TRANSMISSION

T2130/T2180 OCTOBER 1999

(NEW ISSUE)
10-102

SERVICE MANUAL
front.fm Page -ii Thursday, April 15, 1999 2:28 PM

-ii
newknow.fm Page 1 Thursday, May 21, 1998 2:23 PM

PLEASE LET US KNOW!

Your comments and suggestions will help
us improve this manual!
Please complete and mail this form or FAX
your comments to: (610) 709-3800.
Manual: _______________________________ Publication Number: _______
Vehicle Model: _________________________ Model Year: ______________
Do you find procedures properly organized and easy to follow? ! Yes ! 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? ! Yes ! No
If yes, please describe: _____________________________________________
_______________________________________________________________
_______________________________________________________________
Did you find any errors in the procedures or illustrations? ! Yes ! No
If yes, what pages? _______________________________________________
Please explain: ___________________________________________________
_______________________________________________________________
Please include a copy of each page in question and mark your comments and
suggestions.
Name: ________________________________ Phone: (_____) _____-_______
Company: _______________________________________________________
Address: ________________________________________________________
City: _________________________________ State: _______ Zip: _______
Position Title: ____________________________________________________

Thank You For Your Assistance

Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)

DO NOT STAPLE — USE TRANSPARENT TAPE

Busreply.fm Page 1 Thursday, May 21, 1998 2:24 PM

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

NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA

POSTAGE WILL BE PAID BY ADDRESSEE

SERVICE PUBLICATIONS (RTS), 6S3

MACK TRUCKS INC
WORLD HEADQUARTERS
PO BOX M
ALLENTOWN PA 18105-9972

FOLD ALONG THIS LINE

 TRANSMISSION
T2130/T2180
SERVICE MANUAL

OCTOBER 1999 © MACK TRUCKS, INC. 1999

(NEW ISSUE — Replaces T2130/T2180 manual dated 6/90) 10-102
front.fm Page ii Thursday, April 15, 1999 2:28 PM

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
front.fm Page iii Thursday, April 15, 1999 2:28 PM

SAFETY INFORMATION

SAFETY INFORMATION

iii
front.fm Page iv Thursday, April 15, 1999 2:28 PM

SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or render it unsafe. Additional Notes and Service Hints are utilized to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:

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

iv
front.fm Page v Thursday, April 15, 1999 2:28 PM

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.

Engine driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very
dangerous. Do not work on or service engine driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.

REMEMBER,
SAFETY . . . IS NO ACCIDENT!

v
front.fm Page vi Thursday, April 15, 1999 2:28 PM

NOTES

vi
front.fm Page vii Thursday, April 15, 1999 2:28 PM

EXPLANATION OF NUMERICAL CODE

EXPLANATION OF NUMERICAL CODE

vii
front.fm Page viii Thursday, April 15, 1999 2:28 PM

EXPLANATION OF NUMERICAL CODE

EXPLANATION OF 3-DIGIT GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
NUMERICAL CODE GROUP 500 — BRAKES, AUXILIARY
The organization of MACK service manuals has SYSTEMS
been upgraded to standardize manual content GROUP 600 — CAB, TRUCK BODY
according to a reference system based on GROUP 700 — ELECTRICAL
component identification. The new reference
system will help to link the information contained The second two digits of the 3-digit code
in this publication with related information are used to identify the system, assembly or
included in other MACK service-warranty subassembly, as appropriate, within each of
publications, such as associated service the groupings. The codes applicable to this
bulletins, warranty manuals, and the TS477 publication are shown at the COMPONENT
Service Labor Time Standards Manual. HEADINGS as necessary, and may also appear
in the TABLE OF CONTENTS, to guide you to
The system is based on a numerical code, the specific component information.
first digit of which identifies the general
component grouping as listed here: Additionally, a two-character alpha code (i.e.,
[GA] CASE, MAIN) may be shown with each
GROUP 000 — GENERAL DATA operation. This alpha code, in combination with
GROUP 100 — CHASSIS the three-digit Group number, identifies the
GROUP 200 — ENGINE specific assembly, subassembly or part, and
GROUP 300 — CLUTCH, TRANSMISSION, directly relates to the first five positions of the
TRANSFER CASE AND PTO operation code listed in the Service Labor Time
Standards Manual, TS477.

EXAMPLES:
321 GA 3N 45
BASE OPERATION
TRANSMISSION HOUSING
CASE, MAIN
MACK TRANSMISSION, T2180
REPLACE
304429a

viii
front.fm Page ix Thursday, April 15, 1999 2:28 PM

TABLE OF CONTENTS

TABLE OF CONTENTS

ix
front.fm Page x Thursday, April 15, 1999 2:28 PM

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
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT IDENTIFICATION STAMPING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
T2130/T2180 TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Splash Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission Case Oil Cooler Line Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Magnetic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
T2130 AND T2130B GEAR RATIOS AND SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
T2180 AND T2180B GEAR RATIOS AND SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
T2130/T2130B SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Upshifting (Normal Highway) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downshifting (Normal Highway) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
T2180/T2180B SHIFTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Upshifting (Normal Highway) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Downshifting (Normal Highway) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
T2130(B) AND T2180(B) GUIDELINES FOR PTO USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Side-Mounted PTO Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preferred Operating Procedures for Rear Compound Mounted PTO Applications . . . . . . . . . . 11
T2130(B) AND T2180(B) GUIDELINES FOR PTO USE CONTINUED . . . . . . . . . . . . . . . . . . . . . . 12
Preferred Method for Engaging T2130(B)/T2180(B) High Range Gear for Output
Shaft Driven Power Take-Off Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
T2130 AND T2130B POWER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
T2180 AND T2180B POWER FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Checking Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Magnetic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
[320] TRANSMISSION DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
BENCH PROCEDURES (DISASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
[320] TRANSMISSION COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
[321] Main Case Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
[323] Main Case Shift Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
[324] Rear Case Shift Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
[323] Range Shift Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
[323] Range Shift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
[322] Main Drive Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
[322] Front Mainshaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
[322] Rear Mainshaft and Synchronizer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
[321] Rear Mainshaft Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
[321] Front Countershaft Front Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

x
front.fm Page xi Thursday, April 15, 1999 2:28 PM

TABLE OF CONTENTS
[322] Front Countershaft Disassembly (T2130/T2180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
[322] Front Countershaft Disassembly (T2130B/T2180B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
[321] Front Countershaft Rear Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 103
[322] Rear Countershaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
[321] Rear Countershaft Bearing Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
[322] Reverse Idler Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
[300] Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
[322] Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
[322] Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
[323] Shifter Forks, Sliding Clutches and Shift Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
[321] Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
BENCH PROCEDURES (REASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
[320] TRANSMISSION COMPONENT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
[322] Reverse Idler Gear Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
[320] Rear Countershaft Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
[322] Rear Countershaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
[321] Front Countershaft Rear Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
[322] Front Countershaft Reassembly (T2130B/T2180B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
[322] Front Countershaft Reassembly (T2130/T2180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
[321] Front Countershaft Front Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 127
[321] Rear Mainshaft Bearing Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
[322] Rear Mainshaft and Synchronizer Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
[322] Front Mainshaft Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
[322] Main Drive Pinion Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
[323] Range Shift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
[323] Range Shift Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
[324] Rear Case Shift Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
[323] Main Case Shift Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
[320] TRANSMISSION REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
T2130/T2130B AND T2180/T2180B TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 196
T2130 AND T2130B GEAR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
T2180 AND T2180B GEAR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
All Forks and Sliding Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
T2130/T2130B AND T2180/T2180B GENERAL TOLERANCES . . . . . . . . . . . . . . . . . . . . . . . . . 200
TRANSMISSION SPECIFICATIONS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
SCHEMATIC & ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
[543] T2130(B)/T2180(B) AIR CONTROL WITHOUT COMPOUND NEUTRALIZING FOR
PTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
[543] T2130(B)/T2180(B) AIR CONTROL WITHOUT DASH-MOUNTED NEUTRAL SWITCH . . 205
[543] T2130(B)/T2180(B) AIR CONTROL WITH COMPOUND NEUTRALIZING FOR
PTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
[543] T2130(B)/T2180(B) AIR CONTROL WITH DASH-MOUNTED NEUTRAL SWITCH . . . . . . 207
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

xi
front.fm Page xii Thursday, April 15, 1999 2:28 PM

NOTES

xii
10-102d.book Page 1 Thursday, April 15, 1999 2:31 PM

TRANSMISSION IDENTIFICATION

TRANSMISSION IDENTIFICATION

Page 1
10-102d.book Page 2 Thursday, April 15, 1999 2:31 PM

TRANSMISSION IDENTIFICATION

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
13/18 = usable forward speeds
0 = overdrive
B = optional reverse ratio gear set
2. Transmission Serial No.
3. Transmission Assembly (Part) No.
** = digits may vary
4. Assembly No. Revision Level

Page 2
10-102d.book Page 3 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

Page 3
10-102d.book Page 4 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130/T2180 TRANSMISSIONS The main case and the bell housing of the
T2130/T2180 are a one-piece casting, made from
aluminum and heat-treated for strength.
Description
The main case has six and eight bolt openings
The T2130/T2180 transmissions are triple- that allow for the addition of Power Take-Off
countershaft units. They consist of a compact (PTO) units. PTO operation is off the countershaft
main box which houses five nonsynchronized fourth speed gear. The rear case has six and
forward-speed gearsets plus a reverse gearset. eight bolt openings also, to allow for additional
The rear case of the T2130/T2180 transmissions PTO units. PTO operation is off the Hi-range/Hi-
is also a triple countershaft unit. The rear case split gear.
consists of Lo-range and Hi-range gearsets plus
a splitter section. Provisions for Rear-Mounted Power Take-Off
(RMPTO) units are available on these
A single gearshift lever is used to shift through a transmissions. The speed of the compound gears
“progressive-H” shift pattern. In addition, an air- is determined by engine speed and the selected
operated valve (with two selectors), mounted on main case gear. This allows multiple speeds
the shift lever, is used to shift both the range available at the rear case RMPTO unit.
gears and splitter gears in the compound. A
plate-type synchronizer is used to range shift The bearings are housed in cast-iron bearing
between the Hi-range and Lo-range gearsets. retainers (covers). Tapered roller bearings are
used at each end of all transmission
The T2130 provides three reverse speeds, while countershafts.
the T2180 provides four reverse speeds. The
reverse speeds are produced by the gearsets in All gears are of the spur-type design and are in
the main case and by means of the Lo-range, Hi- constant mesh with mating gears. All shifting is
range and splitter gearing in the compound case. done by forks and sliding clutches. The shift rails
and forks are integral with the shift cover for the
The T2180 has 18 forward speeds produced by main case.
five forward gearsets in the main case (Lo, first,
second, third and fourth), along with a splitter The six countershafts, three in the main case and
gearset and the Lo-range and Hi-range gearsets. three in the rear case, are equally spaced around
With the Lo-range gearset in the compound the mainshafts. This design distributes the load
selected, the five main case gearsets can be split equally among the countershafts, thus keeping
shifted to obtain 10 forward speeds, starting with normal deflection and gear tooth loading to a
Lo gear. The main case Lo gear is used only minimum.
when the compound is in Lo range and is not
used in Hi range. To obtain eight additional
forward speeds, the Hi-range gearset in the
compound is selected and the main case
gearshift lever positions of first through fourth are
split shifted a second time, for a total of 18
forward speeds.
The T2130 has 13 forward speeds produced by
the same five gearsets (Lo, first, second, third
and fourth) as the T2180. The T2130, however, is
not split shifted while the compound is in the Lo
range. This provides five forward, Lo-split, Lo-
range speeds. To obtain the remaining eight
forward speeds, the compound Hi-range gearset
is selected and the main case gearshift lever
positions of first through fourth are repeated, only
this time, split shifted for a total of 13 forward
speeds. Refer to T2130 or T2180 SHIFTING
INSTRUCTIONS for complete shifting procedure
information.
Figure 2 — Equal Torque Distribution

Page 4
10-102d.book Page 5 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

LUBRICATION Transmission Case Oil Cooler Line
Plugs
Splash Lubrication
An integral oil cooler pump system has been
All parts inside the transmission are lubricated developed for MACK T200 series transmissions.
by a splash-and-gravity system. To minimize The oil cooler is optional for engine ratings under
churning, only the lower countershaft dips into the 400 hp and chassis ratings under 80,000 GVW.
lubrication oil. As the gears on that countershaft
spin, a constant spray of oil is directed to all The oil cooler system is required when the
internal parts of the transmission. The oil cools as engine rating is equal to or exceeds 400 hp, or
it circulates over the aluminum case. Troughs and the chassis rating is greater than 80,000 GVW.
passages, cast into the inside of the case,
On T2130/T2180 transmissions that are not built
capture and direct oil to the bearings.
with oil cooler pump systems, the tube line
openings are plugged or capped. The main
suction tube area contains a metal plug threaded
into the case and the outlet fitting area receives a
plastic cap.

Figure 3 — Splash Lubrication

1. Outlet Plastic Cap 2. Suction Tube Plug

Figure 4 — Transmission Case Oil Cooler Line Plugs

Page 5
10-102d.book Page 6 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Magnetic Oil Filter
A magnetic oil filter assembly is built into the right
side of the main case. It consists of a trough
arrangement cast into the inside wall of the case
and a removable cover plate (1). The trough is
open at the top to collect oil. The oil is then
channelled past a magnetic plug (2), which
removes ferrous metallic particles from the
passing oil. After passing the magnetic plug, the
oil is channelled upward to an outlet, where it
returns by gravity down into the transmission
case sump. The magnetic plug is removable from
the outside of the transmission without the
necessity of draining the oil since this plug is
above the oil level. The drain plug at the bottom of
the case is also magnetic.

Figure 5 — Magnetic Oil Filter Viewed from Inside Case

Page 6
10-102d.book Page 7 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130 AND T2130B GEAR RATIOS AND SHIFT PATTERN

Gear Position (Main Box) Splitter Range T2130 Ratios T2130B Ratios
Lo Lo Lo 13.91 13.91
1 Lo Lo 8.78 8.78
2 Lo Lo 6.28 6.28
3 Lo Lo 4.52 4.52
4 Lo Lo 3.22 3.22
Range Shift
5 Lo Hi 2.29 2.29
5 Hi Hi 1.94 1.94
6 Lo Hi 1.64 1.64
6 Hi Hi 1.39 1.39
7 Lo Hi 1.18 1.18
7 Hi Hi 1.00 1.00
8 Lo Hi 0.84 0.84
8 Hi Hi 0.71 0.71
R Lo Lo 28.98 12.88
R Lo Hi 7.56 3.36
R Hi Hi 6.41 2.85
Figure 6 — T2130 and T2130B Gear Ratios and Shift Pattern

Page 7
10-102d.book Page 8 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2180 AND T2180B GEAR RATIOS AND SHIFT PATTERN

Gear Position (Main Box) Splitter Range T2180 Ratios T2180B Ratios
Lo Lo Lo 13.91 13.91
Lo Hi Lo 11.80 11.80
1 Lo Lo 8.78 8.78
1 Hi Lo 7.45 7.45
2 Lo Lo 6.28 6.28
2 Hi Lo 5.33 5.33
3 Lo Lo 4.52 4.52
3 Hi Lo 3.83 3.83
4 Lo Lo 3.22 3.22
4 Hi Lo 2.73 2.73
Range Shift
5 Lo Hi 2.29 2.29
5 Hi Hi 1.94 1.94
6 Lo Hi 1.64 1.64
6 Hi Hi 1.39 1.39
7 Lo Hi 1.18 1.18
7 Hi Hi 1.00 1.00
8 Lo Hi 0.84 0.84
8 Hi Hi 0.71 0.71
R Lo Lo 28.98 12.88
R Hi Lo 24.58 10.92
R Lo Hi 7.56 3.36
R Hi Hi 6.41 2.85
Figure 7 — T2180 and T2180B Gear Ratios and Shift Pattern

Page 8
10-102d.book Page 9 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130/T2130B SHIFTING The transmission is now in fifth gear (Hi range, Lo
split). To continue, use a combination of splitter
INSTRUCTIONS selector and shift lever to shift to fifth (Hi range, Hi
The T2130 transmission is a range and split split), sixth (Hi range, Lo split), sixth (Hi range, Hi
shifted unit which has 12 forward gears with an split) and so on, until eighth (Hi range, Hi split) is
extra Lo gear in the Lo range. It features an air- achieved.
operated Lo range, Hi range and splitter section
in the rear compound, controlled by a range Downshifting (Normal Highway)
selector and splitter selector on the shift lever. Shift from eighth (Hi range, Hi split) to eighth (Hi
The Lo range provides five low ratios (includes Lo range, Lo split), then to seventh (Hi range, Hi
gear). In Hi range there are eight additional split) to seventh (Hi range, Lo split) and so on,
forward gears that can be obtained. Reverse gear double-clutching between each gear until fifth (Hi
can be used in Lo and Hi ranges for a total of range, Lo split) is reached.
three reverse speeds.
To downshift from Hi split to Lo split (in same gear
position), as engine speed falls, preselect Lo split,
release the accelerator and reapply it (audible
When making a split shift (from one gear to the shift should be heard). To downshift from Lo split
next gear), the splitter selector must not be in one gear to the next gear Hi split, move the
actuated, either up or down, until the main case is shift lever into neutral, select Hi split, and move
in neutral. When making a split shift (in the same the shift lever to the next lower gear.
gear), especially under heavy load, the splitter While in fifth (Hi range, Lo split), preselect Lo
will not shift until driveline torque is relieved by range with the range selector and move the shift
depressing the clutch pedal or backing off the lever through neutral (range shift automatically
throttle. An audible shift is heard (engine speed occurs) to fourth (Lo range, Lo split). Then,
drops approximately 200 rpm). When making a continue using only the shift lever to shift down to
range shift, it is important to preselect the shift. third, second, first and so on.
This means that the range selector must be
moved to the next position (up or down) before
the gearshift lever is moved. Preselect the range
shift and then move the shift lever through neutral
to the desired gear position. As the lever passes r Be careful not to overspeed the engine
through neutral, the range shift is automatically during downshifting. Damage to powertrain
completed. components may result.
r To avoid transmission damage, do NOT
Upshifting (Normal Highway) change range while moving in reverse gear.
To begin, position the shift lever in neutral and r Make sure air pressure is at least 100 psi
move the range selector to the Hi position (a and unit is warmed before making range
mechanical interlock prevents splitter selector shifts.
movement to Lo position). Next, select Lo split
r Always start in Lo range per shift marker
using the splitter selector. Then select Lo range
plate instructions. Never start higher than
using the range selector.
second (Lo range, Lo split) gear, including
Move the shift lever to the Lo speed gear (Lo when dynamometer testing.
range, Lo split) position. Apply the accelerator, r With truck stationary, do not shift into Hi
engage the clutch and accelerate to governed range and then move the truck. Damage to
speed. Shift up through first, second, third and the synchronizer can result.
fourth speed gears, double-clutching between the
gears.
Continue shifting while in fourth gear (Lo range,
Lo split) by preselecting Hi range with the range
selector and then moving the shift lever through
neutral to the fifth gear position.

Page 9
10-102d.book Page 10 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2180/T2180B SHIFTING Continue shifting while in fourth gear (Lo range,
Hi split) by preselecting Hi range with the range
INSTRUCTIONS selector, moving the shift lever through neutral,
The T2180 transmission is a range- and split- selecting Lo split with the splitter selector and
shifted unit that has 16 forward gears with two moving the shift lever to fifth gear. The
extra Lo gears in the Lo range (Lo split and Hi transmission is now in fifth gear (Hi range, Lo
split). It features an air-operated Lo range, Hi split). To continue, use a combination of splitter
range and splitter section in the rear compound, selector and shift lever to shift to fifth (Hi range, Hi
controlled by a range selector and splitter selector split), sixth (Hi range, Lo split), sixth (Hi range, Hi
on the shift lever. The Lo range provides 10 low split) and so on, until eighth (Hi range, Hi split) is
ratios (includes Lo gear — Lo split and Hi split). In achieved.
Hi range there are eight additional forward gears
that can be obtained. Reverse gear can be used
Downshifting (Normal Highway)
in Lo and Hi ranges for a total of four reverse Shift from eighth (Hi range, Hi split) to eighth (Hi
speeds. range, Lo split), then to seventh (Hi range, Hi
split) to seventh (Hi range, Lo split) and so on,
double-clutching between each gear until fifth (Hi
range, Lo split) is reached.
When making a split shift (from one gear to the
next gear), the splitter selector must not be To downshift from Hi split to Lo split (in same gear
actuated, either up or down, until the main case is position), as engine speed falls, preselect Lo split,
in neutral. When making a split shift (in the same release the accelerator and reapply it (audible
gear), especially under heavy load, the splitter shift should be heard). To downshift from Lo split
will not shift until driveline torque is relieved by in one gear to the next gear Hi split, move the
depressing the clutch pedal or backing off the shift lever into neutral, select Hi split, and move
throttle. An audible shift should be heard (engine the shift lever to the next lower gear.
speed drops approximately 200 rpm). While in fifth (Hi range, Lo split), preselect Lo
When making a range shift, it is important to range with the range selector and move the shift
preselect the shift. This means that the range lever through neutral (range shift automatically
selector must be moved to the next position (up occurs) to fourth (Lo range, Lo split). Then,
or down) before the gearshift lever is moved. continue using the shift lever and splitter selector
Preselect the range shift and then move the shift as described to shift down to Lo (Lo range, Lo
lever through neutral to the desired gear position. split).
As the lever passes through neutral, the range
shift is automatically completed.

r Be careful not to overspeed the engine

Upshifting (Normal Highway) during downshifting. Damage to powertrain
components may result.
To begin, position the shift lever in neutral and
select Lo split using the splitter selector. Then r To avoid transmission damage, do NOT
select Lo range using the range selector. change range while moving in reverse gear.

Move the shift lever to the Lo-speed gear (Lo r Make sure air pressure is at least 100 psi
and unit is warmed before making range
range, Lo split) position. Apply the accelerator,
shifts.
engage the clutch and accelerate to governed
speed. Select Hi with the splitter selector and r Always start in Lo range per shift marker
release the accelerator. Wait for the split shift to plate instructions. Never start higher than
complete and then reapply the accelerator. Shift second (Lo range, Lo split) gear, including
up through first (Lo range, Lo split), first (Lo when dynamometer testing.
range, Hi split), second (Lo range, Lo split), r With truck stationary, do not shift into Hi
second (Lo range, Lo split) and so on, until fourth range and then move the truck. Damage to
(Lo range, Hi split) is reached. Double-clutch the synchronizer can result.
between the gears.

Page 10
10-102d.book Page 11 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130(B) AND T2180(B) 5. Move the dash-mounted compound neutral
control valve to the ON position. This moves
GUIDELINES FOR PTO USE the rear compound synchronizer clutch to a
neutral position.
Side-Mounted PTO Application 6. Engage the PTO.
Information
7. Move the shift lever to the desired main case
For ease of PTO operation, and transmission and gear ratio.
PTO reliability and durability, the recommended 8. Release the clutch pedal to engage the
choice for PTO location is on either opening of clutch.
the main case. Hydraulic pumps, product pumps,
blowers and some mechanical winches, operate 9. Operate the PTO-driven load.
best when the PTO is located on the main case.
DISENGAGING PTO
Properly engineered, direct mount SAE type 1. Depress the clutch pedal to disengage the
splined pump drives, which eliminate PTO shafts clutch.
and joints, should be bracket mounted as close
as possible to the rear engine supports. This 2. Move the shift lever to the NEUTRAL
reduces static and dynamic loads on components position.
and support members. 3. Disengage the PTO.
Rear compound PTO openings are available for 4. Move the dash-mounted compound neutral
applications that require multi-speed capabilities, control valve to the OFF position. This
such as some mechanical winches, or units that moves the rear compound synchronizer
require unique speeds or have multiple PTO clutch to the Lo range.
requirements. To prevent transmission damage 5. Move the shift lever to the desired main case
when using the rear compound PTO locations, gear ratio.
use the following operating procedure.
6. Release the parking brakes.
Preferred Operating Procedures for 7. Release the clutch pedal to engage the
Rear Compound Mounted PTO clutch for vehicle operation, if desired.
Applications
ENGAGING PTO
1. Select Lo split and Lo range, using the
splitter and range selectors on the shift lever.
(The transmission MUST be in Lo range and
Lo split at all times during PTO operation.)
2. Depress the clutch pedal to disengage the
clutch.
3. Set the parking brakes.
4. Move the shift lever to the NEUTRAL
position.

Page 11
10-102d.book Page 12 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130(B) AND T2180(B)
GUIDELINES FOR PTO USE
CONTINUED
Preferred Method for Engaging
T2130(B)/T2180(B) High Range Gear
for Output Shaft Driven Power
Take-Off Operation
METHOD NO. 1
After positioning the vehicle for power take-off
operation, and with vehicle wheels off the ground:
1. Shift the transmission to neutral.
2. Engage power take-off drive.
3. Move range selector to Hi range.
4. Disengage engine clutch and select reverse.
5. Feather the clutch until the transmission
range clutch engagement is heard.
6. Disengage engine clutch.
7. Select “thirteenth” gear for T2130(B) or
“eighteenth” gear for T2180(B).
8. Engage clutch when power take-off
operation is desired.

METHOD NO. 2
After positioning the vehicle for power take-off
operation, and with vehicle wheels on the ground:
1. Shift the transmission to neutral.
2. Move range selector to Hi range.
3. Disengage engine clutch and select reverse.
4. Feather the clutch until the transmission
range clutch engagement is heard.
5. Disengage engine clutch.
6. Engage power take-off drive.
7. Select “thirteenth” gear for T2130(B) or
“eighteenth” gear for T2180(B).
8. Engage clutch when power take-off
operation is desired.

Page 12
10-102d.book Page 13 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2130 AND T2130B POWER
FLOW DIAGRAMS
The following illustrations show power flow
through the T2130 and T2130B transmission in
each gear range (T2130 shown).

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

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

Figure 11 — Third Speed (Lo Split, Lo Range)

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

Figure 12 — Fourth Speed (Lo Split, Lo Range)

Page 13
10-102d.book Page 14 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Figure 13 — Fifth Speed (Lo Split, Hi Range) Figure 16 — Sixth Speed (Hi Split, Hi Range)

Figure 14 — Fifth Speed (Hi Split, Hi Range) Figure 17 — Seventh Speed (Lo Split, Hi Range)

Figure 15 — Sixth Speed (Lo Split, Hi Range) Figure 18 — Seventh Speed (Hi Split, Hi Range)

Page 14
10-102d.book Page 15 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Figure 19 — Eighth Speed (Lo Split, Hi Range) Figure 22 — Reverse Speed (Lo Split, Hi Range)

Figure 20 — Eighth Speed (Hi Split, Hi Range) Figure 23 — Reverse Speed (Hi Split, Hi Range)

Figure 21 — Reverse Speed (Lo Split, Lo Range)

Page 15
10-102d.book Page 16 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

T2180 AND T2180B POWER
FLOW DIAGRAMS
The following illustrations show power flow
through the T2180 and T2180B transmission in
each gear range (T2180 shown).

Figure 26 — First Speed (Lo Split, Lo Range)

Figure 24 — Lo Speed (Lo Split, Lo Range)

Figure 27 — First Speed (Hi Split, Lo Range)

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

Figure 28 — Second Speed (Lo Split, Lo Range)

Page 16
10-102d.book Page 17 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Figure 29 — Second Speed (Hi Split, Lo Range) Figure 32 — Fourth Speed (Lo Split, Lo Range)

Figure 30 — Third Speed (Lo Split, Lo Range) Figure 33 — Fourth Speed (Hi Split, Lo Range)

Figure 31 — Third Speed (Hi Split, Lo Range) Figure 34 — Fifth Speed (Lo Split, Hi Range)

Page 17
10-102d.book Page 18 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Figure 35 — Fifth Speed (Hi Split, Hi Range) Figure 38 — Seventh Speed (Lo Split, Hi Range)

Figure 36 — Sixth Speed (Lo Split, Hi Range) Figure 39 — Seventh Speed (Hi Split, Hi Range)

Figure 37 — Sixth Speed (Hi Split, Hi Range) Figure 40 — Eighth Speed (Lo Split, Hi Range)

Page 18
10-102d.book Page 19 Thursday, April 15, 1999 2:31 PM

DESCRIPTION AND OPERATION

Figure 41 — Eighth Speed (Hi Split, Hi Range) Figure 44 — Reverse Speed (Lo Split, Hi Range)

Figure 42 — Reverse Speed (Lo Split, Lo Range) Figure 45 — Reverse Speed (Hi Split, Hi Range)

Figure 43 — Reverse Speed (Hi Split, Lo Range)

Page 19
10-102d.book Page 20 Thursday, April 15, 1999 2:31 PM

NOTES

Page 20
10-102d.book Page 21 Thursday, April 15, 1999 2:31 PM

COMPONENT LOCATOR

COMPONENT LOCATOR

Page 21
10-102d.book Page 22 Thursday, April 15, 1999 2:31 PM

COMPONENT LOCATOR

1. Main Drive Pinion Assembly 7. Rear Mainshaft and Synchronizer 11. Reverse Idler Gear
2. Main Case Shift Cover Assembly Assembly 12. Front Countershaft Assembly
3. Range Shift Valve 8. Rear Countershaft Bearing Cover 13. Front Countershaft Front Bearing
4. Rear Case Shift Cover Assembly 9. Rear Countershaft Assembly Cover
5. Range Shift Cylinder Assembly 10. Front Countershaft Rear Bearing 14. Front Mainshaft Assembly
6. Rear Mainshaft Bearing Cover Cover
Figure 46 — Major Component Locations for T2130/T2180 Transmissions

Page 22
10-102d.book Page 23 Thursday, April 15, 1999 2:31 PM

TROUBLESHOOTING

TROUBLESHOOTING

Page 23
10-102d.book Page 24 Thursday, April 15, 1999 2:31 PM

TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom Probable Cause Remedy
NOISY 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.
j. Improperly adjusted third/fourth j. Adjust properly.
eccentric pin (SB-323-004)
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 third/fourth i. Adjust properly.
eccentric pin (SB-323-004)
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.
Continued on next page.
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
between clutch housing and flywheel in case.
housing
f. Weak or broken shift rail poppet f. Replace springs.
springs

Page 24
10-102d.book Page 25 Thursday, April 15, 1999 2:31 PM

TROUBLESHOOTING
Symptom Probable Cause Remedy
GEAR DISENGAGEMENT g. Bent or worn shift forks g. Replace forks.
(JUMPING OUT OF GEAR)
h. Broken snap rings h. Replace snap rings.
Continued
i. Shift rail bent or poppet notches worn i. Replace shift rail.
j. Worn taper or chipped teeth on sliding j. Replace sliding clutch and mating gear
clutch teeth if clutch teeth are damaged.
k. Worn or damaged spigot bearing k. Replace bearing.
l. Engine flywheel housing misalignment l. Realign properly.
m. Chassis resonant ride m. Correct resonance.
OIL LEAKS a. Oil level too high a. Drain to correct level.
b. Drain plug, fill plug or magnetic 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 leaking air h. Replace O-rings.
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.)
RANGE SHIFT MALFUNCTIONS a. Low system air pressure a. Wait for pressure to build back 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 cover or e. Replace O-rings.
piston
f. Scored air shift cover bore or pistons f. Repair or replace cover pistons.
g. Defective range selector valve g. Repair or replace as needed.

Page 25
10-102d.book Page 26 Thursday, April 15, 1999 2:31 PM

NOTES

Page 26
10-102d.book Page 27 Thursday, April 15, 1999 2:31 PM

MAINTENANCE

MAINTENANCE

Page 27
10-102d.book Page 28 Thursday, April 15, 1999 2:31 PM

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 oil of the proper
specification (refer to TRANSMISSION
To check the transmission oil, remove the filler SPECIFICATIONS AND CAPACITIES in the
plug on the right-hand side of the case. The oil SPECIFICATIONS section).
should be level with the bottom of the filler plug
hole.
Changing Oil

Current production T200 series 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
internal drive plug. Tightening torque range for
both remains the same at 25–30 lb-ft
(34–41 N•m).

Figure 47 — Correct Oil Level When changing the oil in the transmission, the oil
should be at normal operating temperature.
If oil can be felt only by reaching your finger down Remove the magnetic drain plug from the bottom
into the unit, the oil level is too low. of the transmission case and drain the hot oil
from the unit into an industry-approved recovery
container. Clean and reinstall the magnetic drain
plug. Then tighten plug to 25–30 lb-ft
(34–41 N•m) torque.

Figure 48 — Incorrect Oil Level

Page 28
10-102d.book Page 29 Thursday, April 15, 1999 2:31 PM

MAINTENANCE
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 Be sure to add oil to the transmission through the
CAPACITIES in the SPECIFICATIONS section.) filler hole, NOT the magnetic filter plug hole.
Severe damage due to low oil level may occur
because the baffles of the magnetic filter will
prevent proper filling.

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 N•m) 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
(34–41 N•m) torque.

Air Breathers
The T2130/T2180 transmissions have one air
breather, located on the main case shift cover.
The air breather should be removed and cleaned
with a suitable solvent every time the oil is
changed. Also check to be sure that airflow
through the breather is unobstructed. Reinstall
breather into the main case shift cover and
Figure 49 — Plug Locations tighten until snug.

Page 29
10-102d.book Page 30 Thursday, April 15, 1999 2:31 PM

NOTES

Page 30
10-102d.book Page 31 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY

DISASSEMBLY

Page 31
10-102d.book Page 32 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
[320] TRANSMISSION 1. Clean the transmission externally and mount
it in an overhaul stand. Drain the lubricant
DISASSEMBLY PROCEDURES and plug any air line openings to prevent dirt
from entering.

Unless a complete overhaul is necessary, remove

only those parts required to gain access to faulty Lift and move the transmission with a hoist, using
parts. Do not disturb parts with a heavy press fit the two lifting brackets provided.
(interference fit) unless replacement is
necessary. When replacement is necessary, use
proper press setups and pullers to prevent 2. Disconnect the air lines attached to the
damage to usable parts. range shift cylinder and the rear case shift
cover. Label the air lines for proper
reassembly.
3. Remove the range shift valve 5/32 Allen
screws (outer) and capscrews (inner), using
External inspection of the unit before cleaning the appropriate tools.
and disassembly often reveals information about
existing operating conditions. This may help
when diagnosing problems.

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 50 — Removing Range Shift Valve Allen Screws
(Air Lines Removed for Clarity)

Keep parts such as shim packs, bearing cones,

bearing retainers (covers), bearing cups and
gears with the original countershaft from which
they are removed. Mark each countershaft and
bearing cover before removal. Mark the upper left
front and rear countershafts and bearing covers
(viewed from rear) as number 1. Mark the upper
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.

Page 32
10-102d.book Page 33 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
4. Remove the range shift interlock sleeve,
spring, pin and O-ring from the main case
shift cover.

Figure 52 — Removing Air Lines and Valves

7. Remove the clutch release bearing

assembly, shafts, yoke and clutch brake (if
equipped).
8. Remove the main case shift cover
capscrews.

1. Range Shift Valve 4. Interlock Spring

(Reference) 5. Interlock Pin
2. O-Ring 6. Main Case Shift Cover
3. Interlock Sleeve
Figure 51 — Removing Range Shift Valve

5. Remove the range shift valve, dual-double Figure 53 — Removing Main Case Shift Cover Capscrews
check valve, pressure switch and associated
brackets from the transmission.
6. Leave all air lines and valves connected.
Then remove the valves and air lines as an
assembly.

Page 33
10-102d.book Page 34 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
9. Remove the main case shift cover assembly 12. Reach through the rear case top opening
and cover gasket. and verify that both the splitter sliding clutch
and the synchronizer assembly sliding clutch
are engaged.
13. 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.
14. Remove the drive yoke or drive flange
capscrew and clamp plate.

Figure 54 — Removing Main Case Shift Cover

10. Remove the rear case shift cover

capscrews.

Figure 55 — Removing Rear Case Shift Cover

Capscrews Figure 56 — Removing Clamp Plate and Capscrew

11. Remove the rear case shift cover and

gasket.

To remove the drive yoke bolt, place at least two

gears in both the main case and the rear case
into engagement. This is done to lock the
transmission gearing and prevent it from rotating
while removing the yoke bolt.

Page 34
10-102d.book Page 35 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
15. Remove the drive yoke or drive flange, using 17. Reach inside the rear case opening and
a suitable puller such as J 39477-1 or remove the range shift fork setscrew.
equivalent.

Figure 58 — Removing Range Shift Fork Setscrew

18. Remove the range shift cylinder capscrews.

Figure 57 — Removing Drive Yoke

16. Shift the transmission gears into neutral.

Verify that the transmission is in neutral.

Figure 59 — Removing Range Shift Cylinder Capscrews

Page 35
10-102d.book Page 36 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
19. Remove the range shift cylinder cover and 20. Separate the range shift cylinder from the
O-ring, and set aside. range shift fork by removing the fork
setscrew. Then remove the range shift
cylinder from the case.

Figure 60 — Removing Range Shift Cylinder Cover

Figure 62 — Removing Range Shift Cylinder

21. Remove the range shift fork from the rear

case. Note the offset of the range shift fork.
Straight side of the fork faces the front;
angled side of fork faces the rear.

Figure 61 — Removing Range Shift Cylinder O-Ring Figure 63 — Shift Fork Offset

Page 36
10-102d.book Page 37 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
22. Number the front countershaft front bearing 24. Remove all of the rear countershaft bearing
covers and the rear countershaft bearing cover capscrews.
covers, using a grease pencil. Write number
1 on the upper right front cover (viewed from
front), number 2 on the upper left front cover
(viewed from front) and number 3 on the
lower front cover. Write number 1 on the
upper left rear cover (viewed from rear),
number 2 on the upper right rear cover
(viewed from rear) and number 3 on the
lower rear cover.

Figure 66 — Removing Rear Countershaft Bearing

Cover Capscrews

25. Remove the jackscrew plugs from the

covers.

Figure 64 — Mark Front Countershaft Front Bearing

Covers for Placement

Figure 67 — Removing Jackscrew Plugs

Pry the plugs loose using a thin knife-edge or

Figure 65 — Mark Rear Countershaft Bearing Covers for similar tool. Do not cut through plugs during
Placement
removal. Save for reuse or replace if necessary.
23. Position the transmission vertically, rear end
up.

Page 37
10-102d.book Page 38 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
26. Remove the rear countershaft bearing
covers, shims and O-rings. Jackscrew holes
are provided to assist removal.

Figure 70 — Removing Rear Mainshaft Bearing Cover

Capscrews

29. Remove the rear mainshaft bearing cover.

Jackscrew holes are provided to assist in
Figure 68 — Removing Bearing Cover removal.

27. Mark the rear countershafts so they can be

installed in the same position during
reassembly. Refer to step 22 for number
locations.

Figure 71 — Removing Rear Mainshaft Bearing Cover

Using Jackscrews

Figure 69 — Marking Rear Countershafts

28. Remove the rear mainshaft bearing cover

capscrews. Remove the jackscrew plugs
from the cover.

Figure 72 — Rear Mainshaft Bearing Cover Removed

Page 38
10-102d.book Page 39 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
30. Remove the capscrews and dowel bolts
holding the rear case to the main case (two
capscrews are located inside the rear case).

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
personal injury.

Figure 75 — Removing Inner Rear Case-to-Main Case

Capscrews

31. Lift the rear case from the front case. Lift
only the case, not the compound gearset or
mainshaft and synchronizer assembly.

Figure 73 — Removing Outer Rear Case-to-Main Case

Capscrews

Figure 74 — Removing Dowel Bolts

Figure 76 — Removing Rear Case

Page 39
10-102d.book Page 40 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
32. Using a hoist and a threaded eye-bolt,
remove the mainshaft and synchronizer
assembly from the rear case.

1. Timing Marks

Figure 78 — Removing Compound Countershafts

35. Remove the splitter sliding clutch from the

rear of the front mainshaft.

1. Timing Marks
Figure 77 — Removing Mainshaft and Synchronizer
Assembly

33. Remove the three compound countershafts

from the rear of the transmission.
34. If not already done, mark the rear
countershafts so that they can be installed in
the same location during installation.

Figure 79 — Removing 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 40
10-102d.book Page 41 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
36. Remove the compound Lo-split gear snap 37. Remove the No. 2 (upper right) front
ring using snap ring plier set J 34629 or countershaft rear bearing cover capscrews.
suitable, internal-toothed thrust washer and
38. Using jackscrews, remove the No. 2 (upper
Lo-split gear from the mainshaft.
right) front countershaft rear bearing cover.

To help in removing the compound Lo-split gear

snap ring, use a pry bar to lift the front mainshaft
slightly during removal. This allows more
clearance and frees the snap ring from the snap
ring groove.

Figure 81 — Removing No. 2 Front Countershaft Rear

Bearing Cover

39. Remove the capscrews from the front of the

mainshaft rear bearing cover. Then remove
the cover.

1. Lo-Split Gear 3. Snap Ring Groove

2. Internal-Toothed Thrust
Washer
Figure 80 — Removing Snap Ring, Thrust Washer and
Lo-Split Gear

If not already done, mark the front countershaft

rear bearing covers so they can be installed in the
same position during reassembly. Figure 82 — Removing Mainshaft Rear Bearing Cover
Capscrews

Page 41
10-102d.book Page 42 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
40. Remove the front mainshaft snap ring next 42. Remove the front mainshaft rear bearing
to the rear bearing. spacer and spacer snap ring from the
mainshaft.

Figure 83 — Removing Rear Bearing Snap Ring

41. Remove the front mainshaft rear bearing.

Figure 85 — Removing Front Mainshaft Bearing Spacer

and Snap Ring

43. Remove the snap ring from inside the

reverse speed gear, using suitable snap ring
pliers.

Figure 84 — Removing Front Mainshaft Rear Bearing

Figure 86 — Removing Snap Ring from Inside Reverse

Speed Gear

Page 42
10-102d.book Page 43 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
44. Remove the external-toothed and 45. Position the transmission case horizontally.
internal-toothed thrust washers from inside Remove the main drive pinion bearing cover
the reverse speed gear. capscrews.

Figure 89 — Removing Pinion Bearing Cover Capscrews

Figure 87 — Removing External-Toothed Thrust Washer
46. Remove the main drive pinion assembly.
Jackscrew holes are provided to assist in
removal.

Figure 88 — Removing Internal-Toothed Thrust Washer

Figure 90 — Use Jackscrews to Remove Main Drive

Pinion Assembly

Page 43
10-102d.book Page 44 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
47. Remove main drive pinion assembly from 48. Remove the third/fourth (7th/8th) sliding
the case. clutch.

On T2130/T2180 units built with oil cooler

circulation pumps, the oil pump discharge line
must be removed before the main drive pinion
assembly can be removed.

Figure 93 — Removing Sliding Clutch

49. Using a soft mallet, drive the mainshaft

rearward in the case to free the mainshaft
gears from the countershafts.
50. Remove the No. 2 (upper right) countershaft
from the case by lifting the front end off the
front bearing cone and then sliding the
countershaft through the opening.
1. Oil Pump Discharge Line
Figure 91 — Oil Pump Discharge Line (if equipped)

Removal is easier if the transmission is in the

vertical position.

Figure 92 — Removing Main Drive Pinion Assembly

Figure 94 — Removing No. 2 Countershaft from

Transmission Case

Page 44
10-102d.book Page 45 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
51. Remove the No. 2 (upper left) front
countershaft front bearing cover capscrews.

Figure 97 — No. 2 Front Countershaft Front Bearing

Cover Removed

Figure 95 — Removing No. 2 Front Countershaft Front 53. For non-current production transmissions,
Bearing Cover Capscrews
remove the upper right reverse idler shaft
52. Using jackscrews, remove the No. 2 (upper expansion plug (next to No. 2 countershaft
left) front countershaft front bearing cover. location) using a hammer and sharp punch.

This action destroys the expansion plug. Make

sure replacement expansion plugs are available.

Figure 96 — Removing No. 2 Front Countershaft Front

Bearing Cover

Figure 98 — Removing Upper Right Reverse Idler Shaft

Expansion Plug (Non-Current)

Page 45
10-102d.book Page 46 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
54. Using tool J 34630 or a slide hammer,
remove the upper right reverse idler shaft
(next to No. 2 countershaft location). To
prevent damage to the reverse idler gear, This action destroys the expansion plug. Make
catch the gear as it separates from the shaft. sure replacement expansion plugs are available.

58. Using tool J 34630 or slide hammer, 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.
59. From the top of the case, slide the mainshaft
reverse gear and Lo/reverse sliding clutch
forward toward the front of the transmission.

Figure 99 — Using Tool J 34630 to Remove Reverse

Idler Shaft

Figure 101 — Sliding Reverse Gear and Lo/Reverse

Clutch Forward

60. Using a pry bar, move the rear end of the

No. 1 (upper left) countershaft away from
the mainshaft as far as possible without
damaging the bearing. Block the
countershaft in this position, using wadding
made from rags.
Figure 100 — Removing Reverse Idler Gear and Shaft

55. Remove the No. 1 (upper left) front

countershaft rear bearing cover capscrews.
56. Remove the No. 1 (upper left) front
countershaft rear bearing cover, using
jackscrews. Remove shims with cover.
57. Remove the upper left reverse idler shaft
expansion plug (next to No. 1 countershaft),
using a hammer and sharp punch.

Figure 102 — Moving and Blocking No. 1 (Upper Left)

Countershaft Away from Mainshaft

Page 46
10-102d.book Page 47 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
61. Tip the front end of the mainshaft outward 66. Remove the No. 1 (upper left) front
and remove it from the case. countershaft by pulling and tilting the front
end of the shaft upward.

Be careful when handling the mainshaft

assembly, the reverse gear is free on the shaft
and can fall off during handling.

Figure 104 — Removing No. 1 Upper Left Countershaft

67. Remove the No. 3 (lower) countershaft by

pulling and tilting the front end of the shaft
Figure 103 — Removing the Mainshaft upward.
62. Remove the No. 3 (lower) front countershaft
rear bearing cover capscrews.
63. Remove the No. 3 (lower) front countershaft
rear bearing cover, using jackscrews.
Remove shims with cover.
64. Remove the lower reverse idler shaft
expansion (welch) plug (next to No. 3
countershaft), using a hammer and sharp
punch.

This action destroys the expansion plug. Make

sure replacement expansion plugs are available. Figure 105 — Removing No. 3 Lower Countershaft

65. Using tool J 34630 or a slide hammer,

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.

Page 47
10-102d.book Page 48 Thursday, April 15, 1999 2:31 PM

DISASSEMBLY
68. Remove the remaining No. 1 (upper right,
viewed from front) and No. 3 (lower) front
countershaft front bearing cover capscrews
and bearing covers. Use jackscrews to
remove the covers.

Figure 106 — Remaining No. 1 and No. 3 Front

Countershaft Bearing Covers

Page 48
10-102d.book Page 49 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

BENCH PROCEDURES
(DISASSEMBLY)

Page 49
10-102d.book Page 50 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[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 replacement of
the part is necessary. When replacement is
necessary, use proper pullers and press setups
to prevent damage to usable parts.

[321] Main Case Shift Cover Art Number 300767a

Figure 108 — Shift Cover Assembly

Figure 107 — Main Case Shift Cover Locator

Page 50
10-102d.book Page 51 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

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

2. 1st/2nd Shift Fork 13. Interlock 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 Sleeve and O-Ring 28. Interlock Ball
7. 3rd/4th Shifter 18. Interlock 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
Figure 109 — Exploded View of Main Case Shift Cover

Page 51
10-102d.book Page 52 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Main Case Shift Cover 3. Remove the interlock ball from the cover.
Disassembly
1. Remove the nut and washers from the
interlock rocker bolt.

Figure 112 — Remove Interlock Ball from Cover

Figure 110 — Remove Nut and Washers

2. Remove the interlock rocker and bolt from

the cover.

Figure 111 — Remove Interlock Rocker and Bolt

Page 52
10-102d.book Page 53 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Remove the setscrew from the Lo/reverse 5. Remove the setscrew from the Lo/reverse
shift fork. shifter.

Figure 114 — Removing Setscrew from

Lo/Reverse Shifter
Figure 113 — Removing Setscrew from
Lo/Reverse Shift Fork

Page 53
10-102d.book Page 54 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 116 — Removing Lo/Reverse Shift Fork

Figure 115 — Sliding Lo/Reverse Shift Rail

Page 54
10-102d.book Page 55 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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 Lo/reverse shift rail vertical pocket in line
shop towel over the top opening. The shop with the rail.
towel 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.

Figure 118 — Removing Poppet Ball and Spring

Figure 117 — Pushing Lo/Reverse Shift
Rail Forward

Page 55
10-102d.book Page 56 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 120 — Removing Lo/Reverse Shifter

Figure 119 — Removing Interlock Ball

Page 56
10-102d.book Page 57 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 122 — Removing Setscrew from First/Second

Shift Fork
Figure 121 — Removing Third/Fourth Shift Fork

Page 57
10-102d.book Page 58 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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 first/second shift rail vertical pocket in line
shop towel over the top opening. The shop with the rail.
towel 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 can cause
injury when they are released.

Figure 124 — Removing Poppet Ball and Spring

Figure 123 — Pushing First/Second Shift Rail Forward

Page 58
10-102d.book Page 59 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
16. Remove the interlock ball from the horizontal 17. Remove the interlock pin from the first/
pocket between the first/second shift rail and second shift rail.
the third/fourth shift rail.

Figure 126 — Removing Interlock Pin

Figure 125 — Removing Interlock Ball

Page 59
10-102d.book Page 60 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 129 — Removing Setscrew from Third/Fourth

Shifter

Figure 127 — Removing First/Second Shift Fork

19. Continue sliding the first/second shift rail

until it clears the cover.

Figure 128 — Removing First/Second Shift Rail

Page 60
10-102d.book Page 61 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
21. Push the third/fourth shift rail forward, using 22. Continue sliding the third/fourth shift rail
a metal bar or large screwdriver. Hold a forward out of the shift cover. At the same
shop towel over the top opening. The shop time, remove the third/fourth shifter.
towel prevents the spring and ball under the
rail from popping out and becoming lost.

Poppet balls are spring loaded and can cause

injury when they are released.

Figure 131 — Removing Third/Fourth Shifter

Figure 130 — Pushing Third/Fourth Shift Rail Forward

Page 61
10-102d.book Page 62 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
23. Remove the poppet ball and spring from 24. Remove the poppet ball and spring and
under the third/fourth shift rail. interlock plunger and spring from the
Lo/reverse shifter.

A magnet is helpful in removing the poppet ball

and spring.

Figure 133 — Lo/Reverse Shifter Disassembled

25. Remove the reverse light switch from the

shift cover.

Figure 132 — Removing Poppet Ball and Spring

Figure 134 — Removing Reverse Light Switch

Page 62
10-102d.book Page 63 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
26. Remove the reverse light switch rod.

Art Number 300855a

Figure 135 — Removing Reverse Light Switch Rod Figure 137 — Recovering the Lock Washer, Flat Washer
and Nut
27. Remove the nut and washers from the
third/fourth rocker pin.

Figure 136 — Loosening Third/Fourth Rocker Pin Nut

Page 63
10-102d.book Page 64 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
28. Remove the third/fourth rocker pin and 29. Remove the shift cover breather vent.
rocker arm.

Figure 139 — Removing Breather Vent

Figure 138 — Removing Third/Fourth Rocker Pin and

Rocker Arm

Page 64
10-102d.book Page 65 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[324] Rear Case Shift Cover
Disassembly
In certain operating applications, the 1/8-inch
National Pipe Thread (NPT) air fitting used on the
T2130/T2130B or T2180/T2180B transmission
rear case shift cover, may break at the threaded
end. To prevent this from occurring, the rear case
shift cover may be modified to accept a 1/4-inch
NPT fitting. Air line tube size remains the same.
To modify the shift cover:
1. Remove the rear case shift cover from the
transmission and disassemble.
2. Use a 7/16-inch drill bit to enlarge the hole.
Then use a 1/4-inch pipe tap to cut new
threads. Not all holes are through holes.
Examine the holes before drilling.
3. Thoroughly clean all metal chips and other
Figure 140 — Rear Case Shift Cover Locator debris from the passages before reassembly
with 1/4-inch NPT fittings.

Be careful when enlarging the holes in the rear

case shift cover. Drill only as deep as necessary
to tap the hole, or the air passage may break
through. Also, take care not to crack the boss
when tightening the fittings in the rear case shift
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 141 — Exploded View of Rear Case Shift Cover

Page 65
10-102d.book Page 66 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
1. Remove the setscrew that secures the shift 3. Slide the shift piston out of the housing and
fork to the shift piston. at the same time, remove the shift fork. Note
the orientation of the shift fork; the offset
faces forward.

Figure 142 — Removing Setscrew

Figure 144 — Removing Piston and Shift Fork
2. Remove the piston cover capscrews and
shift piston cover. 4. Remove the piston cover O-ring from the
housing of the shift cover.

Figure 143 — Removing Cover Capscrews

Figure 145 — Removing Piston Cover O-Ring

Page 66
10-102d.book Page 67 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
5. Remove the O-ring (that seals the shaft of 6. Remove the O-ring located on the shift
the piston) from the rear of the shift piston piston.
housing.

Figure 147 — Removing Piston O-Ring

Figure 146 — Removing O-Ring from Rear of Housing

Page 67
10-102d.book Page 68 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Range Shift Cylinder
Disassembly
In certain operating applications, the 1/8-inch
NPT air fitting used on the T2130/T2130B or
T2180/T2180B transmission range shift cylinder,
may break at the threaded end. To prevent this
from occurring, the shift cylinder housing and
cover may be modified to accept 1/4-inch NPT
fittings. Air line tube size remains the same. To
modify the shift cylinder and housing:
1. Remove the range shift cylinder from the
transmission and disassemble.
2. Use a 7/16-inch drill bit to enlarge the hole.
Then use a 1/4-inch pipe tap to cut new
threads. Not all holes are through holes.
Examine the holes before drilling.
3. Thoroughly clean all metal chips and other
Figure 148 — Range Shift Cylinder Locator debris from the passages before reassembly
with 1/4-inch NPT fittings.

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.

Figure 150 — Piston Assembly Partially Removed

1. Shift Fork 9. Shift Cylinder Cover

2. Rail 10. Piston/Rail Nut
3. O-Ring 11. O-Ring
4. Shift Piston 12. Cover Capscrew
5. O-Ring 13. O-Ring
6. Piston Sleeve 14. Breather Vent
7. Shift Cylinder 15. O-Ring
8. O-Ring 16. O-Ring
Figure 149 — Cutaway View of Range Shift Cylinder

Page 68
10-102d.book Page 69 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Remove the sleeve from the shift piston.

Figure 153 — Removing Shift Cylinder Inside O-Ring

Figure 151 — Removing Sleeve from Piston
5. Remove the O-ring from the rear of the shift
3. Remove the shift piston and rail assembly piston.
from the range shift cylinder.
4. Remove the O-ring from the outside front
end of the shift cylinder. Also remove the
shift rail O-ring located inside the cylinder,
using a pick or suitable tool.

Figure 154 — Removing O-Ring from Rear of Piston

6. Remove the front O-ring at the shift rail end

of the piston

Figure 152 — Removing Shift Cylinder Outside O-Ring

Figure 155 — Removing O-Ring from Front of Piston

Page 69
10-102d.book Page 70 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
7. Remove the nut securing the shift piston to 9. Remove the O-ring from the piston sleeve.
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 provides leverage
for loosening the nut. Figure 158 — Removing O-Ring from Sleeve

10. The following figure shows the breather vent

removed (1) and installed (2). Check the
breather vent for free airflow. Clean or
replace, if necessary.

Figure 156 — Removing Shift Piston Retaining Nut

8. Remove the O-ring located on the shift rail.

Figure 157 — Removing Shift Rail O-Ring

Figure 159 — Shift Cylinder Breather Vent Shown
Removed (1) and Installed (2)

Page 70
10-102d.book Page 71 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Range Shift Valve 1. Remove the four (4 mm) interlock valve top
cover screws.

Figure 160 — Range Shift Valve Locator

Figure 162 — Valve Top Cover Screws

2. Separate cover from valve housing and

remove sintered bronze filter.

1. 4-mm Screw 13. Silicon Rubber O-Ring

2. End Cover 14. Glide Ring*
3. End Cover O-Ring* 15. Aluminum Spool Valve 1. Sintered Bronze Filter 3. Valve Housing
4. Bore Sleeve 16. Glide Ring and O-Ring* 2. Cover
5. 4-mm Screw 17. Glide Ring and O-Ring*
6. Silicon Rubber O-Ring* 18. Steel (Locking) Spool Figure 163 — Removing Sintered Bronze Filter
7. Silicon Rubber O-Ring* Valve*
8. Silicon Rubber O-Ring* 19. Viton Rubber O-Ring*
9. Silicon Rubber O-Ring* 20. Valve Housing
10. Top Cover Seal 21. Silicon Rubber O-Ring
11. Top Cover 22. (Not Shown) Mobil!
12. Sintered Bronze Filter* No. 28 Lo-Temp Grease*
*Indicates items included in rebuild kit.
Figure 161 — Cutaway View of Range Shift Valve
Assembly

Page 71
10-102d.book Page 72 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Separate top cover seal from cover and 5. Separate end cap from valve housing and
remove the filter O-ring. remove end cap O-ring.

1. Cover 4. Filter O-Ring 1. O-Ring 2. End Cap

2. Top Cover Seal 5. Valve Housing
3. Sintered Bronze Filter Figure 166 — Removing End Cap and O-Ring

Figure 164 — Removing Top Cover Seal and Filter 6. Remove the aluminum spool valve and the
O-Ring steel (locking) spool valve from the valve
housing. A slight tap of the housing on a
4. Remove the two Allen-head screws (4 mm) work bench surface may be required to
from the valve housing end cap. dislodge the spool valves.

Figure 165 — Removing End Cap Screws

1. Valve Housing 4. O-Ring (For Reference)

2. Steel (Locking) Spool 5. End Cap (For
Valve Reference)
3. Aluminum Spool Valve
Figure 167 — Removing Spool Valves

Page 72
10-102d.book Page 73 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
7. Remove the spool valve bore sleeve with
attached sleeve O-rings. A slight tap on a
table top may be required to dislodge bore
sleeve from valve housing.

Figure 170 — Removing Spool Valve Glide Ring

10. Remove the remaining large and two small
O-rings from the spool valve, using a suitable
probe tool. Avoid scratching the valve.

Figure 168 — Removing Spool Valve Bore Sleeve

8. Remove the bore sleeve end O-ring from the

bottom of the housing, using a suitable tool.
This O-ring seals the end of the bore sleeve
to the housing bore.

Be careful not to scratch the inside of the housing

bore while removing the inner bore sleeve O-ring.
If scratches do occur, discard the valve housing
and replace with new housing.

Figure 171 — Removing Spool Valve O-Ring

11. Remove the two white and two orange
O-rings from the bore sleeve, using a
suitable probe tool.

Figure 169 — Removing Bore Sleeve Inner O-Ring

9. Remove the large and two small outer glide

rings from the aluminum spool valve, using a
suitable probe tool. Avoid scratching the Figure 172 — Removing Bore Sleeve O-Rings
valve. 12. Inspect all parts and replace as necessary.

Page 73
10-102d.book Page 74 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Main Drive Pinion 1. Remove the gasket from the main drive
pinion bearing cover.
Disassembly

Figure 175 — Removing Gasket from Main Drive Pinion

Bearing Cover
Figure 173 — Main Drive Pinion Locator
2. Remove the spiral snap ring from the end of
the main drive pinion shaft, inside the main
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.

Figure 176 — Removing Snap Ring from Main

Drive Pinion

The action of removing the snap ring may destroy

the snap ring. Make sure a replacement snap ring
1. Main Drive Pinion Shaft 7. Bearing
2. Spigot Bearing 8. Spiral Snap Ring
is available.
3. Snap Ring 9. Gasket
4. Main Drive Pinion Gear 10. Pinion Bearing Cover
5. Spiral Snap Ring 11. Oil Seal
6. Snap Ring

Figure 174 — Exploded View of Main Drive Pinion

Page 74
10-102d.book Page 75 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Remove the main drive pinion gear by lifting 5. Remove the spigot bearing from inside the
it straight up. end of the main drive pinion shaft.

Figure 179 — Spigot Bearing Removed from Main Drive

Figure 177 — Removing Main Drive Pinion Gear Pinion Shaft

4. Remove the spigot bearing snap ring from 6. Remove the main drive pinion cover bearing
the main drive pinion, using suitable snap snap ring, using suitable snap ring pliers.
ring pliers.

The large snap ring is very difficult to

compress and remove, and may fly off the
snap ring pliers, causing injury.

Figure 178 — Removing Spigot Bearing Snap Ring

Figure 180 — Removing Main Drive Pinion Cover

Bearing Snap Ring

Page 75
10-102d.book Page 76 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
7. Separate the main drive pinion shaft and
bearing assembly from the main drive pinion
bearing cover.

Figure 181 — Removing Main Drive Pinion Shaft and

Bearing from 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.

Figure 183 — Pressing Bearing Off 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.

Figure 182 — 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.
Figure 184 — Removing Bearing Cover Oil Seal

Page 76
10-102d.book Page 77 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Mainshaft Disassembly

Figure 185 — Front Mainshaft Locator

The splines on the mainshaft are usually not

aligned for the whole length of the shaft. The
recommended procedure is to remove the fourth
and second speed gears, gear thrust washers 1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear
and snap rings, and first/second sliding clutch Gear 5. Lo-Speed Gear
from the front of the shaft (parts shown to the left 2. Second (Sixth) Speed 6. Reverse Speed Gear
of the arrows). Remove the remaining reverse, Gear 7. Mainshaft
3. Sliding Clutch
Lo- and first speed gears, plus sliding clutch and
components from the rear of the shaft (parts Figure 186 — View of Mainshaft and Gears
shown to the right of the arrows).

Page 77
10-102d.book Page 78 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

1. Spigot Bearing Inner Race Snap Ring 15. Internal-Toothed Thrust Washer 29. Mainshaft Snap Ring
2. Spigot Bearing Inner Race 16. External-Toothed Thrust Washer 30. Front Mainshaft
3. Mainshaft Snap Ring 17. Gear Snap Ring 31. Mainshaft Snap Ring
4. Internal-Toothed Thrust Washer 18. First (Fifth) Speed Gear 32. Spacer
5. Fourth (Eighth) Speed Gear 19. Gear Snap Ring 33. Mainshaft Rear Bearing
6. External-Toothed Thrust Washer 20. External-Toothed Thrust Washer 34. Mainshaft Rear Bearing Sleeve
7. Gear Snap Ring 21. Internal-Toothed Thrust Washer 35. Mainshaft Snap Ring
8. Gear Snap Ring 22. Mainshaft Snap Ring 36. Lo-Split Gear
9. External-Toothed Thrust Washer 23. Lo-Speed Gear 37. Internal-Toothed Thrust Washer
10. Internal-Toothed Thrust Washer 24. Sliding Clutch 38. Mainshaft Snap Ring
11. Second (Sixth) Speed Gear 25. Mainshaft Snap Ring 39. Sliding Clutch
12. Mainshaft Snap Ring 26. Internal-Toothed Thrust Washer 40. Spigot Bearing Inner Race
13. Sliding Clutch 27. Reverse Speed Gear 41. Spigot Bearing Inner Race Snap Ring
14. Mainshaft Snap Ring 28. External-Toothed Thrust Washer
Figure 187 — Exploded View of Front Mainshaft

Page 78
10-102d.book Page 79 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
11. If not already done, remove the external- 13. Remove the Lo/reverse sliding clutch from
toothed and internal-toothed thrust washers. the mainshaft.
Then remove the snap ring retaining the
reverse gear to the mainshaft, using suitable
snap ring pliers (fifth snap ring groove from
the rear of the shaft).

Figure 190 — Removing Lo/Reverse Sliding Clutch from

Mainshaft

14. Remove the snap ring retaining the Lo-

speed gear to the mainshaft, using suitable
snap ring pliers (sixth snap ring groove from
the rear of the mainshaft).

1. Fifth Snap Ring Groove 2. Rear of Mainshaft

Figure 188 — Removing Reverse Gear Snap Ring

12. Working at the rear, slide the reverse gear

off the mainshaft.

1. Sixth Snap Ring Groove 2. Rear of Mainshaft

Figure 191 — Removing Lo-Speed Gear Snap Ring

Figure 189 — Removing Reverse Gear from Mainshaft

Page 79
10-102d.book Page 80 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
15. Remove the internal- and external-toothed 18. Remove the first (fifth) speed gear from the
thrust washers from inside the Lo-speed mainshaft. Slide the gear straight off the rear
gear. end of the shaft.

Figure 192 — Removing Internal-Toothed and

External-Toothed Thrust Washers Figure 195 — Removing First Speed Gear from
Mainshaft
16. Slide Lo-speed gear from mainshaft.
19. Remove the first (fifth) speed gear snap ring,
using suitable snap ring pliers.

Figure 193 — Removing Lo-Speed Gear

17. Using suitable snap ring pliers, remove the

snap ring from the outside groove, inside the Figure 196 — Removing First Speed Gear Snap Ring
Lo-speed gear.

Figure 194 — Removing Snap Ring from Inside Lo Gear

Page 80
10-102d.book Page 81 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
20. Remove the first (fifth) speed gear internal- 21. Working at the opposite end of the mainshaft
and external-toothed thrust washers. Then and using suitable snap ring pliers, remove
remove the first (fifth) speed gear mainshaft the snap ring that retains the fourth (eighth)
snap ring, using suitable snap ring pliers speed gear to the mainshaft (first snap ring
(seventh snap ring groove from the rear of groove from the front of the mainshaft).
the mainshaft).

Figure 198 — Removing Fourth Speed Gear Snap Ring

22. Remove the internal- and external-toothed

thrust washers and fourth (eighth) speed
gear from the mainshaft.

1. Seventh Snap Ring 4. External-Toothed Thrust

Groove Washer
2. Snap Ring 5. Rear of Mainshaft
3. Internal-Toothed Thrust
Washer

Figure 197 — Removing Internal- and External-Toothed

Thrust Washers and Snap Ring

Figure 199 — Removing Internal- and External-Toothed

Thrust Washers and Fourth Speed Gear

Page 81
10-102d.book Page 82 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
23. Remove the fourth (eighth) speed gear from 26. Remove the snap ring from inside the
the mainshaft. second (sixth) speed gear, using suitable
snap ring pliers.

Figure 200 — Removing Fourth Speed Gear

24. Remove the snap ring from inside the fourth

(eighth) speed gear. Figure 203 — Removing Second Speed Gear Snap Ring

27. Remove the second (sixth) speed gear

external- and internal-toothed thrust
washers.

Figure 201 — Removing Snap Ring Inside Fourth

Speed Gear

25. Slide the second (sixth) speed gear from the

mainshaft. Figure 204 — Removing Second Speed Gear External-
and Internal-Toothed Thrust Washers

Figure 202 — Removing Second Speed Gear

Page 82
10-102d.book Page 83 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
28. Remove the second (sixth) speed gear 30. Remove the snap ring that retains the
mainshaft snap ring, using suitable snap ring spigot-bearing inner race at the front of the
pliers (second snap ring groove from the mainshaft, using suitable snap ring pliers.
front of the mainshaft).

Figure 207 — Removing Front Spigot Bearing Inner

Race Snap Ring

31. Remove the front spigot bearing inner race,

using a suitable puller such as J 39477-1, or
equivalent.

1. Second Snap Ring 3. Snap Ring Groove

Groove
2. Front of Mainshaft

Figure 205 — Removing Second Speed Snap Ring

29. Remove the first/second sliding clutch from

the mainshaft. Slide straight off splines.

Figure 208 — Removing Front Spigot Bearing

Inner Race

Figure 206 — Removing First/Second

Sliding Clutch

Page 83
10-102d.book Page 84 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
32. Remove the snap ring that retains the
spigot-bearing inner race at the rear of the
mainshaft, using suitable snap ring pliers.

Figure 209 — Removing Rear Spigot-Bearing Inner Race

Snap Ring

33. Remove the rear spigot bearing inner race,

using a suitable puller such as J 39477-1, or
equivalent.

Figure 210 — Removing Rear Spigot-Bearing Inner Race

Page 84
10-102d.book Page 85 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Rear Mainshaft and 2. Remove the smaller shaft snap ring from the
front end of the rear mainshaft.
Synchronizer Disassembly

Figure 211 — Rear Mainshaft and Synchronizer

Component Locator Figure 213 — Removing Smaller Mainshaft Snap Ring

3. Remove the larger gear snap ring from

inside the Hi-range/Hi-split gear.
The current design ball bearing support for the
rear compound mainshaft replaces the non-
current snap ring and thrust washer design. As a
result, individual parts of each design are not
interchangeable. Service old with new as a total
package only. This includes the rear compound
mainshaft and Hi-range/Hi-split gear.

1. Place the rear mainshaft and synchronizer

assembly in a soft-jawed vise, to secure for
disassembly purposes. Rest the Lo-range
gear on top of vise jaws and tighten on shaft.

Figure 214 — Removing Larger Snap Ring in Gear

1. Rear Mainshaft 3. Soft Jaw Inserts

2. Lo-Range Gear
Figure 212 — Position Assembly in Soft Jaw Vise

Page 85
10-102d.book Page 86 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

1. Snap Ring 13. Support Tube 23. Internal-Toothed Thrust Washer

2. Snap Ring 14. Synchronizer Pin 24. Lo-Range Gear Snap Ring
3. Hi-Range/Hi-Split Gear Bearing 15. Sliding Clutch 25. Lo-Range Gear Hub
4. Hi-Range/Hi-Split Gear 16. Preload Spring Assembly 26. Spigot Bearing Snap Ring
5. Snap Ring A. Inner Spring 27. Rear Mainshaft Spigot Bearing
6. Snap Ring B. Outer Spring 28. Rear Mainshaft
7. Spacer (Front Synchronizer Pack) 17. Synchronizer Pin 29. Rear Bearing Snap Ring
8. Friction Disc (4) 18. Clutch Housing 30. Lo-Range Gear
9. Reaction Disc (4) 19. Threaded Insert (3) 31. Rear Bearing Cover Gasket
10. 12-Point Capscrew (3) 20. Reaction Disc (4) 32. Rear Bearing Cover
11. Nonthreaded Insert (3) 21. Friction Disc (4) 33. Rear Bearing Cover Seal
12. Clutch Housing 22. Snap Ring
Figure 215 — Exploded View of Rear Mainshaft and Synchronizer Assembly

Page 86
10-102d.book Page 87 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Remove the Hi-range/Hi-split gear and ball 5. Remove the ball bearing from the Hi-range/
bearing from the synchronizer assembly. Hi-split gear, using a suitable driver and
Place two long-handled pry bars between hammer. Place gear on suitable support to
the synchronizer thrust plate (spacer) and allow bearing to be driven out of front of
Hi-range/Hi-split gear. Apply steady gear.
pressure on gear to overcome the slight
interference fit between shaft and ball
bearing inner race.

Figure 216 — Removing Hi-Range/Hi-Split Gear and Ball

Bearing

1. Bearing Driver 2. Gear Support

Figure 217 — Removing Ball Bearing from Gear

Page 87
10-102d.book Page 88 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
6. Remove the remaining rear snap ring from 8. Remove the spacer from the front
inside the Hi-range/Hi-split gear. synchronizer disc pack.

Figure 220 — Removing Spacer from Disc Pack

1. Rear Snap Ring Groove 2. Gear Machining Relief
Grooves
9. Remove the first internal-toothed friction disc
Figure 218 — Removing Remaining Gear Snap Ring from the front synchronizer disc pack.

7. Remove the remaining snap ring from the

front end of the rear mainshaft.

Figure 219 — Removing Shaft Snap Ring

Figure 221 — Removing Friction Disc

Page 88
10-102d.book Page 89 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
10. Remove the first external-toothed reaction 13. Set the synchronizer assembly aside for
disc from the front synchronizer disc pack. later disassembly.

Figure 224 — Synchronizer Assembly Removed

14. Remove the first external-toothed reaction

disc from the rear synchronizer disc pack.

Figure 222 — Removing Reaction Disc

11. Continue removing the friction and reaction

discs until all are removed.
12. Remove the synchronizer assembly from the
rear mainshaft.

Figure 225 — Removing Reaction Disc

15. Remove the first internal-toothed friction disc

from the rear synchronizer disc pack.

Figure 223 — Removing Synchronizer Assembly

Figure 226 — Removing Friction Disc

Page 89
10-102d.book Page 90 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
16. Continue removing the friction and reaction 19. Remove the larger snap ring that secures
discs until all are removed. the Lo-range gear to the gear hub.
17. Remove the shaft snap ring from inside the
Lo-range gear hub.

Figure 227 — Removing Shaft Snap Ring

18. Remove the internal-toothed thrust washer

from inside the Lo-range gear hub.
Figure 229 — Removing Gear-to-Hub Snap Ring

20. Remove the Lo-range gear from the hub.

Notice that the ground surface on the gear
faces the front of the transmission.

Figure 230 — Removing Lo-Range Gear from Hub

Figure 228 — Removing Hub Thrust Washer

Page 90
10-102d.book Page 91 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
21. Remove the Lo-range gear hub from the rear
mainshaft.

Figure 231 — Removing Lo-Range Gear Hub from Rear

Mainshaft

22. Remove the spigot bearing snap ring from

inside the front end of the rear mainshaft.
Figure 233 — Removing Spigot Bearing from Rear
Mainshaft

SYNCHRONIZER DISASSEMBLY

Figure 232 — Removing Spigot Bearing Snap Ring

23. Using a suitable bearing puller, remove the

spigot bearing from the front end of the rear
mainshaft.
1. 12-Point Screw 7. Clutch Housing
2. Nonthreaded Insert 8. Threaded Insert
3. Clutch Housing 9. Support Tube
4. Synchronizer Pin 10. Preload Spring
5. Sliding Clutch Assembly
6. Synchronizer Pin

Figure 234 — Exploded View of Synchronizer

Page 91
10-102d.book Page 92 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
1. Remove the 12-point screws and threaded
and nonthreaded inserts from the
synchronizer assembly.
As you remove the synchronizer sliding clutch
and pins, notice that the pins and the sliding
clutch are marked with the letter “R”, which
stands for “Rear.” All the R marks on either end of
the pins are placed on the same side of the
sliding clutch marked with the letter R. During
reassembly, make sure to coordinate all R marks
on both the pins and sliding clutch of the
synchronizer assembly. All R marks must face the
rear of the transmission when installed.

Figure 235 — Removing 12-Point Screws

2. Remove the clutch housing from the

assembly.
3. Remove the three support tubes and
preload springs from the synchronizer
assembly.

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

Faces Rearward Pins, Faces Rearward

Figure 237 — Letter “R” on Sliding Clutch and

Synchronizer Pins

5. Remove the synchronizer pins from the

remaining clutch housing.

Figure 236 — Remove Synchronizer Support Tubes and

Preload Springs

4. Remove the sliding clutch from the

remaining clutch housing.

Figure 238 — Removing Synchronizer Pins

6. Thoroughly clean the synchronizer assembly

and inspect for damage.

Page 92
10-102d.book Page 93 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Rear Mainshaft Bearing Cover 1. Remove the gasket from the bearing cover.
Disassembly 2. Remove the snap ring securing the bearing
in the rear mainshaft bearing cover, using
suitable snap ring pliers.

Figure 239 — Rear Mainshaft Bearing Cover Locator

Figure 241 — Removing Snap Ring from Rear Mainshaft

Bearing Cover

3. Remove the bearing from the rear mainshaft

bearing cover, using a suitable puller.

1. Bearing Cover 4. Bearing

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 240 — Exploded View of Rear Mainshaft Bearing
Cover

Figure 242 — Removing Bearing from Bearing Cover

Page 93
10-102d.book Page 94 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Remove the oil seal from the rear mainshaft
bearing cover, using a hammer and blunt
punch. Drive the seal out from the opposite
side. Discard the cover gasket.

Figure 243 — Using Hammer and Blunt Punch to

Remove Oil Seal

This action destroys the oil seal. Make sure a

replacement oil seal is readily available.

5. Thoroughly clean the rear mainshaft bearing

and bearing cover, and inspect for damage.

Page 94
10-102d.book Page 95 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Front Countershaft Front The following procedure applies to all three front
countershaft front bearing covers.
Bearing Cover Disassembly
1. Remove the O-ring from the shoulder of the
front countershaft front bearing cover.

Figure 244 — Front Countershaft Front Bearing Cover

Locator
Figure 246 — Removing O-Ring from Shoulder of Front
Countershaft Front Bearing Cover

2. Remove the bearing cone from the front

countershaft front bearing cover, using a
suitable puller.

1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Figure 245 — Exploded View of Front Countershaft
Front Bearing Cover

Figure 247 — Removing Bearing Cone from Front

Countershaft Front Bearing Cover

3. Thoroughly clean the bearing cover and

inspect for damage.

Page 95
10-102d.book Page 96 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Countershaft
Disassembly (T2130/T2180)
Do not attempt to press-remove the reverse
gear from the shaft. This gear is integral with
the shaft and could fragment explosively
when pressing action is attempted.

The following procedure applies only to the three

T2130/T2180 front countershafts.
1. Press the front countershaft main drive gear
off the front of the countershaft.

Figure 248 — Front Countershaft Locator

Figure 250 — Pressing Main Drive Gear Off Shaft

1. Bearing Cup 7. Lo-Speed Gear

2. Main Drive Gear 8. Rear Spacer
3. Fourth Speed Gear 9. Key
4. Second Speed Gear 10. Front Countershaft
5. Front Spacer (Integral Reverse)
6. First Speed Gear 11. Bearing Cone

Figure 249 — Exploded View of T2130/T2180 Front

Countershaft

Page 96
10-102d.book Page 97 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Press the fourth (eighth) speed gear off the 3. Press the second (sixth) speed gear off the
front of the countershaft. front of the countershaft.

Figure 252 — Pressing Second Speed Gear Off Shaft

Figure 251 — Pressing Fourth Speed Gear Off Shaft

Page 97
10-102d.book Page 98 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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 shaft.

Figure 255 — Pressing Off Lo-Speed Gear

7. Remove the remaining rear spacer off the

front countershaft.
8. Press the rear bearing cone off the rear end
of the countershaft.

Figure 253 — Removing Spacer

5. Press the first (fifth) speed gear off the

countershaft.

Figure 256 — Pressing Off Rear Bearing Cone

Figure 254 — Pressing Off First Speed Gear

Page 98
10-102d.book Page 99 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
9. Remove the key from the keyway of the front 10. Remove the bearing cup from the front
countershaft. countershaft main drive gear, using a
suitable puller.

Figure 257 — Removing Key

Figure 258 — Removing Bearing Cup from Main

Drive Gear

Page 99
10-102d.book Page 100 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Countershaft 1. Place the countershaft in the press with the
rear of the shaft up. Press the reverse speed
Disassembly (T2130B/T2180B) gear and bearing cone from the rear end of
the countershaft. Note that the recess of the
reverse speed gear faces the rear bearing
cone.

The reverse, Lo and first speed gears on the

countershaft must be pressed off the rear end
of the shaft. The forward end of the shaft is
slightly larger in diameter than the rear end of
the shaft. If you try to press any of these three
gears from the front end of the shaft, the
gears may crack or fragment explosively. This
could cause severe personal injury.

Figure 259 — Front Countershaft Locator

Figure 261 — Pressing Reverse Speed Gear and Bearing

Cone Off Shaft

2. Remove the rear spacer from the shaft.

3. Press the Lo-speed gear and the first (fifth)
speed gear off the rear of the countershaft.

1. Bearing Cup 7. Key

2. Main Drive Gear 8. Bearing Cone
3. Fourth Speed Gear 9. Reverse Speed Gear
4. Second Speed Gear 10. Rear Spacer
5. Front Spacer 11. Lo-Speed Gear
6. Countershaft 12. First Speed Gear
Figure 260 — Exploded View of T2130B/T2180B Front
Countershaft

The following procedure applies only to the three

T2130B/T2180B front countershafts.
Figure 262 — Pressing Lo-Speed and First Speed
Gears Off Shaft

Page 100
10-102d.book Page 101 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Remove the front spacer from the shaft. 6. Press the fourth (eighth) speed gear off the
front of the countershaft.
5. Press the front countershaft main drive gear
off the front of the countershaft. Note that
the hub of the gear faces rearward.

Figure 264 — Pressing Fourth Speed Gear Off Shaft

Figure 263 — Pressing Main Drive Gear Off Shaft
7. Remove the key from the keyway of the front
countershaft.

Figure 265 — Removing Key

Page 101
10-102d.book Page 102 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
8. Remove the bearing cup from the front
countershaft main drive gear, using a
suitable puller.

Figure 266 — Removing Bearing Cup from Main

Drive Gear

Page 102
10-102d.book Page 103 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Front Countershaft Rear The following procedure applies to all three front
countershaft rear bearing covers.
Bearing Cover Disassembly
1. Remove the front and rear bearing cups
from the front countershaft rear bearing
cover.

Figure 267 — Front Countershaft Rear Bearing Cover

Locator
Figure 269 — Removing Front Bearing Cup

1. Front Bearing Cup 3. Rear Bearing Cup

2. Bearing Cover
Figure 270 — Removing Rear Bearing Cup
Figure 268 — Exploded View of Front Countershaft Rear
Bearing Cover 2. Thoroughly clean the bearing cover and
inspect for damage.

Page 103
10-102d.book Page 104 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Rear Countershaft The following procedure applies to all three rear
countershafts.
Disassembly

Do not attempt to press the Lo-range gear off

these rear countershafts. The gear is integral
with the shaft and can explode if pressed.

1. Press the rear bearing cone off the rear

countershaft, using a bearing separator such
as J 8176 or equivalent.

Figure 271 — Rear Countershaft Locator

Figure 273 — Pressing Off Rear Bearing Cone

2. Press the rear countershaft Lo-split gear and

the front bearing cone off the countershaft.

1. Front Bearing Cone 6. Rear Countershaft

2. Lo-Split Gear (Lo-Range Gear Part of
3. Spacer Shaft)
4. Hi-Range/Hi-Split Gear 7. Rear Bearing Cone
5. Key
Figure 272 — Exploded View of Rear Countershaft Figure 274 — Pressing Off Lo-Split Gear and Bearing
Cone

Page 104
10-102d.book Page 105 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Remove the spacer located between the
Lo-split gear and the Hi-range/Hi-split gear.
4. Press the Hi-range/Hi-split gear from the
countershaft. Note that the hub of the gear
faces forward.

Figure 275 — Pressing Off Hi-Range/Hi-Split Gear

5. Remove the key from the keyway of the rear

countershaft.

Page 105
10-102d.book Page 106 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Rear Countershaft Bearing The following procedure applies to all three rear
countershaft bearing covers.
Cover Disassembly
1. Remove the shim(s) and O-ring from the
shoulder of the countershaft rear bearing
cover. Tag the shim(s) and record the
markings for use during assembly.

Figure 276 — Rear Countershaft Bearing Cover Locator

Figure 278 — Removing Cover Shims and O-Ring

2. Remove the bearing cup from the bearing

cover, using puller J 21834-4 or suitable
puller.

1. Bearing Cup 3. Shim(s)

2. O-Ring 4. Bearing Cover
Figure 277 — Exploded View of Rear Countershaft
Bearing Cover

Figure 279 — Removing Bearing Cup from Cover

3. Thoroughly clean the bearing cover and

inspect for damage.

Page 106
10-102d.book Page 107 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Reverse Idler Gear The following procedure applies to all three
reverse idler gears.
Disassembly
1. Press the bearing out of the reverse idler
gear, using a suitable driver.

Figure 280 — Reverse Idler Gear Locator

Figure 282 — Pressing Out Reverse Idler Gear Bearing

1. Thrust Washer 3. Bearing 2. Thoroughly clean the reverse idler gear and
2. Reverse Idler Gear 4. Reverse Idler Shaft inspect for damage.
Figure 281 — Exploded View of Reverse Idler Gear
Assembly (Current Production)

Page 107
10-102d.book Page 108 Thursday, April 15, 1999 2:31 PM

NOTES

Page 108
10-102d.book Page 109 Thursday, April 15, 1999 2:31 PM

INSPECTION OF PARTS

INSPECTION OF PARTS

Page 109
10-102d.book Page 110 Thursday, April 15, 1999 2:31 PM

INSPECTION OF PARTS
[300] Inspection and Cleaning [322] Gears
Thoroughly clean the cases, covers and all other Replace all gears having teeth that show signs of
parts of the transmission. Remove all grease, oil abrasive wear, scratching (except normal
and foreign matter, using a suitable safety manufacturing tool marks), ridging, scoring,
solvent. Dry the parts with moisture-free surface fatigue, pitting, spalling, corrosive wear,
compressed air. digging in or cracking. Gears should always be
inspected using magnaflux (or similar system) for
[322] Bearings cracks that would not otherwise 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 (A) between the fork (2) and
sliding clutch (1) groove exceeds the limit
specified in T2130/T2180 SPECIFICATIONS
Do not spin the bearings with compressed air. section.
Doing so can damage the bearings.

Inspect each bearing for flaking, cracks, fractures,

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

oil to the bearings. (Refer to Recommended SAE
Grade Gear Oil in TRANSMISSION
SPECIFICATIONS AND CAPACITIES.) Turn the
races and bearings slowly by hand to be sure
they move freely and are smooth. If there is
resistance to movement, or if the bearing cones
or cups feel rough, replace the bearings.

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
grease from new bearings.
Do not handle bearings with dirty hands. Rags Figure 283 — Fork and Clutch Detail
must be clean and lint free.

Clean bearings that are satisfactory for

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

Page 110
10-102d.book Page 111 Thursday, April 15, 1999 2:31 PM

INSPECTION OF PARTS
Replace shift rails if they are cracked in either
the poppet or setscrew holes. If the clearance
between the shift rail and housing (cover) bore
exceeds 0.010-inch (0.254 mm) maximum, Be careful when using any abrasive polishing
determine which part is worn before replacing. methods, such as emery or crocus cloth, on a
Shaft wear can be checked by measuring the sealing surface. It is possible to leave micro-
shaft at an unworn location. Then measure the grooves on the sealing surface. This can cause
shaft at the worn area and compare oil to leak past the sealing lip(s) of the oil seal.
measurements. When measuring a shift rail, the With this condition, a new seal will not stop the oil
reading should be an average of diameter leak.
measurements taken at four locations. Compare
one side of the shaft to the other, AB–CD as
shown in the following figure. Be careful when installing a shaft through a new
seal (or seal over shaft). Lubricate the shaft
before inserting it through the seal. Splines,
keyways and holes in a shaft can damage seals
unless care is taken. Lubricate the seal to prevent
damage during the initial start-up period, before
normal lubrication begins. Keep anti-seize and
sealing compounds away from oil seals.

If an oil seal does not have a preapplied sealant

on its outer diameter, apply an appropriate sealer
around the outside diameter to prevent leaks.

Lip-type oil seals are precision elements requiring

close attention and care during installation.
Figure 284 — Measuring Shift Rail

[321] Oil Seals The quality of the installation method and tools
used has a direct influence on the life of the seal.
When an overhaul is required, replace all oil
Do not use a block of wood or discarded bearing
seals. Be careful to ensure that the sealing
as a substitute for the proper seal driver.
surface of any seal is not damaged, turned back
However, with some seal applications a seal
or cut. A nick on a shaft sealing surface can cut
driver may not be available. In these situations,
the seal. Remove sharp edges that can damage
light tapping in a circular motion using a light,
the seal (chamfer edges if possible). Press seals
broad-faced hammer is acceptable.
into housings using smooth, even pressure to
prevent cocking the seal.
For the seal to function properly, install it squarely
with respect to the shaft center line. The seal
should be kept square within 0.010-inch
(0.254 mm) Total Indicated Runout (TIR).
Squareness of the seal to the shaft is controlled
by using the proper seal installation tools, as
shown in the following two figures.

Page 111
10-102d.book Page 112 Thursday, April 15, 1999 2:31 PM

INSPECTION OF PARTS
Press seals into housings using smooth, even General Inspection
pressure to prevent cocking or distorting the seal.
Gently press the seal into place. Correct Any cracked transmission case should be
installation depth is achieved as the driver tool replaced. Check all components for wear or
bottoms against the positioning tool, as shown. damage. Replace all parts as required. Replace
all gaskets, O-rings, and any part that shows
mutilation or damage. Repair all stripped threads,
using a thread repair insert that is compatible with
patch-lock type capscrews.

General Reassembly Instructions

Refer to the Torque and Tolerance Specification
tables for fits and limits.

Coat all working metal parts, especially the

bearings, with fresh, clean, specified gear oil
while reassembling the transmission. This
ensures immediate lubrication and helps prevent
parts seizure during start-up. (Refer to
Recommended SAE Grade Gear Oil in
TRANSMISSION SPECIFICATIONS AND
CAPACITIES.)

When installing bearings, use proper bearing

drivers. When pressing a bearing onto a shaft,
apply force to the inner race of the bearing. When
Figure 285 — Main Drive Pinion Oil Seal Tools pressing a bearing into a housing (bearing 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.

Figure 286 — Rear Mainshaft Bearing Cover Oil

Seal Tools

Page 112
10-102d.book Page 113 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

BENCH PROCEDURES
(REASSEMBLY)

Page 113
10-102d.book Page 114 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[320] TRANSMISSION COMPONENT REASSEMBLY
[322] Reverse Idler Gear The following procedure applies to all three
reverse idler gears and refers to non-current
Reassembly production only.

1. Install a new expansion plug into the reverse

idler shaft, rounded side up. Seat it by
driving the plug down with a driver. The
driver should be solid rather than hollow and
cylindrical with an end diameter equal to that
of the expansion plug. The end of the driver
should be flat, not rounded.

Figure 287 — Reverse Idler Gear Locator

1. Thrust Washer 3. Bearing

2. Reverse Idler Gear 4. Reverse Idler Shaft
Figure 288 — Exploded View of Reverse Idler Gear
Assembly (Current Production)

Figure 289 — Seating Expansion Plug

(Non-Current Production)

Page 114
10-102d.book Page 115 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Install a new bearing into the reverse idler
gear. Press until flush with gear surface. The
bearing must not protrude on either side of
the gear surface.

1. Stamped End of 2. Press Tool Leader or

Bearing Pilot
3. Reverse Idler Gear
Figure 291 — Installation of Drawn Cup Bearings

Figure 290 — Pressing Bearing into Gear

Drawn cup needle bearings (reverse idler gear

bearings) have a specific direction that they must
be installed. The radius end of the bearing is to
be installed first. The flat end (the end with
identification markings) faces against the angled
shoulder of the pressing tool.

Page 115
10-102d.book Page 116 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[320] Rear Countershaft Bearing The following procedure applies to all three rear
countershaft bearing covers.
Cover Reassembly
1. Press a new bearing cup into the cover,
using a suitable driver.

Figure 292 — Rear Countershaft Bearing Cover Locator

Figure 294 — Pressing Bearing Cup into Cover

1. Bearing Cup 3. Shim(s) 2. Keep the original shims and a new O-ring
2. O-Ring 4. Bearing Cover
with each cover for reassembly. Bearing
Figure 293 — Exploded View of Rear Countershaft preload adjustments must be made before
Bearing Cover installing shim pack and O-ring.

Page 116
10-102d.book Page 117 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Rear Countershaft 1. Install the key into the keyway of the rear
countershaft, using a soft-faced mallet.
Reassembly

Figure 297 — Installing Key

Figure 295 — Rear Countershaft Locator
2. Press the rear countershaft Hi-range/Hi-split
gear onto the rear countershaft. Place the
gear onto the shaft, with the protruding hub
facing the front of the shaft.

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.

1. Front Bearing Cone 6. Rear Countershaft

2. Lo-Split Gear (Lo-Range Gear Part of
3. Spacer Shaft)
4. Hi-Range/Hi-Split Gear 7. Rear Bearing Cone
5. Key
Figure 296 — Exploded View of Rear Countershaft

The following procedure applies to all three rear

countershaft assemblies.

Remember to apply the recommended oil to all

Figure 298 — Pressing on Hi-Range/Hi-Split Gear
shaft and gear surfaces before pressing parts.

Page 117
10-102d.book Page 118 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Install the spacer onto the shaft. 5. Press a new front bearing cone onto the
rear countershaft, using a suitable driver.
Apply force to only the inner race of the
bearing cone.

Figure 299 — 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 301 — Pressing on Front Bearing Cone

6. Press a new rear bearing cone onto the rear

countershaft, using a suitable driver. Apply
force to only the inner race of the bearing
cone.

Figure 302 — Pressing on Rear Bearing Cone

Figure 300 — Pressing on Lo-Split Gear

Page 118
10-102d.book Page 119 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Front Countershaft Rear 1. Press new front and rear bearing cups into
the front countershaft rear bearing cover,
Bearing Cover Reassembly using a suitable driver.
2. Set the front countershaft rear bearing cover
aside for later installation.

Figure 303 — Front Countershaft Rear Bearing

Cover Locator

Figure 305 — Pressing Front Bearing Cup into Cover

1. Front Bearing Cup 3. Rear Bearing Cup

2. Bearing Cover
Figure 304 — Exploded View of Front Countershaft Rear
Bearing Cover

The following procedure applies to all three front

countershaft rear bearing covers.

Figure 306 — Pressing Rear Bearing Cup into Cover

Page 119
10-102d.book Page 120 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Countershaft The following procedure applies only to the three
T2130B/T2180B front countershafts.
Reassembly (T2130B/T2180B)

Remember to apply the recommended oil to all

shaft and gear surfaces before pressing parts
together.

Do not attempt to press the reverse, Lo or first

speed gears onto the front end of the
countershaft. The front end of the shaft is
slightly larger in diameter than the rear of the
shaft. Attempting to press any of these three
Figure 307 — Front Countershaft Locator
gears onto the front end of the shaft can
cause the gears to crack and fragment
explosively. These fragments could cause
injury or death.

1. Press a new bearing cup into the front

countershaft main drive gear, using a
suitable driver.

1. Bearing Cup 7. Key

2. Main Drive Gear 8. Bearing Cone
3. Fourth Speed Gear 9. Reverse Speed Gear
4. Second Speed Gear 10. Rear Spacer
5. Front Spacer 11. Lo-Speed Gear
6. Countershaft 12. First Speed Gear
Figure 308 — Exploded View of T2130B/T2180B Front
Countershaft

Figure 309 — Pressing Bearing Cup into Main

Drive Gear

Page 120
10-102d.book Page 121 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Install the key into the keyway of the front 4. Press the fourth (eighth) speed gear onto
countershaft, using a soft-faced mallet. the shaft approximately 2-1/4 inches from
the front end of the shaft to start.

Figure 310 — Installing Key

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 Figure 312 — Pressing Fourth Speed Gear onto Shaft
pressed on. This material can collect between the
gears and prevent proper seating. 5. Press the main drive gear onto the shaft until
the end of the shaft is even with the inner
3. Press the second (sixth) speed gear onto surface of the gear. The protruding hub of
the shaft approximately 2–3 inches from the the gear faces the rear of the shaft.
front end of the shaft to start. The next two
gears will press this gear to the proper
location. Do not exceed 3 inches at this time.
For all pressing operations on this countershaft
assembly, use a driver or other pressing tool that
covers the end of the shaft and part of the main
drive gear hub front surface. See the following
figure for tool dimensions.

Figure 311 — Pressing Second Speed Gear onto Shaft Figure 313 — Pressing Tool Dimensions

Page 121
10-102d.book Page 122 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
6. Press the main drive gear onto the front of 7. Position the front end of the shaft on the
the countershaft with the protruding hub of driver (press tool), to maintain evenness of
the gear facing rearward. Using a suitable the shaft during the remainder of the
pressing tool for support, press until the end pressing operations in this procedure.
of the shaft is exactly flush with the gear hub
8. Install the longer (front) spacer onto the
front surface.
shaft next to the second (sixth) speed gear.
Then press the first (fifth) speed gear onto
the shaft from the rear. Press until gear
seats and compresses spacer against the
second (sixth) speed gear.

Do not attempt to press the reverse, Lo or first

speed gears onto the front end of the
countershaft. The front end of the shaft is
slightly larger in diameter than the rear of the
shaft. Attempting to press any of these three
gears onto the front end of the shaft can
Figure 314 — Main Drive Gear Pressed Flush onto Shaft
cause the gears to crack and fragment
(Tool Keeps Shaft and Gear Even) explosively, and cause injury or death.

1. Main Drive Gear 3. Pressing Tool Figure 316 — Pressing First Speed Gear onto Shaft
2. Countershaft 4. Support Block
Figure 315 — Supporting Main Drive Gear and Shaft

Page 122
10-102d.book Page 123 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
9. Press the Lo-speed gear onto the shaft until
seated against the first speed gear.

Figure 317 — Pressing Lo-Speed Gear onto Shaft

10. Install the shorter (rear) spacer onto the

shaft next to the Lo-speed gear.
Figure 319 — Pressing Reverse Speed Gear onto Shaft

12. Press a new bearing cone onto the rear end

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.

Figure 318 — Installing Shorter (Rear) Spacer onto Shaft

11. Press the reverse speed gear onto the shaft

until the spacer is compressed against the
Lo-speed gear. Install the gear with the
recess facing the rear end of the shaft. The
recess allows full installation of the bearing
cone. Figure 320 — Pressing Rear Bearing Cone onto Shaft

Page 123
10-102d.book Page 124 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Countershaft The following procedure applies only to the three
T2130/T2180 front countershafts.
Reassembly (T2130/T2180)

Remember to apply the recommended oil to all

shaft and gear surfaces before pressing parts
together.

1. Press a new bearing cup into the front

countershaft main drive gear, using a
suitable driver.

Figure 321 — Front Countershaft Locator

Figure 323 — Pressing Bearing Cup into Main

Drive Gear

1. Bearing Cup 7. Lo-Speed Gear

2. Main Drive Gear 8. Rear Spacer
3. Fourth Speed Gear 9. Key
4. Second Speed Gear 10. Front Countershaft
5. Front Spacer 11. Bearing Cone
6. First Speed Gear
Figure 322 — Exploded View of T2130/T2180 Front
Countershaft

Page 124
10-102d.book Page 125 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Install the key into the keyway of the front 5. Press the first (fifth) speed gear onto the
countershaft, using a soft-faced mallet. front of the shaft.

Figure 324 — Installing Key

3. Install the rear spacer onto the shaft next to

the reverse speed gear (part of shaft).

Figure 326 — Pressing First Speed Gear onto Shaft

During all pressing operations involving a key and
keyway, watch the key to make sure that no 6. Install the front spacer onto the shaft next to
material is shaved off as each gear is being the first (fifth) speed gear.
pressed on. This material can collect between the 7. With spacer in place, press the second
gears and prevent proper seating. (sixth) speed gear onto the shaft.

4. With spacer in place, press the Lo-speed

gear onto the front countershaft.

Figure 327 — Pressing Second Speed Gear onto Shaft

Figure 325 — Pressing Lo-Speed Gear onto Shaft

Page 125
10-102d.book Page 126 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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 328 — 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 330 — Pressing Rear Bearing Cone onto Shaft
the rear of the shaft.

Figure 329 — Pressing Main Drive Gear onto Shaft

Page 126
10-102d.book Page 127 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Front Countershaft Front The following procedure applies to all three front
countershaft front bearing covers.
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 only.

Figure 331 — Front Countershaft Front Bearing

Cover Locator

Figure 333 — Pressing Bearing Cone onto Cover

2. Install a new O-ring onto the shoulder of the

front bearing cover.

1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Figure 332 — Exploded View of Front Countershaft
Front Bearing Cover

Figure 334 — Installing O-Ring onto Front Cover

3. Set the assembly aside for later installation.

Page 127
10-102d.book Page 128 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[321] Rear Mainshaft Bearing Cover 1. Press a new oil seal into the rear mainshaft
bearing cover, using J 39854 seal driver, or
Reassembly equivalent. Refer to the INSPECTION OF
PARTS (Oil Seals) section for installation
instructions and seal precautions.

Figure 335 — Rear Mainshaft Bearing Cover Locator

Figure 337 — Pressing Oil Seal into Rear Mainshaft

Bearing Cover

1. Bearing Cover 4. Bearing

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 336 — Exploded View of Rear Mainshaft Bearing
Cover

Figure 338 — Oil Seal Driver

Page 128
10-102d.book Page 129 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Press the bearing into the cover, using a 4. Install a new rear mainshaft bearing cover
suitable driver. Apply force to only the outer gasket. Make sure the oil passageways in
race of the bearing. the gasket line up with the oil passageways
in the cover.

Figure 341 — Installing Gasket onto Cover

Figure 339 — Pressing Bearing into Cover

3. Install the snap ring to secure the bearing in

the rear mainshaft bearing cover, using
suitable snap ring pliers.

Figure 340 — Installing Snap Ring

Page 129
10-102d.book Page 130 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Rear Mainshaft and
Synchronizer Reassembly
As you install 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
on both the pins and sliding clutch of the
synchronizer assembly. All R marks must face the
rear of the transmission when installed.

Figure 342 — Rear Mainshaft and Synchronizer Locator

SYNCHRONIZER REASSEMBLY

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

Faces Rearward Pins, Faces Rearward
Figure 344 — Synchronizer Pins and Sliding Clutch
Temporarily Assembled to Show “R” Marks

1. 12-Point Screw 7. Clutch Housing

2. Nonthreaded Insert 8. Threaded Insert
3. Clutch Housing 9. Support Tube
4. Synchronizer Pin 10. Preload Spring
5. Sliding Clutch Assembly
6. Synchronizer Pin
Figure 345 — Installing Synchronizer Pins
Figure 343 — Exploded View of Synchronizer

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 in
the following figure.

Page 130
10-102d.book Page 131 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

1. Snap Ring 13. Support Tube 23. Internal-Toothed Thrust Washer

2. Snap Ring 14. Synchronizer Pin 24. Lo-Range Gear Snap Ring
3. Hi Range/Hi Split Gear Bearing 15. Sliding Clutch 25. Lo-Range Gear Hub
4. Hi Range/Hi Split Gear 16. Preload Spring Assembly 26. Spigot Bearing Snap Ring
5. Snap Ring A. Inner Spring 27. Rear Mainshaft Spigot Bearing
6. Snap Ring B. Outer Spring 28. Rear Mainshaft
7. Spacer (Front Synchronizer Pack) 17. Synchronizer Pin 29. Rear Bearing Snap Ring
8. Friction Disc (4) 18. Clutch Housing 30. Lo-Range Gear
9. Reaction Disc (4) 19. Threaded Insert (3) 31. Rear Bearing Cover Gasket
10. 12-Point Capscrew (3) 20. Reaction Disc (4) 32. Rear Bearing Cover
11. Nonthreaded Insert (3) 21. Friction Disc (4) 33. Rear Bearing Cover Seal
12. Clutch Housing 22. Snap Ring
Figure 346 — Exploded View of Rear Mainshaft and Synchronizer Assembly

Page 131
10-102d.book Page 132 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

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

Faces Rearward Pins, Faces Rearward
Figure 349 — Synchronizer Pins and Sliding Clutch
Showing “R” Marks (Preload Springs Removed for
Clarity)
Figure 347 — Assembling Preload Springs

3. Position the synchronizer sliding clutch on

the bench with the marked letter “R” facing
up. Install the three preload springs into the With this sliding clutch design, it is very important
sliding clutch holes provided. The smaller to make sure that the clutch is facing in the
holes are ramped and found halfway correct direction when installed. This is due to the
between the three largest holes. differing number of clutch teeth on the Lo-range
and Hi-range sides of the range clutch. The Lo-
range side contains 21 clutching teeth and the Hi-
range side contains 22 clutching teeth. Incorrectly
installing the sliding clutch prevents proper
shifting.

5. Install the three support tubes into the

synchronizer assembly.

Figure 348 — Installing Preload Springs into

Sliding Clutch

4. Install the sliding clutch (with preload

springs) over the synchronizer clutch
housing and pins. Make sure the marked
letter “R” on the clutch is facing in the same
direction as the R marked on the pins.
Figure 350 — Install Support Tubes into Assembly

6. Install the remaining synchronizer housing

over the pins, tubes and springs. Align the
housing with the pin heads.

Page 132
10-102d.book Page 133 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
7. Install the three 12-point screws, plus
threaded and nonthreaded inserts into the
largest holes of the synchronizer assembly.

Figure 351 — Installing 12-Point Screws and Inserts

8. Tighten the three 12-point screws to

specification, using a suitable hex wrench to Figure 353 — Installing Spigot Bearing
hold the threaded inserts.

Figure 352 — Tightening 12-Point Screws

9. Press a new spigot bearing into the front of

the rear mainshaft.

Drawn cup needle bearings (spigot bearings)

have a specific direction in which they must be
installed. The radius end of the bearing must be
installed first. The flat end (the end with
identification markings) faces against the angled
shoulder of the pressing tool.
1. Stamped End of 2. Press Tool Leader or
Bearing Pilot
3. Rear Mainshaft
Figure 354 — Installation of Drawn Cup Bearings

Page 133
10-102d.book Page 134 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
10. Install the snap ring into the front end of the 12. Install the Lo-range gear over the hub.
rear mainshaft to retain the spigot bearing. Notice that the ground surface on the gear
faces the front of the transmission.

Figure 357 — Installing Lo-Range Gear

13. Install the larger snap ring that secures the

Lo-range gear to the gear hub.

Figure 355 — Installing Spigot Bearing Snap Ring

11. Install the Lo-range gear hub onto the rear

mainshaft.

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

hub are open and free to channel oil to the
synchronizer discs.

Figure 358 — Installing Lo-Range Gear-to-Hub

Snap Ring

Figure 356 — Installing Lo-Range Gear Hub

Page 134
10-102d.book Page 135 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
14. Install the internal-toothed thrust washer into
the Lo-range gear hub.
Before and during installation, make sure to
lubricate all synchronizer assembly friction and
reaction discs and associated parts (gear and
gear hub) using the recommended lubricant. This
prevents premature wear to individual parts of the
assembly during initial transmission start-up.

17. Install the first internal-toothed friction disc

into the Lo-range gear, and then install the
first external-toothed reaction disc onto the
friction disc just installed.

Figure 359 — Installing Internal-Toothed Thrust Washer

15. Install the Lo-range gear hub shaft snap ring

into the groove of the rear mainshaft just
above the previously installed internal-
toothed thrust washer. Figure 361 — Installing Friction Disc

Figure 360 — Installing Lo-Range Gear Hub Shaft Figure 362 — Installing Reaction Disc
Snap Ring
18. Continue adding friction and reaction discs
16. Lubricate all synchronizer friction and into the Lo-range gear, alternating types,
reaction discs, using the recommended until four of each have been installed.
lubricant.
19. Align the tangs (external teeth) of the
reaction discs and then install the
synchronizer assembly over the rear
mainshaft. Engage the slots of the
synchronizer clutch housing with the tangs
of all four reaction discs.

Page 135
10-102d.book Page 136 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
21. Install an internal-toothed friction disc into
the synchronizer forward clutch housing.
Make sure that the synchronizer assembly is
installed with the “R” markings on the clutch and
pins, facing the rear of the mainshaft against the
discs just installed.

Figure 363 — Installing Synchronizer Assembly Figure 365 — Installing Friction Disc

20. Install an external-toothed steel reaction disc 22. Continue installing discs, alternating types,
into the synchronizer forward clutch housing. until four of each type are installed. The last
disc installed should be an internal-toothed
friction disc.
23. Install the spacer onto the front synchronizer
disc pack.

Figure 364 — Installing Reaction Disc

Figure 366 — Installing Spacer

Page 136
10-102d.book Page 137 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

The current design ball bearing support for the

rear compound mainshaft replaces the
noncurrent snap ring and thrust washer design.
As a result, individual parts of each design are
not interchangeable. Service old with new as a
total package only. This includes the rear
compound mainshaft and Hi-range/Hi-split gear.

24. Install the shaft snap ring into the second

groove from the front end of the rear
mainshaft.

1. Rear Snap Ring Groove 2. Gear Machining Relief

Grooves
Figure 368 — Installing Gear Snap Ring

26. Align the internal teeth of the friction discs

and spacer. Then, install the Hi-range/Hi-
split gear into the synchronizer assembly
Figure 367 — Installing Shaft Snap Ring (smaller diameter of gear slips into disc
splines).
25. Install the larger gear snap ring into the
second from rear groove of the Hi-range/Hi-
split gear.

There are four grooves on the inside of the

Hi-range/Hi-split gear. The two outer grooves are
relief grooves and are not to be used to retain
snap rings. To properly retain the current design
ball bearing, use only the two inner snap ring
grooves.

Figure 369 — Installing Hi-Range/Hi-Split Gear into

Synchronizer

Page 137
10-102d.book Page 138 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
27. Insert the ball bearing into the Hi-range/ 29. Install the shaft snap ring into the front
Hi-split gear, over the front of the shaft. groove of the rear mainshaft, against the
inner race of the ball bearing.

Figure 370 — Inserting Ball Bearing

Figure 372 — Installing Shaft Snap Ring
28. Using a suitable driver and hammer, seat the
ball bearing into the gear against the gear 30. Install the remaining gear snap ring into the
and shaft snap rings previously installed. second (forward) groove from the front of the
gear.

Figure 373 — Installing Gear Snap Ring

Figure 371 — Installing Ball Bearing

Page 138
10-102d.book Page 139 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
31. Paint three sets of corresponding timing
marks on the teeth of both the Hi-range/Hi-
split gear and the Lo-range gear.
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 374 — Painting Timing Marks on Gears

Page 139
10-102d.book Page 140 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Front Mainshaft Reassembly

Figure 375 — Front Mainshaft Locator

The splines on the front mainshaft are usually not

aligned for the entire length of the shaft. The
recommended procedure is to install the first/
second sliding clutch, second (sixth) and fourth
(eighth) speed gears, gear thrust washers and
1. Fourth (Eighth) Speed 4. First (Fifth) Speed Gear
snap rings onto the front of the shaft. Install the Gear 5. Lo-Speed Gear
remaining reverse gear, Lo/reverse sliding clutch, 2. Second (Sixth) Speed 6. Reverse Speed Gear
Lo-speed gear, first (fifth) speed gear, thrust Gear 7. Front Mainshaft
washers and snap rings onto the rear of the shaft. 3. Sliding Clutch

Figure 376 — View of Mainshaft and Gears

Page 140
10-102d.book Page 141 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

1. Spigot Bearing Inner Race Snap Ring 15. Internal-Toothed Thrust Washer 29. Mainshaft Snap Ring
2. Spigot Bearing Inner Race 16. External-Toothed Thrust Washer 30. Front Mainshaft
3. Mainshaft Snap Ring 17. Gear Snap Ring 31. Mainshaft Snap Ring
4. Internal-Toothed Thrust Washer 18. First (Fifth) Speed Gear 32. Spacer
5. Fourth (Eighth) Speed Gear 19. Gear Snap Ring 33. Mainshaft Rear Bearing
6. External-Toothed Thrust Washer 20. External-Toothed Thrust Washer 34. Mainshaft Rear Bearing Sleeve
7. Gear Snap Ring 21. Internal-Toothed Thrust Washer 35. Mainshaft Snap Ring
8. Gear Snap Ring 22. Mainshaft Snap Ring 36. Lo-Split Gear
9. External-Toothed Thrust Washer 23. Lo-Speed Gear 37. Internal-Toothed Thrust Washer
10. Internal-Toothed Thrust Washer 24. Sliding Clutch 38. Mainshaft Snap Ring
11. Second (Sixth) Speed Gear 25. Mainshaft Snap Ring 39. Sliding Clutch
12. Mainshaft Snap Ring 26. Internal-Toothed Thrust Washer 40. Spigot Bearing Inner Race
13. Sliding Clutch 27. Reverse Speed Gear 41. Spigot Bearing Inner Race Snap
14. Mainshaft Snap Ring 28. External-Toothed Thrust Washer Ring
Figure 377 — Exploded View of Front Mainshaft

Page 141
10-102d.book Page 142 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
1. Install a new spigot bearing inner race onto 3. Install a new spigot bearing inner race onto
the front of the mainshaft, using a suitable the rear of the front mainshaft. Use a
driver and hammer. suitable driver and press, if necessary.
Install the retaining snap ring.

Figure 380 — Installing Spigot Bearing Inner Race

Figure 378 — Installing Spigot Bearing Inner Race

2. Install the inner race snap ring, using

suitable snap ring pliers.

Figure 381 — Installing Inner Race Snap Ring

Figure 379 — Installing Inner Race Snap Ring

Page 142
10-102d.book Page 143 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Working at the front of the mainshaft, install 6. 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 from the front of the shaft.
shaft.

Figure 382 — Installing First Speed Gear Snap Ring

5. Install the first/second sliding clutch onto the

mainshaft.

1. Second Snap Ring 3. Snap Ring Groove

Groove
2. Front of Mainshaft

Figure 384 — Installing Second Speed Gear Mainshaft

Snap Ring

7. Install the second (sixth) speed gear

internal-toothed and external-toothed thrust
washers onto the mainshaft against the
previously installed snap ring.

Figure 383 — Installing First/Second Sliding Clutch onto

Mainshaft

Figure 385 — Installing Internal-Toothed and External-

Toothed Thrust Washers

Page 143
10-102d.book Page 144 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
8. Install the snap ring into the snap ring 10. 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 386 — Installing Snap Ring into Second

Speed Gear Figure 388 — Installing Snap Ring into Fourth
Speed Gear
9. Install the second (sixth) speed gear onto
the mainshaft, with the clutch teeth facing 11. 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.

Figure 387 — Installing Second Speed Gear onto

Mainshaft Figure 389 — Installing Fourth Speed Gear

Page 144
10-102d.book Page 145 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
12. Install the fourth (eighth) speed gear 14. 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 external-
washer). toothed thrust washer face forward toward
the internal-toothed thrust washer.

Figure 390 — Installing Internal- and External-Toothed

Thrust Washers

13. Install the fourth (eighth) speed gear snap

ring onto the mainshaft, inside the fourth
speed gear.

1. Seventh Snap Ring 4. External-Toothed Thrust

Groove Washer
2. Snap Ring 5. Rear of Mainshaft
3. Internal-Toothed Thrust
Washer

Figure 392 — Installing Internal- and External-Toothed

Thrust Washers

15. Install the snap ring into the snap ring

groove of the first (fifth) speed gear, farthest
from the clutch teeth.

Figure 391 — Installing Fourth Speed Gear Snap Ring

Figure 393 — Installing Snap Ring into First Speed Gear

Page 145
10-102d.book Page 146 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
16. Install the first (fifth) speed gear onto the 19. Install the Lo-speed gear external-toothed
mainshaft with the clutch teeth facing the and internal-toothed thrust washers onto the
front of the shaft. mainshaft. Make sure the oil groove side of
the external-toothed thrust washer faces
rearward.

Figure 394 — Installing First Speed Gear onto Mainshaft

17. Install the snap ring into the groove of the

Lo-speed gear, farthest away from the clutch
teeth. Figure 397 — Installing Internal- and External-Toothed
Thrust Washers

20. Install the snap ring for the Lo-speed gear

onto the mainshaft.

Figure 395 — Installing Snap Ring into Lo-Speed Gear

18. Install the Lo-speed gear onto the mainshaft

with clutch teeth facing rearward.

1. Sixth Snap Ring Groove 2. Rear of Mainshaft

Figure 398 — Installing Internal- and External-Toothed

Thrust Washers

Figure 396 — Installing Lo-Speed Gear

Page 146
10-102d.book Page 147 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
21. Install the Lo/reverse sliding clutch onto the
mainshaft.

Figure 399 — Installing Lo/Reverse Sliding Clutch onto

Mainshaft
1. Fifth Snap Ring Groove 2. Rear of Mainshaft
22. Install the reverse speed gear onto the
mainshaft with clutch teeth facing the sliding Figure 401 — Installing Reverse Speed Gear Snap Ring
onto Mainshaft
clutch.
24. To make it easier to install the mainshaft into
the main case:
r Slide the Lo/reverse sliding clutch
The reverse speed gear thrust washers and forward until it engages the Lo-speed
remaining snap ring will be installed after the gear.
mainshaft has been installed into the case, during
transmission reassembly. r Slide the reverse speed gear over the
Lo/reverse sliding clutch until fully
engaged.

The following parts will be reinstalled during

transmission reassembly:
r Internal-toothed thrust washer (26).
r External-toothed thrust washer (28).
r Reverse speed gear snap ring (29).

Figure 400 — Installing Reverse Speed Gear onto

Mainshaft

23. Install the snap ring retaining the reverse

gear to the mainshaft, using suitable snap
ring pliers. Fifth snap ring groove from the
rear of the shaft.
Figure 402 — Moving Sliding Clutch and Reverse Speed
Gear Forward

Page 147
10-102d.book Page 148 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[322] Main Drive Pinion Reassembly 1. Press the ball bearing onto the main drive
pinion shaft. Support the inner race of the
bearing while pressing.

Figure 403 — Main Drive Pinion Locator

1. Press 4. Main Drive Pinion Shaft

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

Figure 405 — Installing Main Drive Pinion Bearing

2. To retain the ball bearing, install the spiral

snap ring. To do this, use a circular motion
while pressing the snap ring tightly into the
groove on the shaft.

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

Figure 404 — Exploded View of Main Drive Pinion

Figure 406 — Installing Spiral Snap Ring

Page 148
10-102d.book Page 149 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 407 — 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 and seal
precautions.

Figure 409 — Installing Main Drive Pinion Assembly into

Drive Pinion Bearing Cover

Figure 408 — Installing Bearing Cover Oil Seal

Page 149
10-102d.book Page 150 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
6. Install the main drive pinion bearing snap
ring, using suitable snap ring pliers.

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 bevelled and

Figure 411 — Installing Spigot Bearing and Snap Ring
faces out. The flat side of the snap ring goes
against the bearing. 8. Install the main drive pinion gear onto the
pinion shaft. Install the spiral snap ring,
using a circular motion while pressing the
snap ring tightly into the groove on the shaft.

Figure 410 — Installing Snap Ring into Main Drive Figure 412 — Installing Main Drive Pinion Gear and
Pinion Bearing Cover Spiral Snap Ring

7. Install the spigot bearing into the end of the 9. Install a new bearing cover gasket, using
main drive pinion shaft by hand. Then, install sealant between the gasket and cover. Make
the retaining snap ring. sure the oil passage hole and capscrew
holes in the gasket align with the cover holes.

Drawn cup needle bearings (spigot bearings)

have a specific direction in which they must be
installed. The radius end of the bearing must be
installed first. The flat end of the bearing faces
out.

Figure 413 — Installing Main Drive Pinion Bearing Cover

Gasket

Page 150
10-102d.book Page 151 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Range Shift Valve 1. Install the two orange and two white O-rings
onto the bore sleeve. The two white O-rings
are placed closest to the smaller diameter of
the sleeve and the two orange O-rings are
placed closest to the larger diameter end of
the sleeve.

Figure 414 — Range Shift Valve Locator

1. Orange O-Rings 2. White O-Rings

Figure 416 — Installing O-Rings

2. Install the O-rings onto the aluminum spool

valve.

1. 4-mm Screw 13. Silicon Rubber O-Ring

2. End Cover 14. Glide Ring*
3. End Cover O-Ring* 15. Aluminum Spool Valve
4. Bore Sleeve 16. Glide Ring and O-Ring*
5. 4-mm Screw 17. Glide Ring and O-Ring* Figure 417 — Installing O-Rings on Spool Valve
6. Silicon Rubber O-Ring* 18. Steel (Locking) Spool
7. Silicon Rubber O-Ring* Valve*
8. Silicon Rubber O-Ring* 19. Viton Rubber O-Ring*
9. Silicon Rubber O-Ring* 20. Valve Housing
10. Top Cover Seal 21. Silicon Rubber O-Ring*
11. Top Cover 22. (Not Shown) Mobil!
12. Sintered Bronze Filter* No. 28 Lo-Temp Grease*
*Indicates items included in rebuild kit.
Figure 415 — Cutaway View of Range Shift
Valve Assembly

Page 151
10-102d.book Page 152 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Install the glide rings over the O-rings just 5. Mark the locator tab on the bore sleeve with
installed on the spool valve. a grease pencil to aid in installation.

Figure 418 — Installing Glide Rings Figure 420 — Mark Locator Tab

4. Install the green bore sleeve-to-valve 6. Apply a heavy coat of Mobil! No. 28 low-
housing O-ring, using a probe and hand temperature grease, available in a 50 gram
pressure. Make sure O-ring bottoms in tube, or equivalent low-temperature grease
housing bore. to the four O-rings.

1. Green O-Ring 2. Housing Bore Figure 421 — Apply Grease to O-Rings

Figure 419 — Installing Green O-Ring

Page 152
10-102d.book Page 153 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
7. Install the bore sleeve into the valve housing, 9. Lubricate the aluminum spool valve and
noting the position of the sleeve locating glide rings with low-temperature grease.
tab to the housing slot. The tab on the Then install the valve into the bore sleeve.
bore sleeve faces the top cover area. Seat
the bore sleeve until flush with the end of the
valve housing.

Figure 424 — Installing Aluminum Spool Valve

10. Lubricate with low-temperature grease and

then install the end cover O-ring into the
Figure 422 — Install Bore Sleeve groove on the end of the valve housing.

8. Lubricate the steel (locking) spool valve with

Mobil! No. 28 low-temperature grease, or
equivalent. Then install it into the bore
sleeve with the wide end of the valve
inserted first.

Figure 425 — Installing End Cover O-Ring

Figure 423 — Install Steel (Locking) Spool Valve

Page 153
10-102d.book Page 154 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
11. Locate the end cover to the end of the
housing. Install the end cover screws and
tighten to 30–40 lb-in (3.4–4.5 N•m) torque.

Make sure the stepped protrusion on the end

cover lines up with the housing bore and fits
inside the O-ring. Rotate the end cover so that
the letter “P” on the cover faces the top of the
valve housing.

1. Sintered Bronze Filter 3. Filter O-Ring

2. Valve Housing
Figure 427 — Installing O-Ring and Filter

13. Install the top cover seal into the groove of

the top cover. Lightly lubricate the seal
before installation, and make sure all
portions of the seal are properly located.

Figure 426 — Installing Valve Housing End Cover

12. Install the filter O-ring and bronze filter into

the filter bore of the housing. Set the filter on
top of the O-ring

Lightly lubricate the O-ring with Mobil! No. 28

low-temperature grease, or equivalent before
installation. Overlubricating the O-ring may cause 1. Housing Top Cover 3. Valve Housing
filter restriction. Make sure to properly seat the 2. Top Cover Seal
O-ring. Figure 428 — Installing Top Cover Seal

Page 154
10-102d.book Page 155 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
14. Install the top cover and cover screws.
Tighten the screws to 30–40 lb-in
(3.4–4.5 N•m) torque.

Figure 429 — Installing Top Cover

15. Set the assembly aside for later installation

onto the main case shift cover.

Page 155
10-102d.book Page 156 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Range Shift Cylinder
Reassembly
The nut securing the piston to the rail is tightened
to a torque of 75–105 lb-ft (102–142 N•m).

1. The following figure shows the breather vent

removed (1) and installed (2). Check the
breather vent for free airflow. Clean or
replace, if necessary.

Figure 430 — Range Shift Cylinder Locator

Figure 432 — Shift Cylinder Breather Vent

1. Shift Fork 9. Shift Cylinder Cover Before installation, lightly lubricate all O-rings for
2. Rail 10. Piston/Rail Nut the range shift cylinder piston, sleeve and rail with
3. O-Ring 11. O-Ring
4. Shift Piston 12. Cover Capscrew
a multipurpose grease that meets MACK
5. O-Ring 13. O-Ring specification MG-C.
6. Piston Sleeve 14. Breather Vent
7. Shift Cylinder 15. O-Ring
8. O-Ring 16. O-Ring
Figure 431 — Cutaway View of Range Shift Cylinder

Page 156
10-102d.book Page 157 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
2. Install the O-ring onto the piston sleeve.

To prevent damage to the shift rail or piston when

removing the nut, temporarily install the shift fork
and tighten the setscrew. This provides leverage
for tightening the nut. Remove the shift fork for
later installation.

Figure 433 — Installing Piston Sleeve O-Ring

3. Install the small O-ring located on the shift

rail.

Figure 435 — Tightening Shift Piston Retaining Nut

5. Install the front O-ring at the shift rail end of

the piston

Figure 434 — Installing Shift Rail O-Ring

4. Insert the rail into the piston and install and

tighten the shift rail nut to 75–105 lb-ft
(102–142 N•m) torque.

Do not clamp the shift piston or shift rail in a vise.

This can cause damage to the piston or rail,
Figure 436 — Installing Shift Piston Front O-Ring
preventing proper shifting.

Page 157
10-102d.book Page 158 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
6. Install the O-ring onto the rear of the shift 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 overlubricate.
Too much grease can clog the breather vent.

Figure 437 — 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 440 — Installing Sleeve onto Shift Piston

10. Push the piston assembly into the cylinder.

Figure 438 — Installing Shift Cylinder Outside O-Ring

Figure 441 — 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 439 — Installing Shift Cylinder Inside O-Ring

Page 158
10-102d.book Page 159 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[324] Rear Case Shift Cover 1. Install a new O-ring onto the shift piston.
Reassembly

Figure 444 — Installing Shift Piston O-Ring

Figure 442 — Rear Case Shift Cover Locator 2. Install a new O-ring into the rear of the shift
piston housing. This seals the shaft of the
piston.

Figure 445 — Installing O-Ring into Rear of Housing

3. Install a new piston cover O-ring onto the

front of the housing.

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 443 — Exploded View of Rear Case Shift Cover

Lubricate the shift cover O-rings with a

multipurpose grease meeting MACK specification
MG-C, during installation.
Figure 446 — Installing O-Ring onto Front of Housing

Page 159
10-102d.book Page 160 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
4. Install the piston into the housing and at the 5. Align the shift fork setscrew with the
same time, install the shift fork. Note the setscrew hole in the shaft of the piston.
orientation of the shift fork; the offset faces Tighten the setscrew to 35–50 lb-ft
forward. (47–68 N•m) torque.

Figure 447 — Installing Piston and Shift Fork

Figure 448 — Tightening Shift Fork Setscrew

6. Install the piston cover and capscrews.

Tighten the capscrews to 17–21 lb-ft
(23–29 N•m) torque.

Figure 449 — Installing Piston Cover and Capscrews

Page 160
10-102d.book Page 161 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
[323] Main Case Shift Cover 2. Install the third/fourth rocker pin and rocker
arm. Be sure to position the washer, bushing
Reassembly and washer on the rocker pin as illustrated.
The bottom washer is positioned between
the rocker arm and main case shift cover.

Figure 450 — Main Case Shift Cover Locator

1. Install the shift cover breather vent into the

cover.

Figure 452 — Installing Third/Fourth Rocker Pin and

Rocker Arm

Figure 451 — Installing Breather Vent Occasionally, due to assembly tolerances,

particularly in units which have been operated,
the current production rocker pivot pin will not
center the fourth/fifth clutch sufficiently to prevent
clutch tooth contact when the fourth/fifth shift rail
is in neutral. For transmissions with a history of
clutch tooth contact, the noncurrent eccentric
pivot pin, which is available for service, should be
installed and adjusted per instructions found in
the REASSEMBLY section of this manual.

Page 161
10-102d.book Page 162 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES

1. Third/Fourth Shift Fork 12. Washer 23. Breather

2. First/Second Shift Fork 13. Interlock 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. First/Second Shift Rail
6. Lo/Reverse Shift Fork 17. Interlock Sleeve and O-Ring 28. Interlock Ball
7. Third/Fourth Shifter 18. Interlock Spring 29. Interlock Pin
8. Third/Fourth Rocker Pin 19. Third/Fourth Rocker Pin Hardware 30. Interlock Ball
9. Washer 20. Interlock Rocker 31. Third/Fourth Shift Rail
10. Third/Fourth Rocker Arm 21. Interlock Rocker Bolt 32. Lo/Reverse Shifter Ball
11. Bushing 22. Pipe Plug 33. Lo/Reverse Shifter Spring
Figure 453 — Exploded View of Main Case Shift Cover

Page 162
10-102d.book Page 163 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
3. Install the third/fourth pin lock washer, flat 4. Install the reverse light switch rod into the
washer and nut. Tighten nut to 40–50 lb-ft shift cover.
(54–68 N•m) torque.

Figure 456 — Installing Reverse Light Switch Rod

5. Install the reverse light switch into the shift

Figure 454 — Installing Washers and Nut cover.

Figure 455 — Tightening Nut

Figure 457 — Installing Reverse Light Switch

Page 163
10-102d.book Page 164 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
6. Install the poppet ball and spring for the
third/fourth shift rail.

Figure 459 — Installing Shift Rail and Shifter

8. Press the poppet ball down while sliding the

third/fourth shift rail over the ball. A hollow
tube works well to press down the ball.
Figure 458 — Installing Poppet Ball and Spring

7. Slide the third/fourth shift rail into the cover.

At the same time, install the third/fourth
shifter onto the shift rail.

Figure 460 — Pushing Poppet Ball Down

Page 164
10-102d.book Page 165 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
9. Align the setscrew in the third/fourth shifter
with the notch in the shift rail. Tighten the
setscrew to 35–50 lb-ft (47–68 N•m) torque.

Figure 461 — Tightening Setscrew

Figure 463 — Installing First/Second Shift Fork
10. Slide the first/second shift rail into the shift
cover. At the same time, install the
first/second shift fork onto the shift rail.

Figure 462 — Installing First/Second Shift Rail

Page 165
10-102d.book Page 166 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
11. Install the interlock pin into the first/second 12. Install the interlock ball between the
shift rail. first/second shift rail and the third/fourth shift
rail.

Figure 464 — Installing Pin into First/Second Shift Rail

Figure 465 — Installing Interlock Ball Between Rails

Page 166
10-102d.book Page 167 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
13. Install the poppet ball and spring for the first/
second shift rail.

Figure 467 — Pressing Poppet Ball Down

15. Align the setscrew in the first/second shift

fork with the notch in the shift rail. Tighten
Figure 466 — Installing Poppet Ball and Spring the setscrew to 35–50 lb-ft (47–68 N•m)
torque.
14. Press the poppet ball down while sliding the
first/second shift rail over the ball. A hollow
tube works well to press down the ball.

Figure 468 — Tightening Setscrew

Page 167
10-102d.book Page 168 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 471 — Installing Lo/Reverse Shifter

Figure 469 — 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.

Figure 470 — Assembling Lo/Reverse Shifter

Page 168
10-102d.book Page 169 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 473 — Installing Poppet Ball and Spring

Figure 472 — Installing Interlock Ball

Page 169
10-102d.book Page 170 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
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.

Figure 475 — Installing Lo/Reverse Shift Fork

Figure 474 — Pushing Poppet Ball Down

Page 170
10-102d.book Page 171 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
23. Continue sliding the Lo/reverse shift rail as 25. Align the setscrew in the Lo/reverse shifter
shown and then, install the interlock pin into with the notch in the shift rail. Tighten the
the rail. setscrew to 35–50 lb-ft (47–68 N•m) torque.

Figure 478 — Tightening Setscrew

Figure 476 — Sliding Lo/Reverse Shift Rail

24. Finish sliding the shift rail through the fork

and into position.

Art Number 302545a

Figure 477 — Shift Rail in Position

Page 171
10-102d.book Page 172 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
26. Align the setscrew in the Lo/reverse shift fork 27. Install the interlock ball into the opening next
with the notch in the shift rail. Tighten the to the interlock rocker location of the cover.
setscrew to 35–50 lb-ft (47–68 N•m) torque.

Figure 480 — Installing Interlock Ball into Cover

28. Install the interlock rocker and bolt into the

cover.

Figure 479 — Tightening Setscrew

Figure 481 — Installing Interlock Rocker and Bolt

Page 172
10-102d.book Page 173 Thursday, April 15, 1999 2:31 PM

BENCH PROCEDURES
29. Install the nut and washers onto the interlock
rocker bolt, and tighten to 20–25 lb-ft
(27–34 N•m) torque.

Figure 482 — Installing Nut and Washers

Page 173
10-102d.book Page 174 Thursday, April 15, 1999 2:31 PM

NOTES

Page 174
10-102d.book Page 175 Thursday, April 15, 1999 2:31 PM

REASSEMBLY

REASSEMBLY

Page 175
10-102d.book Page 176 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
[320] TRANSMISSION
REASSEMBLY PROCEDURES
Locate the three gear tooth spaces on the
mainshaft fourth (eighth) speed gear, stamped
with the letter “O”. Paint the front of each tooth
Locate the stamped letter “O” on the front of each space with white paint for greater visibility when
front countershaft fourth (eighth) speed gear that timing the countershafts later. If there are no
aligns with the keyway. Paint the front of the stamped letters, count the number of gear teeth
corresponding gear tooth with white paint for (result should be divisible by three). Place a white
greater visibility when timing the countershafts paint mark on any tooth space. Then count
later. Do this for each of the three front around one-third of the total spaces and place the
countershafts. 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.

New Art Number

304377a

Figure 483 — Gear Tooth Marked for Timing

Figure 484 — Gear Tooth Spaces Marked for Timing

Page 176
10-102d.book Page 177 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
1. Install the No. 1 (upper right, when viewed 4. Temporarily position a shim pack over one of
from front) and No. 3 (lower) front the front countershaft rear bearing cover
countershaft front bearing covers and openings. Mark the overhang of the shim
capscrews. Make sure new O-rings are in pack at the reverse idler shaft opening of the
place. Tighten the capscrews to 36–54 lb-ft case. This helps position the reverse idler
(49–73 N•m) torque. shaft and prevents bearing cover
interference with the shaft. Mark all idler
shaft openings.

The bearing cover fits into the flat on the idler

shaft to retain the shaft and prevent it from
rotating.

Figure 485 — No. 1 and No. 3 Front Countershaft Front

Bearing Covers Installed

2. With the main case in a vertical position,

front end down, install the No. 3 (lower) front
countershaft into the main transmission
case.

Figure 487 — Marking Idler Shaft Opening

Figure 486 — Installing Lower No. 3 Countershaft into

Main Case

3. Position the countershaft to center it over the

front bearing.

Page 177
10-102d.book Page 178 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
5. Install the No. 3 (lower) reverse idler shaft 7. Maintaining mark alignment, use a brass
into the opening provided next to the hammer to tap the reverse idler shaft (next
installed countershaft. As the reverse idler to No. 3 countershaft) into the case until it
shaft is inserted into the case, install (in bottoms (flat on idler shaft flush with case).
order) the reverse idler gear and thrust Be sure to maintain mark alignment.
washer onto the shaft, from inside the case.

Make sure that the small bore thrust washer is

Prior to transmission production date 12/6/98 aligned correctly with the idler shaft while tapping
(serial No. 8Y0417), T2130/T2180 transmissions the idler shaft into place. If not aligned, damage
used two thrust washers on the reverse idler to the thrust washer may result.
shaft.

Figure 490 — Tapping Reverse Idler Shaft into Place

1. Large Bore Thrust 2. Small Bore Thrust
Washer Not Used on Washer (Only) is 8. For non-current production transmissions,
Current Units Installed on Current use a blunt punch and hammer, install a
Units
new welch (expansion) plug into the reverse
Figure 488 — Order of Reverse Idler Shaft and idler shaft, if not previously done.
Components

6. 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.

Figure 491 — Installing Welch Plug

(Non-Current Production)

Figure 489 — Aligning Reverse Idler Shaft with Marks

Page 178
10-102d.book Page 179 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
SETTING FRONT COUNTERSHAFT BEARING Example:
PRELOAD
a. Begin the procedure, using enough
9. Install enough shims under the No. 3 (lower) shims under the cover to produce
front countershaft rear bearing cover to measurable end play.
produce measurable countershaft end play.
Then install the cover and tighten the b. Measure countershaft end play. For this
capscrews to 40–50 lb-ft (54–68 N•m) example, end play is 0.100 inch.
torque. Measure end play of the c. Remove 0.100-inch shims from the
countershaft, using a dial indicator. shim pack to obtain zero end play.
d. Remove (subtract) additional
0.003–0.007 inch shims from the pack
to obtain the specified preload.
Use a pry bar to move the countershaft up and
down while measuring end play on the dial e. Total shim thickness removed from the
indicator. shim pack, to obtain 0.003–0.007 inch
preload, must be 0.103–0.107 inch.

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.

11. After determining the correct shim thickness,

install the shim pack onto the front
countershaft rear cover.

1. Dial Indicator Set J 5959-01

Figure 492 — Measuring Countershaft End Play

10. For the No. 3 (lower) countershaft,

measured end play determines the Figure 493 — Installing Shim Pack
thickness of shims that must be removed
from the shim pack to obtain zero end play.
Then remove additional shim thickness to
obtain the required 0.003–0.007 inch
preload.

Page 179
10-102d.book Page 180 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
12. Install the No. 3 (lower) front countershaft
rear bearing cover by aligning and lightly
tapping the cover in place. Install the
capscrews and tighten to 40–50 lb-ft
(54–68 N•m) torque.

Do not use the bearing cover capscrews to pull

any bearing cover into place. Damage to the
bearings or bearing cover may result. Make sure
all components are properly in place before
tightening the capscrews.

Figure 495 — Moving and Blocking No. 1 (Upper Left)

Countershaft Away from Mainshaft

16. 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.

Figure 494 — Installing Countershaft Rear Bearing

Cover
Reverse gear is not secured to the shaft and
13. Tip the No. 1 (upper left, when viewed from
can fall off if not careful.
the rear) front countershaft into position as
described earlier for the No. 3 (lower)
countershaft.
14. Install the reverse idler shaft, gear and thrust
washer (next to No. 1 countershaft) as
described in the steps for the lower reverse
idler shaft and gear installation.
15. Pry the No. 1 (upper left) countershaft to the
outside, using a suitable pry bar. Block the Art Number
rear end of the countershaft off center, using 302425a
a folded rag.

Figure 496 — Installing Mainshaft into Case

Page 180
10-102d.book Page 181 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
17. Place the transmission in a horizontal
position, if not already done.
18. Move the reverse gear and Lo/reverse
sliding clutch to normal positions.
19. Position the mainshaft, No. 3 (lower)
countershaft and No. 1 (upper right, when
viewed from the 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 498 — Installing No. 2 Reverse Idler Shaft

Timing the shafts is easier if the transmission is in and Gear
a horizontal position, rotated 15 degrees
counterclockwise, as viewed from the rear of the 21. Shift the Lo/reverse sliding clutch and
transmission case. reverse gear rearward, to allow the gear
teeth on the reverse speed gear to engage
all three reverse idler gears. Temporarily
install a folded rag between the Lo and
reverse speed gears to hold them in place.

Figure 497 — Timing Gears with Mainshaft in Place

20. Install the remaining reverse idler shaft, gear

and thrust washer (next to No. 2 Figure 499 — Sliding Lo/Reverse Sliding Clutch and
countershaft) as described in the steps for Reverse Speed Gear to Engage Gear Teeth
the lower (No. 3) reverse idler shaft and
gear. Move the reverse speed gear on the
mainshaft as far as possible. When installing
the reverse idler shaft and gear, make sure
that the thrust washer is held in place. For
non-current production, install the welch
plug into the reverse idler shaft, if not
already done.

Page 181
10-102d.book Page 182 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
22. Working through the opening at the rear of
the case, install the reverse speed gear
mainshaft snap ring onto the shaft, if not
already done. Install into fifth groove from
rear of shaft.

Figure 500 — Installing Reverse Gear Mainshaft

Snap Ring
Figure 502 — Installing External-Toothed Thrust Washer

23. Install the internal-toothed and external- 24. Install the snap ring on the inside of the
toothed thrust washers onto the mainshaft. reverse gear, using suitable snap ring pliers.
The grooves on the external-toothed thrust
washer face forward.

Figure 503 — Installing Reverse Gear Snap Ring

Figure 501 — Installing Internal-Toothed Thrust Washer

Page 182
10-102d.book Page 183 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
25. Install the mainshaft snap ring (located just
behind the reverse speed gear and before
the spacer) onto the mainshaft, using
suitable snap ring pliers. Install into fourth Do not attempt to pull any bearing cover in place,
groove from rear of shaft. 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 N•m)
torque.
29. Install the front mainshaft rear bearing thrust
spacer onto the mainshaft, against the last
snap ring. Make sure that the oil grooves
face forward.
Figure 504 — Installing Spacer Snap Ring onto
Mainshaft

26. Install the remaining No. 2 (upper right)

countershaft. Align the timing marks on the
countershaft with the mainshaft. All three
countershafts and mainshaft timing marks
should be aligned at this point.

Figure 505 — Gear Timing Marks Aligned

27. Install the No. 2 (upper left, when viewed

from front) 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 N•m) torque. Figure 506 — Installing Bearing Spacer

Page 183
10-102d.book Page 184 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
30. Install the front mainshaft rear bearing. 33. Install the front mainshaft rear bearing cover
and capscrews. Tighten the capscrews to
40–50 lb-ft (54–68 N•m) torque.

Figure 507 — Installing Front Mainshaft Rear Bearing

31. Install the front mainshaft rear bearing

mainshaft snap ring. Figure 509 — Installing Front Mainshaft Rear Bearing
Cover

34. Working at the front of the mainshaft, install

the third/fourth sliding clutch.
To install the snap ring that retains the rear
bearing, it may be necessary to raise the
mainshaft using a pry bar.

Figure 510 — Installing Sliding Clutch

Figure 508 — Installing Snap Ring

32. Install the No. 2 (upper right) 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 N•m)
torque.

Page 184
10-102d.book Page 185 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
35. Install the main drive pinion assembly and
tighten the bearing cover capscrews to
36–54 lb-ft (49–73 N•m) torque.

Main drive pinions for these transmissions are

designed with the equivalent of three degrees
0.069–0.071 inch (1.753–1.803 mm) of 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.

1. Upper Discharge Tube 2. Lower Discharge Tube

Fitting Fitting
Figure 512 — Tighten Upper and Lower Discharge
Tube Fittings

36. Locate the stamped letter “O” on the rear

face of the rear compound Lo-split gear at
three tooth spaces 120 degrees apart. If
there are no stamped letters, count the
number of teeth (result should be divisible by
three). Paint three white marks, each
120 degrees apart, located on the rear face
of the gear, on the tooth spaces.

Figure 511 — Tightening Main Drive Pinion Bearing

Cover Capscrews

Reinstall the oil pump discharge line (if equipped)

that was removed at disassembly. Tighten the
upper and lower portions of the discharge tube to
36–39 lb-ft (49–53 N!m) using a crowfoot adapter
and torque wrench.

Figure 513 — Mark Lo-Split Gear

Page 185
10-102d.book Page 186 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
37. Install the compound Lo-split gear onto the 40. Install the sliding clutch onto the mainshaft.
front mainshaft. The clutch teeth of the gear The external teeth on the sliding clutch face
face rearward. rearward.
38. Rotate transmission mainshaft to align the
three timing marks on the rear compound
Lo-split gear with the approximate center
lines of the three front countershafts.

Figure 516 — Installing the Sliding Clutch

41. Locate the stamped letter “O” on the rear

face of each rear countershaft Lo-split gear.
1. Gear Timing Marks If there is no stamped letter, mark the gear
Figure 514 — Installing and Aligning Lo-Split Gear tooth on each countershaft that is directly in
line with the keyway of the countershaft.
39. Install the compound Lo-split gear internal- Paint a corresponding timing mark on the
toothed thrust washer and retaining snap Hi-range/Hi-split gear tooth, directly in line
ring onto the front mainshaft in the location with the tooth marked on the Lo-split gear.
shown. 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
keyway. Then mark the remaining gears.

1. Lo-Split Gear 3. Snap Ring Groove

2. Internal-Toothed Thrust
Washer
Figure 515 — Thrust Washer and Snap Ring Location

Page 186
10-102d.book Page 187 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
43. Obtain the rear mainshaft and synchronizer
assembly. Paint three equally spaced sets of
double timing marks on the gear teeth
surrounding every 10th space between two
teeth, for the Hi-range/Hi-split gear. Paint
three equally spaced sets of double timing
marks on the gear teeth surrounding every
18th space between two teeth, for the
Lo-range gear.
44. Using a hoist and a threaded eye-bolt, install
the rear mainshaft and synchronizer
assembly between the rear countershafts.
Make sure to retain timing mark alignment.

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 rear mainshaft gears.

Figure 517 — Marking Rear Countershaft Gears

42. Position each of the three rear countershafts

so that the single timing mark on each
countershaft Lo-split gear enters the mating
set of timing marks on the rear compound
mainshaft Lo-split gear. Install each
countershaft on the cup of its mating front
countershaft rear bearing cover.

1. Align Timing Marks as Assembly is Lowered

1. Align Timing Marks Figure 519 — Installing Rear Mainshaft and
Synchronizer Assembly
Figure 518 — Installing and Aligning Timing Marks

Page 187
10-102d.book Page 188 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
45. Remove the threaded eye bolt from the end 50. Install a new gasket onto the rear mainshaft
of the rear mainshaft. bearing cover, if not already done. Note the
location of the lubrication hole.
46. Install a new case-to-case gasket on the
gasket surface of the main case. 51. Install the rear mainshaft bearing cover
assembly to the rear case and secure with
47. Install the rear case over the rear compound
capscrews. Tighten the capscrews to
gearset and onto the main case and gasket.
40–50 lb-ft (54–68 N•m) torque.
48. Install the rear case dowel bolts and nuts
and tighten them to 66–80 lb-ft
(89–108 N•m) torque.
49. Install the inner and outer (case-to-case)
capscrews to secure the rear case to the
main case. There are two inner capscrews
located just inside the rear compound cover
opening. Tighten the inner and outer
case-to-case capscrews to 62–78 lb-ft
(89–108 N•m) torque.

Figure 522 — Installing Rear Mainshaft Bearing Cover

Assembly and Tightening Capscrews

52. Install the rear compound countershaft

bearing covers. Determine the shim pack
thickness for each rear countershaft bearing
preload adjustment, using the procedure
described in the example that follows.
53. Working at the rear of the countershafts,
temporarily install the rear countershaft
bearing covers, leaving the capscrews
loose. Do not install shim packs or O-rings at
Figure 520 — Tightening Outer Case-to-Case this time. Measure the space between the
Capscrews bearing cover and transmission case, using
two feeler gauge sets. Take at least two
measurements and average the results.

A more accurate measurement can be obtained if

the transmission is in a vertical position and each
bearing cover is hand-held firmly against the
countershaft rear bearings.

Figure 521 — Tightening Inner Case-to-Case Capscrews

Page 188
10-102d.book Page 189 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
55. When all shim packs have been determined,
install the rear compound countershaft
bearing covers, shim packs, O-rings and
cover capscrews. Then tighten the
capscrews to 40–50 lb-ft (54–68 N•m)
torque. Use new O-rings when installing the
covers.

Figure 523 — Measuring to Determine Shim Pack

Thickness

54. For each countershaft, remove the bearing

cover and add enough shims to bring the
space under the bearing cover to zero. Then
remove enough shim thickness to obtain the
required 0.002–0.006 inch preload.
Figure 524 — Tightening Rear Countershaft Bearing
Example: Cover Capscrews
a. Begin the procedure using no shims or
56. Install the drive yoke, clamp plate and
O-rings under the cover.
retaining capscrew onto the rear mainshaft.
b. Measure the space under the cover.
For this example, the space is
0.100 inch.
c. A 0.100-inch shim pack is needed to fill To install the drive yoke, clamp plate and
the measured space. capscrew, place at least two gears in both the
main case and the rear case into engagement.
d. Remove (subtract) 0.002–0.006 inch This is done to lock the gearing and prevent it
shims from the pack to obtain the from rotating while tightening the yoke capscrew.
specified preload.
e. To obtain the required 0.002–0.006 inch
preload, final shim pack thickness must 57. Reach into the rear case top opening and
be 0.094–0.098 inch, for this example. verify that the splitter sliding clutch and
synchronizer assembly sliding clutch are
both engaged at the same time with the
Hi-range/Hi-split gear.
Preload is negative end play or “crush.” It cannot
58. Reach into the main case top opening and
be measured directly. Determining shim thickness
move at least two sliding clutches into
must be done carefully, as described, to obtain
engagement. This locks up the gearing to
the correct preload on the bearings.
prevent it from turning while tightening the
drive yoke capscrew.

Page 189
10-102d.book Page 190 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
59. Tighten the drive yoke capscrew to 61. Install the range shift cylinder into the rear
494–600 lb-ft (670–814 N•m) torque. When case. Line up the shift fork with the shift rail
finished, make sure all gear sliding clutches as the cylinder is installed. Install the
and the rear compound sliding clutches are cylinder so that the breather vent is facing
returned to the normal neutral positions. down and the air port is facing up.

Figure 525 — Torquing Clamp Plate Capscrew Figure 527 — Installing Range Shift Cylinder

60. Make sure the synchronizer sliding clutch is 62. Install the range shift cylinder cover,
in the neutral position. Install the range shift capscrews and new O-ring.
fork into the case and engage fingers to the
63. Tighten the range shift cylinder cover
sliding clutch. The straight side of the fork (1)
capscrews to 17–21 lb-ft (23–29 N•m)
faces the front and the angled side of the
torque.
fork (2) faces the rear.

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.

Figure 526 — Installing Range Shift Fork

Figure 528 — Tightening Range Shift Cylinder Cover

Capscrews

Page 190
10-102d.book Page 191 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
64. Align the setscrew in the shift fork with the 68. Install the rear case shift cover, lift bracket
setscrew hole in the shift rail. Tighten the and cover capscrews. Make sure to align the
setscrew to 35–50 lb-ft (47–68 N•m) torque. shift fork with the sliding clutch. Tighten the
capscrews to 24–36 lb-ft (33–49 N•m)
torque.

The lift bracket capscrews are slightly longer than

the remainder of the shift cover capscrews. Make
sure the longer capscrews are used to secure the
lift bracket. The lift bracket is placed at the right
rear corner of the shift cover.

Figure 529 — Tightening Shift Fork Setscrew

65. Clean the gasket or sealant surface of the

rear case shift cover.
66. Make sure that the sliding clutch next to the
rear compound Lo-split gear is placed in the Figure 530 — Tightening Rear Case Shift Cover
neutral position. Capscrews

67. Install a new rear case shift cover gasket. 69. Clean the gasket or sealant surface of the
Use a small amount of adhesive or grease to main case shift cover.
hold it in place. Apply sealant to the shift
cover sealing surface of the case. 70. Install a new main case shift cover gasket.
Use a small amount of adhesive or grease to
hold it in place.
71. Make sure the shift forks on the cover and
the sliding clutches on the mainshaft are in
the neutral position for proper alignment.

Page 191
10-102d.book Page 192 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
72. Align the shift forks with the sliding clutches 74. Position the air control valves and air lines
and install the main case shift cover. that were removed as an assembly.

Figure 531 — Installing Main Case Shift Cover Assembly

Figure 533 — Positioning Air Lines and Valves
73. Install the main case shift cover and lift
bracket capscrews and tighten to 24–36 lb-ft
(33–49 N•m) torque. Install the lifting bracket
and longer capscrews at the left front corner
of the main case shift cover as shown. On the very rare occasion of clutch tooth contact,
the noncurrent eccentric pivot pin, which is
available for service should be installed.
Adjustment of the eccentric pivot is as follows:

The lift bracket capscrews are slightly longer than 1. Loosen the locknut on the eccentric pin.
the remainder of the shift cover capscrews. Make While rotating the transmission input shaft
sure the longer capscrews are used to secure the by hand, adjust the eccentric pin until gear
lift bracket. clash occurs. Note the position of the
eccentric pin.
2. Turn the eccentric pin in the other direction
until gear clash occurs again and note the
position of the eccentric pin.
3. Return the eccentric pin to a point midway
between the two positions.
4. Tighten the locknut to 40–50 lb-ft
(54–68 N•m).

Figure 532 — Tightening Main Case Shift Cover

Capscrews

Page 192
10-102d.book Page 193 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
76. Position the range shift valve over the tip of
the lock pin. Install the two (outer) Allen-
head 5/32-inch screws and torque to
specification.

1. Allen-Head Screws 2. Range Shift Valve

Figure 534 — Adjusting Eccentric Pin (5/32 inch)
Figure 536 — Tightening Range Shift Interlock Valve
75. Install the interlock O-ring, pin, spring and Screws (Air Lines Removed for Clarity)
sleeve into the main case shift cover.
77. Install the two (inner) hex head screws and
torque to specification.

1. Interlock Pin 4. O-Ring

2. Interlock Spring 5. Main Case Shift Cover
3. Interlock Sleeve (For Reference) 1. Hex Head Screws 2. Range Shift Valve
Figure 535 — Range Shift Interlock Figure 537 — Tightening Remaining Range Shift Valve
Screws (Air Lines Removed for Clarity)

Page 193
10-102d.book Page 194 Thursday, April 15, 1999 2:31 PM

REASSEMBLY
78. If air lines were removed from the range shift
valve, dual double check valve or the shift
cylinder or cover, reconnect the air lines.
Refer to the piping diagrams in the
SCHEMATICS section at the end of this
manual.
79. Install the transmission drain plug and
magnetic filter plug and torque to
specification.
80. Install the clutch release bearing assembly,
shafts, yoke and clutch brake (if equipped).
81. Reinstall the transmission into the chassis of
the vehicle.
82. Fill the transmission to the proper oil level,
using the recommended lubricant. Refer to
TRANSMISSION SPECIFICATIONS
AND CAPACITIES found in the
SPECIFICATIONS section.
83. Install and tighten the filler plug to
specification.

RANGE SHIFT VALVE CHECK

84. Reconnect all remaining air lines and gear
shift linkage/gearshift lever.
85. Check range shift valve operation to make
sure that the rear compound range shift
does not occur without being in neutral.

Page 194
10-102d.book Page 195 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS

SPECIFICATIONS

Page 195
10-102d.book Page 196 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS
T2130/T2130B AND T2180/T2180B TORQUE SPECIFICATIONS

Item and Location Torque — Lb-Ft (N•m)

1. Main Drive Pinion Bearing Cover Capscrews* 36–54 (49–73)
2. Shift Cover Capscrews (Main Case/Rear Case)* 24–36 (33–49)
3. Third/Fourth Pivot Pin Locknut 40–50 (54–68)
4. Shifter and Shift Fork Setscrews 35–50 (47–68)
5. Front Mainshaft Rear Bearing Cover Capscrews 40–50 (54–68)
6. Splitter Shift Piston and Range Shift Cylinder Cover Capscrews 17–21 (23–29)
7. Splitter and Range Shift Fork Setscrews 35–50 (47–68)
8. Range Shift Piston-to-Rail Retaining Nut 75–105 (102–142)
9. Rear Mainshaft Bearing Cover Capscrews* 40–50 (54–68)
10. Drive Flange (or Yoke) Clamp Plate Capscrew 494–600 (670–814)
11. Rear Countershaft Bearing Cover Capscrews* 40–50 (54–68)
12. Synchronizer Special 12-Point Screws (Quantity 3) 24–28 (33–38)
13. Front Countershaft Rear Bearing Cover Capscrews 40–50 (54–68)
14. Drain Plug 25–30 (34–41)
15. Front Countershaft Front Bearing Cover Capscrews* 36–54 (49–73)
— Front Case-to-Rear Case Capscrews 62–78 (84–106)
— Front Case-to-Rear Case Dowel Bolts 66–80 (89–108)
— Filler Plug 55 (75) Max.
— Magnetic Filter Plug 25–30 (34–41)
— Range Shift Interlock Rocker Nut 20–25 (27–34)
— Range Shift Valve Mounting Screws (Two Hex, Two Allen) 84–96 lb-in (9–11)
— Range Shift Valve Top Cover and End Cover Screws 30–40 lb-in (3.4–4.5)
* Indicates that fastener has epoxy-coated threads. Fastener can be reused a maximum of five times.
Figure 538 — Torque Specifications (T2130/T2180 Shown)

Page 196
10-102d.book Page 197 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS
T2130 AND T2130B GEAR IDENTIFICATION

T2130 T2130B
Mainshaft Gear Number of Outside Mainshaft Gear Number of Outside
(Main Box) Teeth Diameter (Main Box) Teeth Diameter
1. Main Drive Pinion (3rd/7th) 33 5.633 1. Main Drive Pinion (3rd/7th) 33 5.633
2. 4th/8th Speed Gear 27 4.692 2. 4th/8th Speed Gear 27 4.692
3. 2nd/6th Speed Gear 39 6.603 3. 2nd/6th Speed Gear 39 6.603
4. 1st/5th Speed Gear 45 7.539 4. 1st/5th Speed Gear 45 7.539
5. Lo-Speed Gear 54 8.754 5. Lo-Speed Gear 54 8.754
6. Reverse Speed Gear 54 9.601 6. Reverse Speed Gear 42 8.129
Mainshaft Gear (Compound) Mainshaft Gear (Compound)
7. Lo-Split Gear 27 4.754 7. Lo-Split Gear 27 4.754
8. Hi-Range/Hi-Split Gear 30 5.204 8. Hi-Range/Hi-Split Gear 30 5.204
9. Lo-Range Gear 54 8.996 9. Lo-Range Gear 54 8.996
Countershaft Gear (Main Box) Countershaft Gear (Main Box)
10. Main Drive Gear 47 7.583 10. Main Drive Gear 47 7.583
11. 4th/8th Speed (PTO) Gear 54 8.514 11. 4th/8th Speed (PTO) Gear 54 8.514
12. 2nd/6th Speed Gear 40 6.641 12. 2nd/6th Speed Gear 40 6.641
13. 1st/5th Speed Gear 33 5.757 13. 1st/5th Speed Gear 33 5.757
14. Lo-Speed Gear 25 4.404 14. Lo Speed Gear 25 4.404
15. Reverse Speed (Part of Shaft) 12 2.625 15. Reverse Speed Gear 21 4.273
16. Reverse Idler Gear 24 4.520 16. Reverse Idler Gear 19 3.983
Countershaft Gear (Compound) Countershaft Gear (Compound)
17. Lo-Split Gear 52 8.519 17. Lo-Split Gear 52 8.519
18. Hi-Range/Hi-Split Gear 49 8.001 18. Hi-Range/Hi-Split Gear 49 8.001
19. Lo-Range Gear (Part of Shaft) 23 4.205 19. Lo-Range Gear (Part of Shaft) 23 4.205
Figure 539 — T2130 and T2130B Gear Identification (T2130 Shown)

Page 197
10-102d.book Page 198 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS
T2180 AND T2180B GEAR IDENTIFICATION

T2180 T2180B
Mainshaft Gear Number of Outside Mainshaft Gear Number Outside
(Main Box) Teeth Diameter (Main Box) of Teeth Diameter
1. Main Drive Pinion (3rd/7th) 33 5.633 1. Main Drive Pinion (3rd/7th) 33 5.633
2. 4th/8th Speed Gear 27 4.692 2. 4th/8th Speed Gear 27 4.692
3. 2nd/6th Speed Gear 39 6.603 3. 2nd/6th Speed Gear 39 6.603
4. 1st/5th Speed Gear 45 7.539 4. 1st/5th Speed Gear 45 7.539
5. Lo-Speed Gear 54 8.754 5. Lo-Speed Gear 54 8.754
6. Reverse Speed Gear 54 9.601 6. Reverse Speed Gear 42 8.129
Mainshaft Gear (Compound) Mainshaft Gear (Compound)
7. Lo-Split Gear 27 4.754 7. Lo-Split Gear 27 4.754
8. Hi-Range/Hi-Split Gear 30 5.204 8. Hi-Range/Hi-Split Gear 30 5.204
9. Lo-Range Gear 54 8.996 9. Lo-Range Gear 54 8.996
Countershaft Gear (Main Box) Countershaft Gear (Main Box)
10. Main Drive Gear 47 7.583 10. Main Drive Gear 47 7.583
11. 4th/8th Speed (PTO) Gear 54 8.514 11. 4th/8th Speed (PTO) Gear 54 8.514
12. 2nd/6th Speed Gear 40 6.641 12. 2nd/6th Speed Gear 40 6.641
13. 1st/5th Speed Gear 33 5.757 13. 1st/5th Speed Gear 33 5.757
14. Lo-Speed Gear 25 4.404 14. Lo-Speed Gear 25 4.404
15. Reverse Speed (Part of Shaft) 12 2.625 15. Reverse Speed Gear 21 4.273
16. Reverse Idler Gear 24 4.520 16. Reverse Idler Gear 19 3.983
Countershaft Gear (Compound) Countershaft Gear (Compound)
17. Lo-Split Gear 52 8.519 17. Lo-Split Gear 52 8.519
18. Hi-Range/Hi-Split Gear 49 8.001 18. Hi-Range/Hi-Split Gear 49 8.001
19. Lo-Range Gear (Part of Shaft) 23 4.205 19. Lo-Range Gear (Part of Shaft) 23 4.205
Figure 540 — T2180 and T2180B Gear Identification (T2180 Shown)

Page 198
10-102d.book Page 199 Thursday, April 15, 1999 2:31 PM

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
inch inch inch
pads and sliding clutch
*If unit has experienced disengagement, clearance must not exceed 0.030 inch maximum.

Figure 541 — Sliding Clutch Clearances

Spring Specifications
Springs Free Length Load Length Under Load
Lo/Reverse Shifter Ball Spring 1.562 inches 41.8 ± 5 lbs. 0.875 inch
Lo/Reverse Shifter Plunger
1.500 inches 22.0 ± 2 lbs. 0.625 inch
Spring
Shift Rail Poppet Ball Springs
2.251 inches 42.4 ± 3 lbs. 1.539 inches
(3)
Range Shift Interlock Pin 18.7 lbs. 1.120 inches
1.310 inches
Spring 31.2 lbs. 1.000 inches

Page 199
10-102d.book Page 200 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS
T2130/T2130B AND T2180/T2180B GENERAL TOLERANCES

Component Specification
1. Mainshaft 4th/8th-to-2nd/6th Speed Gear (Floating Gear) End Play 0.024–0.081 inch
2. Mainshaft Lo-to-1st/5th Speed Gear (Floating Gear) End Play 0.020–0.080 inch
3. Mainshaft Reverse Gear-to-Gear Spacer (Floating Gear) End Play 0.003–0.050 inch (Shaft Seated)
4. Mainshaft Compound Lo-Split Gear End Play 0.005–0.041 inch
5. Rear Mainshaft Hi-Range/Hi-Split Gear End Play 0.006–0.040 inch
6. Rear Mainshaft Lo-Range Gear End Play 0.002–0.026 inch
7. Rear Countershaft Bearing Preload 0.002–0.006 inch
8. Reverse Idler Gear End Play 0.010–0.090 inch (Shaft Flush with Case Wall)
9. Front Countershaft Bearing Preload 0.003–0.007 inch
— Shift Rails to Mating Bore Clearance 0.010-inch maximum
Figure 542 — Gear End Play and Bearing Preload (T2130/T2180 Shown)

Page 200
10-102d.book Page 201 Thursday, April 15, 1999 2:31 PM

SPECIFICATIONS
TRANSMISSION SPECIFICATIONS AND CAPACITIES
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mack Trucks, Inc.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overdrive, Triple Countershaft, Range and Splitter
Shift
Range Shift Synchronizer . . . . . . . . . . . . . . . . . . . . Plate Type, Four Friction/Four Reaction Discs Each
for Hi Range and Lo Range
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selective, One Lever Manual with Air-Shifted Rear
Compound
Speeds — T2130/T2130B . . . . . . . . . . . . . . . . . . . 13 Forward, 3 Reverse
Speeds — T2180/T2180B . . . . . . . . . . . . . . . . . . . 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 — T2130/T2130B/T2180/T2180B . . . Approx. 30 pints (depends on angle of installation in
chassis)
Recommended SAE Grade Gear Oil for All
Temperature Operations, MACK GO-J and
GO-J Plus* Specification:
• 90, 140, 80W-90, 80W-140, 85W-140 for
Mineral Base
• 75W-90, 75W-140, 80W-140 for Synthetic
Base
* GO-J Plus is required for MACK geared
component extended service drain intervals.

Page 201
10-102d.book Page 202 Thursday, April 15, 1999 2:31 PM

NOTES

Page 202
10-102d.book Page 203 Thursday, April 15, 1999 2:31 PM

SCHEMATIC & ROUTING DIAGRAMS

SCHEMATIC & ROUTING

DIAGRAMS

Page 203
10-102d.book Page 204 Thursday, April 15, 1999 2:31 PM

SCHEMATIC & ROUTING DIAGRAMS

[543] T2130(B)/T2180(B) AIR CONTROL WITHOUT COMPOUND
NEUTRALIZING FOR PTO OPERATION

Figure 543 — T2130(B)/T2180(B) Air Control Schematic

Page 204
10-102d.book Page 205 Thursday, April 15, 1999 2:31 PM

SCHEMATIC & ROUTING DIAGRAMS

[543] T2130(B)/T2180(B) AIR CONTROL WITHOUT
DASH-MOUNTED NEUTRAL SWITCH

Figure 544 — T2130(B)/T2180(B) Air Piping Diagram

Page 205
10-102d.book Page 206 Thursday, April 15, 1999 2:31 PM

SCHEMATIC & ROUTING DIAGRAMS

[543] T2130(B)/T2180(B) AIR CONTROL WITH COMPOUND
NEUTRALIZING FOR PTO OPERATION

Figure 545 — T2130(B)/T2180(B) Air Control Schematic

Page 206
10-102d.book Page 207 Thursday, April 15, 1999 2:31 PM

SCHEMATIC & ROUTING DIAGRAMS

[543] T2130(B)/T2180(B) AIR CONTROL WITH DASH-MOUNTED
NEUTRAL SWITCH

Figure 546 — T2130(B)/T2180(B) Air Piping Diagram

Page 207
10-102d.book Page 208 Thursday, April 15, 1999 2:31 PM

NOTES

Page 208
10-102d.book Page 209 Thursday, April 15, 1999 2:31 PM

SPECIAL TOOLS & EQUIPMENT

SPECIAL TOOLS & EQUIPMENT

Page 209
10-102d.book Page 210 Thursday, April 15, 1999 2:31 PM

SPECIAL TOOLS & EQUIPMENT

SPECIAL TOOLS
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 39854 Seal Driver
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
J 7804-01 Yoke and Flange Remover
J 5959-01 Dial Indicator Set

Above tools are available from:

KENT-MOORE
O.E. TOOL AND EQUIPMENT GROUP
SPX CORPORATION
28635 MOUND ROAD
WARREN, MICHIGAN 48092-3499

TEL: 1-800-328-6657
FAX: 1-800-578-7375

Page 210
10-102d.book Page 211 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

DISASSEMBLED VIEWS

Page 211
10-102d.book Page 212 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

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

2. 1st/2nd Shift Fork 13. Interlock 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 Sleeve and O-Ring 28. Interlock Ball
7. 3rd/4th Shifter 18. Interlock 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
Figure 547 — Exploded View of Main Case Shift Cover

Page 212
10-102d.book Page 213 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Spigot Bearing Inner Race Snap Ring 15. Internal-Toothed Thrust Washer 29. Mainshaft Snap Ring
2. Spigot Bearing Inner Race 16. External-Toothed Thrust Washer 30. Front Mainshaft
3. Mainshaft Snap Ring 17. Gear Snap Ring 31. Mainshaft Snap Ring
4. Internal-Toothed Thrust Washer 18. First (Fifth) Speed Gear 32. Spacer
5. Fourth (Eighth) Speed Gear 19. Gear Snap Ring 33. Mainshaft Rear Bearing
6. External-Toothed Thrust Washer 20. External-Toothed Thrust Washer 34. Mainshaft Rear Bearing Sleeve
7. Gear Snap Ring 21. Internal-Toothed Thrust Washer 35. Mainshaft Snap Ring
8. Gear Snap Ring 22. Mainshaft Snap Ring 36. Lo-Split Gear
9. External-Toothed Thrust Washer 23. Lo-Speed Gear 37. Internal-Toothed Thrust Washer
10. Internal-Toothed Thrust Washer 24. Sliding Clutch 38. Mainshaft Snap Ring
11. Second (Sixth) Speed Gear 25. Mainshaft Snap Ring 39. Sliding Clutch
12. Mainshaft Snap Ring 26. Internal-Toothed Thrust Washer 40. Spigot Bearing Inner Race
13. Sliding Clutch 27. Reverse Speed Gear 41. Spigot Bearing Inner Race Snap Ring
14. Mainshaft Snap Ring 28. External-Toothed Thrust Washer
Figure 548 — Exploded View of Front Mainshaft

Page 213
10-102d.book Page 214 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Cover O-Ring 7. Shift Fork Setscrew

2. Piston O-Ring 8. Splitter Shift Fork 1. 4-mm Screw 13. Silicon Rubber O-Ring
3. Splitter Shift Piston 9. Capscrew (4) 2. End Cover 14. Glide Ring*
4. Capscrew (10) 10. Piston Cover 3. End Cover O-Ring* 15. Aluminum Spool Valve
5. Rear Case Shift Cover 11. Shaft O-Ring 4. Bore Sleeve 16. Glide Ring and O-Ring*
6. Gasket 5. 4-mm Screw 17. Glide Ring and O-Ring*
6. Silicon Rubber O-Ring* 18. Steel (Locking) Spool
Figure 549 — Exploded View of Rear Case Shift Cover 7. Silicon Rubber O-Ring* Valve*
8. Silicon Rubber O-Ring* 19. Viton Rubber O-Ring*
9. Silicon Rubber O-Ring* 20. Valve Housing
10. Top Cover Seal 21. Silicon Rubber O-Ring*
11. Top Cover 22. (Not Shown) Mobil!
12. Sintered Bronze Filter* No. 28 Lo-Temp Grease*
*Indicates items included in rebuild kit.
Figure 550 — Cutaway View of Range Shift
Interlock Valve Assembly

Page 214
10-102d.book Page 215 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Shift Fork 9. Shift Cylinder Cover

2. Rail 10. Piston/Rail Nut
3. O-Ring 11. O-Ring
4. Shift Piston 12. Cover Capscrew
5. O-Ring 13. O-Ring
6. Piston Sleeve 14. Breather Vent
7. Shift Cylinder 15. O-Ring
1. Main Drive Pinion Shaft 7. Bearing 8. O-Ring 16. O-Ring
2. Spigot Bearing 8. Spiral Snap Ring
3. Snap Ring 9. Gasket Figure 552 — Cutaway View of Range Shift Cylinder
4. Main Drive Pinion Gear 10. Pinion Bearing Cover
5. Spiral Snap Ring 11. Oil Seal
6. Snap Ring
Figure 551 — Exploded View of Main Drive Pinion

Page 215
10-102d.book Page 216 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Snap Ring 13. Support Tube 23. Internal-Toothed Thrust Washer

2. Snap Ring 14. Synchronizer Pin 24. Lo-Range Gear Snap Ring
3. Hi-Range/Hi-Split Gear Bearing 15. Sliding Clutch 25. Lo-Range Gear Hub
4. Hi-Range/Hi-Split Gear 16. Preload Spring Assembly 26. Spigot Bearing Snap Ring
5. Snap Ring A. Inner Spring 27. Rear Mainshaft Spigot Bearing
6. Snap Ring B. Outer Spring 28. Rear Mainshaft
7. Spacer (Front Synchronizer Pack) 17. Synchronizer Pin 29. Rear Bearing Snap Ring
8. Friction Disc (4) 18. Clutch Housing 30. Lo-Range Gear
9. Reaction Disc (4) 19. Threaded Insert (3) 31. Rear Bearing Cover Gasket
10. 12-Point Capscrew (3) 20. Reaction Disc (4) 32. Rear Bearing Cover
11. Nonthreaded Insert (3) 21. Friction Disc (4) 33. Rear Bearing Cover Seal
12. Clutch Housing 22. Snap Ring
Figure 553 — Exploded View of Rear Mainshaft and Synchronizer Assembly

Page 216
10-102d.book Page 217 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Figure 556 — Exploded View of Front Countershaft
Front Bearing Cover

1. 12-Point Screw 7. Clutch Housing

2. Nonthreaded Insert 8. Threaded Insert
3. Clutch Housing 9. Support Tube
4. Synchronizer Pin 10. Preload Spring
5. Sliding Clutch Assembly
6. Synchronizer Pin
Figure 554 — Exploded View of Synchronizer

1. Bearing Cover 4. Bearing

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 555 — Exploded View of Rear Mainshaft Bearing
Cover
1. Bearing Cup 7. Lo-Speed Gear
2. Main Drive Gear 8. Rear Spacer
3. Fourth Speed Gear 9. Key
4. Second Speed Gear 10. Front Countershaft
5. Front Spacer 11. Bearing Cone
6. First Speed Gear
Figure 557 — Exploded View of T2130/T2180 Front
Countershaft

Page 217
10-102d.book Page 218 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Bearing Cup 7. Key 1. Front Bearing Cone 6. Rear Countershaft

2. Main Drive Gear 8. Bearing Cone 2. Lo-Split Gear (Lo-Range Gear Part of
3. Fourth Speed Gear 9. Reverse Speed Gear 3. Spacer Shaft)
4. Second Speed Gear 10. Rear Spacer 4. Hi-Range/Hi-Split Gear 7. Rear Bearing Cone
5. Front Spacer 11. Lo-Speed Gear 5. Key
6. Countershaft 12. First Speed Gear
Figure 560 — Exploded View of Rear Countershaft
Figure 558 — Exploded View of T2130B/T2180B Front
Countershaft

1. Bearing Cup 3. Shim(s)

1. Front Bearing Cup 3. Rear Bearing Cup 2. O-Ring 4. Bearing Cover
2. Bearing Cover
Figure 561 — Exploded View of Rear Countershaft
Figure 559 — Exploded View of Front Countershaft Rear Bearing Cover
Bearing Cover

Page 218
10-102d.book Page 219 Thursday, April 15, 1999 2:31 PM

DISASSEMBLED VIEWS

1. Thrust Washer 3. Bearing

2. Reverse Idler Gear 4. Reverse Idler Shaft
Figure 562 — Exploded View of Reverse Idler Gear
Assembly (Current Production)

Page 219
10-102d.book Page 220 Thursday, April 15, 1999 2:31 PM

NOTES

Page 220
10-102d.book Page 221 Thursday, April 15, 1999 2:31 PM

INDEX

INDEX

Page 221
10-102d.book Page 222 Thursday, April 15, 1999 2:31 PM

INDEX
A I
AIR BREATHERS. . . . . . . . . . . . . . . . . . . . . . .29 INSPECTION AND CLEANING . . . . . . . . . . . 110
ALL FORKS AND SLIDING CLUTCHES . . . .199 INSPECTION OF PARTS. . . . . . . . . . . . . . . . 109

B L
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BENCH PROCEDURES (DISASSEMBLY) . . .49
BENCH PROCEDURES (REASSEMBLY) . . . 113 M

C MAGNETIC OIL FILTER . . . . . . . . . . . . . . . 6, 29

MAIN CASE SHIFT COVER . . . . . . . . . . . . . . 50
CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . .28 MAIN CASE SHIFT COVER
CHECKING OIL . . . . . . . . . . . . . . . . . . . . . . . .28 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 52
COMPONENT LOCATOR . . . . . . . . . . . . . . . .21 MAIN CASE SHIFT COVER
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 161
D MAIN DRIVE PINION REASSEMBLY . . . . . . 148
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION AND OPERATION. . . . . . . . . . .3
O
DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . 211
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . .31 OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
DOWNSHIFTING (NORMAL HIGHWAY). . .9, 10
P
F
PREFERRED METHOD FOR ENGAGING
FITS AND LIMITS. . . . . . . . . . . . . . . . . . . . . .199 T2130(B)/T2180(B) HIGH RANGE GEAR
FRONT COUNTERSHAFT DISASSEMBLY FOR OUTPUT SHAFT DRIVEN POWER
(T2130/T2180) . . . . . . . . . . . . . . . . . . . . . .96 TAKE-OFF OPERATION . . . . . . . . . . . . . . 12
FRONT COUNTERSHAFT DISASSEMBLY PREFERRED OPERATING PROCEDURES
(T2130B/T2180B) . . . . . . . . . . . . . . . . . . .100 FOR REAR COMPOUND MOUNTED
FRONT COUNTERSHAFT FRONT BEARING PTO APPLICATIONS . . . . . . . . . . . . . . . . . 11
COVER DISASSEMBLY. . . . . . . . . . . . . . .95
FRONT COUNTERSHAFT FRONT BEARING R
COVER REASSEMBLY . . . . . . . . . . . . . .127
FRONT COUNTERSHAFT REAR BEARING RANGE SHIFT CYLINDER DISASSEMBLY . . 68
COVER DISASSEMBLY. . . . . . . . . . . . . .103 RANGE SHIFT CYLINDER REASSEMBLY. . 156
FRONT COUNTERSHAFT REAR BEARING RANGE SHIFT VALVE. . . . . . . . . . . . . . . 71, 151
COVER REASSEMBLY . . . . . . . . . . . . . . 119 REAR CASE SHIFT COVER
FRONT COUNTERSHAFT REASSEMBLY DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 65
(T2130/T2180) . . . . . . . . . . . . . . . . . . . . .124 REAR CASE SHIFT COVER
FRONT COUNTERSHAFT REASSEMBLY REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 159
(T2130B/T2180B) . . . . . . . . . . . . . . . . . . .120 REAR COUNTERSHAFT BEARING
FRONT MAINSHAFT DISASSEMBLY . . . . . . .77 COVER DISASSEMBLY . . . . . . . . . . . . . 106
FRONT MAINSHAFT REASSEMBLY . . . . . .140 REAR COUNTERSHAFT BEARING
COVER REASSEMBLY . . . . . . . . . . . . . . 116
G REAR COUNTERSHAFT DISASSEMBLY . . 104
REAR COUNTERSHAFT REASSEMBLY . . . 117
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 REAR MAINSHAFT AND SYNCHRONIZER
GENERAL INSPECTION . . . . . . . . . . . . . . . . 112 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 85
GENERAL REASSEMBLY REAR MAINSHAFT AND SYNCHRONIZER
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 112 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 130

Page 222
10-102d.book Page 223 Thursday, April 15, 1999 2:31 PM

INDEX
REAR MAINSHAFT BEARING COVER T2130(B)/T2180(B) AIR CONTROL
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . .93 WITHOUT DASH-MOUNTED NEUTRAL
REAR MAINSHAFT BEARING COVER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 205
REASSEMBLY . . . . . . . . . . . . . . . . . . . . .128 T2130/T2130B AND T2180/T2180B
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .175 GENERAL TOLERANCES . . . . . . . . . . . . 200
REVERSE IDLER GEAR DISASSEMBLY . . .107 T2130/T2130B AND T2180/T2180B
REVERSE IDLER GEAR REASSEMBLY. . . . 114 TORQUE SPECIFICATIONS . . . . . . . . . 196
T2130/T2130B SHIFTING INSTRUCTIONS . . . 9
S T2130/T2180 TRANSMISSIONS . . . . . . . . . . . . 4
T2180 AND T2180B GEAR
SCHEMATIC & ROUTING DIAGRAMS . . . . .203
IDENTIFICATION . . . . . . . . . . . . . . . . . . . 198
SHIFTER FORKS, SLIDING CLUTCHES
T2180 AND T2180B GEAR RATIOS AND
AND SHIFT RAILS . . . . . . . . . . . . . . . . . . 110
SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . 8
SIDE-MOUNTED PTO APPLICATION
T2180 AND T2180B POWER FLOW
INFORMATION. . . . . . . . . . . . . . . . . . . . . . 11
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . .210
T2180/T2180B SHIFTING INSTRUCTIONS . . 10
SPECIAL TOOLS & EQUIPMENT . . . . . . . . .209
TRANSMISSION CASE OIL COOLER LINE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .195
PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPLASH LUBRICATION . . . . . . . . . . . . . . . . . .5
TRANSMISSION COMPONENT
SPRING SPECIFICATIONS . . . . . . . . . . . . . .199
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . 50
TRANSMISSION COMPONENT
T
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . 114
T2130 AND T2130B GEAR TRANSMISSION DISASSEMBLY
IDENTIFICATION . . . . . . . . . . . . . . . . . . .197 PROCEDURES . . . . . . . . . . . . . . . . . . . . . 32
T2130 AND T2130B GEAR RATIOS AND TRANSMISSION IDENTIFICATION. . . . . . . . . . 1
SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . .7 TRANSMISSION REASSEMBLY
T2130 AND T2130B POWER FLOW PROCEDURES . . . . . . . . . . . . . . . . . . . . 176
DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . .13 TRANSMISSION SPECIFICATIONS AND
T2130(B) AND T2180(B) GUIDELINES FOR CAPACITIES . . . . . . . . . . . . . . . . . . . . . . 201
PTO USE . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 23
T2130(B)/T2180(B) AIR CONTROL WITH TROUBLESHOOTING CHART . . . . . . . . . . . . 24
COMPOUND NEUTRALIZING FOR PTO
OPERATION. . . . . . . . . . . . . . . . . . . . . . .206 U
T2130(B)/T2180(B) AIR CONTROL
UNIT IDENTIFICATION STAMPING
WITH DASH-MOUNTED NEUTRAL
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . .207
UPSHIFTING (NORMAL HIGHWAY). . . . . . 9, 10
T2130(B)/T2180(B) AIR CONTROL
WITHOUT COMPOUND NEUTRALIZING
FOR PTO OPERATION . . . . . . . . . . . . . .204

Page 223
10-102d.book Page 224 Thursday, April 15, 1999 2:31 PM

NOTES

Page 224
 TRANSMISSION
T2130/T2180
SERVICE MANUAL

PRINTED IN U.S.A.
10-102 MACK TRUCKS, INC. 1999