9-, 10- and 13-Speed Transmissions

Revised 12-98

$2.50

9-, 10- and 13-Speed

Transmissions

Maintenance Manual 26A

Design Level One

Design Level Two

Service Notes

This Maintenance Manual describes the correct service and repair procedures for the nine-speed, ten-speed and

thirteen-speed Design Level One and Design Level Two manual transmissions.

You must follow your company safety procedures when you service or repair equipment. Be sure you understand all the

procedures and instructions before you begin work on the unit. Meritor uses the following types of notes to give warning

of possible safety problems and to give information that will prevent damage to equipment:

WARNING

A warning indicates procedures that must be followed exactly. Personal injury can occur if the

procedure is not followed.

CAUTION

A caution indicates procedures that must be followed exactly. If the procedure is not followed,

damage to equipment or components can occur. Personal injury can also occur in addition to damage

or malfunctioning of equipment or components.

TORQUE

This symbol is used to indicate fasteners that must be tightened to a specific tourque value.

NOTE

A note indicates an operation, procedure or instruction that is important for correct service. A note

can also give information that will make service easier and quicker.

Some procedures require the use of special tools for safe and correct service. Failure to use these special tools when

required, can cause injury to service personnel or damage to vehicle components.

Silicone Gasket Materials

WARNING

When you apply some silicone gasket materials, small amounts of acid vapor are present. To prevent

possible serious personal injury, make sure the work area is well-ventilated. If the silicone gasket

material gets into your eyes, flush them with water for 15 minutes. Have your eyes checked by a

doctor as soon as possible.

Loctite?

WARNING

Take care when using Loctite to avoid serious personal injury. Follow the manufacturer's instructions

to prevent irritation to the eyes and skin. If Loctite gets into your eyes, flush them with water for 15

minutes. Have your eyes checked by a doctor as soon as possible.

Cleaning Solvents

WARNING

If you use solvents, hot solution tanks or alkaline solutions incorrectly, serious personal injury can

occur. To prevent serious personal injury, follow the instructions supplied by the manufacturer of

these products. Do NOT use gasoline to clean parts. Gasoline can explode and cause serious

personal injury.

CAUTION

?

Use only solvent cleaners to clean ground or polished metal parts. Hot solution tanks or water

and alkaline solutions will damage these parts. You can use isopropyl alcohol, kerosene or diesel

fuel for this purpose.

?

If required, use a sharp knife to remove gasket material from parts. Take care not to damage

ground or polished surfaces.

Table of Contents

SUBJECT

PAGE

Section 1 - General Information ................................................................................... 5

Description .................................................................................................................... 5

Identification .................................................................................................................. 6

Nine-Speed Manual Transmissions .............................................................................. 6

Ten-Speed Manual Transmissions ............................................................................... 6

Thirteen-Speed Manual Transmissions ........................................................................ 6

Design Level 1 Manual Transmissions ......................................................................... 6

Design Level 2 Manual Transmissions ......................................................................... 8

Gear Timing .................................................................................................................. 9

Gasket Sealant ........................................................................................................... 12

Removing Gasket Sealant .......................................................................................... 12

Installing Gasket Sealant ............................................................................................ 12

Inspecting Used Parts ................................................................................................. 15

Repairing or Replacing Parts ...................................................................................... 19

Cleaning Ground or Polished Parts ............................................................................ 19

Cleaning Rough Parts ................................................................................................. 19

Drying the Cleaned Parts ............................................................................................ 19

Preventing Corrosion or Rust on Cleaned Parts ......................................................... 19

Section 2 - Lubrication and Maintenance.................................................................. 20

Transmission Oil Specifications .................................................................................. 20

Transmissions Oil Coolers .......................................................................................... 20

Scheduled Maintenance ............................................................................................. 21

Checking and Adjusting the Oil Level ......................................................................... 21

Checking the Condition of the Breather Vent ............................................................. 22

Checking Fastener Torque ......................................................................................... 22

Inspecting the Transmission for Leaks and Damage .................................................. 22

Draining and Replacing the Transmission Oil ............................................................. 23

Adjusting Remote Shift Housing Linkage ................................................................... 24

Lubricating the Remote Shift Housing ........................................................................ 24

Section 3 - In Vehicle Service ..................................................................................... 25

Removing the Shift Lever and Tower Assembly ......................................................... 25

Installing the Shift Lever and Tower Assembly ........................................................... 25

Removing the Slave Valve .......................................................................................... 27

Installing the Slave Valve ............................................................................................ 27

Removing the Air Filter and Regulator Assembly ....................................................... 28

Installing the Air Filter and Regulator Assembly ......................................................... 29

Removing the Output Yoke and Oil Seal .................................................................... 29

Installing the Oil Seal and Output Yoke ...................................................................... 30

Removing and Installing the Remote Control Assembly ............................................. 33

Page 1

8188C-TOC

1

2/1/99, 12:48 PM

Table of Contents (Continued)

SUBJECT

PAGE

Section 4 - Removing and Installing the Transmission .......................................... 34

Removing the Transmission ....................................................................................... 34

Installing the Transmission ......................................................................................... 36

Section 5 - Overhauling the Shift Lever and Tower Assembly ............................... 41

Disassembling the Aluminum Tower Assembly .......................................................... 41

Assembling the Aluminum Tower Assembly ............................................................... 43

Disassembling the Cast Iron Tower Assembly ........................................................... 46

Assembling the Cast Iron Tower Assembly ................................................................ 47

Section 6 - Remote Control Assembly ...................................................................... 48

Disassembling the Remote Control Assembly ............................................................ 48

Assembling the Remote Control Assembly ................................................................ 49

Section 7 - Removing and Installing the Top Cover Assembly............................... 50

Removing the Top Cover Assembly ........................................................................... 50

Installing the Top Cover Assembly ............................................................................. 52

Section 8 - Overhauling the Top Cover Assembly ................................................... 54

Disassembling the Standard and Forward Position Top Cover Assembly ................. 54

Assembling the Standard and Forward Position Top Cover Assembly ...................... 60

Disassembling the Standard and Forward Position ¡°X¡± Bar

Top Cover Assembly ................................................................................................ 66

Assembling the Standard and Forward Position ¡°X¡± Bar Top Cover Assembly .......... 72

Section 9 - Removing and Installing the Input Shaft................................................ 79

Removing the Input Shaft ........................................................................................... 79

Installing the Input Shaft ............................................................................................. 81

Section 10 - Removing and Installing the Clutch Housing ...................................... 83

Removing the Clutch Housing .................................................................................... 83

Installing the Clutch Housing ...................................................................................... 83

Section 11 - Removing and Installing the Auxiliary Case........................................ 85

Removing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ............... 85

Installing the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ................. 90

Removing the Auxiliary Case-Thirteen-Speed Transmissions ................................... 94

Installing the Auxiliary Case-Thirteen-Speed Transmissions ..................................... 98

Removing the Auxiliary Drive Gear ........................................................................... 102

Installing the Auxiliary Drive Gear ............................................................................. 103

Section 12 - Overhauling the Main Case ................................................................. 104

Removing the Mainshaft ........................................................................................... 104

Removing the Input Shaft ......................................................................................... 110

Removing the Main Countershafts ........................................................................... 113

Page 2

8188C-TOC

2

2/1/99, 12:48 PM

Table of Contents (Continued)

SUBJECT

PAGE

Section 12 - Overhauling the Main Case(Continued) ............................................ 104

Removing the Reverse Idler Gear Assembly ............................................................ 114

Removing the Oil Pump ............................................................................................ 115

Removing the Magnets ............................................................................................. 116

Removing the PTO Covers ....................................................................................... 116

Installing the PTO Covers ......................................................................................... 117

Installing the Magnets ............................................................................................... 117

Installing the Oil Pump .............................................................................................. 118

Installing the Reverse Idler Gear Assemblies ........................................................... 118

Installing the Input Shaft ........................................................................................... 119

Installing the Main Countershafts ............................................................................. 123

Installing the Mainshaft ............................................................................................. 125

Section 13 - Overhauling the Auxiliary Drive Gear................................................. 134

Disassembling the Auxiliary Drive Gear Assembly ................................................... 134

Assembling the Auxiliary Drive Gear Assembly ........................................................ 136

Section 14 - Overhauling the Mainshaft .................................................................. 137

Disassembling the Mainshaft .................................................................................... 137

Assembling the Mainshaft ......................................................................................... 139

Section 15 - Overhauling the Main Countershafts ................................................. 150

Disassembling the Main Countershaft ...................................................................... 150

Assembling the Main Countershaft ........................................................................... 152

Section 16 - Overhauling the Auxiliary Case .......................................................... 155

Disassembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ...... 155

Assembling the Auxiliary Case-Nine-Speed and Ten-Speed Transmissions ........... 163

Disassembling the Auxiliary Case-Thirteen-Speed Transmissions .......................... 174

Assembling the Auxiliary Case-Thirteen-Speed Transmissions ............................... 182

Section 17 - Main Countershaft End Play Adjustment ........................................... 193

Checking and Adjusting the End Play of the Main Countershafts ............................ 193

Section 18 - Auxiliary Countershaft End Play Adjustment .................................... 200

Checking and Adjusting the End Play of the Auxiliary Countershafts ....................... 200

Section 19 - Troubleshooting ................................................................................... 207

General Information .................................................................................................. 207

Troubleshooting Other Systems ............................................................................... 208

Troubleshooting Leaks ............................................................................................. 209

Troubleshooting Vibrations ....................................................................................... 209

Troubleshooting Noises ............................................................................................ 210

Troubleshooting Operating Conditions ..................................................................... 211

Page 3

8188C-TOC

3

2/1/99, 12:48 PM

 ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download