap ring onto the output shaft.

Then, install the internal-toothed thrust
washer over the output shaft and against the
snap ring.
Figure 265 — Installing External-Toothed

Thrust Washer
Page 115

25. Install the snap ring inside the Hi range/ 27. Install the external-toothed and
Hi split gear, using suitable snap ring pliers. internal-toothed thrust washers over the
front end of the output shaft. Note that the oil
grooves of the external-toothed thrust
washer face the front of the shaft toward the
Figure 266 — Installing Snap Ring into Gear
26. Install the Hi range/Hi split gear over the end

of the output shaft.
Figure 268 — Installing Thrust Washers
28. Install the remaining snap ring onto the front

end of the output shaft, using suitable snap
ring pliers.
Figure 267 — Installing Hi Range/Hi Split Gear
Figure 269 — Installing Snap Ring onto Front of Shaft
Page 116

29. Paint three sets of corresponding timing
marks on the teeth of both the Hi range/
Hi split gear and the Lo-range gear as
shown:
r Paint two teeth on either side of every
10th space on the Hi range/Hi split gear.
r Paint two teeth on either side of every
18th space on the Lo-range gear.
Figure 270 — Painting Timing Marks on Gears
Page 117
10-112e2.fm Page 118 Tuesday, June 23, 1998 2:51 PM

[322] Front Mainshaft Reassembly
1. Install the inner race of the spigot bearing
onto the front of the shaft, using a suitable
driver and press.
The splines on the front mainshaft are not usually

aligned for the entire length of the shaft. It is 300805a
easier to install some components onto the front
of the shaft and some components onto the rear Figure 272 — Installing Spigot Bearing Inner Race
of the shaft, as indicated in the following figure by
the parts shown to the left or right of the arrows. 2. Install the inner race snap ring, using
Working at the front of the shaft, install the suitable snap ring pliers.
first/second sliding clutch, second (sixth) and
fourth (eighth) speed gears, thrust washers and
snap rings. Working at the rear of the shaft, install
the first (fifth) speed gear, Lo speed gear,
Lo/reverse sliding clutch, reverse speed gear,
thrust washers and snap rings.
Figure 273 — Installing Inner Race Snap Ring
1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear

2. Second (Sixth) Speed 6. Reverse Speed Gear
Gear 7. Mainshaft
3. Sliding Clutch
Figure 271 — View of Mainshaft and Gears
Page 118
1. Spigot Bearing Inner Race Snap 14. Mainshaft Snap Ring 27. Reverse Speed Gear
Ring 15. Internal-Toothed Thrust Washer 28. External-Toothed Thrust Washer
2. Spigot Bearing Inner Race 16. External-Toothed Thrust Washer 29. Gear Snap Ring
3. Mainshaft Snap Ring 17. Gear Snap Ring 30. Front Mainshaft
4. Internal-Toothed Thrust Washer 18. First (Fifth) Speed Gear 31. Mainshaft Snap Ring
5. Fourth (Eighth) Speed Gear 19. Gear Snap Ring 32. Spacer
6. External-Toothed Thrust Washer 20. External-Toothed Thrust Washer 33. Mainshaft Rear Bearing
8. Gear Snap Ring 22. Mainshaft Snap Ring 35. Mainshaft Snap Ring
9. External-Toothed Thrust Washer 23. Lo Speed Gear 36. Main Drive Gear
10. Internal-Toothed Thrust Washer 24. Sliding Clutch 37. Internal-Toothed Thrust Washer
11. Second (Sixth) Speed Gear 25. Mainshaft Snap Ring 38. Mainshaft Snap Ring
12. Mainshaft Snap Ring 26. Internal-Toothed Thrust Washer 39. Sliding Clutch
13. Sliding Clutch
Figure 274 — Exploded View of Front Mainshaft
Page 119

3. Working at the front of the mainshaft, install 5. Install the second (sixth) speed gear
the first (fifth) speed gear mainshaft snap mainshaft snap ring into the second snap
ring into the third snap ring groove of the ring groove of the shaft.
shaft.
Figure 275 — Installing First Speed Gear Snap Ring Figure 277 — Installing Second Speed Gear Mainshaft
Snap Ring
4. Install the first/second sliding clutch onto the
mainshaft. 6. Install the second (sixth) speed gear
internal-toothed and external-toothed thrust
washers onto the mainshaft.
300808a
Figure 276 — Installing First/Second Sliding Clutch

onto Mainshaft
Figure 278 — Installing Internal-Toothed and
External-Toothed Thrust Washers
Page 120

7. Install the snap ring into the snap ring 9. Install the snap ring into the snap ring
groove of the second (sixth) speed gear, groove of the fourth (eighth) speed gear,
using suitable snap ring pliers. farthest away from the clutch teeth, using
suitable snap ring pliers.
Figure 279 — Installing Snap Ring into Second

Speed Gear Figure 281 — Installing Snap Ring into Fourth
Speed Gear
8. Install the second (sixth) speed gear onto
the mainshaft, with the clutch teeth facing 10. Install the fourth (eighth) speed gear onto
rearward and the snap ring facing forward. the mainshaft with the clutch teeth facing
forward and the snap ring facing rearward.
300817a
Figure 280 — Installing Second Speed Gear

onto Mainshaft Figure 282 — Installing Fourth Speed Gear
Page 121

11. Install the fourth (eighth) speed gear 13. Working at the rear of the mainshaft, install
external-toothed and internal-toothed thrust the first (fifth) speed gear internal-toothed
washers. Place the oil groove side of the and external-toothed thrust washers. Slide
external-toothed thrust washer facing them forward against the previously installed
forward (toward the internal-toothed thrust snap ring. The oil grooves of the
washer). external-toothed thrust washer face forward
toward the internal-toothed thrust washer.
Figure 283 — Installing Fourth Speed Gear Figure 285 — Installing First Speed Gear Internal-
Thrust Washers Toothed and External-Toothed Thrust Washers
12. Install the fourth (eighth) speed gear snap 14. Install the snap ring into the groove of the
ring onto the mainshaft, inside the fourth first (fifth) speed gear, farthest from the
speed gear. clutch teeth.
300811a
Figure 286 — Installing Snap Ring into First
Speed Gear
Figure 284 — Installing Fourth Speed Gear Snap Ring
Page 122

15. Install the first (fifth) speed gear onto the 17. Install the Lo speed gear onto the mainshaft
mainshaft with the clutch teeth facing the with clutch teeth facing rearward.
front of the shaft.
Figure 289 — Installing Lo Speed Gear

Figure 287 — Installing First Speed Gear
onto Mainshaft 18. Install the Lo speed gear external-toothed
and internal-toothed thrust washers onto the
16. Install the snap ring into the groove of the Lo mainshaft. Make sure the oil groove side of
speed gear, farthest away from the clutch the external-toothed thrust washer faces
teeth. rearward.
Figure 290 — Installing Internal-Toothed and External-

Figure 288 — Installing Snap Ring into Lo Speed Gear Toothed Thrust Washers
Page 123

19. Install the snap ring for the Lo speed gear 22. To make it easier to install the mainshaft into
onto the mainshaft. the case:
r Slide the Lo/reverse sliding clutch
forward until it engages the Lo speed
gear.
r Slide the reverse speed gear over the
Lo/reverse sliding clutch until fully
engaged.
The following parts will be reinstalled during

transmission reassembly steps:
300827a r Mainshaft snap ring (25)
Figure 291 — Installing Lo Speed Gear Mainshaft r Internal-toothed thrust washer (26)
Snap Ring
r External-toothed thrust washer (28)
20. Install the Lo/reverse sliding clutch onto the r Reverse speed gear snap ring (29). Refer to
mainshaft. Figure 274.
Figure 292 — Installing Lo/Reverse Sliding Clutch

Figure 294 — Moving Sliding Clutch and Reverse Speed
21. Install the reverse speed gear onto the Gear Forward
mainshaft with clutch teeth facing the sliding
clutch.
Figure 293 — Installing Reverse Speed Gear

onto Mainshaft
Page 124

[322] Main Drive Pinion Reassembly
5
4
1. Press 4. Main Drive Pinion Shaft

2. Spacer Tube 5. Sleeve
3. Driver 6. Bearing
Figure 296 — Installing Main Drive Pinion Bearing
6
7 2. To retain the ball bearing, install the spiral
8 snap ring using a circular motion, while
pressing the snap ring tightly into the groove
9 on the shaft.
10
11
300743a
1. Main Drive Pinion Shaft 7. Bearing

6. Snap Ring
Figure 295 — Exploded View of Main Drive Pinion
300658a
1. Press the ball bearing onto the main drive
pinion shaft. Support the inner race of the Figure 297 — Installing Spiral Snap Ring
bearing while pressing.
Page 125

3. Position a new oil seal in the main drive 5. Press the main drive pinion shaft and
pinion bearing cover. bearing assembly into the main drive pinion
bearing cover.
300657a
Figure 298 — Positioning Bearing Cover Oil Seal
4. Install the oil seal into the front of the main

drive pinion bearing cover. Refer to the
INSPECTION OF PARTS (Oil Seals) section
for installation instructions.
Figure 300 — Installing Main Drive Pinion Assembly into

Drive Pinion Bearing Cover
300664a
Figure 299 — Installing Bearing Cover Oil Seal
Page 126

6. Install the main drive pinion bearing snap 8. Install the main drive pinion gear onto the
ring, using suitable snap ring pliers. pinion shaft. Install the spiral snap ring using
a circular motion while pressing the snap
ring tightly into the groove on the shaft.
The large snap ring is very difficult to

compress and may fly off the snap ring pliers,
causing injury.
One side of the large snap ring is beveled and

faces out. The flat side of the snap ring goes
against the bearing.
300662a
Figure 303 — Installing Main Drive Pinion Gear and

Spiral Snap Ring
9. Install a new bearing cover gasket, using

sealant between the gasket and cover. Make
sure the oil passage hole and capscrew
holes in the gasket align with the cover
holes.
300574a
Figure 301 — Installing Snap Ring into Main Drive

Pinion Bearing Cover
7. Install the spigot bearing into the end of the

main drive pinion shaft by hand. Also install
the spigot bearing retaining snap ring.
300663a
Figure 304 — Installing Main Drive Pinion Bearing Cover

Gasket
300572a
Figure 302 — Installing Spigot Bearing Snap Ring
Page 127

[323] Range Shift Cylinder Reassembly
1. The following figure shows the breather vent
removed (No. 1) and installed (No. 2). Check
the breather vent for free airflow. Clean or
replace, if necessary.
Figure 306 — Shift Cylinder Breather Vent
1. Shift Fork 9. Shift Cylinder Cover

3. O-Ring 11. O-Ring Before installation, lightly lubricate all O-rings for
4. Shift Piston 12. Cover Capscrew the range shift cylinder piston, sleeve and rail with
5. O-Ring 13. O-Ring a multipurpose grease that meets MACK
6. Piston Sleeve 14. Breather Vent
7. Shift Cylinder 15. O-Ring
specification MG-C.
Figure 305 — Cutaway View of Range Shift Cylinder
The nut securing the piston to the rail in the

piston/rail assembly is tightened to a torque of
75–105 lb-ft (102–142 NNm).
Page 128

2. Install the O-ring onto the piston sleeve.
300739a
Figure 307 — Installing Piston Sleeve O-Ring Figure 309 — Tightening Shift Rail Nut
3. Install the small O-ring onto the shift rail. 5. Install the front O-ring onto the shift rail end
of the piston.
Figure 308 — Installing Shift Rail O-Ring
4. Insert the rail into the piston and then install

and tighten the shift rail nut to 75–105 lb-ft Figure 310 — Installing Shift Piston Front O-Ring
Do not clamp the shift piston or shift rail in a vise.

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

installing the nut, temporarily install the shift fork
and tighten the setscrew. This gives a leverage
advantage for tightening the nut. Remove the shift
fork for later installation.
Page 129

6. Install the shift piston rear O-ring onto the 8. Install the shift piston and rail assembly into
piston. the range shift cylinder.
9. Install the sleeve onto the rear end of the
shift piston. To ease installation, lubricate
the inside diameter of the sleeve with MG-C
specification grease. Do not over-lubricate.
Too much grease can clog the breather vent.
Figure 311 — Installing Shift Piston Rear O-Ring
7. Install the outside O-ring onto the front of the

shift cylinder (shift cylinder-to-case O-ring).
Also install the shift rail O-ring located inside
the cylinder.
Figure 314 — Installing Sleeve onto Shift Piston
10. Push the piston assembly into the cylinder.
Figure 312 — Installing Shift Cylinder Outside O-Ring

300644a
Figure 315 — Pushing Piston Assembly into Cylinder
11. Set aside the range shift cylinder assembly,

the shift cylinder cover, capscrews and new
cover O-ring, for later installation into the
rear compound case.
Figure 313 — Installing Shift Cylinder Inside O-Ring
Page 130

Rear Case Shift Cover
Figure 317 — Installing Shift Piston O-Ring
2. Install the O-ring (that seals shaft of piston)

into the rear of the shift piston housing.
Figure 318 — Installing O-Ring into Rear of Housing
1. Cover O-Ring 7. Shift Fork Setscrew 3. Install the piston cover O-ring onto the front
2. Piston O-Ring 8. Splitter Shift Fork of the housing.
3. Splitter Shift Piston 9. Capscrew (4)
4. Capscrew (10) 10. Piston Cover
5. Rear Case Shift Cover 11. Shaft O-Ring
6. Gasket
Figure 316 — Exploded View of Rear Case Shift Cover
Lubricate the shift cover O-rings with a

multipurpose grease meeting MACK specification
MG-C during installation.
1. Install the O-ring onto the shift piston.
Figure 319 — Installing O-Ring onto Front of Housing
Page 131

4. Install the piston into the housing and at the
same time, install the shift fork. Note the
orientation of the shift fork. The offset faces
forward.
Figure 320 — Installing Piston and Shift Fork
5. Align the shift fork setscrew with the

Figure 321 — Tightening Shift Fork Setscrew
setscrew hole in the shaft of the piston.
Tighten the setscrew to 35–50 lb-ft 6. Install the piston cover and capscrews.
(47–68 NNm) torque. Tighten the capscrews to 17–21 lb-ft
Figure 322 — Installing Piston Cover and Capscrews
Page 132

[323] Main Case Shift Cover Reassembly
1. Install the breather vent into the shift cover.
300745a
Figure 324 — Installing Third/Fourth Pin and

Rocker Arm
300744a
3. Install the third/fourth rocker pin lock washer,
Figure 323 — Installing Breather Vent flat washer and nut. Tighten nut to
40–50 lb-ft (54–68 NNm) torque.
2. Install the third/fourth rocker pin and rocker
arm. Be sure to position the washer, bushing
and washer on the rocker pin as illustrated.
The bottom washer is positioned between
the rocker arm and main case shift cover.
Figure 325 — Installing Washers and Nut
Page 133

4. Install the reverse light switch rod into the 5. Install the reverse light switch into the
cover. cover.
Figure 326 — Installing Reverse Light Switch Rod
300735a
Figure 327 — Installing Reverse Light Switch
Page 134

Figure 328 — Exploded View of Main Case Shift Cover
Page 135

6. Install the poppet ball and spring for the 7. Slide the third/fourth shift rail into the cover.
third/fourth shift rail. At the same time, install the third/fourth
shifter onto the shift rail.
Figure 330 — Installing Shift Rail and Shifter

300747a
Figure 329 — Installing Poppet Ball and Spring
Page 136

8. Press the poppet ball down while sliding the 9. Align the setscrew in the third/fourth shifter
third/fourth shift rail over the ball. A hollow with the notch in the shift rail. Tighten the
tube works well to press down the ball. setscrew to 35–50 lb-ft (47–68 NNm) torque.
300621a
300712a
Figure 331 — Pushing Poppet Ball Down Figure 332 — Tightening Setscrew
Page 137

10. Slide the first/second shift rail into the shift 11. Install the interlock pin into the first/second
cover. At the same time, install the shift rail.
first/second shift fork onto the shift rail.
300750a
Figure 333 — Installing First/Second Shift Rail
300760a
Figure 335 — Installing Pin into First/Second Shift Rail
Figure 334 — Installing First/Second Shift Fork
Page 138

12. Install the interlock ball between the 13. Install the poppet ball and spring for the
first/second shift rail and the third/fourth shift first/second shift rail.
rail.
300759a
300754a
Figure 336 — Installing Interlock Ball Between Rails
Page 139

14. Press the poppet ball down while sliding the 15. Align the setscrew in the first/second shift
first/second shift rail over the ball. A hollow fork with the notch in the shift rail. Tighten
tube works well to press down the ball. the setscrew to 35–50 lb-ft (47–68 NNm)
torque.
300711a
300710a
Figure 338 — Pressing Poppet Ball Down

Figure 339 — Tightening Setscrew
Page 140

16. Slide the Lo/reverse shift rail into the shift 18. Install the Lo/reverse shifter onto the shift
cover. At the same time, install the rail, behind the third/fourth shift fork.
third/fourth shift fork onto the shift rail.
300756a
Figure 342 — Installing Lo/Reverse Shifter
Figure 340 — Installing Third/Fourth Shift Fork
17. Install the poppet ball and spring into the

Lo/reverse shifter, followed by the spring and
plunger. Depress the poppet ball and spring
into the shifter to allow the spring and
plunger to pass. The poppet ball rests in the
radius of the plunger.
300746a
Figure 341 — Assembling Lo/Reverse Shifter
Page 141

19. Install the interlock ball between the 20. Install the poppet ball and spring for the
Lo/reverse shift rail and the first/second shift Lo/reverse shift rail.
rail.
300755a
300762a
Figure 343 — Installing Interlock Ball
Page 142

21. Press the poppet ball down while sliding the 22. Install the Lo/reverse shift fork onto the
Lo/reverse shift rail over the ball. A hollow Lo/reverse shift rail.
tube works well to press down the ball.
300765a
300727a
Figure 346 — Installing Lo/Reverse Shift Fork
Figure 345 — Pushing Poppet Ball Down
Page 143

23. Continue sliding the shift rail as shown. 25. Align the setscrew in the Lo/reverse shifter
with the notch in the shift rail. Tighten the
setscrew to 35–50 lb-ft (47–68 NNm) torque.
Figure 347 — Sliding Lo/Reverse Shift Rail
24. Install the interlock pin (see Figure 347) into 300729a
the Lo/reverse shift rail. Finish sliding the Figure 349 — Tightening Setscrew
shift rail through the fork and into position.
Figure 348 — Finish Sliding Shift Rail into Position
Page 144

26. Align the setscrew in the Lo/reverse shift fork 28. Install the interlock rocker and bolt into the
with the notch in the shift rail. Tighten the cover.
setscrew to 35–50 lb-ft (47–68 NNm) torque.
Figure 352 — Install Interlock Rocker and Bolt
29. Install the nut and washers onto the interlock

rocker bolt and tighten to 20–25 lb-ft
300726a
Figure 350 — Tightening Setscrew
27. Install the interlock ball into the opening next

to the interlock rocker location of the cover.
Figure 353 — Install Nut and Washers
Figure 351 — Install Interlock Ball into Cover
Page 145
NOTES
Page 146
10-112f.fm Page 147 Monday, June 22, 1998 11:20 AM
300 REASSEMBLY
REASSEMBLY
Page 147
300 REASSEMBLY
[320] TRANSMISSION REASSEMBLY PROCEDURES
Locate the stamped letter “O” on the front of each Locate the three gear tooth spaces on the
front countershaft fourth (eighth) speed gear that mainshaft fourth (eighth) speed gear, stamped
aligns with the keyway. Paint the front of the with the letter “O”. Paint the front of each tooth
corresponding gear tooth with white paint for space with white paint for greater visibility when
greater visibility when timing the countershafts timing the countershafts later. If there are no
later. Do this for each of the three front stamped letters, count the number of gear teeth
countershafts. (result should be divisible by three). Place a white
paint mark on any tooth space. Then, count
around one-third of the total spaces and place the
second white mark. Finally, count around one-
third of the total spaces again and place the third
white mark. The three marks should now be
evenly spaced around the gear.
Figure 354 — Gear Tooth Marked for Timing
Figure 355 — Gear Tooth Spaces Marked for Timing
Page 148
300 REASSEMBLY
1. Install the No. 1 (upper right) and No. 3
(lower) front countershaft front bearing
covers and capscrews (make sure new
O-rings are in place). Tighten the capscrews The bearing cover fits into the flat on the idler
to 36–54 lb-ft (49–73 NNm) torque. shaft to retain the shaft and prevent it from
rotating.
300478a
300433a
Figure 356 — No. 1 and No. 3 Front Countershaft Front
Bearing Covers Installed
Figure 358 — Marking Idler Shaft Opening
2. Place the transmission in the vertical
position and install the No. 3 (lower) front 4. Install the reverse idler shaft (next to No. 3
countershaft into the main transmission countershaft) into the opening provided. As
case, by tipping into position, front end the reverse idler shaft is inserted into the
downward. Center the countershaft over the case, install (in order) the large opening
front bearing. thrust washer, reverse idler gear and small
opening thrust washer onto the shaft from
inside the case.
300434a
Figure 357 — Installing Lower No. 3 Countershaft into
Main Case
Figure 359 — Order of Reverse Idler Shaft and
3. Temporarily position a shim pack over one of Components
the front countershaft rear bearing cover
openings. Mark the overhang of the shim
pack at the reverse idler shaft opening of the
case. This helps position the reverse idler
shaft and prevents bearing cover
interference with the shaft. Mark all idler
shaft openings.
Page 149
300 REASSEMBLY
5. Align the flat on the end of the reverse idler
shaft (next to No. 3 countershaft) with the
mark made along the edge of the shim pack.
3
3
3
300424a
Figure 362 — Installing Welch Plug
300421a
SETTING FRONT COUNTERSHAFT BEARING
PRELOAD
Figure 360 — Aligning Reverse Idler Shaft with Marks
8. Install enough shims under the front
6. Maintaining mark alignment, tap the reverse countershaft rear bearing cover to produce
idler shaft (next to No. 3 countershaft) into measurable countershaft end play. Then,
the case until it bottoms (flat on idler shaft install the cover and tighten the capscrews
flush with case), using a brass hammer. to 40–50 lb-ft (54–68 NNm) torque. Measure
end play of the countershaft, using a dial
indicator.
Make sure that the small bore thrust washer is

aligned correctly with the idler shaft while tapping
the idler shaft into place. If not aligned, damage Use a pry bar to move the countershaft up and
to the thrust washer may result. down while measuring end play on the dial
indicator.
Figure 361 — Tapping Reverse Idler Shaft into Place
7. Using a blunt punch and hammer, install a

new welch (expansion) plug into the reverse
idler shaft if not already done.
Figure 363 — Measuring Countershaft End Play for

Bearing Preload
Page 150
300 REASSEMBLY
9. For each countershaft, measured end play 11. Install the No. 3 (lower) front countershaft
determines the thickness of shims that must rear bearing cover by aligning and lightly
be removed to get zero end play. Then tapping the cover into place. Install the
remove additional shim thickness to get the capscrews and tighten to 40–50 lb-ft
required 0.003–0.007 inch preload. (54–68 NNm) torque.
Example:
r Begin the procedure, using enough
shims under the cover to produce
measurable end play.
r Measure countershaft end play. For this
example, the end play is 0.100 inch.
r Remove 0.100-inch shims from the pack
to get zero end play.
r Remove (subtract) additional
0.003–0.007 inch shims from the pack to
get the specified preload.
r Total shim thickness removed from the
shim pack, to get the required Figure 365 — Installing Countershaft Rear Bearing
0.003–0.007 inch preload, must be Cover
0.103–0.107 inch.
12. Tip the No. 1 (upper left, when viewed from
rear) front countershaft into position as
described earlier.
Preload is negative end play or “crush.” It cannot 13. Install the reverse idler shaft, gear and thrust
be measured directly. Determining shim thickness washers (next to No. 1 countershaft) as
must be done carefully, as described, to obtain described in the steps for the lower reverse
the correct preload on the bearings. idler shaft and gear installation.
14. Pry the No. 1 (upper left) countershaft to the
10. After determining the correct shim thickness, outside, using a suitable pry bar. Block the
install the shim pack onto the front rear end of the countershaft off center, using
countershaft rear cover. a folded rag.
Figure 364 — Installing Shim Pack and O-Ring
Page 151
300 REASSEMBLY
15. Install the mainshaft into the case.
Before the mainshaft is installed, slide the

Lo/reverse sliding clutch forward until it fully
engages the Lo speed gear. Slide the reverse
speed gear forward until it fully engages the
sliding clutch.
Reverse gear is not secured to the shaft and can Figure 367 — Timing Gears with Mainshaft in Place
fall off if not careful.
19. Install the remaining reverse idler shaft,
gear and thrust washers (next to No. 2
countershaft) as described in the steps for
the lower (No. 3) reverse idler shaft and
gear. Move the reverse speed gear on the
mainshaft as far forward as possible. When
installing the reverse idler shaft and gear,
make sure that the forward thrust washer is
held in place. Install the welch plug into the
reverse idler shaft, if not previously done.
20. Shift the Lo/reverse sliding clutch and
reverse gear rearward, to allow the gear
teeth on the reverse speed gear to engage
all three reverse idler gears. Place a folded
rag between the Lo and reverse speed gears
to hold them in place.
Figure 366 — Installing Mainshaft into Case
16. If not already done, place the transmission in

the horizontal position.
17. Move the reverse gear and Lo/reverse
sliding clutch to normal positions.
18. Position the mainshaft, No. 3 (lower)
countershaft and No. 1 (upper right, when
viewed from front) countershaft so that the
timing marks on the gears are aligned. Roll
the shafts into place and make sure gear
timing is correct.
Figure 368 — Moving Sliding Clutch and Reverse Speed

Gear to Engage Gear Teeth
Timing the shafts is easier if the transmission is in
a horizontal position, rotated 15 degrees 21. Working through the opening at the rear of
counterclockwise, as viewed from the rear of the the case, install the mainshaft reverse speed
transmission case. gear snap ring onto the mainshaft. See
Figure 369.
Page 152
300 REASSEMBLY
22. Install the internal-toothed and 23. Install the snap ring on the inside of the
external-toothed thrust washers onto the reverse speed gear, using suitable snap ring
mainshaft. The oil grooves on the external- pliers.
toothed thrust washer face forward.
Figure 369 — Installing Internal-Toothed Thrust Washer Figure 371 — Installing Reverse Speed Gear Snap Ring
24. Install the shaft snap ring (located just

behind the reverse speed gear and before
the spacer) onto the mainshaft, using
suitable snap ring pliers.
Figure 370 — Installing External-Toothed Thrust Washer
Figure 372 — Installing Snap Ring onto Mainshaft

Behind Reverse Speed Gear
Page 153
300 REASSEMBLY
25. Install the No. 2 (upper left, when viewed
from front) countershaft.
Do not attempt to pull any bearing cover in place,
using the bearing cover capscrews. Damage to
the bearings or bearing cover may result. Make
sure all components are properly in place before
tightening the capscrews.
28. Install the No. 1 (upper left) countershaft

rear bearing cover. Determine shim pack
thickness for proper bearing preload
adjustment, as described earlier for the
No. 3 lower countershaft. Tighten the rear
cover capscrews to 40–50 lb-ft (54–68 NNm)
torque.
29. Install the front mainshaft rear bearing
Figure 373 — Installing No. 2 Countershaft spacer (thrust washer) over the mainshaft.
26. Align the timing marks on the No. 2
countershaft with the mainshaft. All three
countershafts and mainshaft timing marks
should be aligned at this point.
Figure 375 — Installing Bearing Spacer
30. Install the front mainshaft rear bearing.

300431a
Figure 374 — Gear Timing Marks Aligned
27. Install the No. 2 (upper left) countershaft

front bearing cover. Pull up on the
countershaft with one hand and wiggle or
tap the cover into place. Tighten the cover
capscrews to 36–54 lb-ft (49–73 NNm)
torque.
Figure 376 — Installing Front Mainshaft Rear Bearing
Page 154
300 REASSEMBLY
31. Install the front mainshaft rear bearing 33. Install the front mainshaft rear bearing cover
mainshaft snap ring. and capscrews. Tighten the capscrews to
40–50 lb-ft (54–68 NNm) torque.
In order to install the snap ring that retains the

rear bearing, it may be necessary to raise the
mainshaft using a pry bar.
Figure 377 — Installing Snap Ring Figure 378 — Installing Front Mainshaft Rear Bearing
Cover
32. Install the No. 2 (upper right) countershaft
rear bearing cover. Determine shim pack 34. Working at the front of the mainshaft, install
thickness for proper bearing preload the third/fourth sliding clutch.
adjustment, as described earlier for the No. 3
lower countershaft. Tighten the rear cover
capscrews to 40–50 lb-ft (54–68 NNm) torque.
Figure 379 — Installing Third/Fourth Sliding Clutch
Page 155
300 REASSEMBLY
35. Install the main drive pinion assembly and 36. Obtain the rear compound Lo-split gear.
tighten the bearing cover capscrews to Paint three equally spaced sets of double
36–54 lb-ft (49–73 NNm) torque. timing marks on the gear teeth surrounding
every ninth space between two teeth.
Main drive pinions for these transmissions are

designed with 0.069–0.071 inch (three degrees)
backlash between the shaft splines and the
mating splines of the main drive pinion gear. This
amount of backlash was designed to eliminate a
rattling noise that can occur when the engine is
idling with the clutch engaged.
Figure 382 — Marking Lo-Split Gear

2 1
37. Install the rear compound Lo-split gear onto
the front mainshaft. The clutch teeth of the
gear face rearward.
38. Install the rear compound Lo-split gear
3
internal-toothed thrust washer and retaining
snap ring onto the front mainshaft in the
300436a location shown in Figure 383.
Figure 380 — Tightening Main Drive Pinion Bearing

Cover Capscrews
2 1
3
Figure 383 — Thrust Washer and Snap Ring Location
with Gear Timing Marks Aligned
300437a
Figure 381 — Main Drive Pinion Assembly Installed
Page 156
300 REASSEMBLY
39. Rotate the rear compound Lo-split gear so 41. Install the three rear countershafts so that
that the three sets of timing marks on the the single timing mark on each countershaft
gear line up with the center line of each front Lo-split gear enters the mating set of timing
countershaft. See Figure 383. marks on the rear compound Lo-split gear.
40. Obtain the three rear countershafts. Mark
the gear tooth that corresponds with the
letter “O” stamping on the Lo-split gear of
each countershaft. Paint a corresponding
timing mark on the Hi range/Hi split gear
tooth, directly in line with the tooth
marked on the Lo-split gear. Paint a
corresponding timing mark on the Lo-range
gear also.
If the “O” stamping is not visible, locate the gear

tooth on the countershaft that aligns with the
keyway. Mark the closest tooth that aligns with the Figure 385 — Installing and Aligning Rear Countershafts
keyway. Then, mark the remaining gears.
42. Rotate the three rear countershafts so that
the timing marks on each Lo-split gear line
up with the center line of the front main
shaft.
43. Tilt the three countershafts outward slightly
without disturbing the timing marks and then
install the sliding clutch. The external clutch
teeth on the sliding clutch face rearward.
Figure 384 — Marking Rear Countershaft Gears
Page 157
300 REASSEMBLY
44. Obtain the output shaft and synchronizer 47. Install a new case-to-case gasket on the
assembly. Paint three equally spaced sets of gasket surface of the main case.
double timing marks on the gear teeth
48. Install the rear case over the rear compound
surrounding every 10th space between two
gearset and onto the main case and gasket.
teeth for the Hi range/Hi split gear. Paint
three equally spaced sets of double timing 49. Install the dowel bolts and nuts and tighten
marks on the gear teeth surrounding every to 66–80 lb-ft (89–108 NNm) torque.
18th space between two teeth for the
50. Install the inner and outer (case-to-case)
Lo-range gear.
capscrews to secure the rear case to the
45. Suspend the output shaft and synchronizer main case. There are two inner capscrews
assembly using a hoist and suitable output located just inside the rear compound cover.
yoke retaining nut with welded strap. Install Tighten the inner and outer case-to-case
the output shaft and synchronizer assembly. capscrews to 62–78 lb-ft (84–106 NNm)
torque.
Make sure the single timing mark on each

countershaft Hi range/Hi split gear and Lo-range
gear aligns with the double timing marks painted
on the corresponding output shaft gears.
Figure 387 — Tightening Outer Case-to-Case

Capscrews
Figure 386 — Installing Output Shaft

and Synchronizer Assembly
46. Remove the nut with welded strap from the

output shaft.
Figure 388 — Tightening Inner Case-to-Case Capscrews
Page 158
300 REASSEMBLY
SETTING REAR COUNTERSHAFT BEARING 53. For each countershaft, remove the bearing
PRELOAD cover and add enough shims to bring the
51. Install the rear compound rear countershaft space under the bearing cover to zero. Then
bearing covers. Determine the shim pack remove enough shim thickness to get the
thickness for each rear countershaft bearing required 0.002–0.006 inch preload.
preload adjustment, using the procedure
described in the example that follows. Example:
52. Working at the rear of the rear r Begin the procedure using no shims
countershafts, temporarily install the rear under the cover.
countershaft bearing covers, leaving the r Measure the space under the cover. For
capscrews loose. Do not install shims or this example, the space is 0.100 inch.
O-rings at this time. Measure the space
between the bearing cover and the r A 0.100-inch shim pack is needed to “fill”
transmission case, using two feeler gauge the measured space.
sets. Take at least two more measurements. r Remove (subtract) 0.002–0.006 inch
Then average the results. shims from the pack to get the specified
preload.
r To obtain the required 0.002–0.006 inch
preload, final shim pack thickness must
A more accurate measurement can be obtained if be 0.094–0.098 inch for this example.
the transmission is in a vertical position and the
covers are hand held firmly against the
countershaft rear bearings.
Preload is negative end play or “crush.” It cannot
be measured directly. Determining shim thickness
must be done carefully, as described, to obtain
the correct preload on the bearings.
54. When all shim packs have been determined,

install the rear compound countershaft
bearing covers, shim packs and cover
capscrews and tighten the capscrews to
40–50 lb-ft (54–68 NNm) torque. Use new
O-rings when installing the covers.
Figure 389 — Measuring to Determine Shim Pack

Thickness
Figure 390 — Tightening Rear Countershaft Bearing

Cover Capscrews
Page 159
300 REASSEMBLY
55. Install a new gasket onto the output housing 57. Install either the collapsible- or ground-type
and then install the housing onto the rear spacer (the correct length of the spacer was
case. Note the location of the lubrication previously determined in the Rear Output
hole. Housing Reassembly section pages
105–108). Also install the outer bearing
cone into the output housing over the output
shaft.
Figure 391 — Installing Output Housing
56. Install and tighten the output housing

capscrews to the recommended torque Figure 393 — Installing Spacer (Collapsible Type
specification. Shown) and Outer Bearing Cone
58. Seat the outer bearing cone and spacer,

using a blunt punch and hammer. Working in
a circular motion, tap lightly around the inner
race of the bearing cone only.
Figure 392 — Tightening Output Housing Capscrews
Figure 394 — Seating the Bearing Cone and Spacer
Page 160
300 REASSEMBLY
59. Install the output housing oil seal. Lightly tap 61. Reach through the rear case top opening
the seal into place using a broad, flat-faced and verify that the splitter sliding clutch and
hammer until the seal is seated in the the synchronizer assembly sliding clutch are
housing bore. Refer to Oil Seals in the both engaged.
INSPECTION OF PARTS section for seal
62. Reach into the main case top opening and
installation and precautions.
move at least two sliding clutches into
engagement.
63. Tighten the drive yoke retaining nut to the
required torque specification.
Figure 395 — Installing Output Housing Oil Seal
60. Install the drive yoke and retaining nut.
Figure 397 — Tightening Drive Yoke Nut
64. Move the synchronizer sliding clutch to

neutral position. Install the range shift fork
into the case and engage fingers to the
sliding clutch. The straight side of the fork (1)
faces the front and the angled side of the
fork (2) faces the rear.
Figure 396 — Installing Drive Yoke and Nut 2

1
To install the drive yoke nut of the T2180A

transmission, place at least two gears in both the
main case and rear case into engagement. This
is done to lock the gearing and prevent it from
300799a
rotating while tightening the yoke nut.
Figure 398 — Installing Range Shift Fork
Page 161
300 REASSEMBLY
65. Install the range shift cylinder into the rear 68. Align the setscrew in the shift fork with the
case. Line up the shift fork with the shift rail setscrew hole in the shift rail. Tighten the
as the cylinder is installed. Install the setscrew to 35–50 lb-ft (47–68 NNm) torque.
cylinder so that the breather vent is facing
down and the air port is facing up.
Figure 399 — Installing Range Shift Cylinder
66. Install the range shift cylinder cover,

capscrews and new O-ring.
Figure 401 — Tightening Shift Fork Setscrew
69. Clean the gasket surface of the rear case

shift cover.
70. Make sure that the sliding clutch next to the
rear compound Lo-split gear is placed in the
neutral position.
71. Install the rear case shift cover, lift bracket
and cover capscrews. Make sure to align the
shift fork with the sliding clutch. Tighten the
torque.
Figure 400 — Installing Range Shift Cylinder,
Capscrews, Cover and O-Ring
67. Tighten the range shift cylinder cover

torque.
Do not overtighten the four long capscrews that

hold the range shift cylinder and cover to the rear
case. Overtightening can cause the rear cover to
bend.
Page 162
300 REASSEMBLY
75. Install the lifting bracket at the front of the
main case top cover as shown.
The lift bracket capscrews are slightly longer than
the remainder of the top cover capscrews. Make
sure the longer capscrews are used to secure the
lift bracket. The lift bracket is placed at the right The lift bracket capscrews are slightly longer than
rear corner of the shift cover. the remainder of the top cover capscrews. Make
sure the longer capscrews are used to secure the
lift bracket.
Figure 402 — Installing Rear Case Shift Cover
72. Install a new main case top cover gasket.

Use a small amount of adhesive or grease to
hold it in place. Figure 404 — Lifting Bracket Placement
73. Make sure the shifters on the top cover and
the sliding clutches on the mainshaft are in 76. Install the remaining shorter top cover
the neutral position for shift fork alignment. capscrews and tighten to 24–36 lb-ft
74. Align the shift forks with the sliding clutches
and install the main case top cover. 77. Install the interlock valve O-ring, pin, spring
and sleeve into the main case top cover.
Refer to Figure 328 on page 135.
Figure 403 — Installing Main Case Top Cover
Page 163
300 REASSEMBLY
78. Install the valves and air lines that were 80. Reconnect the air lines attached to the
removed as an assembly. range shift cylinder and the rear case shift
cover. Refer to the SCHEMATICS section.
81. Install the transmission drain plug and
magnetic filter plug and torque to
specification.
82. Install the clutch release bearing assembly,
shafts, yoke and clutch brake (if equipped).
83. Reinstall the transmission into the chassis of
the vehicle.
84. Fill the transmission to the proper fill level,
using the recommended lubricant. Refer to
Transmission Specifications and Capacities
found in the SPECIFICATIONS section.
Figure 405 — Installing Air Lines and Valves

85. Install and tighten the filler plug to
as an Assembly specification.
79. Install the range shift valve, dual-double

check valve, inversion valve, air directional
valve and associated brackets onto the
transmission. Torque all fasteners to
specification.
Page 164
10-112g.fm Page 165 Monday, June 22, 1998 11:18 AM
300 SPECIFICATIONS
SPECIFICATIONS
Page 165
300 SPECIFICATIONS
TORQUE SPECIFICATIONS
Item Location Torque — Lb-Ft (NNm)

1 Main Drive Pinion Bearing Cover Capscrews* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–54 (49–73)
2 Main Case Shift Cover Capscrews* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–36 (33–49)
3 Third/Fourth Rocker Pin Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 (54–68)
4 Shifter and Shift Fork Setscrews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–50 (47–68)
5 Mainshaft Rear Bearing Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 (54–68)
6 Splitter Shift Piston Cover Capscrews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–21 (23–29)
7 Splitter and Range Shift Fork Setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–50 (47–68)
8 Rear Case Shift Cover Capscrews* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–36 (33–49)
9 Range Shift Piston-to-Rail Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75–105 (102–142)
10 Range Shift Cylinder Cover Capscrews*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–21 (23–29)
11 Mainshaft Output Housing Capscrews* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 (54–68)
12 Drive Yoke Nut** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450–500 (600–670)
13 Rear Countershaft Bearing Cover Capscrews*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 (54–68)
14 Synchronizer Special 12-Point Screws (Quantity 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 24–28 (33–38)
15 Main Case Countershaft Rear Bearing Cover Capscrews* . . . . . . . . . . . . . . . . . . . . 40–50 (54–68)
16 Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–30 (34–41)
17 Front Countershaft Front Bearing Cover Capscrews* . . . . . . . . . . . . . . . . . . . . . . . . . 36–54 (49–73)
— Main Case-to-Rear Case Capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62–78 (84–106)
— Main Case-to-Rear Case Dowel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66–80 (89–108)
— Oil Filler Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 (75) Max.
— Magnetic Oil Filter Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–30 (34–41)
— Range Shift Interlock Rocker Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–25 (27–34)
— Range Shift Interlock Valve Mounting Screws* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 (10–11)
— Double Check Valve Mounting Screws (Air Piping for Compound Neutralizing) . . . . . 60–84 lb-in (7–9)
* Indicates that fastener has epoxy-coated threads. Fastener can be reused a
maximum of five times.
** Indicates drive yoke nut has self-locking feature. Nut can be reused three times.
Page 166
300 SPECIFICATIONS
GEAR IDENTIFICATION
GEAR IDENTIFICATION CHART
Gear Number of Outside

Identifier Mainshaft Gears Teeth Diameter
Main Box
1 Main Drive Pinion 37 5.633
(Third/Seventh)
2 Fourth/Eighth 27 4.692
3 Second/Sixth 39 6.603
4 First/Fifth 45 7.539
5 Lo Gear 54 8.754
6 Reverse Gear 54 9.601
Rear Compound
7 Lo-Split Gear (Mounts on 27 4.754
Front Mainshaft)
8 Hi Range/Hi Split Gear 30 5.204
9 Lo-Range Gear 54 8.996
Countershaft Gears
Main Box
10 Main Drive Gear 47 7.583
11 Fourth/Eighth (PTO) 54 8.514
12 Second/Sixth 40 6.641
13 First/Fifth 33 5.757
14 Lo Gear 25 4.404
15 Reverse Gear 12 2.625
16 Reverse Idler Gear 24
Rear Compound
17 Lo-Split Gear 52 8.519
18 Hi-Range/Hi-Split Gear 49 8.001
19 Lo-Range Gear 23 4.205
Page 167
300 SPECIFICATIONS
FITS AND LIMITS
All Forks and Sliding Clutches
Minimum New Maximum New Maximum Wear
(1) Clearance between fork 0.005 0.020 0.050*
pad and clutch groove inch inch inch
(2) Clearance between 0.073 0.087 0.135
synchronizer shift fork pads inch inch inch
and sliding clutch
*If unit has history of disengagement, clearance must not exceed 0.030 inch maximum.
Spring Specifications
Springs Free Length Load Length Under Load
Lo/Reverse Shifter Ball
Spring 1.562 inch 41.8 ± 5 lbs. 0.875 inch
Lo/Reverse Shifter Plunger
Spring 1.500 inch 22.0 ± 2 lbs. 0.625 inch
Shift Rail Poppet Ball
Springs (3) 2.251 inch 42.4 ± 3 lbs. 1.539 inch
Range Shift Interlock Valve
Pin Spring 1.310 inch 18.7 lbs. 1.120 inch
31.2 lbs. 1.000 inch
Page 168
300 SPECIFICATIONS
GENERAL TOLERANCES
Component Tolerance
Shift Rail-to-Mating Housing Bore 0.010 inch maximum
Reverse Idler Gear End Play 0.010–0.090 inch
Shaft Flush with Case Wall
Front Countershaft Bearing Preload 0.003–0.007 inch
Rear Countershaft Bearing Preload 0.002–0.006 inch
Mainshaft Reverse Gear to Reverse 0.003–0.050 inch
Gear Spacer End Play Shaft Seated
Mainshaft Lo Speed Gear to Mainshaft
First/Fifth Speed Gear End Play 0.020–0.080 inch
Mainshaft Fourth/Eighth Speed Gear to Mainshaft
Second/Sixth Speed Gear End Play 0.024–0.081 inch
Lo-Split Gear End Play 0.005–0.041 inch
Rear Mainshaft Hi Range/Hi Split Gear End Play 0.006–0.040 inch
Rear Mainshaft Lo-Range Gear End Play 0.002–0.026 inch
Output Housing Tapered Roller Bearing
Preload — Ground Spacer 0.001–0.004 inch
Output Housing Tapered Roller Bearing
Preload — Collapsible Spacer 1.5–5.0 lbs. pull
Page 169
300 SPECIFICATIONS
TRANSMISSION SPECIFICATIONS AND CAPACITIES
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mack Trucks, Inc.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Triple Countershaft, Overdrive, Range and Splitter
Shift
Range Shift Synchronizer . . . . . . . . . . . . . . . . . . . . .Plate Type, Four Friction Discs and Four Reaction
Discs Each for High and Low Range
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selective, One Lever Manual with Air-Shifted

Rear Compound
Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Forward, 4 Reverse
Bell Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SAE No. 1, Integral with Main Case
Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Aluminum, Heat Treated
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spur Type
Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fine Pitch Rolled Involute
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Splash Lubrication
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Integral, Magnetic
Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic
PTO Openings: Left Side . . . . . . . . . . . . . . . . . . . .Std. SAE 8-Hole (Main Case and Rear Case)
Right Side . . . . . . . . . . . . . . . . . . .Std. SAE 6-Hole (Main Case and Rear Case)
Oil Capacity: T2180A . . . . . . . . . . . . . . . . . . . . . . . .Approx. 30 Pints (depends on angle of installation
in chassis)
Recommended SAE Grade Gear Oil for All
Temperature Operations: T2180A
r MACK GO-J Specification 80W-90, 85W-140
for Mineral Base, (80W-140 Synthetic)
r MACK GO-J Plus* Specification 75W-90,
for Synthetic Base
* GO-J Plus is required for MACK geared
component extended service drain intervals.
Page 170
300 SCHEMATICS
SCHEMATICS
Page 171
300 SCHEMATICS
[543] T2180A AIR CONTROL WITH COMPOUND
NEUTRALIZING FOR PTO
Page 172
300 SCHEMATICS
[543] T2180A AIR CONTROL WITH COMPOUND
Page 173
300 SCHEMATICS
[543] T2180A AIR CONTROL WITHOUT COMPOUND
Page 174
300 SCHEMATICS
[543] T2180A AIR CONTROL WITHOUT COMPOUND
Page 175
NOTES
Page 176
300 SPECIAL TOOLS
SPECIAL TOOLS
Page 177
300 SPECIAL TOOLS
SPECIAL TOOLS
J 34629 Snap Ring Pliers Set

J 34630 Reverse Idler Shaft Removal Tool
J 29048 Tapered Feeler Gauge
J 29369-1 Bearing Puller
J 29369-2 Bearing Puller
J 2619-01 Slide Hammer
J 36052 Positioning Tool
J 36053 Seal Driver
J 8092 Driver Handle
J 39477-1 Bar Type Puller
J 8176 Bearing Separator
J 24407 30–250 lb-ft Torque Wrench
J 23775-01 100–600 lb-ft Torque Wrench
OEM-4052 Internal Puller
Above tools are available from:
KENT-MOORE
O.E. TOOL & EQUIPMENT GROUP
SPX CORPORATION
28635 MOUND RD.
WARREN, MI 48092-3499
TEL 1-800-328-6657
FAX 1-800-578-7375
Page 178
INDEX
INDEX
Page 179
INDEX
A I
AIR BREATHERS . . . . . . . . . . . . . . . . . . . . . .29 INSPECTION OF PARTS . . . . . . . . . . . . . . . . 91
ALL FORKS AND SLIDING CLUTCHES . . . .168 INSPECTION AND CLEANING . . . . . . . . . . . 92
B L
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .92 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 7
BENCH PROCEDURES . . . . . . . . . . . . . .45, 95
M
C
MAGNETIC OIL FILTER . . . . . . . . . . . . . . . 7, 29
CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . .28 MAIN CASE SHIFT COVER . . . . . . . . . . . . . . 46
CHECKING OIL . . . . . . . . . . . . . . . . . . . . . . . .28 MAIN CASE SHIFT COVER
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 48
D MAIN CASE SHIFT COVER
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 133
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . .6
MAIN DRIVE PINION DISASSEMBLY . . . . . . 65
DESCRIPTION AND OPERATION . . . . . . . . . .5
MAIN DRIVE PINION REASSEMBLY . . . . . . 125
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .31
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 27
DOWNSHIFTING . . . . . . . . . . . . . . . . . . . . . . .10
O
E
OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . .15
P
F
POWER FLOW DIAGRAMS . . . . . . . . . . . . . . 11
FRONT COUNTERSHAFT DISASSEMBLY . .82
FRONT COUNTERSHAFT FRONT BEARING
R
COVER DISASSEMBLY . . . . . . . . . . . . . . .81
FRONT COUNTERSHAFT FRONT BEARING REAR CASE SHIFT COVER . . . . . . . . . . . . 131
COVER REASSEMBLY . . . . . . . . . . . . . . .104 RANGE SHIFT CYLINDER DISASSEMBLY . . 62
FRONT COUNTERSHAFT REAR BEARING RANGE SHIFT CYLINDER
COVER DISASSEMBLY . . . . . . . . . . . . . . .86 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 128
FRONT COUNTERSHAFT REAR BEARING REAR CASE SHIFT COVER . . . . . . . . . . . . . 60
COVER REASSEMBLY . . . . . . . . . . . . . . .100 REAR COUNTERSHAFT BEARING
FRONT COUNTERSHAFT COVER DISASSEMBLY . . . . . . . . . . . . . . . 89
REASSEMBLY . . . . . . . . . . . . . . . . . . . . .101 REAR COUNTERSHAFT BEARING
FRONT MAINSHAFT DISASSEMBLY . . . . . .68 COVER REASSEMBLY . . . . . . . . . . . . . . . 97
FRONT MAINSHAFT REASSEMBLY . . . . . .118 REAR COUNTERSHAFT DISASSEMBLY . . . 87
REAR COUNTERSHAFT REASSEMBLY . . . 98
G REAR MAINSHAFT (OUTPUT SHAFT) AND
SYNCHRONIZER DISASSEMBLY . . . . . . . 74
GEAR IDENTIFICATION . . . . . . . . . . . . . . . .167
REAR MAINSHAFT (OUTPUT SHAFT) AND
GEAR RATIOS AND SHIFT PATTERN . . . . . .8
SYNCHRONIZER REASSEMBLY . . . . . . 109
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
REAR OUTPUT HOUSING
GENERAL INSPECTION . . . . . . . . . . . . . . . . .94
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 80
GENERAL REASSEMBLY
REAR OUTPUT HOUSING
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .94
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 105
GENERAL TOLERANCES . . . . . . . . . . . . . .169
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 147
REVERSE IDLER GEAR DISASSEMBLY . . . 90
REVERSE IDLER GEAR REASSEMBLY . . . . 96
Page 180
INDEX
S TRANSMISSION COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 46
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . .171
TRANSMISSION COMPONENT
SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . .9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 96
SHIFTER FORKS, SLIDING CLUTCHES
TRANSMISSION DISASSEMBLY
AND SHIFT RAILS . . . . . . . . . . . . . . . . . . . .92
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 32
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . .177
TRANSMISSION IDENTIFICATION . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .165
TRANSMISSION REASSEMBLY
SPLASH LUBRICATION . . . . . . . . . . . . . . . . . .7
PROCEDURES . . . . . . . . . . . . . . . . . . . . . 148
SPRING SPECIFICATIONS . . . . . . . . . . . . .168
TRANSMISSION SPECIFICATIONS
AND CAPACITIES . . . . . . . . . . . . . . . . . . . 170
T
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 23
T2180A AIR CONTROL WITH COMPOUND TROUBLESHOOTING CHART . . . . . . . . . . . . 24
NEUTRALIZING FOR PTO . . . . . . . .172, 173
T2180A AIR CONTROL WITHOUT U
COMPOUND NEUTRALIZING
UNIT IDENTIFICATION STAMPING
FOR PTO . . . . . . . . . . . . . . . . . . . . . .174, 175
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
T2180A TRANSMISSION . . . . . . . . . . . . . . . . .6
UPSHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TORQUE SPECIFICATIONS . . . . . . . . . . . . .166
Page 181
NOTES
Page 182
TRANSMISSION
T2180A
SERVICE MANUAL
PRINTED IN U.S.A.
10-112 MACK TRUCKS, INC. 1998

Transmission: Service Manual

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TRANSMISSION

T2180A JUNE 1998

PLEASE LET US KNOW!

Thank You For Your Assistance

DO NOT STAPLE — USE TRANSPARENT TAPE

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

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BY ADDRESSEE

SERVICE PUBLICATIONS (RTS), 6S3

FOLD ALONG THIS LINE

JUNE 1998 © MACK TRUCKS, INC. 1998

Directs attention to unsafe practices which could result in personal injury or

An operating procedure, practice, condition, etc., which is essential to emphasize.

2. Before working on a vehicle, place the transmission in neutral, set the

EXPLANATION OF NUMERICAL CODE

EXPLANATION OF NUMERICAL CODE

EXPLANATION OF NUMERICAL CODE

300 TRANSMISSION IDENTIFICATION

300 TRANSMISSION IDENTIFICATION

Figure 1 — Location of Identification Stamping on Left Side of Main Case

300 TRANSMISSION IDENTIFICATION

Figure 2 — Differences Between T2180 and T2180A Transmissions

300 DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

300 DESCRIPTION AND OPERATION

Figure 3 — Equal Torque Distribution

300 DESCRIPTION AND OPERATION

Figure 4 — Splash Lubrication

Figure 5 — Magnetic Oil Filter Viewed from Inside Case

300 DESCRIPTION AND OPERATION

300 DESCRIPTION AND OPERATION

300 DESCRIPTION AND OPERATION

To downshift from Hi-split to Lo-split in the same

300 DESCRIPTION AND OPERATION

Figure 8 — First Speed (Lo-Split, Lo-Range)

Figure 6 — Lo Speed (Lo-Split, Lo-Range)

Figure 9 — First Speed (Hi-Split, Lo-Range)

Figure 7 — Lo Speed (Hi-Split, Lo-Range)

Figure 10 — Second Speed (Lo-Split, Lo-Range)

300 DESCRIPTION AND OPERATION

300 DESCRIPTION AND OPERATION

300 DESCRIPTION AND OPERATION

Figure 25 — Reverse Speed (Hi-Split, Lo-Range)

300 EXPLODED VIEWS

300 EXPLODED VIEWS

1. 3rd/4th Shift Fork 12. Washer 23. Breather

300 EXPLODED VIEWS

1. Shift Fork 9. Shift Cylinder Cover

300 EXPLODED VIEWS

9 1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear

300 EXPLODED VIEWS

300 EXPLODED VIEWS

300 EXPLODED VIEWS

1. Rear Output Housing 3. Gasket

1. Bearing Cup 7. Lo Speed Gear

1. Front Bearing Cup 3. Rear Bearing Cup

300 EXPLODED VIEWS

1. Thrust Washer 4. Expansion Plug

1. Bearing Cone 5. Key

1. Bearing Cup 3. Shim

Current production T2180A transmissions are

If oil can only be felt by reaching your finger down

OK container. Clean and reinstall the magnetic drain