SM2457EN 4K SvcMan 02 2001
SM2457EN 4K SvcMan 02 2001
SM2457EN 4K SvcMan 02 2001
Service
Manual
Allison Transmission
4000 MH
HD 4060, 4060P, 4060R, 4060PR
HD 4560, 4560P, 4560R, 4560PR
HD 4070/4076
B 500, B 500P, B 500R, B 500PR
2001 FEBRUARY
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Pro-Link is a registered trademark of Micro Processor Systems, Inc.
DEXRON is a registered trademark of General Motors Corp.
Biobor JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.
Loctite is a registered trademark of the Loctite Corporation.
Teflon is a registered trademark of the DuPont Corporation.
TranSyndTM is a trademark of Castrol, Ltd.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
Transmissions Truck, Tractor, etc.
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
If you leave the vehicle and the engine is running, the vehicle can move suddenly and
you or others could be injured. If you must leave the engine running, do not leave the
vehicle until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they are properly
engagedand
Chock the wheels and take any other steps necessary to keep the vehicle from
moving.
Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct
contact with the hot fluid or the hot sump may result in bodily injury.
DO NOT conduct a converter stall test until the following actions are taken. The
parking brake and/or emergency brakes must be set and properly engaged and the
wheels must be chocked. Warn personnel to keep clear of the vehicle and its travel path.
Failure to do so can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon seals; toxic gases are produced by burning Teflon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning
a bearing without lubrication can damage the bearing.
DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder
until air and hydraulic pressure have been bled from the retarder.
PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when
installing or removing a transmission from the repair stand. Transmission dry weights
are as follows:
4000 MH/HD/B 500 (Basic) 377 kg (831 lb)
With PTO Provision 405 kg (893 lb)
With Retarder 411 kg (906 lb)
With PTO and Retarder 439 kg (968 lb)
HD 4070 w/ PTO and Retarder 555 kg (1224 lb)
Get help when lifting the control module. Assistance from a hoist or another person
may be required. The control module weighs approximately 25 kg (55 lb).
Get help when lifting the C6 adapter housing module. Assistance from a hoist or
another person may be required. The C6 adapter housing module weighs
approximately 68kg (150 lb).
Carefully release spring force. Piston springs are highly compressed. Personal injury
can occur if the spring force is not controlled.
Place the P3 planetary assembly on its side to avoid possible injury while disassembling
the planetary.
Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
Be sure that lifting equipment and the repair stand can properly support the weight of
the transmission being serviced. The dry weights are:
HD 4060/4560/B 500PR Series 440 kg (968 lb)
HD 4060/4560/B 500P Series 406 kg (893 lb)
HD 4070PR 640 kg (1411 lb)
HD 4070P 606 kg (1336 lb)
56. FRONT SUPPORT AND OIL PUMP MODULE b. Disassembly of Temperature Sensor . . 522
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 55 c. Disassembly of Retarder Housing . . . . 524
b. Assembly of Front Support . . . . . . . . . . . 57 d. Disassembly of P3 Planetary
c. Assembly of Pump Housing . . . . . . . . . 58 Carrier Assembly . . . . . . . . . . . . . . . . . 524
57. ROTATING CLUTCH MODULE e. Disassembly of Retarder
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 58 Stator Assembly . . . . . . . . . . . . . . . . . . 525
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 510 f. Assembly of Retarder Stator . . . . . . . . . 525
58. C3/C4 AND MAIN HOUSING MODULE g. Assembly of P3 Planetary
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 512 Carrier Assembly . . . . . . . . . . . . . . . . . 526
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 513 h. Assembly of Retarder Housing
59. MAIN SHAFT MODULE Assembly. . . . . . . . . . . . . . . . . . . . . . . . 526
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 514 i. Assembly of the Retarder Valve Body. . 527
b. Assembly (4000 MH, HD 4060, and j. Disassembly of Retarder Valve Body. . 528
B 500 Models Only) . . . . . . . . . . . . . . . 514 k. Disassembly of Temperature Sensor. . . 528
c. Assembly
(HD 4070/4076 Models Only) . . . . . . . 515 l. Disassembly of Retarder Housing. . . . . 528
m. Disassembly of P3 Planetary Carrier
510. P1 PLANETARY MODULE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 529
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 515
n. Disassembly of Retarder Stator. . . . . . . 529
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 515
o. Assembly of Retarder Stator . . . . . . . . . 530
511. P2 PLANETARY MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 517 p. Assembly of P3 Planetary
Carrier Assembly. . . . . . . . . . . . . . . . . . 530
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 517
q. Assembly of Retarder Housing
512. P3 PLANETARY MODULE Assembly . . . . . . . . . . . . . . . . . . . . . . . . 530
(HD 4070/4076 Models Only)
r. Assembly of the Retarder Valve Body. . 531
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 518
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 518 515. RETARDER AND OUTPUT SHAFT
MODULE (HD 4070 Models Equipped
513. C6 ADAPTER HOUSING MODULE
With Retarder)
(HD 4070/4076 Models Only)
a. Disassembly of Ring Gear and Hub a. Disassembly of Retarder Valve Body. . 532
Assembly . . . . . . . . . . . . . . . . . . . . . . . 518 b. Disassembly of Temperature Sensor . . 532
b. Disassembly . . . . . . . . . . . . . . . . . . . . . 518 c. Disassembly of Retarder Housing . . . . 532
c. Disassembly of P4 Planetary Carrier
d. Disassembly of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . 519
Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
d. Disassembly of Remaining C6 Parts. . . 519
e. Completion of Retarder Housing
e. Assembly . . . . . . . . . . . . . . . . . . . . . . . 520
Disassembly . . . . . . . . . . . . . . . . . . . . . 533
f. Assembly of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . . 521 f. Disassembly of Retarder Stator
g. Assembly of C6 Clutch . . . . . . . . . . . . 521 Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
g. Assembly of Retarder Stator
514. RETARDER AND P3 PLANETARY
Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
MODULE (4000 MH, HD 4060, HD 4560,
And B 500 Models Equipped With Retarder) h. Assembly of Retarder Housing . . . . . . 534
a. Disassembly of Retarder Valve Body . . 522 i. Assembly of Output Shaft Assembly . . 534
CROSS-SECTION VIEWS
Foldout
EXPLODED VIEWS
Foldout
PTO
(TOP RIGHT POSITION)
FEEDTHROUGH HARNESS
CONNECTOR
MOUNTING PAD
ENGINE-SPEED SENSOR
OUTPUT-SPEED SENSOR
TURBINE-SPEED SENSOR
FILL TUBE
COOLER PORTS
NAMEPLATE
V06829
.
Figure 11. Model 4000 MH/HD 4060P/4560P/B 500P Transmission Right-Rear View
FEEDTHROUGH
HARNESS
CONNECTOR
MOUNTING PAD
(BOTH SIDES)
PTO
(BOTTOM LEFT POSITION)
MAIN-PRESSURE TAP
COOLER PORTS
V06830
Figure 12. Model 4000 MH/HD 4060P/4560P/B 500P Transmission Left-Rear View
FILL TUBE
PTO
(TOP RIGHT POSITION)
FEEDTHROUGH HARNESS
CONNECTOR
RETARDER
TEMPERATURE
CONNECTOR
"K" SOLENOID
CONNECTOR
TORQUE CONVERTER
MODULE
NAMEPLATE
TURBINE-SPEED SENSOR
ENGINE-SPEED SENSOR
MOUNTING PAD
V01732
Figure 13. Model 4000 MH/HD 4060PR/4560PR/B 500PR Transmission Right-Front View
FEEDTHROUGH HARNESS
CONNECTOR
MOUNTING PAD
OUTPUT-SPEED
PTO PAD SENSOR
(BOTTOM LEFT POSITION)
RETARDER
MAIN-PRESSURE TAP
COOLER PORTS
Figure 14. Model 4000 MH/HD 4060PR/4560PR/B 500P Transmission Left-Rear View
BREATHER
PTO PROVISION
C6 ADAPTER
HOUSING
RETARDER
OUTPUT
MOUNTING PAD FLANGE
PTO PROVISION
MOUNTING PAD
V05579
PTO PROVISION
(TOP RIGHT POSITION)
HARNESS
CONNECTOR
C6 ADAPTER
HOUSING
MOUNTING PAD
INPUT
SPEED
SENSOR
TURBINE
SPEED
SENSOR
FILL T UBE
V06832
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WORKERS
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Division of General Motors Corporation
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self-diagnostic capabilities
UNITE CA
Indianapolis, Indiana
XXXXXXXXXX 29509045
MODEL
15. MAJOR COMPONENTS
NO. XX XXXX
a. Input Module. The Input Module includes:
Prior to 4/14/98 V02003.02
Engine adaptation
D
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I MP
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Torque converter
AN
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Div. of General Motors Corp.
BIL
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Control module
Indicates planetary gear type automatic
HD
transmission
Shift selector 4 Indicates series
Sensors 0 = Indicates close ratio
0,5
5 = Indicates wide ratio
Wiring harness (customer-furnished)
6,7 Indicates number of forward ranges
The ECU is a high-speed digital computer that 6 Indicates major model change
receives information from the sensors and shift
selector. This information is processed and shift P Indicates PTO drive provision
commands are sent to the control module for range R Indicates integral retarder
selection.
B 500PR
g. Transmission Fluid Filters. Two disposable B Indicates bus or coach application
external-access filters are part of the control module. 5 Indicates series
Each filter is in a separate cavity which permits 0 Indicates close ratio
removal and replacement without complete loss of
transmission fluid. 0 Indicates major model change
P Indicates PTO drive provision
h. Transmission Fluid Coolers. The 4000 MH/ R Indicates integral retarder
HD 4000/B 500 has provision for remote or integral
transmission fluid coolers.
17. EXPLODED
i. C6 Adapter Housing Module. The C6 adapter (DISASSEMBLED) VIEWS
housing module is unique to the HD 4070/4076 Exploded views illustrate the 4000 MH/HD 4000/
models. It provides a seventh range and is located B 500 Series transmission parts in relation to each
between the main housing and rear cover/retarder. other. The parts numbering system in the exploded
views is used in all procedures described in the text.
j. Rear Cover. A rear cover is standard equipment
on the 4000 MH/HD 4000/B 500. The output shaft can
be provided with a variety of companion flanges or 18. DIAGNOSIS
yokes.
NOTE:
k. Output Retarder and Output Flange. The Refer to TS2470EN (WTEC II) or TS2973EN
optional output retarder module replaces the standard (WTEC III), Electronic Controls Troubleshooting
rear cover. An output flange or yoke is available for Manual, for in-depth troubleshooting procedures.
use with the retarder.
3. Seal all openings and the breather with 7. As soon as the transmission is cool enough to
moisture-proof tape. touch, seal all openings and the breather with
moisture-proof tape.
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum 8. Coat all exposed, unpainted surfaces with
(MIL-C-11796, Class 2). preservative grease such as petrolatum
(MIL-C-11796), Class 2.
5. If additional storage time is required, repeat
Steps (2) through (4) at yearly intervals. 9. If additional storage time is required, repeat
Steps (2) through (8) at yearly intervals,
except, it is not necessary to drain the
d. One Year Storage (With Fluid)
transmission each year. Just add VCI #10 and
1. Drain the fluid and replace the oil filter Biobor JF (or equivalents).
elements.
GEAR DATA:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary helical, constant mesh
4000 MH/HD 4060/
Range B 500 Ratios HD 4560 Ratios HD 4070/4076 Ratios
First . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51:1 4.70:1 7.63
Second . . . . . . . . . . . . . . . . . . . . . . . . 1.91:1 2.21:1 3.51
Third. . . . . . . . . . . . . . . . . . . . . . . . . . 1.43:1 1.53:1 1.91
Fourth . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 1.00:1 1.43
Fifth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.74:1 0.76:1 1.00
Sixth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64:1 0.67:1 0.74
Seventh. . . . . . . . . . . . . . . . . . . . . . . . 0.64
Reverse. . . . . . . . . . . . . . . . . . . . . . . . 4.80:1 5.55:1 4.8
ENGINE-DRIVEN POWER TAKEOFF PROVISION:
Positions . . . . . . . . . . . . . . . . . . . . . . 8 oclock and 1 oclock (viewed from rear)
PTO Unit Ratings at the Transmission
PTO Drive Gear . . . . . . . . . . . . . . . . . Maximum torque through one pad: 930 Nm (685 lb ft)
Maximum torque through both pads simultaneously: 1595 Nm (1175 lb ft)
(NOTE: No more than 930 Nm (685 lb ft) allowed through any
single pad)
HYDRAULIC SYSTEM:
Fluid type . . . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260,
DEXRON-III, C-4 (Refer to Paragraph 210.)
Filters, main and cooler . . . . . . . . . . . Dual integral, replaceable cartridge type
SIZE:
4000 MH/HD 4060/ 4000 MH/HD 4060/
4560/B 500 4560/B 500
with PTO drive without PTO drive
Length (transmission mounting face to rear of output shaft)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.7 mm (33.26 in.) 771.7 mm (30.38 in.)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.6 mm (33.29 in.) 772.6 mm (30.42 in.)
Length (transmission mounting flange to output flange
798.7 mm (31.45 in.) 725.7 mm (28.57 in.)
mounting face on P3 carrier). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth (standard sump, centerline to lowest point) . . . . . . . . . . . 375.8 mm (14.80 in.) 373.2 mm (14.69 in.)
Dry weight (add 16.0 kg (35.0 lb) if integral cooler is used)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 kg (968 lb) 411 kg (906 lb)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kg (893 lb) 377 kg (831 lb)
HD 4070/4076 HD 4070/4076
with PTO drive without PTO drive
Length (transmission mounting face to rear of output shaft)
with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.1 mm (43.47 in.) 1031.1 mm (40.59 in.)
Length (transmission mounting flange to output flange mounting
face on output shaft)
with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 798.7 mm (31.45 in.) 725.7 mm (28.57 in.)
Depth (standard sump, centerline to lowest point) . . . . . . . . . . . 375.8 mm (14.80 in.) 375.8 mm (14.80 in.)
Dry weight (add 16.0 kg (35.0 lb) if integral cooler is used)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 kg (1441 lb) 612 kg (1349 lb)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606 kg (1336 lb) 578 kg (1274 lb)
a. Preparation. Clean all dirt from around the end 4. Insert the dipstick into the tube and remove.
of the fluid fill tube before removing the dipstick. Do Check the fluid level. Repeat the check
not allow dirt or foreign matter to enter the procedure to verify the reading.
transmission. Dirt or foreign matter in the hydraulic
system may clog passages and cause undue
5. If the fluid level is within the COLD RUN
transmission part wear or sticking valves.
band, the transmission can be operated until
the fluid is hot enough to perform a HOT
b. Consistency of Readings. Always check the fluid RUN check. If the fluid level is not within the
level reading at least twice using the following COLD RUN band, add or drain as necessary
procedure. Consistency (repeatable readings) is to bring the fluid level to the middle of the
important to maintaining proper fluid level. If COLD RUN band.
inconsistent readings persist, check the transmission
breather to be sure it is not clogged. If readings are 6. Perform a hot check at the first opportunity
still inconsistent, contact your nearest Allison after normal operating temperature is reached
distributor or dealer. 7193C (160200F).
FULL
HOT
7193C (160200F)
Converter-out temperature
DIMENSION A
SEE CHART 82104C (180220F)
ADD
HOT
BELOW 132.6 mm
(5.22 in.) If a transmission temperature gauge is not
DIMENSION B
COLD
FULL
present, check fluid level when the engine
DIMENSION C water temperature gauge has stabilized and the
COLD
ADD
transmission has been operated under load for
at least one hour.
13.8 mm (0.54 in.) REFERENCE DIMENSION D
TRANSMISSION DETERMINED BY 2. Park the vehicle on a level surface and shift to
CONTROL MODULE INSTALLATION
N (Neutral). Apply the parking brake and
SPLIT LINE
chock the wheels. Allow the engine to idle
DIMENSION DIMENSION DIMENSION (500800 rpm).
A B C
106.7 mm 76.2 mm 66.0 mm
(4.20 in.) (3.00 in.) (2.60 in.)
V02511 3. With the engine running, remove the dipstick
from the tube and wipe clean.
Figure 21. Fluid Dipstick Markings 4. Insert the dipstick into the tube and remove.
Check fluid level. Repeat the check procedure
to verify the reading.
28. HOT CHECK (Figure 21) 5. If the fluid level is not within the HOT RUN
band, add or drain as necessary to bring the
fluid level within the band. Safe operating level
WARNING!
is within the HOT RUN band on the dipstick
If you leave the vehicle and the engine is running, (refer to Figure 21).
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you:
29. KEEPING FLUID CLEAN
Put the transmission in N (Neutral)and
Apply the parking brake and emergency
brakes and make sure they are properly en- CAUTION:
gagedand Containers or fillers that have been used for
Chock the wheels and take any other steps antifreeze or engine coolant solution must
necessary to keep the vehicle from moving. NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene
glycol which, if put into the transmission, can
cause clutch plate failure.
CAUTION:
An accurate fluid level check cannot be made
unless the engine is idling (500800 rpm) in a. Foreign Material. Prevent foreign material from
N (Neutral), the transmission fluid is at the entering the transmission by using clean containers,
proper temperature, and the vehicle is on a level fillers, etc. Lay the dipstick in a clean place while
surface. filling the transmission.
1000 Hours 1000 Hours 1000 Hours 2000 Hours 1000 Hours 2000 Hours
* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd that is
required to fill the transmission to the proper level. A mixture of TranSynd or TES 295 equivalent vs. non-TranSynd other than as defined in this
paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3.
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the
published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized
by the use of fluid analysis.
27
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
b. Fluid Analysis. Transmission protection and fluid serious damage. The transmission must be completely
change intervals can be optimized by monitor- disassembled, inspected, and cleaned. Remove all
ing fluid oxidation according to the tests and traces of the coolant and varnish deposits resulting
limits shown in Table 23. Consult your local from engine coolant contamination. Replace friction
telephone directory for fluid analysis firms. To clutch plates contaminated with engine coolant.
ensure consistent and accurate fluid analysis,
c. Metal
use only one fluid analysis firm. Refer to the
Technicians Guide for Automatic Transmission
Fluid, GN2055, for additional information. CAUTION:
Table 23. Fluid Oxidation Measurement Limits If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all
Test Limit bearings in the transmission.
Viscosity 25% change from new fluid
Total Acid Number +3.0* change from new fluid Metal particles in the fluid (except for the minute
particles normally trapped in the oil filter) may
Solids 2% by volume maximum
indicate internal transmission damage. When these
* mg of KOH to neutralize a g of fluid. particles are found in the sump, the transmission must
be disassembled and closely inspected to find the
source. Metal contamination requires complete
CAUTION: transmission disassembly. Clean all internal and
Contaminated fluid can leave the oil cooler external hydraulic circuits, cooler, and all other areas
contaminated. The cleanliness of the oil cooler where the particles could lodge.
affects the cleanliness of the transmission fluid. If
there is any doubt about the cleanliness of the 213. FLUID AND FILTER
cooler, replace the cooler. CHANGE PROCEDURE
CAUTION:
1. To replace the oil filters on units prior to
Do not use the bolts to draw filter covers to the
S/N 6610009730, remove twelve bolts 5, two sump. This can damage the covers, seals, or sump.
filter covers 4, two O-rings 2, two square cut
seals 3, and two filters 1 from the bottom of the
control module. 5. Install filter 1 and cover 4 assemblies into the
2. To replace the oil filters on units beginning filter compartment. Index each filter/cover
with S/N 6610009730, remove twelve bolts 5, assembly to the holes in the channel plate/
two filter covers 4, two gaskets 8, two sump. Push the filter/cover assemblies in by
O-rings 7, two O-rings 6, and two filters 1 from hand to seat the seals.
the bottom of the control module.
6. Install six bolts 5 into each cover 4 and tighten
3. When reinstalling parts on units prior to them to 5161 Nm (3845 lb ft).
S/N 6610009730, lubricate and install an
O-ring 2 on each cover 4. Install a square cut c. Refill Transmission
seal 3 on each cover 4. Lubricate filter O-ring
and install filters 1 onto covers 4.
NOTE:
For units prior to S/N 6610027897, when the drain
plug cannot be properly tightened due to channel
plate thread damage, take the following corrective
action:
LUBE
MAIN Rotate the original plug until all remaining
threads in the channel plate are removed.
Remove the drain plug and any residual alu-
minum particles. Use caution to prevent any
loose particles from entering the channel
plate.
Install a new longer drain plug (see Parts
Catalog PC2456EN) using a mechanical
ratchet, ensuring the plug is straight in the
9 11 bore.
1 10
2 Remove the plug and clean any aluminum
PRIOR TO 6
S/N 6610009730 3 7 particles from the plug and the bore. Reinstall
8 the new plug and O-ring. Tighten the plug to
4 STARTING WITH
5 LUBE S/N 6610009730 2532 Nm (1824 lb ft).
MAIN
V06833 If the longer drain plug will not tighten, see
Paragraph 518f for channel plate rework
procedure.
Figure 22. Filter Change
2. After refill, check the fluid level (refer to 215. TRANSMISSION STALL TEST
Paragraphs 26 through 28). The quantity of AND NEUTRAL COOL-DOWN
refill fluid will be less than the initial fill due to
fluid remaining in the external circuits and
CHECK
transmission cavities. Table 24 shows typical
initial fill quantities. a. Purpose
1. Use the stall test to determine if poor vehicle
Table 24. Transmission Fluid Capacity performance is due to the engine or the
transmission.
Item Being Filled Initial Fill*
4000 MH/ 4.00 inch Sump 48.0 liters 2. Determine the maximum engine speed attained
HD 4000/B 500 PTO Provision 51.0 quarts with the engine at full throttle and the torque
4000 MH/ 4.00 inch Sump 45.0 liters converter turbine not moving or stalled.
HD 4000/B 500 No PTO Provision 48.0 quarts
4000 MH/ 2.00 inch Sump 41.0 liters 3. Compare the engine speed from the stall test to
HD 4000/B 500 PTO Provision 43.0 quarts the value established from engine
4000 MH/ 2.00 inch Sump 38.0 liters manufacturers specifications.
HD 4000/B 500 No PTO Provision 40.0 quarts
Additional Fill For Cooler* NOTE:
Direct-mount Non-retarder 1.0 liter Engine stall point data can be obtained from the
1.1 quart engine manufacturer or from the equipment dealer
Additional Fill For Retarder Accumulator* or distributor.
Remote Accumulator 0.6 liter
0.6 quart 4. Use stall checks for troubleshooting only. Do
* Does not include hoses or fittings. not use stall checks as part of routine or
preventive maintenance.
NOTE:
NOTE:
Environmental conditions, such as ambient
Because smoke controls and throttle-delay temperature, altitude, and engine accessory loss
mechanisms inhibit engine acceleration, the stall variations, affect the power input to the converter.
testing will need to be started while the vehicle is Under such conditions, stall speed can vary from
moving. specification by 150 rpm and still be accepted as
within normal range.
4. Slowly depress the vehicle service brakes 2. An extremely low stall speed (such as 33
while staying at full throttle. percent of the specified engine stall rpm),
during which the engine does not smoke, may
5. When the vehicle comes to a stop, record the indicate a freewheeling torque converter stator.
engine rpm this is stall speed.
3. If the fluid does not cool during the two minute
6. Proceed immediately with Paragraph f, Neutral cool-down check, a stuck stator may be the
Cool-Down Check Procedure. source of the problem.
f. Neutral Cool-Down Check Procedure 4. If the engine stall speed meets the specification
and the cool-down check shows that
1. The neutral cool-down check determines if the transmission fluid cools properly, refer to the
transmission fluid cools properly following an Allison Transmission Electronic Control
engine load condition. Perform this check Troubleshooting Manual (TS2470EN for
immediately after the engine speed has been WTEC II or TS2973EN for WTEC III).
recorded in the stall test.
LOCKUP
PRESSURE TAP
C6 PRESSURE TAP
(On left side of
adapter housing,
near the bottom)
MAIN
C5
C4
C3
C1 C2
MAIN
LUBE
DRAIN PLUG
OIL FILTER
COVERS LUBE PRESSURE CLUTCH PRESSURE
TAP TAPS
V05596
4. If clutch pressures are not within specification, 6. Return the transmission to its original
take corrective action to replace the internal configuration. (Remove instrumentation and
parts of the transmission necessary to correct
reinstall any components removed for the
the problem.
pressure testing.)
5. Recheck pressure values after the transmission
has been repaired.
PREVENTIVE MAINTENANCE
1C C1 C5 13001800 070 [010] (C1) 3.5 min.
[189261] 040 [05.8] (C5) [0.5 min.]
Copyright 2001 General Motors Corp.
Loose or worn bearing causing excess seal 5. Remove oil seal 1 using tool J 24171-A or
wear equivalent.
1 7
8
4
3
5
6
9
10
12
11
V06834
NOTE:
V05151.02
Bolts 11 and washers 12 are available in Service
Bolt Kit P/N 29535910 as described in Figure 26. Installing Redesigned Two-Bolt
SIL 15-WT-98. The convex end of belleville washer Flange Retention Kit
12 MUST contact the head of bolt 11 as shown in
Figure 26. DO NOT use locktab 9 with washer 12 219. OUTPUT FLANGE/YOKE AND
and bolt 11. OIL SEAL MAINTENANCE
(HD 4070/4076 Models Only)
4. Insert two bolts 11 through belleville a. Disassembly (Figure 27)
washers 12 and retainer plug 6 or one bolt 8
through plug 7. 1. Remove one bolt 6, O-ring 4, retainer plug 5,
and O-ring 3.
5. Install an O-ring 5 over the threaded end of
each bolt 11 or 8 so that the O-ring seats 2. Remove flange 2 or yoke 7. Inspect journal
against the retainer plug. sealing area. Minimum journal area diameter is
6. Install retainer plug 6 or 7 into the yoke or flange. 85 mm (3.346 inch).
Tighten bolts 11 to 3035 Nm (2226 lb ft). 3. Remove oil seal 1 using tool J 24171-A or
Tighten bolt 8 to 7080 Nm (5160 lb ft). equivalent.
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;; 2
;;;;;;;;;;;
;;;;;;;;;;;
1
;;;;;;;;;;;
;;;;;;;;;;;
7
3
4 5
6
V05578
Figure 27. Output Flange and Oil Seal (HD 4070/4076 Models)
5. Install an O-ring 4 over the threaded end of Oil Fill Tube 42c(2)
bolt 6 so that the O-ring seats against the Remote Mount Manifold 42c(3)
retainer plug. Input, Turbine, and
Output Speed Sensor 42c(8)
6. Install retainer plug 5 into the yoke or flange.
Tighten bolt 6 to 7080 Nm (5160 lb ft). Control Module 42e
120 cm
(48 INCHES)
200 cm
(78 INCHES) OIL DRAIN STEEL TOP
TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 INCHES) 35 mm (1-1 2 INCH) DEEP
35 mm (1-1 2 INCH) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 INCH BOARD)
FOR TOP FRAME
10x10 cm AND LEG BRACKETS
(4x4 INCH LEGS)
V00660
1 5
2 3 4
11
7 9 10
8
14
12 13 15 16
17
18
19
20
23
24
26
21 22 25 27
28
29
1
2 3 4
5 6
7 8
10
9 23
11
14
16 17
15
12
13
18 19
20
22
21
Figure 33
Kent-Moore Item Reference
Tool No.** Number Description Paragraph
J 3940 1 Bearing Race Remover 515e,f,o,q; 517c
J 8092 2 Drive Handle 515i,t; 517e
J 24171-A 3 Seal Remover 219a; 515c,n; 517a
J 35923-4 11 Spring Compressor Tool Base 513d,e; 517d
J 35926-A 13 Transmission Lifting Bracket (Modified to lift 42a; 62a
HD 4070 models)
J 35926-UPD NA Modification Template (Used To Modify J 35926 to NA
become J 35926-A)
J 37030-2 10 C5 Spring Compressor 515f,q,r; 517c
J 37030-3 11 C1, C2, and C5 Spring Compressor Tool Base 515f,q,r; 517c
J 37032 4 Input Seal Installer 515g
J 37033 5 Output Bearing Cup Installer 515g,h,r,s; 517d
J 37034 9 Output Bearing Installer/Drive Sleeve 513d,e,f,r,s,t,u; 515g,h,i,j;
517d,e,f; 62r,t
J 37035 6 Spanner Nut Torque Tool Set 515c,j,n,u; 517a,f; 62r,s,t
J 37036 8 Turbine Shaft Bushing/Output Bushing/P2 Carrier 515i,t; 517e
Bushing Installer
J 41445 12 Transmission Holding Bracket 42a; 62a
J 42048 23 Retarder Flow Valve Spring Compressor 515c,j,n,u
J 43020 15 P3 Planetary Lifting Ring 42m
J 43023 16 P4 Planetary Bushing Installer 513f
J 43024 17 Output Shaft Seal Installer 62r,t
J 43025 18 C5 Return Spring 513d,e; 517d
J 43046 19 Torque Wrench Adapter 42l; 62l
J 43047 20 Bearing Installer/Remover 513d,e
J 43202 21 Output Shaft Bearing Installer 515i,t; 517e
J 43278 7 Output Shaft Holding Tool 515c,j,u; 517a,f; 62r,t
J 43922 22 Measuring Blocks And Straight Edge 62m,n
J 43975 14 HD 4070 Tool Kit (Includes the following special NA
tools: J 43020, J 43023, J 43024, J 43025, J 43046,
J 43047, J 43202, J 43278, and J 43922)
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066
3. Before inspection, lubricate bearings with f. Inspecting Cast Parts and Machined Surfaces
transmission fluid.
1. Inspect bores for wear, scratches, grooves, and
d. Inspecting Bearings dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
deeply scratched or grooved.
CAUTION:
2. Inspect all fluid passages for obstructions. If an
If excessive metal contamination has occurred, obstruction is found, remove it with
replacement of all bearings is recommended.
compressed air, or by working a soft wire back
and forth through the passage and flushing it
1. Inspect bearings for rough rotation. Replace a with mineral spirits.
bearing if its rotation is still rough after
3. Inspect mounting faces for nicks, burrs,
cleaning and lubrication.
scratches, and foreign matter. Remove any
2. Inspect bearings for scored, pitted, scratched, defects with crocus cloth or a soft stone. Clean
cracked, or chipped races, and for excessive the part. If scratches are deep, replace the
roller or ball wear. Replace the bearing if any defective part.
of these defects are found.
4. Inspect threaded openings for damaged
3. Inspect a defective bearings bore and mating threads. Chase damaged threads with the
shaft for grooved, burred, or galled conditions correct size tap.
that indicate the bearing has been turning in the
5. Inspect the ribs inside the main housing for
bore or on the shaft. If shaft or bore damage
reaction plate wear grooves in the side of the
cannot be repaired with crocus cloth, replace
ribs. Replace housings that have wear grooves
the defective part.
beyond wear limits. (Refer to Wear Limits,
4. When removing a bearing, do not apply Table 71 in Section 7.)
pressure across the balls. This can cause
6. Replace housings or other cast parts that are
brinelling and bearing failure.
cracked.
5. If a bearing must be removed or installed
without the proper tool, press only on the 7. Inspect all machined surfaces for damage that
race which is adjacent to the mounting could cause fluid leakage or other malfunction.
surface. Rework or replace defective parts.
e. Keeping Bearings Clean. Ball or roller bearing 8. Inspect the oil tracks of the control module and
failures are usually caused by dirt or grit in the main housing for porosity, broken lands,
bearing. Keep bearings clean during removal and cracks, dirt, and land surface imperfections.
installation. Observe the following rules to ensure These imperfections will cause severe fluid
maximum bearing life: leakage leading to transmission failure.
Do not unwrap new bearings until they are to g. Inspecting Bushings and Thrust Washers
be installed.
1. Inspect bushings for scores, burrs, sharp edges,
Do not remove the grease in which new and evidence of overheating. Remove scores
bearings are packed until they are to be with crocus cloth. Remove burrs and sharp
installed. edges with a scraper or knife blade. Before
Do not lay bearings on a dirty bench. Place re-installing, carefully check bushings for
bearings on clean paper, or lint-free cloth. signs of distress.
2. Replace bushings that are out-of-round, deeply 2. Inspect gear teeth for wear that has changed
scored, or excessively worn. Inspect parts the original tooth shape. If this condition is
mated to bushings to ensure they are not found, replace the gear.
damaged or worn beyond use.
3. Inspect the thrust face of gears for scores,
3. Inspect thrust washers for distortion, scores, scratches, and burrs. Remove such defects with
burrs, and wear. Replace a thrust washer if a soft stone. If scratches and scores cannot be
defective or worn. removed with a soft stone, replace the gear.
4. Inspect gears for load pattern and signs of
h. Inspecting Sealrings and Gaskets distress. Any sign of distress indicates that a
1. Inspect piston sealrings and lip-type seals for gear failure during operation is possible.
nicks, cuts, tears, splits, and pattern damage. A Reusing distressed gears is an individual
damaged seal can indicate rough or sharp customer decision based upon experience.
edges in piston grooves or on a mating surface Backlash cannot be used to establish critical
that could damage a new seal. gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores, or
2. Inspect piston sealring grooves for nicks, burrs, galls long before gear wear becomes critical.
dents, or displaced metal that could damage
j. Inspecting Splined Parts
the new seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and 1. Inspect splined parts for stripped, twisted,
crocus cloth. Thoroughly clean all residue chipped, or burred splines. Remove burrs with
from the piston before assembly. a soft stone. Replace the part if other defects
are found. Spline wear is not considered
3. Replace all composition gaskets. harmful except where it affects the fit of the
splined parts.
4. Inspect hook-type sealrings for wear, broken
hooks, and distortion. Install a new hook-type 2. Spline wear is determined by measuring and
sealring if the old ring shows any wear on its comparing the unworn and worn areas of the
outside diameter, or if there is excessive side spline. This can also be checked by comparing
wear. Install a new sealring if there is wear on feeler gauge thickness to the depth of the worn
the sealring outside diameter mating surface. area. Replace parts having excessive spline
wear. (Refer to Wear Limits, Section 7.)
5. Inspect clutch housing sealing surfaces for 3. Backlash cannot be used to establish critical
nicks, burrs, dents, or displaced metal that spline wear. Accurate backlash measurement
could interfere with mating parts or damage requires the mating parts to be concentrically
the piston seal. Remove raised metal, sharp located.
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue k. Inspecting Threaded Parts. Inspect threaded
from the housing before assembly. parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
6. Measure butt-joint sealring end gap by
inserting the sealring into its respective sealing l. Inspecting Retaining Rings. Inspect all retaining
bore. Use a feeler gauge to measure end gap. rings for nicks, distortion, or excessive wear. Replace
Discard sealrings that do not meet the retaining ring if any of these defects are found. The
specifications. (Refer to Wear Limits, retaining ring must snap tightly into its groove to
Section 7.) function properly.
1. When replacing lip-type seals, make sure the 5. Pack the sealring and its groove with a liberal
spring-loaded lip is toward the fluid to be amount of oil-soluble grease.
sealed (toward the inside of the unit). Coat the
inside of the seal with high temperature grease 6. Roll the sealring to about half its free diameter
(MIL-G-3545A or equivalent) to protect the and hold it for about 10 seconds. Being careful
seal during shaft installation and to provide not to spread the sealring more than necessary,
lubrication during initial operation. slide it onto the hub. Place one end of the
sealring into the groove and gradually work the
2. The circumference of some seals is precoated seal into the groove.
with a dry sealant. The sealant is usually
colored for easy identification. Precoated seals h. Bearings
do not require any additional sealant before
1. When removing a bearing, do not apply
installation.
pressure across the balls. This can cause
3. Before installation, apply a non-hardening brinelling and bearing failure.
sealant to the circumference of seals not
2. If a bearing must be removed or installed
precoated with a dry sealant.
without an installation sleeve, drive or press
g. Butt-Joint Sealrings only on the race which is adjacent to the
mounting surface. If a press is not available,
carefully seat the bearing with a drift and a
CAUTION: hammer, driving against the supported race.
If humidity is allowed to penetrate and expand a
i. Bushings. Whenever a new bushing is being
butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will installed, NEVER allow the pressing tool to bottom
permit transmission fluid to leak from the clutch against a needle thrust bearing. ALWAYS make sure
piston cavity and cause clutch slippage. Do not that the pressing tool bottoms against the part that the
open the sealed package until you are ready to bushing is being pressed into.
install the sealring.
j. Electrical Components. For inspection and
repair of electrical components, refer to the MD/HD/
1. Butt-joint sealrings require special handling B Series Troubleshooting Manual TS2470EN
during assembly. The sealrings contain (WTEC II Controls) or TS2973EN (WTEC III
materials that absorb moisture from the Controls).
4. Disconnect all hydraulic hoses from the PTO drive shaft from the PTO
transmission. If a retarder is installed, 3. If the transmission supports the rear of the
disconnect the accumulator line from the engine, place a jack or other support under the
retarder housing. Remove the hoses from the engine.
vehicle if they interfere with the transmission
removal. Plug all openings to keep dirt from 4. Securely support the transmission with a hoist,
entering the hydraulic system. jack, or other suitable removal equipment.
5. If an integral cooler is used, drain coolant from 5. Remove all bolts, nuts, washers, spacers, and
the cooler and disconnect coolant hoses. supports that attach the transmission to the
Remove the hoses from the vehicle if they vehicle and the engine.
REAR OUTPUT
FRONT COOLER COOLER SPEED
PORTS (OPTIONAL) PORTS SENSOR
PTO CONTROLS
OUTPUT SPEED SENSOR AND LINES
RETARDER
TEMPERATURE
ACCUMULATOR LINE SENSOR
(RETARDER ONLY)
FEEDTHROUGH
HARNESS
CONNECTOR
1. Mount holding bracket J 35926 or J 35926-A 5. Remove two bolts 22 and locktab 21 or two
(HD 4070 models), with holding bracket bolts 23 and two belleville washers 24 or one
J 41445 attached, onto the main housing bolt 19. Discard locktab 21 and bolts 22,
module. bolts 23 and washers 24, or bolt 19.
1 2
4
3
3
1
4
V06836
25 ENGINE
SPEED 1 2 7
SENSOR
TURBINE 4
SPEED 3 5
SENSOR 6
13
9
OUTPUT
SPEED
SENSOR 13
18
19
16
14
17
20
21
22
24
10 23
11 12
V06837
NOTE:
The integral oil cooler is only available on non-
retarder transmissions in the HD/B 500 Series.
ENGINE
SPEED SENSOR 1. Remove two bolts 11 and seventeen bolts 12.
Remove cover 13, gasket 14, and two
O-rings 10.
TURBINE
OUTPUT SPEED SENSOR 2. Remove plate assembly 9 and four O-rings 8.
SPEED SENSOR V06838
3. Remove nine bolts 7 and nine washers 6.
Figure 43. Speed Sensors Remove cooler housing 3 and gasket 1.
5
4
3
1
11
8
4 2 9
5
6 7 10
8
19
18 17
11 19
18 17 10
16 11
15
12
14
13 11 V06843
CAUTION:
The control module or filters may contain re-
sidual transmission fluid.
Be sure the external part of feedthrough harness
connector 3 (clip and/or bracket nut) has been
disconnected from external brackets before re-
moving the control module.
NOTE:
1
Transmissions between S/N 6610009662 and
6610009762 may contain control module to main
housing bolts that are too short. See Figure 46 for 3
the correct and incorrect bolt descriptions. Replace
the incorrect bolts and inspect the main housing
threads. 2
2
5
1. Remove forty-three bolts 4 and 5 retaining 4
V06839
control module 2 to the main housing module,
including the bolts retaining the filter covers. Figure 45. Control Module Removal
10.9 9.8
M 50 mm M
55 mm (1.969 in.)
(2.165 in.)
7 8
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
WARNING! 5
6
V06842
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs Figure 49. Removal of Retarder Module
approximately 34 kg (75 lb). (Units Prior to S/N 6610066447)
2 2
2 2
2 2
2 2
1
2 2 2
8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844
Figure 410. Removal of Retarder Module (Units Beginning With S/N 6610066447)
9 8 7
WARNING!
V05373
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb). Figure 411. Removal of Retarder and Output
Shaft Module (Units Prior to S/N 6610066447)
2. Thread an M14 eye bolt into the end of the
output shaft and lift the retarder and output
shaft module 5 from the transmission.
3. Remove and discard retarder housing gasket 3
from the retarder and output shaft module. 4 4
BOLT, M12 x 1.75 x 55 4 4
(12) MARKED 4
4. Remove twelve bolts 4 (Figure 413), three 4 4
bolts 6, two bolts 7, four bolts 8, and four
bolts 9 that secure retarder module 5 to main 4 4
6. Remove retarder gasket 3 from main housing Figure 412. Retarder and Output Shaft Module Bolts
module 1 or from retarder module 5. (Units Prior to S/N 6610066447)
1
4 4
4 4
2 4 4
4 4
3 4
4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845
Figure 413. Removal of Retarder Module (Units Beginning With S/N 6610066447)
j. Removal of Rear Cover Module k. Removal of Rear Cover And Output Shaft
(All Models Except HD 4070/4076) Module (HD 4070/4076 Models)
1. If used, remove the rear support bracket.
1. If used, remove the rear support bracket.
2. Remove fourteen bolts 4 (Figure 415 and 416).
2. Remove nineteen bolts 5 (Figure 414) and
Remove five bolts 5.
washer 4, if present.
3. Thread an M14 eye bolt into output shaft 7 and
3. Thread an M10 or M14 eye bolt into the output lift upward to remove rear cover module 6.
shaft and lift upward to remove rear cover
4. Remove rear cover gasket 3 from C6 adapter
module 3.
housing module 2 or from rear cover module 6.
4. Remove rear cover gasket 2 from main housing
module 1 or from rear cover module 3. 1
3 4
1 5
2
4
5
3 V05580
V06846
4 4
BOLT, 4 5 5 4
METRIC HEAVY 5 5
(5) MARKED 5 5
5
V05374
V05576
3
4
WARNING!
Get help when lifting the C6 adapter housing 5
module. Assistance from a hoist or another
person may be required. The C6 adapter housing J 43020
module weighs approximately 68kg (150 lb).
V05375
HD 4560
1 E01271.01
1 2
4000 MH/HD 4060/4070/4076/B 500 3 2
V01737.02 3
1
1 C5
2
3
E02516.01 V01272
CAUTION:
Always remove the turbine speed sensor be-
fore removing the rotating clutch module to
avoid possible damage to the turbine speed
sensor.
When you remove rotating clutch module 1, 1
carefully place it on the workbench and pre-
vent it from rolling off the bench.
CAUTION:
Ensure the main housing module is horizontal
when removing the C3/C4 clutch assembly.
THRUST
SURFACE
OF THRUST DIM. B
TURBINE DIM. A SURFACE
HUB OF
TURBINE
HUB
J 38548
E02517.01
21. Dimension C must be 0.080.36 mm (0.003 26. Perform the measurement again. Dimension C
0.014 inch). must be 0.080.36 mm (0.0030.014 inch). If
22. If dimension C is not correct, then a shim is dimension C is not correct, then a shim change
needed. Select the proper shim from Table 51 is needed. Disassemble the converter and reas-
and proceed with Step (24). semble without shim 30, and go back to
Step (17).
23. If dimension C is correct, proceed with
Step (28).
27. If dimension C is correct, proceed with
24. Disassemble the converter and reassemble us- Step (28).
ing selected shim.
25. Install four nuts 6, evenly spaced, onto four 28. Install the remaining thirty-two nuts 6 onto T-head
T-head bolts 37. Tighten the nuts to 3035 Nm bolts 37. Tighten all the nuts to 3035 Nm
(2226 lb ft). (2226 lb ft).
1. Using a mallet, lightly tap PTO gear 7. For models without PTO provision, inspect
assembly 10 into converter housing 19 until bushing 8 inside pump housing 9 for wear or
the gear assembly is seated. damage. Measure the ID of the pump bushing.
Maximum ID allowed is 89.19 mm
2. Use guide bolts to install bearing retainer (3.511 inch).
assembly 3, rocking the retainer while 8. If worn or damaged, remove bushing 8 from
installing it. pump housing 9.
3. Install eleven bolts 2 to hold bearing retainer 9. Install gear set 11 into pump housing 9.
assembly 3 and PTO gear assembly 10 to Measure pump gear side clearance of both
housing 19. Tighten the bolts to 5161 Nm gears. Maximum allowable clearance is
(3845 lb ft). 0.10 mm (0.004 inch) (Figure 55).
CAUTION:
Use the correct wrench size to avoid crushing the MAX DEPTH OF
breather. GEAR CAVITY
19.04 mm (0.75 in.) V01899.01
6. Install breather 20. Tighten the breather to Figure 53. Measuring Gear-Cavity Depth
1216 Nm (912 lb ft). of the Pump Housing
PUMP
HOUSING
MAX ID OF
GEAR CAVITY
150.25 mm (5.915 in.)
V01277.01 MAX GEAR TOOTH
TIP CLEARANCE
0.15 mm (0.006 in.)
Figure 54. Measuring Gear-Cavity Diameter V02519
of the Pump Housing
Figure 56. Measuring Gear Tooth Tip Clearance
DRIVE
GEAR
PUMP PUMP HOUSING
HOUSING MAX SIDE DRIVEN GEAR MAX CLEARANCE BETWEEN
CLEARANCE DRIVEN GEAR OD AND PUMP
0.10 mm (0.004 in.) V02518 DRIVEN GEAR HOUSING 0.30 mm (0.012 in.)
V02520
Figure 55. Measuring Gear Side Clearance Figure 57. Measuring Driven Gear
of the Pump Housing Clearance to the Pump Housing
FRONT
FRONT SUPPORT (20) TOP
DOWEL PINS E
(19 )
DOWEL PIN
14.5 mm
GROUND SLEEVE (0.57 in.)
INSTALL REMOVE
SPLINE OD T.I.R.
0.13 mm
(0.005 in.)
E
RELIEF VALVE
SECTION E-E BORE
BOTTOM
VIEW A
VIEW B
To install, align flat on
ground sleeve with arrow
on front support.
20
VIEW C V01344.03
7. Install wear plate 13. Secure with fourteen 6. Measure the wear surface thickness of C2
bolts 14. Tighten the bolts to 5161 Nm backplate 39. Minimum thickness allowed is
(3845 lb ft). 7.90 mm (0.311 inch). Check flatness of the
backplate. Maximum allowable distortion is
8. Install bearing 26 using a press, and tools 0.15 mm (0.006 inch).
J 37038 and J 8092. Press bearing 26 flush to
0.25 mm (0.009 inch) below the surface. 7. Remove C2 clutch pack seven friction
plates 38 and seven steel reaction plates 37.
c. Assembly of Pump Housing (Foldout 6,A) 8. Measure the thickness of each friction plate 38.
Minimum thickness allowed is 2.92 mm
NOTE: (0.115 inch). Measure the oil groove depth and
Steps (1), (2), and (3) below apply only to cone of each friction plate. Minimum groove
transmissions without PTO provision. depth allowed is 0.20 mm (0.008 inch).
Maximum cone allowed is 0.25 mm (0.010 inch).
1. If removed, install bushing 8 into pump 9. Measure the thickness and cone of each steel
housing 9 using a press, and tools J 37038 and reaction plate 37. Minimum thickness allowed
J 8092. is 2.41 mm (0.095 inch). Maximum cone
2. Install oil seal 5 using a press, and tools allowable is 0.25 mm (0.010 inch).
J 37032 and J 37034. 10. Remove C2 drive hub 36, including two thrust
3. Install O-ring 4. bearings 35. Inspect the splines of the C2 drive
hub. Maximum spline wear allowed is
4. If removed, install bushing 12 into drive 0.38 mm (0.015 inch).
(inner) gear of gear set 11. Align the staking in
the pre-staked bushing with the slots in the 11. Remove C1 drive hub 34. Inspect the splines of
inside gear of gear set 11. Use tool J 39954. the C1 drive hub. Maximum allowable spline
wear is 0.38 mm (0.015 inch).
5. Lubricate pump gear set 11 and install the gear
set in pump housing 9 or 10.
NOTE:
6. Retain the pump housing to the front support Beginning with S/N 6610032320, the C1 clutch
with eight bolts 6. Tighten the bolts to 5161 Nm apply plate and backplate are not identical. Consult
(3845 lb ft). a current parts catalog and rebuild with the
7. Measure the end gap of three rotating improved design where the apply plate is thinner
sealrings 25 before installation. Insert the and the backplate is thicker. This change provides
improved C1 backplate life and better retention of
sealrings into the rotating clutch hub bore
the backplate retaining ring.
and measure end gap with a feeler gauge.
Sealring end gap must be 1.001.44 mm
(0.0400.056 inch). Refer to Paragraph 36g. 12. Remove C1 retaining ring 33 and C1 clutch
8. Install three rotating sealrings 25 on front pack one backplate 32, seven friction
support 20 hub. plates 30 and six steel reaction plates 31, and
one apply plate 29.
57. ROTATING CLUTCH MODULE 13. Measure the thickness of each friction plate 30.
Minimum allowable thickness is 2.92 mm
a. Disassembly (Foldout 6,B) (0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
1. Remove retaining ring 43. depth allowable is 0.20 mm (0.008 inch). Max-
2. Remove P1 sun gear assembly 41. imum cone allowed is 0.25 mm (0.010 inch).
J 37030-3
J 37030-3
HANDLE
HANDLE
FLAT WASHER
FLAT WASHER
BEARING J 35923-2
BEARING J 35923-2
J 37030-1
VIEW A VIEW B
J 37030-3
VIEW C
VIEW D
ALIGNMENT SLOTS V06847
11. Install C1 spring assembly 25. Aligning mark 17. Install thrust bearing 14 onto the rotating as-
on balance piston with slot on the C1 clutch sembly 13.
piston, install balance piston 26 onto the C1
piston. NOTE:
12. Install tool J 35923-2 (Figure 59, View A), Beginning with S/N 6610032320, the C1 clutch
apply plate and backplate are not identical. Consult
that includes the bearing, washer, and handle.
a current parts catalog and rebuild with the
Tighten tool to compress C1 spring assembly improved design where the apply plate is 2.00 mm
and install retaining ring 28 into the hub of the (0.157 inch) thinner and the backplate is 2.00 mm
rotating clutch assembly. Remove tool. (0.157 inch) thicker and reshaped. This change
provides improved C1 backplate life and better
13. If removed, install bushing 5 into turbine shaft retention of the backplate retaining ring. See Figure
assembly 3 or 6 using tools J 37036 and 510 for pictorial information.
J 8092.
V05566
20. Install a thrust bearing 35 on each side of C2 6. Inspect four thrust plates 5 and twelve rivets 6 on
drive hub 36, and install this assembly over C1 clutch backplate 4. Minimum allowable thrust plate 5
drive hub 34. thickness at the contact surface is 2.82 mm
(0.111 inch). Maximum allowable distortion of
21. Install C2 clutch plates seven friction backplate 4 is 0.15 mm (0.006 inch). Maximum
plates 38 and seven steel reaction plates 37. In- allowable step wear of backplate 4 is 0.13 mm
stall clutch plates alternately, starting with a (0.005 inch). If replacement is necessary,
steel reaction plate 37. remove the thrust plates by drilling out the
rivets.
22. Install C2 pressure plate 39. Install C2 retain-
ing ring 40. 7. Remove P1 ring gear 7. Inspect the clutch
splines of the P1 ring gear. Maximum
23. If removed, install thrust bearing 42 on sun
allowable spline wear is 0.38 mm (0.015 inch).
gear assembly 41.
24. Install P1 sun-gear drive hub 41. Install retain- 8. Remove the C3 clutch pack five friction
ing ring 43. plates 8 and four steel reaction plates 9.
19. Remove piston return plate 23 with four return 5. To assemble the C3 housing (if thrust plates
spring assemblies 22 attached. Inspect were removed), install four thrust plates 18
plate 23. Minimum allowable thickness of using twelve rivets 17 into C3 clutch
plate 23 is 4.91 mm (0.193 inch) housing 19. Use tool J 39534 to cold form
rivets. Insert the rivet from the front so that the
20. Remove spring retainer assembly 24 and pre-formed head is below the active surface of
piston 27 from C4 housing 28. If present, the thrust plate. Use the cold forming tool to
remove sealrings 25 and 26 from non-molded, upset the rivet at the rear of the clutch housing
one-piece piston 27 and discard these parts. to complete the riveted joint. A correctly
Inspect splines in C4 clutch housing 28. formed rivet upset will be 4.00 mm
Maximum spline wear allowed is 1.15 mm (0.157 inch) in diameter and be no more than
(0.045 inch). 1.00 mm (0.039 inch) above the surface of the
clutch housing. The thrust plate must be tightly
attached to the housing; no movement is
b. Assembly (Foldout 7) allowed.
1. Replace non-molded piston 27 with new
6. Replace non-molded piston 15 with a molded
molded piston 27. Install piston 27 into C4
piston 15. Install C3 clutch piston 15 into C3
housing 28. Install spring retainer assembly 24.
clutch-housing assembly 19.
2. If removed, install spring assemblies 22 and 7. Install C3 clutch housing assembly 19 with
attach them securely to piston return plate 23. clutch piston 15 on top of the assembled C4
clutch housing assembly. Ensure index notches
3. Install piston return plate 23 with four return on the clutch housings are aligned. Install
spring assemblies 22. spring retainer assembly 12.
RADIUS ADDED ON
INDEXING FLAT SHARP FLAT EDGE EDGE 0.25-1.50 mm
NO WEAR
ABNORMAL WEAR
INDEXING RING
VIEW A
PLANETARY SPINDLE
VIEW B
DIMENSION A
VIEW C VIEW D
View C and D New Design Beginning January 1, 2000 V06848
3. Install six spindles 6 so the lower step is 7. Install internal retaining ring 2 into P2 ring
positioned for proper installation of indexing gear 15, connecting P1 planetary carrier
ring 5. assembly 3 and the P2 planetary ring gear.
511. P2 PLANETARY MODULE 2. Install two roller bearings 10 into the center of
pinion gear 11. Install thrust washers 9 and 12
a. Disassembly (Foldout 9,B) in P2 planetary carrier 7, align thrust washer
tangs with slots in the planetary, and retain
1. Remove retaining ring 2. them with oil-soluble grease. Slide the pinion
gear and two bearing sets, into the side of the
2. Remove P3 ring gear 15. Remove and inspect
P2 planetary carrier between the thrust
thrust bearing assembly 14.
washers. Repeat the procedure with the three
3. Check P2 planetary carrier pinion end play. remaining pinion gears.
Pinion end play must not exceed 0.94 mm
(0.037 inch). Check all four pinion gears. CAUTION:
4. Remove internal retaining ring 4. Remove If abnormal wear existed on the indexing ring of
indexing ring 5. Remove four pinion units prior to S/N 6610018759, replace all
spindles 13 from P2 carrier 7. spindles with the sharp edge condition shown in
Figure 512, View B. If the wear on the indexing
ring is minor, flip it over to get a fresh reaction
NOTE: point for the spindle. Replace the indexing ring if
both corners of the indexing ring are worn.
For units prior to S/N 6610018759, inspect the Failure to take corrective action may allow the
indexing ring for abnormal wear as shown in spindle to rotate which may reduce or shut off
Figure 512, View A. Also inspect the planetary lubrication to the pinion bearings and thrust
spindles for the sharp edge condition as shown in washers.
Figure 512, View B.
1. Check pinion end play. Pinion end play must a. Disassembly of Ring Gear And Hub Assembly
not exceed 0.94 mm (0.037 inch). Repeat the
check on the three remaining pinion gears 9. 1. Remove ring gear and hub assembly 45.
J 35923-4
d. Disassembly of Remaining C6 Parts
1. Lift C6 clutch pack from C6 adapter housing
module eight friction plates 28 and nine
steel reaction plates 27.
e. Assembly
1. Turn C6 adapter housing assembly 21 over and
place on press stand.
V05583
2. Place ball bearing 26 in C6 adapter housing
assembly 21.
Figure 515. Removal of Ball Bearing from
3. Place special tool J 43047 and J 37034 on ball C6 Adapter Housing
bearing 26 (Figure 516).
NOTE:
Bearing 26 is properly seated when it is against the
shoulder at the bottom of the bearing bore and is
1.573.35 mm (0.0620.132 inch) below the machined
J 37034
face of the adapter housing at the top of the bearing
bore. J 43047
V05582
NOTE:
Do not install ring gear and hub assembly 45 in the
Figure 518. Bottom View of C6 Adapter Housing
C6 adapter housing module until final transmission
and J 35923-4
assembly. Measurement for selective shim is
f. Assembly of P4 Planetary Carrier Assembly performed during final buildup.
1. Install two needle bearings 42 into the center
of pinion gear 41. Install thrust washers 40 in g. Assembly of C6 Clutch
P4 planetary carrier 37. Align thrust washer
tangs with slots in carrier 37 and retain them 1. Install the C6 clutch pack in the C6 adapter
with oil-soluble grease. Slide pinion gear 41 housing nine steel reaction plates 27 and
and two bearings 42 into the side of P4 eight friction plates 28, stacked alternately,
planetary carrier 37 between thrust washers 40. starting with a steel reaction plate 27. Stack all
Repeat the procedure for the five remaining plates so plate cone faces the same direction.
pinion gears. Steel plates 27 mesh with the C6 adapter
housing and friction plates 28 mesh with C6
2. Install six spindles 39 so the lower step is clutch hub 43.
positioned for proper installation of indexing
ring 35. 2. Install C6 backplate 29.
J 37034
3. Remove channel plate gasket 91, channel
plate 90, two separator plate gaskets 88, and
solenoid separator plate 89.
J 43023
700 LOW PT
3.0C
1,000,000
100,000
SENSOR RESISTANCE ()
10,000
1,000
100
10
1
40 14 68 122 176 230 284 338 392 F
Figure 520. Temperature Sensor Chart Units Beginning With S/N 6610026472
2. If removed, install bushing 5 inside the end of 8. If components were replaced, check pinion end
output shaft 6 using installer J 37036, drive play. Pinion end play must not exceed 0.94 mm
handle J 8092, and a press. (0.037 inch). Check all four pinion gears.
NOTE:
Replacement indexing rings should look like the CAUTION:
example in Figure 512, View C. The ring has Over-tightening bearing retainer locknut 60 will
increased hardness for wear resistance and is damage cone and roller bearing assemblies 17
stamped with HD5. Replacement spindles should and 58 and cups 24 and 52.
look like the example in Figure 512, View D. The
spindle has a revised Dimension A for reduced
clearance with the indexing ring and has a 2 7. Using tool J 37035, install and tighten
stamped on the rear end. bearing retainer locknut 60 to 193207 Nm
(143152 lb ft).
Figure 521. P3 Carrier Turning Torque 9. Install retarder control body assembly 65 and
Check Retarder Equipped nine bolts 64 that retain it to retarder
4. Remove five bolts 65, solenoid cover 68, and 2. Remove tachograph plug 39 and brass
solenoid cover gasket 69. Disconnect solenoid washer 40.
connector 67 from solenoid 70 to remove
3. Remove retaining ring 50 and plug 49.
cover 68 and gasket 69.
5. Remove retaining pin 78 from the back side of 4. Use J 42048 to compress plug 33. Remove
the retarder control body. Remove solenoid retaining ring 32 and tool J 42048. Remove
assembly 70 from control body 77. Remove plug 33, O-ring 34, spring 35, and retarder
and discard O-rings 71 and 72. valve 36. Remove spring pin 37 only if
damaged.
6. Check the resistance of retarder solenoid 70.
Resistance must be 25 Ohms.
NOTE:
7. Remove retarder control valve 73 from retarder Output seal 60 must be removed before retainer
control body 77. locknut 59 can be removed.
8. Remove pressure tap plug assembly 84 from
retarder control body. Remove and discard 5. If not removed, remove output oil seal
O-ring 85. assembly 60 using seal removal tool
J 24171-A.
9. Remove retaining ring 83, plug 82, O-ring 81,
and spring 80 from retarder control body 77. 6. Straighten the tangs of locknut retainer 58 to
allow rotation and removal of bearing retainer
10. Remove pin 79, valve stop 74, spring 75, and locknut 59. Remove locknut 59 using special
exhaust backfill valve 76 from retarder control tool J 37035. Remove locknut retainer 58.
body 77.
7. Support retarder housing 41 so that P3
k. Disassembly of Temperature Sensor planetary carrier assembly 3 can be removed
(Foldout 10,E) from the retarder housing. Place special tool
1. Remove temperature sensor retainer bolt 48 J 37035-1 over the output shaft splines and
and temperature sensor retainer 47. Carefully against the threaded shoulder of the P3
remove temperature sensor assembly 45 from planetary carrier. Press on J 37035-1 with a
retarder housing 41. hydraulic press or drive on J 37035-1 with a
8. Remove three bolts 52 to allow removal of 4. Check pinion end play. Pinion end play must
retarder stator assembly 18 from retarder not exceed 0.94 mm (0.037 inch). Repeat the
housing 41. Remove retarder housing check on the three remaining pinion gears.
gasket 28.
5. Remove retaining ring 7. Remove indexing
9. Remove rotor assembly 29. Remove ring 8. Remove four planetary spindles 12.
sealrings 27 and 30 from rotor
assembly 29. Inspect splines inside rotor 29. 6. Slide pinion gear 14, thrust washers 13 and 16,
Maximum spline wear allowed is 0.38 mm and two bearing assemblies 15 from the side of
(0.015 inch). P3 planetary carrier 9. Repeat the procedure
with three remaining pinion gears.
10. If replacement is required, remove cone and
roller bearing assembly 57 from the retarder 7. Measure the thickness and any step wear for
housing. If necessary to replace, remove bear- eight thrust washers 13 and 16. Minimum
ing cup 51 using bearing tool J 3940. allowable thickness of the thrust washers is
1.40 mm (0.055 inch). Maximum step wear
11. Remove bolt 96, jumper manifold 95 or remote allowed is 0.12 mm (0.005 inch).
side manifold 97, and gasket 94 from the rear
of retarder housing 41.
NOTE:
12. Remove nine bolts 44, cover 43, and gasket 42 For HD 4560 (wide ratio) transmissions, pro-
from the bottom of retarder housing 41. ceed with Step (8).
m. Disassembly of P3 Planetary For all other models, skip Step (8) and proceed
Carrier Assembly (Foldout 10,E) with Step (9).
9. Using tool J 37035, install and tighten 3. Install exhaust backfill valve 76, spring 75,
bearing retainer locknut 59 to 193207 Nm stop 74, and pin 79.
(143152 lb ft).
4. Install new O-rings 71 and 72 onto solenoid 70
10. Support retarder housing 41 so that the turning and insert into solenoid mounting bore of the
torque of the P3 carrier assembly 3 can be retarder control body 77.
checked after installation of bearing retainer
locknut 59 (Figure 521). Use tool J 37035-1
to check turning torque. Maximum turning CAUTION:
torque is 3 Nm (27 lb in.). When inserting solenoid retaining pin 78, be
certain it is installed into the off-center hole in
the solenoid bore. Installing the pin in the bore
NOTE: centerline hole will destroy the solenoid.
Delay bending the retainer tang and installing
output oil seal assembly 60 until final assembly of
5. Install, smooth end first, solenoid retaining
the transmission.
pin 78 into the off-center hole in the solenoid
bore of retarder control body 77.
11. Install plug 49 and retaining ring 50.
6. Connect solenoid connector 67 on cover 68 to
12. If removed, install spring pin 37 into retarder solenoid 70 after gasket 69 is properly
valve 36 and insert into valve bore. Install positioned. Install gasket 69, solenoid
7. Install two guide pins into the retarder control 5. Remove retaining pin 63 from the back side of
body mounting flange bolt holes on retarder the retarder control body. Remove solenoid 58
housing 41. from control body 62. Remove and discard
O-rings 59 and 60.
8. Install gasket 90, channel plate 89, solenoid
separator plate gaskets 87 on both sides of 6. Check the resistance of retarder solenoid 58.
separator plate 88, and solenoid separator Resistance must be 25 Ohms.
plate 88.
7. Remove retarder control valve 61 from retarder
9. Install retarder control body assembly 64 and control body 62.
nine bolts 63 that retain it to retarder
housing 41. Tighten the bolts to 2429 Nm 8. Remove pressure tap plug 71 and O-ring 70
(1821 lb ft). from retarder control body.
10. Skip to Paragraph 518. 9. Remove pin 64, retaining ring 68, plug 67,
O-ring 66, and spring 65 from retarder control
body 62.
515. RETARDER AND OUTPUT
10. Remove pin 64, valve stop 55, spring 56, and
SHAFT MODULE (HD 4070 exhaust backfill valve 57 from retarder control
Models Equipped With Retarder) body 62.
NOTE:
Output seal 42 must be removed before bearing re-
tainer locknut 41 can be removed.
J 43278
J 43278
J 37035-3
V05588
V05592
2. Remove rotor assembly 18. Remove 3. Remove outer sealring 11 from C5 clutch
sealrings 16 and 19 from rotor assembly 18. piston 10.
Inspect splines inside rotor 18. Maximum
spline wear allowed is 0.38 mm (0.015 inch). 4. Remove inner sealring 12 from C5 clutch
piston 10.
3. If replacement is required, remove cone and
roller bearing assembly 42 from the retarder
5. If replacement is necessary, remove bearing
housing. If replacement is necessary, remove
cup 13 using bearing tool J 3940.
bearing cup 41 using bearing tool J 3940.
1. Inspect the splines on output shaft assembly 3. 3. Align the tang notch on the back of the C5
Maximum spline wear allowed is 0.38 mm clutch piston with the tang on the retarder
(0.015 inch). stator before installing C5 clutch piston 10 into
retarder stator 14. Install C5 clutch piston 10
2. If replacement is necessary, remove cone and into retarder stator 14.
roller bearing assembly 6.
4. Install spring and retainer assembly 9, aligning
3. If replacement is necessary, remove output the tab in the spring and retainer assembly with
shaft bushing 4. the notch in retarder stator 14.
8. Install gasket 78, channel plate 77, solenoid 8. If replacement is required, remove cone and
separator plate gaskets 75 on both sides of roller bearing 37 from rear cover assembly 27.
separator plate 76, and solenoid separator If necessary to replace, remove bearing cup 36
plate 76. using bearing tool J 3940.
7. Measure the thickness and any step wear for d. Beginning Rear Cover Assembly
eight washers 15 and 18. Minimum allowable (Foldout 10,B)
thickness of the thrust washers is 1.40 mm 1. If removed, install bearing cup 26 using
(0.055 inch). Maximum step wear allowed is bearing tool J 37033, and bearing cup 36 using
0.12 mm (0.005 inch). bearing tool J 37033 and drive sleeve J 37034.
4. Install thrust washer 12 and retaining ring 13. f. Completion of Rear Cover Assembly
(Foldout 10,B)
5. Install two roller bearing assemblies 17 into
the center of pinion gear 16. Install thrust 1. Place P3 carrier assembly 5 on the work table
washers 15 and 18 in P3 planetary carrier 11. (with the output shaft up) and place rear cover
Align the thrust washer tangs with the slots in assembly 27 over the output shaft.
J 73035-1
V00223.02
V05598
CAUTION:
Over-tightening bearing retainer locknut 29 will
damage roller bearings 9 and 27 and bearing
cups 16 and 21. If the torque wrench and breaker
bar positions in Figure 529 are reversed, the
bearing retainer nut will be overtorqued. Be sure
V05589
wrenches are positioned ONLY as shown in
Figure 529.
4. Install and tighten bearing retainer locknut 29 Figure 529. Bearing Retainer Locknut
Torque Rear Cover Equipped
using special tools J 37035 and J 43278.
Place the torque wrench and a breaker bar as
shown in Figure 529. Rotate the torque
wrench in the counterclockwise direction and
tighten the nut to 7488 Nm (5565 lb ft).
NOTE:
V05593
Delay bending the retainer tangs and installing
output seal assembly 30 until final assembly of the
transmission. Figure 530. Turning Torque Check Rear
Cover Equipped
NOTE:
7. Remove two retaining bolts 171 or 181 and oil
Part callout numbers 1128 are on Foldout 11,A level sensor assembly 170 or 182. Clean the oil
and 129214 on Foldout 11,B. level sensor with a soft clean cloth. Refer to
Troubleshooting Manual TS2470EN or
TS2973EN for proper sensor operation.
a. Disassembly of Control Valve Module
(Foldout 11) 8. Remove either bolt 5, two bolts 7, suction-filter
housing 4, face seal 6, suction filter 3, and
gasket 2 or three bolts 10, face seal 11, suction
NOTE:
filter assembly 12, and gasket 13. Discard
For units prior to S/N 661009730, proceed to suction filter 3 or 12 and install a new filter at
Step (1). rebuild.
For units with S/N 661009730 up to
6610015591, skip Step (1) and go to Step (2). 9. Remove either three bolts 93 or seven bolts 93
(when plate 9 is not present), face seal 94, and
For units beginning with S/N 15591, skip
rotating clutch solenoid body assembly 95.
Step (1) through (3) and go to Step (4).
10. Remove eight bolts 115, two face seals 116, and
1. If not previously removed, remove two filter stationary clutch solenoid body assembly 117.
covers 206, two square-cut seals 208, two
O-rings 209, and two filters 210. Skip Step (2) 11. Remove two bolts 130 and main valve body as-
and go to Step (3). sembly 131.
2. If not previously removed, remove two filter 12. If present, remove five bolts 147, cover 148,
covers 206, two gaskets 207, two O-rings 208, and C6 control valve body assembly 149 (Fig-
two O-rings 209, and two filters 210. ure 531).
148
150
151 NOTE:
Solenoid retention pins 119 must be removed from
152 149 the BOTTOM of the solenoid body. Note the
154
153 grooved end of pin for positive retention.
160 155
159 156
1. Remove three solenoid retention pins 119 from
161
bottom of solenoid body.
162
164 157 2. Remove three solenoids 123, three O-rings 125,
165 158
163 166 167
three O-rings 124, three valves 121, and three
springs 120. Check resistance of the solenoids.
V06864
Solenoid resistance must be 25 Ohms.
Figure 531. Disassembly/Assembly of C6 Control
Valve Body 3. Remove valve retention pin 122.
b. Disassembly of Rotating Clutch Solenoid Body 4. Remove stop 126, spring 127, and valve 128.
(Foldout 11)
5. Remove solenoid separator plate 129.
1. Remove two bolts 96 and then remove C3
pressure switch assembly 97.
d. Disassembly of C6 Control Valve Body
2. Check contact resistance of the C3 pressure (HD 4070/4076 Models Only)
switch. Maximum allowable resistance is 1. Remove retaining pin 159 and C6 regulator
2 Ohms when the contacts are closed and must valve solenoid 154 (Figure 531).
be 20,000 Ohms minimum when the contacts
are open. Check the pressure at which the 2. Remove regulator valve 153 and spring 152
switch opens and closes. Both events must (Figure 531).
occur between 159255 kPa (2337 psi). Test
block J 33884-25 is available to help make 3. Remove retaining pin 159 and C6 interlock
these checks. valve solenoid 163 (Figure 531).
6. Remove valve retention pin 114. Remove 2. Remove solenoid retention pin 148 from
stop 113, spring 112, and valve 111. bottom of the solenoid body.
4. Remove valve retention pin 132. 12. Remove valve retention pin 154.
5. Remove stop 135, spring 134, and lockup 13. Remove stop 157, spring 156, and C2 latch
valve 133. valve 155.
6. Remove valve retention pin 136. 14. Remove valve retention pin 158.
7. Remove stop 139, spring 138, and lube 15. Remove stop 161, spring 160, and exhaust
regulator valve 137. back pressure valve 159.
9. Remove stop 143, spring 142, and main 1. If damaged, remove two dowel pins 191 or
regulator valve 141. 199.
CAUTION:
If threads were damaged by the drain plug or if
proper drain plug torque could not be attained,
refer to SIL 5-WT-98, Rev. A for an approved
channel plate rework procedure and information
about a longer drain plug for improved thread
life and torque holding capability.
7. Install C2 latch valve 155, spring 156, and 4. Inspect solenoid filter screen 150, if present,
stop 157. for debris and damage. Replace it if necessary
(Figure 531).
8. Install valve retention pin 154.
5. Install new O-rings 164 and 165 on interlock
9. Install control main valve 145, spring 146, and valve solenoid 163, and install the solenoid in
stop 147. the valve bore (Figure 531).
10. Install valve retention pin 144. 6. Check regulator valve 153 and its bore for
wear and damage (Figure 531).
11. Install main regulator valve 141, spring 142,
and stop 143. 7. Insert regulator valve 153 in the bore and
check it for free movement (Figure 531).
WARNING! 8. Install regulator valve 153 and spring 152 in
Spring 142 is highly compressed. Be extremely the valve bore (Figure 531).
careful during assembly. Personal injury can
occur if the spring force is not controlled. 9. Install new O-rings 155 and 156 on the
regulator valve solenoid (Figure 531).
12. Install spring compressor J 35924 10. Install regulator valve solenoid 154 in its bore
(Figure 532). Compress spring 142, install (Figure 531).
valve retention pin 140, and carefully remove
J 35924 tool. 11. Insert solenoid retention pins 159, smooth end
first, from the bottom (separator plate side) of
13. Install lube regulator valve 137, spring 138, body 151 into body 151. Seat pins using ham-
and stop 139. mer and countersink the pins (Figure 531).
4. Install pressure switch assembly 97 and two 11. Prepare two filter covers 206, two square-cut
bolts 96. Tighten bolts to 58 Nm (4471 lb in.). seals 208, two O-rings 209, and two filters 210
for installation at final transmission assembly.
l. Assembly of Control Valve Module
(Foldout 11) 12. Prepare two filter covers 206, two gaskets 207,
two O-rings 208, two O-rings 209, and two fil-
1. Install main valve body assembly 131 and two ters 210 for installation at final transmission
bolts 130. Tighten bolts finger tight. assembly.
NOTE:
All parts must be cleaned and lubricated before
assembly. 2 E01274.01
CAUTION: 1
CAUTION:
E01273.01
Ensure that main housing is horizontal when
installing the C3/C4 clutch module. Figure 62. Rotating Clutch Module Installation
E02516.01
HD 4560
1
V01272
1 2
HD 4060/B 500 3
V01737
Figure 63. Front Support/Charging
Pump Module Installation Figure 66. Main Shaft Module Installation
i. Main Shaft Selective Shim Measurement 5. Measure dimension D, from top of the straight
(Close Ratio Models) (Figure 67) edge to the gasket.
1. Place a straight edge across the retarder or rear 6. Measure dimension E, the thickness of the
cover mounting surface of the main housing. straight edge. Subtract dimension E from
dimension D the remainder is dimension F.
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the 7. Dimension G is the remainder of C minus
main shaft bearing spacer. F and determines the thickness of the
selective shim.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension A 8. Install the proper thickness selective shim and
the remainder is dimension C. the thrust bearing.
DIM. A DIM. B
DIM. F
DIM. C
DIM. D
RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G
Figure 67. Main Shaft Selective Shim Measurement For 4000 MH/HD 4060/B 500 (Close Ratio)
DIM. A DIM. B
DIM. F
DIM. C
DIM. D
RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G
Figure 68. Main Shaft Selective Shim Measurement For HD 4560 (Wide Ratio)
WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
5
J 43046
3
4
J 43020
V05590
V05375
;
BOLT
(C6 adapter housing
to main housing)
A
TORQUE WRENCH
J 43046
Tw Ta
CLOCKWISE
ROTATION
L
C6 ADAPTER HOUSING
L TOP VIEW
Tw = Ta X
L+A
L = Effective length of torque wrench
A = Effective length of special tool
Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench)
Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)
V05591
m. P3 Planetary Selective Shim Measurement surface. Place the P4 ring gear hub over the
(HD 4070/4076 Models Equipped With output shaft. Place two measuring blocks
Retarder) (Figure 613) included in special tool J 43922 on the front
face of retarder. Place the straight edge
1. Place a straight edge across the rear face of the
included in J 43922 across the top of the
C6 adapter housing with uncompressed
measuring blocks included in J 43922.
retarder housing gasket.
2. Measure dimension A, from top of the straight 6. Measure dimension D from top of the straight
edge to the selective shim thrust surface on the edge to the face of the retarder.
P3 carrier face.
7. Measure dimension E from the top of the
3. Measure dimension B, thickness of straight straight edge J 43922 to the face of the P4 ring
edge. Subtract dimension B from dimension A gear hub.
the remainder is dimension C (measurement
between rear face of adapter housing with 8. Subtract dimension E from dimension D
uncompressed gasket and P3 carrier face). remainder is dimension F (measurement
between front face of retarder and P4 ring gear
4. Remove retarder housing gasket. hub face)
5. Place the retarder module output end down 9. Dimension G is the remainder of C minus F
(facing the bench top) on supports, so the and determines the thickness of the selective
output shaft is not contacting the bench shim, dimension G.
;;; DIM. B
STRAIGHT EDGE
;;; GASKET
;;
;;; ;;;
J 43922 INSTALLED
STRAIGHT EDGE MEASURING
J 43922 BLOCK (2), J 43922
; DIM. F DIM. E
;;;
;; ;;;;;;; ;;;
;;
DIM. D
;;; ;
; ; ;;;;;;;;;
;;
;;;
;;
;;; ;
;;;;;;;
No Gasket
SUPPORTS
Figure 613. P3 Planetary Shim Measurement (HD 4070/4076 Models Equipped With Retarder)
;;; DIM. B
STRAIGHT EDGE
;;; GASKET
;;
;;; ;;;
J 43922 INSTALLED
STRAIGHT EDGE MEASURING
;; ;;;
J 43922 BLOCK (2), J 43922
;;; ;;;
DIM. A DIM. C
DIM. F DIM. E
;;;
;;;; ;; ;;; ;; ;;;
DIM. D
;; ;;; ;; ;;;
;; ;;
;;
;; ;;;
No Gasket
; ;
SUPPORTS
Figure 614. P3 Planetary Shim Measurement (HD 4070/4076 Models Equipped With Rear Cover)
8. Subtract dimension E from dimension D 2. Install the proper selective shim 12 from
remainder is dimension F (measurement previous step.
between front face of rear cover and P4 ring
gear hub face). 3. Install P4 ring gear 46 and hub 47 into P4 ring
gear 46. Install retaining ring 48 into P4 ring
9. Dimension G is the remainder of C minus F gear and hub assembly 45.
and determines the thickness of the selective
shim dimension G. 4. Install ring gear and hub 45 (Foldout 9,C).
WARNING! 6 7
Get help when lifting the retarder module.
Assistance from a hoist or another person may be 1
required. The retarder module weighs 3
approximately 34 kg (75 lb). 4
5
V06865
3. Place retarder module 2 on main housing 6
using a hoist and sling as a lifting fixture. If Figure 616. Retarder Module Installation
used, install the rear support bracket. (Units Prior to S/N 6610066447)
8 8
BOLT, M12 x 1.45 x 55 8 8
(12) MARKED 8
8 8
8 8
8 8
4 8
8
BOLT, M12 x 1.45 x 105 4
3 3
(2) MARKED 4 3 3 5
5
A
TOLERANCE BOLT, M10 x 1.5 x 385 5
A A A
A A RING (11) 5 5 5 5
(7) MARKED 5
LOCATION
MARKED A BOLT, M12 x 1.45 x 350
A A A A A (4) MARKED 3 V06876
REAR VIEW OF C6 ADAPTER HOUSING V05391
Figure 617. Retarder Module Bolts
Figure 615. Tolerance Ring Locations (Units Prior to S/N 6610066447)
2 2
2 2
2 2
2 2
1
2 2 2
8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844
Figure 618. Retarder Module Installation (Units Beginning With S/N 6610066447)
DO NOT reuse a tang once it has been bent. Use a 9. Install output shaft oil seal 42 (Foldout 10,C)
new locknut retainer 40 (Foldout 10,C). using special tools J 43024 and J 37034, and
rubber mallet (Figure 621).
4 4
BOLT, M12 x 1.75 x 55 4 4
(12) MARKED 4
4 4
4 4 J 37034
4 4
J 43024
7 4
4
BOLT, M12 x 1.75 x 105 7
6 6
(2) MARKED 7 6 6 8
8
BOLT, M10 x 1.5 x 345 8
8 8 8 8
(7) MARKED 8
BOLT, M12 x 1.75 x 350
(4) MARKED 6 V06866
V05594
Figure 620. Installation of Retarder and Output Figure 621. Installation of Output Shaft Oil Seal
Shaft Module Bolts (Units Prior to S/N 6610066447) (HD 4070/4076 Models Equipped With Retarder)
1
4 4
4 4
2 4 4
4 4
3 4
4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845
Figure 622. Installation of Retarder and Output Shaft Module (Units Beginning With S/N 6610066447)
NOTE:
DO NOT reuse a tang once it has been bent. Use a
new locknut retainer 43 (Foldout 10,F).
2. Install a NEW rear cover gasket 1 on main 6. Locate two locking tabs on retainer 38
housing 4. (Foldout 10,B) and bend them up into notches
on locknut 39.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture. 7. Install output shaft oil seal 5 (Figure 623)
Install rear support bracket, if used. using tool J 37031.
3. Place rear cover module 6 on main housing 1 7. Install output shaft oil seal 30 (Foldout 10,D)
using a hoist and sling as a lifting fixture. using tool J 43024 and J 37034 and rubber
Install rear support bracket, if used. mallet (Figure 627).
4. Install fourteen bolts 4 and install five bolts 5. BOLT, M12 x 1.75 x 45
Tighten bolts to 100120 Nm (7488 lb ft) (14) MARKED 4
4 4
(Figure 625). 4 4
4 4
5. Retighten bearing retainer locknut using tool 4 4
J 37035 and J 43278. Place the torque wrench
and a breaker bar as shown in Figure 626. 4 4
Rotate the torque wrench in the
counterclockwise direction and tighten the nut 4 4
to 7488 Nm (5564 lb ft). BOLT, 4 4
5 5
METRIC HEAVY 5 5
(5) MARKED 5 5
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 28 (Foldout 10,D).
V05576
3 4 J 43278
J 37035-3
V05580
V05589
Figure 624. Installation of Rear Cover and Output Figure 626. Tightening Bearing Retainer Locknut
Shaft Module Rear Cover Equipped
J 37034
1
J 43024 3
2
4
V06868
V05595
2. The splines of the ground sleeve and turbine
Figure 627. Installation of Output Shaft Oil Seal shaft must engage with their respective splines
(HD 4070/4076 Models Equipped With Rear Cover)
in the torque converter module. The tangs on
u. Installation of Converter Housing Module the converter-pump hub must engage the
(Figure 628) charging pumps drive gear or the PTO oil
pump drive hub.
1. Install guide bolts to ease converter housing 1
installation and keep gasket 2 in place. 3. Using a hoist and sling, install torque converter
module 6 into the converter housing module
2. Position the transmission input end up. Install
(Figure 629, View A).
a NEW converter housing gasket 2 on main
housing module 4.
4. Ensure that the torque converter is properly
3. Lower converter housing 1 onto main seated. If PTO equipped, rotate the PTO gear
housing 4. If the transmission is PTO to engage the pump hub with the charging
equipped, rotate the PTO drive gear to align pump. Proceed with the selective shim
the gear tangs with the charging pump. measurement.
4. Install seven bolts 3 into the inside of converter
housing 1. Use mechanical fingers, or a similar 5. Install converter end play gauge J 38548
tool, when installing these bolts. and tighten the attaching bolt to 2734 Nm
(2025 lb ft). Prevent turbine shaft rotation by
5. Remove the two guide bolts and install the using one of the following methods:
remaining bolts 3. Tighten all bolts 3 to 5161 Nm
(3845 lb ft). Insert a screwdriver into the vanes on the
v. Installation of Torque Converter Module rotating clutch module (Figure 629,
(Figure 629) View B).
1. The torque converter is installed over the If the control module is in place, apply air
turbine shaft which rotates inside the stator pressure through the lockup pressure tap
shaft or ground sleeve. The splines on the and use a heel bar, screwdriver, and bolts.
ground sleeve engage the converter stator. The Insert the heel bar into a torque converter
splines on the turbine shaft engage the housing bolt hole. Insert two bolts into the
converter turbine. The end of the turbine shaft flexplate adapter bolt holes. Then place a
is threaded and machined to accept the screwdriver at an angle to prevent converter
converter retaining bolt and lockup sealring. rotation (Figure 629, View C).
ID
Dimension C Use P/N Shim Thickness (Ref.) No.
0.41290.6598 mm (0.01630.0259 inch) 29505688 4.000 mm (0.157 inch) 0
0.65990.8378 mm (0.02600.0329 inch) 29505681 4.203 mm (0.165 inch) 1
0.83791.0158 mm (0.03300.0399 inch) 29505682 4.381 mm (0.172 inch) 2
1.01591.1938 mm (0.04000.0469 inch) 29505683 4.559 mm (0.179 inch) 3
1.19391.3708 mm (0.04700.0539 inch) 29505684 4.736 mm (0.186 inch) 4
1.37091.5488 mm (0.05400.0609 inch) 29505685 4.914 mm (0.193 inch) 5
1.54891.7268 mm (0.06100.0679 inch) 29505686 5.092 mm (0.200 inch) 6
1.72691.9048 mm (0.06800.0749 inch) 29507793 5.270 mm (0.207 inch) 7
1.90491.9733 mm (0.07500.0776 inch) 29507794 5.448 mm (0.214 inch) 8
7 8
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
Figure 629. Torque Converter Module Installation and Selective Shim Measurement
WARNING!
Get help when lifting the control module.
Assistance from another person may be
required. The control module weighs 1
approximately 25 kg (55 lb).
on the control module properly engages the Figure 630. Control Module Installation
external connector in the main housing.
5. Align the control module bolt holes with the x. Installation of Externally Mounted Parts
guide pins. Ensure the feedthrough harness (Figure 631)
standoff is aligned with the feedthrough hole in 1. If not previously installed, install
the main housing. transmission breather 25. Tighten breather to
6. Lower the control module over the guide pins 1216 Nm (912 lb ft).
until it seats against the main housing and the
2. Install fill tube seal 9, fill tube 8, bracket 6,
feedthrough harness standoff seats against the
and screw 5. Tighten screw to 24-29 Nm
tapered feedthrough hole in the main housing
(1821 lb ft). Install dipstick 7.
or engages the external main transmission
connector. 3. If used, install new cooler port gasket 10. Install
7. Install filter cover assemblies prepared in remote mount manifold 11 and six bolts 12.
Paragraph 518. Tighten bolts to 5161 Nm (3845 lb ft).
4. Install output flange 13 or yoke 14.
NOTE: 5. Install O-ring 16 on plug 18 or 20.
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent NOTE:
thread seizure. Bolts 23 and washers 24 are available in Service
Bolt Kit P/N 29535910 as described in
SIL 15-WT-98. The convex end of belleville washer
8. Remove the guide pins and install thirty-four
24 MUST contact the head of bolt 23 as shown in
bolts 4 and nine bolts 5 (4 inch sump) or 43 Figure 632. DO NOT use locktab 21 with
bolts 5 (2 inch sump). Tighten the bolts to washer 24 and bolt 23.
5161 Nm (3845 lb ft).
9. Install clip 19 (Foldout 11) on the exterior of 6. Insert two bolts 23 through belleville washers
the feedthrough harness connector near the 24 and retainer plug 20 or one bolt 19 through
main housing. plug 18.
25 ENGINE
SPEED 1 2 7
SENSOR
TURBINE 4
SPEED 3 5
SENSOR 6
13
9
OUTPUT
SPEED
SENSOR 13
18
19
16
14
17
20
21
22
24
10 23
11 12
V06837
8. Install retainer plug 18 or 20 into the yoke Using hoist, remove transmission and holding fixture
or flange. Tighten bolts 23 to 3035 Nm from repair stand and prepare for vehicle installation.
(2226 lb ft). Tighten bolt 19 to 7080 Nm
(5160 lb ft). NOTE:
y. Installation of Power Takeoff Refer to Mechanics Tips MT2159EN or MT3004EN
(Figure 633) for preparing transmission for installation and
installing the transmission into a vehicle.
1. If removed, install two PTO pilot screws 4.
1 2
4
3
3
1
4
V06836
Wear Limit
Illustration Description mm (inches)
Foldout 4,B TORQUE CONVERTER MODULE
10 Converter Cover Bushing, Maximum ID 66.91 2.634
12 Lockup Piston Assembly, Minimum Thickness 6.53 0.257
14 Damper Assembly Plate, Maximum Distortion 0.51 0.020
14 Damper Assembly Plate, Minimum Thickness 8.51 0.335
14, 18 Turbine-To-Damper, Maximum Spline Wear 0.38 0.015
15 Backplate, Maximum Distortion 0.15 0.006
15 Backplate, Minimum Wear Surface Thickness 11.79 0.464
18 Turbine Hub, Minimum OD 66.69 2.626
19 Turbine Hub Sealring, Maximum ID 61.77 2.432
24 Stator Thrust Plate, Minimum Thickness 9.45 0.372
36 Converter Pump Hub, Minimum OD 88.99 3.504
Wear Limit
Illustration Description mm (inches)
Foldout 6,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 89.19 3.511
9, 10 Pump Housing Gear, Maximum Cavity Depth 19.04 0.750
9, 10 Pump Housing Gear, Maximum Cavity Diameter 150.25 5.915
9, 10, 11 Driven Gear-To-Pump Housing, Maximum Diametric Clearance 0.30 0.012
9, 10, 13 Gear-To-Plate, Maximum Side Clearance 0.10 0.004
11 Gear Set, Maximum Gear Tooth Tip Clearance 0.15 0.006
12 Pump Gear Bushing, Maximum ID 66.93 2.635
16, 17 Ground Sleeve, Minimum OD In Bushing Area 66.67 2.625
16, 17, 20 Spline OD, Maximum Total Runout 0.13 0.005
20 Front Support, Minimum OD 119.81 4.717
25 Front Support Seal, Minimum End Gap 1.00 0.040
25 Front Support Seal, Maximum End Gap 1.44 0.056
Wear Limit
Illustration Description mm (inches)
Wear Limit
Illustration Description mm (inches)
Foldout 10,B REAR COVER AND P3 MODULE (4000 MH, HD 4060, HD 4560,
and B 500 MODELS)
5 P3 Planetary Carrier Assembly, Maximum End Play 0.94 0.037
7 Output Shaft Bushing, Maximum ID 36.14 1.423
8 Output Shaft, Maximum Spline Wear 0.38 0.015
15, 18 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
15, 18 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
Wear Limit
Illustration Description mm (inches)
Foldout 10,C RETARDER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS
PRIOR TO S/N 6610066447)
4 Output Shaft Bushing, Maximum ID 36.14 1.423
5 Output Shaft, Maximum Spline Wear 0.38 0.015
16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501
18 Rotor Assembly 0.38 0.015
Foldout 10,D REAR COVER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS)
7 Output Shaft Bushing, Maximum ID 36.14 1.423
8 Output Shaft, Maximum Spline Wear 0.38 0.015
Foldout 10,F RETARDER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS
STARTING WITH S/N 6610066447)
4 Output Shaft Bushing, Maximum ID 36.14 1.423
5 Output Shaft, Maximum Spline Wear 0.38 0.015
16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501
18 Rotor Assembly 0.38 0.015
* Individual springs
** For the complete spring assembly
Table 71. Spring Data (contd)
Length under load
Approx.
Spring Free
No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Color Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
10,A 35 Retarder Flow Valve 29515101 Green 16 3.78 36.58 106.68 73.66 133.4
(0.149) (1.440) (4.200) (2.900) (29.99)
10,A, C, E, 35, 25, 35, Retarder Flow Valve 29515692 No Code 11.4 4.12 36.17 114.3 91.1 213.3
and F 25 (0.162) (1.424) (4.500) (3.587) (47.95)
26 25 24 23 22 21 20 19 18 17 16 15 V02535.01
Foldout 1. Model 4000 MH, HD 4060, B 500 (Close Ratio) Transmission Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 2
1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Breather
8 Main housing
9 Main shaft
10 C3 clutch
11 C4 clutch
12 P2 sun gear
13 C5 clutch
14 Output shaft
15 Rear cover
16 C5 piston
17 P3 module
18 Oil level sensor
19 Control module
20 P2 module
21 P1 module
22 C2 clutch
23 C1 clutch
24 Turbine shaft
25 PTO drive gear
26 Ground sleeve
27 Converter housing module
1 2 3 4 5 6 7 8 9 10 11 12 13 14
27 26 25 24 23 22 21 20 19 18 17 16 15 V02536.01
Foldout 2. Model HD 4560 (Wide Ratio) Transmission With PTO Provision Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
27 26 25 24 23 22 21 20 19 18 V02537.03
Foldout 3. Model 4000 MH, HD 4060, B 500 (Close Ratio) Transmission With Retarder Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3,A
1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 Shim
13 C5 clutch
14 P3 sun gear
15 C5 piston assembly
16 C6 adapter housing module
17 C6 clutch
18 P4 ring gear
19 Rear cover
20 Output shaft
21 C6 piston
22 P4 planetary
23 P4 sun gear
24 Selective shim
25 P4 shaft flange
26 P3 planetary
27 Control valve assembly
28 P2 planetary
29 P1 planetary
30 C2 clutch
31 C1 clutch
32 Turbine shaft
33 Converter ground sleeve
34 Converter housing
;;
; ;; ;; ;;
;; ; ;; ;
;;;
;; ;;
;; ;; ;;
;;;;
;;;;
;;
;;
;; ;;;
;;
;; ;;;;
;;;;;
;
;;;;
;;; ;; ;;;; ;;; ;
; ;;;
;;
; ;;;; ;;
;;; ; ; ;
;
;; ; ;; ;
;; ;;;;;
;;;;
;; ;; ; ; ;
; ;
;
;; ; ;; ;;
;;
;;;
;;
34
; 33 32
31
;;
; ;
; ;
30 29
;;
;; 28
; ;
; ; 27 26
25 24 23 22 21
V05265.01
1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 Shim
13 C5 clutch
14 P3 sun gear
15 C5 piston assembly
16 C6 adapter housing module
17 C6 clutch
18 P4 ring gear
19 Retarder stator
20 Retarder rotor
21 Retarder and output shaft module
22 Output shaft
23 C6 piston
24 P4 planetary
25 P4 sun gear
26 Selective shim
27 P4 shaft flange
28 P3 planetary
29 Control valve assembly
30 P2 planetary
31 P1 planetary
32 C2 clutch
33 C1 clutch
34 Turbine shaft
35 Converter ground sleeve
36 Converter housing
;;;; ; ;;;; ;;
;;
;;
;;; ;; ;;;;;;;;;
; ;;; ;;;
;;;; ;;
;
;
;;
;;
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;;
;; ;
;
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; ;;
; ; ;; ;;;;
; ;;;;;
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;;
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;;
;;;
;;;
; ;;;;
; ;; ;;; ;; ;; ;;;;;;;;;
; ;; ; ;;
;; ;;
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;; ;;;; ;;
; ;;
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;; ;;
;;
;;;;
;;
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;; ;
;;;; ;; ;; ;;
;;;; ; ;;; ;; ;;;; ;; ;;
;; ;; ;;;;
;
;; ;;;;; ;; ;;;;
;;
;;;;
;; ;;
;; ;;;;
;;
;;;;
;; ; ; ;;
;;;;
;;;;
;;
;;;;
; ; ;;;;;; ;;;
;; ; ;;;
; ; ; ; ; ;;;; ;;
;;;; ;;
; ; ;;
;;; ; ; ; ;; ;
;;;;;; ;;;;;;;;
;;;;
;
;
;
;; ; ;; ;;
;;;
;;
36
; 35 34
33
;;
; ;
; ;
32 31
;;
;; 30
; ;
; ; 29 28
27 26 25 24 23
V05266.01
1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Oil vent assembly
8 Main housing
9 Main shaft
10 C3 clutch
11 C4 clutch
12 P2 sun gear
13 Shim
14 C5 clutch
15 P3 sun gear
16 C5 piston assembly
17 C6 adapter housing module
18 C6 clutch
19 P4 ring gear
20 Retarder stator
21 Retarder rotor
22 Retarder and output shaft module
23 Output shaft
24 C6 piston
25 P4 planetary
26 P4 sun gear
27 Selective shim
28 P4 shaft flange
29 P3 planetary
30 Control valve assembly
31 P2 planetary
32 P1 planetary
33 C2 clutch
34 C1 clutch
35 Turbine shaft
36 PTO drive gear
37 Converter ground sleeve
38 Converter housing
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
38 37 36 35 34 33 29 28 27 26 25 24
32 31 30 V05646.02
Foldout 3,C. HD 4070/4076 With Retarder and PTO Provision Cross Section
F OLDOUT 4,A
2 3
4
5
1 Crank hub adapter 23 Flexplate
6
2 Bolt, M8 x 1.25 x 20 (12), A 24 Flexplate
7 8
3 Flexplate assembly 25 Bolt, M8 x 1.25 x 25 (28), A
4 Bolt plate (6) 26 Flexplate adapter assembly 1 9
10
5 Flexplate 27 Ring gear
6 Flexplate (3) 28 Flexplate adapter
7 Bolt, M8 x 1.25 x 25 (28), A 29 Wear plate
13 11
8 Flexplate adapter assembly 30 Bolt, 58-18 x 2 (6), A 12
9 Ring gear 31 Bolt, M8 x 1.25 x 25 (12), A 14
15
10 Flexplate adapter 32 Flexplate assembly
16
11 Wear plate 33 Bolt plate (6)
12 Bolt, M8 x 1.25 x 45 (12), A 34 Flexplate 17
18
13 Ring gear assembly 35 Flexplate
14 Ring gear 36 Bolt, M8 x 1.25 x 25 (16 or 28), A
15 Flexplate 37 Flexplate adapter assembly
20 21 19
16 Flexplate (3) 38 Ring gear
22
17 Bolt, M8 x 1.25 x 25 (28), A 39 Flexplate adapter
23
18 Flexplate adapter 40 Wear plate 24
19 Wear plate 41 Bolt (2), A
25 26
20 Bolt, M8 x 1.25 x 25 (12), A 27
21 Flexplate assembly Torque Nm lb ft
28
22 Bolt plate (6) A 2429 1821
31 32
33
34 29
30
35
36
37
38
39
40
41
L00182
1
1 Retaining ring 22 Converter stator assembly (complete) 2 8
2 Converter end plug 23 Retaining ring 3 9
3 O-Ring 24 Stator thrust plate assembly
4 Converter end plug, A 25 LH stator thrust washer
10 11
7
5 Torque converter module 26 Stator race
4 12
6 Nut (36), B 27 Stator spring (13)
7 Torque converter cover assembly 28 Stator roller (13) 5
13
(complete) 29 Stator and cam assembly 6
8 Converter cover assembly 30 Shim, 0.27 mm (0.010 inch) 14
9 Converter cover 30 Shim, 0.48 mm (0.019 inch)
10 Bushing 30 Shim, 0.711 mm (0.028 inch) 18 15
19
11 Lockup piston sealring 31 Thrust bearing race
12 Lockup piston assembly 32 Pump thrust bearing assembly 17
13 Lockup piston sealring 20
33 O-Ring 21
14 Damper assembly 34 Thrust bearing race 23
15 Lockup clutch backplate 24
35 Converter pump assembly (complete)
16 Bolt, M8 x 1.25 (44), B 25
36 Converter pump assembly 26
17 Thrust bearing assembly 37 T-head bolt (36) 28
18 Turbine assembly 29 16
19 Turbine hub sealring
Torque Nm lb ft 30
20 Thrust bearing assembly
A 5060 3744 31
21 Star plate
27 32
B 3035 2226
22 33
34
36
37
35
V06850
2
1
4
3
24
2 25
5 26
3
6
7
8
4 9
20
6 15
10
16 17 18
5 11
10 9
7 12
21 13
11
14
23
19
8 22
29
28
27
V03918.02
V05395
Foldout 5,A. Converter Housing Module Exploded View Foldout 5,B. Converter Housing Module With PTO Provision Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 6
2
3
4
8
2
5 9
7
1
7 11
8 6 10
4
12 13
5 9
3
21
14
22 15
1 16
17
23 18
10
24 19
11
6 25
12 13 16 20
15 26
27
28
33 29
14 18
17 30
20 34 31
19
35
36
21
35
25 37
38 32
26
23 22
24
39
40
41
42
V02818.01 43 V06870
Foldout 6,A. Front Support and Oil Pump Module Exploded View Foldout 6,B. Rotating Clutch Module Exploded View
F OLDOUT 7
3
1 C3/C4 clutch assembly 29 C5 clutch friction plate (8)
2 Bolt, M10 x 1.5 x 90 (14), A 30 C5 clutch reaction plate 6
35 30
29
V06851
WIDE RATIO
4
1
5
2
6
V06878
A B
1 P1 planetary module 1 P2 planetary module
2 Internal retaining ring 2 Retaining ring
3 P1 planetary carrier assembly 3 P2 planetary carrier assembly
4 Retaining ring 4 Internal retaining ring
5 P1 indexing ring 5 P2 indexing ring
6 P1 pinion spindle (6) 6 Carrier and bushing assembly
7 P1 planetary carrier/bushing assembly 7 P2 planetary carrier
8 P1 planetary carrier 8 Bushing
9 P1 carrier bushing 9 Thrust washer (4)
10 P1 thrust washer (6) 10 Roller bearing (8)
11 P1 pinion gear (6) 11 P2 pinion gear (4)
12 Roller bearing assembly (12) 12 Thrust washer (4)
13 P1 thrust washer (6) 13 P2 pinion spindle (4)
14 Thrust bearing assembly 14 Thrust bearing assembly
15 P2 ring gear 15 P3 planetary ring gear
1
2
14
15
3 4 3
4
5
5
6
7
7
8 15
8
9
14
6
9
13
10
10
11 11
12
13 12
V06852
V03630.01
Foldout 9,A. P1 Planetary Module Exploded View Foldout 9,B. P2 Planetary Module Exploded View
F OLDOUT 9,C
2 12 16 14
1 P3 carrier module 24 Pressure tap plug
3 17 15
2 Internal retaining ring, 219 OD 25 O-ring, 8.92 ID
4 1 18
3 P3 indexing ring 26 Ball bearing assembly
4 P3 planetary carrier 27 C6 reaction plate (9) 5
19
5 P4 shaft flange 28 C6 friction plate (8) 7 6
8
6 Shim locating ring 29 C6 backplate 9 20
13
7 P3 planetary spindle 30 P4 sun gear 10
8
8 P3 thrust washer (8) 31 Thrust bearing
9 P3 pinion gear (4) 32 P4 carrier assembly
10 Roller bearing assembly (8) 33 Internal retaining ring 11
11 Flange head bolt, M12 x 1.75 x 45 (14), A 34 Internal retaining ring, 235 OD
12 Shim, (selective), 0.27 mm 35 Indexing ring
Shim, (selective), 0.54 mm 36 P4 carrier and bushing assembly
Shim, (selective), 0.81 mm
37 P4 carrier
Shim, (selective), 1.08 mm 22 26
Shim, (selective), 1.35 mm 38 P4 carrier bushing 21 27
28
Shim, (selective), 1.62 mm 39 P4 planetary spindle (6)
Shim, (selective), 1.89 mm 40 P4 planetary thrust washer (12)
Shim, (selective), 2.16 mm 23
41 P4 pinion gear (6)
Shim, (selective), 2.43 mm 25
42 Caged needle bearing (12) 24
13 Adapter housing gasket
43 C6 clutch drum hub 23 25
14 C6 adapter housing module
44 Thrust bearing assembly 24
15 Piston assembly 30 29
45 P4 ring gear and hub assembly
16 External retaining ring 31
46 P4 ring gear
17 Piston return spring assembly 32
47 P4 ring gear hub
18 Piston
48 Retaining ring
19 Piston OD sealring 43
49 Star tolerance ring (11)
20 Piston ID lip-type sealring
Torque Nm lb ft 44
21 Adapter housing assembly
46 45
22 Adapter housing A 100120 7488
23 Plug assembly (2), B B 1013 710
33 47
34 37 49
38 36 48
35 39
41
42
40
V06854
Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (HD 4070/4076 Models Only) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 10,A
1 Retarder housing gasket 53 Bolt, M8 x 1.25 x 25 (3), C
2 Retarder and P3 planetary module 54 Speed sensor assembly
3 P3 planetary carrier assembly 55 O-Ring
4 Output shaft assembly 56 Speed sensor retainer
5 Bushing 57 Bolt, M8 x 1.25 x 20, B
6 Output shaft 58 Cone and roller bearing assembly
7 Internal retaining ring 59 Locknut retainer
8 P3 indexing ring 60 Bearing retainer locknut, D
9 P3 planetary carrier 61 Oil seal assembly
10 Thrust washer 62 Sensor shipping cover
11 External retaining ring 63 Bolt, M12 x 1.75 x 55 (12), E
12 P3 planetary spindle (4) 64 Bolt, M8 x 1.25 x 100 (9), B
13 P3 thrust washer (4) 65 Retarder control body assembly
14 P3 pinion gear (4) 66 Bolt, M8 x 1.25 x 55 (5), B
15 Roller bearing assembly (4 groups of 2) 67 Shipping cover
16 P3 thrust washer (4) 68 Solenoid connector
17 Cone and roller bearing assembly 69 Modulating solenoid cover
18 Retarder stator assembly 70 Solenoid cover gasket
19 External retaining ring 71 Solenoid
20 Spring and retainer assembly 72 O-Ring
21 C5 clutch piston 73 O-Ring
22 C5 piston outer sealring 74 Retarder control valve
23 C5 piston inner sealring 75 Valve stop
24 Roller bearing cup 76 Spring, 7.8 OD x 29.2
25 Retarder stator 77 Exhaust backfill valve
26 O-Ring 78 Retarder control body
27 Retarder sealring 79 Retaining pin, 2.5 OD x 40
28 Retarder housing gasket 80 Retaining pin, 3 OD x 43
29 Rotor assembly 81 Spring
30 Retarder sealring 82 O-Ring
31 Retarder housing assembly 83 Plug
32 Retaining ring 84 Retaining ring
33 Valve plug 85 Pressure tap plug assembly
34 O-Ring 86 O-Ring
35 Valve spring 87 Pressure tap plug, F
36 Retarder valve 88 Separator plate gasket (2)
37 Spring pin 89 Solenoid separator plate
38 Tachograph plug, A if used with brass 90 Channel plate
washer 42; B if used with O-Ring 42 91 Channel plate gasket
39 Brass washer (later models); 92 Bolt, M12 x 1.75 x 165 (4), E
O-Ring (earlier models) 93 Bolt, M12 x 1.75 x 105 (2), E
40 Retarder housing 94 Bolt, M10 x 1.5 x 160 (7), G
41 Temperature sensor assembly (TID2) 95 Shipping cover
42 O-Ring
Torque Nm lb ft
43 Retainer A 6067 4549
44 Bolt, M8 x 1.25 x 20, B B 2429 1821
45 Temperature sensor assembly (TID1) C 1215 911
46 O-Ring D * *
47 Connector E 100120 7488
48 Retainer F 1013 710
49 Bolt, M8 x 1.25 x 20, B G 5161 3845
50 Valve plug
51 Retaining ring * Before module is installed 193207 Nm (143152 lb ft);
52 Roller bearing cup After Module is installed 7488 Nm (5564 lb ft)
17
19
20
21
18
22
3
2
4 23
5 24
25
6
7
8
26
9
10
11
12
13
14 65 95
15 67
16 66 68
64 69
71 70
53 44 72 75
43 63 73 76
27 41 74 77
42 49
48 47 62 78
45
79
28 46
80 87
86
29 30 55 56 57 85
54 81
40 82
51 52
50 83
39 84
38 88 88
37 91 90 89
58
59
31 60
61
35 36
33 92
32 94
34 93
V06855
Foldout 10,A. Retarder And P3 Planetary, Retarder Valve Body Module (Units Prior to S/N 6610066447) Exploded View
F OLDOUT 10,B
17 38
18 39
40
V06856
Foldout 10C. Retarder and Output Shaft Module (HD 4070/4076 Models Prior to S/N 6610066447) Exploded View
F OLDOUT 10,D
14 External sealring 12
15 Internal lip-type sealring
16 Roller bearing cup 13
10
17 Rear cover assembly 14
23
18 Rear cover 15 22
19 Tachograph plug, B 16 26
24
20 Washer 17 25
18
21 Roller bearing cup
22 Speed sensor assembly
23 Self-locking bolt, M8 x 1.25 x 20, C
27
24 Speed sensor retainer
25 O-Ring 28 19 20
26 Sensor shipping cover 29
27 Roller bearing assembly
30
28 Locknut retainer
21
29 Output speed sensor nut
30 Output seal assembly
Torque Nm lb ft
A 100120 7488
B 6067 4450
C 2429 1821
V06858
Foldout 10D. Rear Cover and Output Shaft Module (HD 4070/4076 Models Only) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 10,E
70 Solenoid 94 Gasket
71 O-Ring 95 Jumper manifold
72 O-Ring 96 Bolt, M10 x 1.5 x 30, G
73 Retarder control valve 97 Remote side manifold
74 Valve stop 98 Bolt, M10 x 1.5 x 160 (3), G
75 Spring, 7.8 OD x 29.2
99 Connector shipping cover
76 Exhaust backfill valve
77 Retarder control body Torque Nm lb ft
78 Retaining pin, 2.5 OD x 40 A 6067 4549
B 2429 1821
79 Retaining pin, 3 OD x 43 C 1215 911
80 Spring D * *
81 O-Ring E 100120 7488
F 1013 710
82 Plug
G 5161 3845
83 Retaining ring
* Before module is installed 193207 Nm (143152 lb ft);
84 Pressure tap plug assembly After Module is installed 7488 Nm (5564 lb ft)
17
19
20
21
18
22
3
2
4 23
5 24 25
6
7
8
26
9
10
11
12
13
14 64 99
15 66
16 65 67
63 68
70 69
52 48 71 74
47 62 72 75
27 45 73 76
46
61 77
78
28
79 86
85
29 30 54 55 56 84
38 53 80
41 81
50
49 51 82
40 83
39 87 87
37 90 89 88
57
58
31 59
35 36 60
33 42
32 43
34 44
91 97
93
92 94 98
95
96
V06859
Foldout 10,E. Retarder And P3 Module (Units Starting With S/N 6610066447) Exploded View
F OLDOUT 10,F
1
Stator housing gasket 48 Speed sensor retainer
2
Retarder module 49 Self-locking bolt, M8 x 1.25 x 20, D 1
3
Output shaft assembly 50 Sensor cover 4
3
4
Bushing, 28 ID 51 Flange head bolt, M12 x 1.75 x 55 (12), E
5
Output shaft 52 Flange head bolt, M8 x 1.25 x 100 (9), D
6
Roller bearing assembly 53 Retarder control valve body assembly 5
7
Retarder stator assembly 54 Flange head bolt, M8 x 1.25 x 55 (5), D
8 6
8
External retaining ring, 181 ID 55 Solenoid connector 9
9
C5 piston return spring and retainer assembly 56 Solenoid cover
10
C5 clutch piston 57 Solenoid cover gasket 10
7
11
External sealring, 315.17 ID 58 Solenoid, N/C 11
12
Internal lip-type sealring, 214.06 OD 59 O-Ring
2
13
Roller bearing cup 60 O-Ring
14
Retarder stator housing 61 Retarder control valve 12
15
O-Ring, 11.48 ID 62 Valve stop 13
16
Rotating sealring, 146 OD 63 Spring, 7.8 OD x 29.2
17
Retarder housing gasket 64 Exhaust backfill valve
18
Rotor assembly 65 Retarder control valve body 14
19
Rotating sealring, 146 OD 66 Dowel pin, 2.5 x 40 15
20
Flange head bolt, M8 x 1.25 x 25 (3), A 67 Dowel pin, 3 x 43
21
Retarder Housing Assembly 68 Spring
22
Internal retaining ring, 45.82 OD 69 O-Ring, 21.9 ID
23
Valve plug 70 Valve plug 79
24
O-Ring, 34.6 ID 71 Internal retaining ring 53
25
Valve spring, 36.17 OD x 114.3 72 Pressure tap plug assembly
26
Retarder valve 73 O-Ring, 8.92 ID
27
Spring pin, 5 x 45 74 Pressure tap plug, 716-20, F 54 55
28
Plug and retarder housing assembly 75 Separator plate gasket (2) 52 56
29
Tachograph plug, M18 x 1.5, B 76 Separator solenoid plate 58 57
30
Washer, M18 77 Channel plate
31
Retarder housing 78 Channel plate gasket 38 59 62
20
32
Gasket 79 Retarder connector shipping cover 51 60 63
16 37
35 61
33
Cover 80 Gasket 64
34
Bolt, M8 x 1.25 x 25 (9), D 81 Jumper manifold
36
35
Temperature sensor assembly 82 Bolt, M10 x 1.5 x 30 50 65
66
36
O-Ring 83 Remote side manifold 17 74
37
Thermistor protection bracket 84 Bolt, M10 x 1.5 x 354 (3) 67 73
38
Self-locking bolt, M8 x 1.25 x 20, D 85 Flange head bolt, M10 x 1.5 x 345 (7), G 18 19 47 48 49 72
39
Valve plug 86 Flange head bolt, M12 x 1.75 x 350 (4), E 28 46 68
40
Internal retaining ring, 45.82 OD 87 Flange head bolt, M12 x 1.75 x 105 (2), E 31 69
40 70
30 39 41
41
Roller bearing cup 29
75 71
Torque Nm lb ft 75
42
Cone and roller bearing assembly 78 77 76
A 1215 911 27
43
Locknut retainer 42
44
Bearing retainer locknut B 6067 4549 43
C * * 21 44
(output speed sensor nut), C
D 2429 1821 25 26 45
45 Oil seal assembly 23 32
46 Speed sensor assembly E 100120 7488 22
F 1013 710 33
47 O-Ring, 15.37 ID 24 34 86
G 5161 3845
85
83
* Before module is installed 193207 Nm (143152 lb ft); 80
After Module is installed 7488 Nm (5564 lb ft) 87 81
84
82
V06860
Foldout 10F. Retarder and Output Shaft Module (HD 4070/4076 Models Starting With S/N 6610066447) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 11,A
12
4
31
30 26 13
3
29
50
36
70
1 25
29
23 24
24 23
2 28 22
61 14
25 21 19
DE
18
26
TA
BE CH
FO CO
66
CO RE NNEC
NT DR
RO OP TOR
L MO PING
DU
20
LE
65 27
64 15
14 17
63
91 69 56 34
90 68 67 57 33 32
62
16
89 92 58 55
88 72 59 40
87 72 70 60 40 39
38
37
35 36
86 71 73 36 41
54
85 72 53 40
84 76 52 44
83 79 74 51 47 42
77 45
78 75 46 43
82 81 80 50 49 48
116
93
115 94
95
96
99 98 97
117
103
100
105
104
118 114 106
113 102
112 101
128 107
108
127 119
126 102
120 101
111 109
121
125
124
122
123 110
V06861
4
1
5
13
14
15
16
11
8 10
12
2 120
150
0
12 250 C
300
F
0
10
TRANS
OIL
TEMP
3
4 6
29
7 20
5 30 9
6 19
31 17
7 32
18
8
21
22
1 2
9
1
2
24
25
26
28
23 27
V00439.01
V00201
Foldout 12,A. Output Flange And Yoke Exploded View Foldout 12,B. Support Equipment Exploded View
F OLDOUT 13
CONVERTER IN Cooler
Conv
Regulator Lube Lube
CONVERTER OUT
Overdrive Conv
Knockdown Flow
Lockup
EX Lube
Regulator
F A B C D E
LU C1 C2 C3 C4 C5
N/C N/O N/O N/C N/C N/C EX
Ctl. Main
G FWD Main Filter
N/C Reg.
ONOFF
EX Main
Exhaust Pump
Main
C2 Backfill
Main
C4 C5 Regulator
Suction
C1 Filter
C1 C2 C3 C4 C5
Sump
Accumulator/
Relay Valve SOLENOIDS ENERGIZED A B E
CLUTCH APPLIED C5
C1 C3
Latch MAIN COOLER/LUBE
CONTROL MAIN EX. BACKFILL
C3 Pressure EXHAUST CONVERTER
C2 EX
Switch SUCTION C5
Latch V00330.03