Service Manual: Allison Transmission

SM2148EN
Service
Manual
Allison Transmission
M D 3 0 6 0 , M D 306OP, MD 3060PR, MD 3060R
M D 3 0 6 6 , M D 3066P, MD 3066PR, MD 3066R
MD 3070PT
M D 3 5 6 0 , M D 356OP, MD 3560PR, MD 3560R
B 300, B 3OOP, B 3 0 0 P R , B 300R
B 400, B 4OOP, B 400PR, B 400R
1998 December
Alllson ll?ansmlss10n
Division of General Motors Corporation
P.O. Box 894 Indianapolis, Indiana 46206-0894
Printed in the U.S.A. Copyright 0 1998 General Motors Corp.

MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL
ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL

DISPLAYS AND BUTTON NAMES
Shift Selector or Diagnostic Data Reader/Tool (DDR) button and display names are printed in bold capital letters
(UP (?) arrow, DOWN (J) arrow, DISPLAY MODE, MONITOR, SELECT, etc.).
The actual message displayed (text and/or letters) is printed within double quotation marks (“O L”, “O K”, etc.).
TRADEMARK USE
The following trademarks are the property of the companies indicated:
l Pro-Link® is a registered trademark of Micro Processor Systems, Inc.

l DEXRON® is a registered trademark of General Motors Corporation.
l Biobor® JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel
Additives Company.
l Teflon® is a registered trademark of the DuPont Corporation.
l Loctite® is a registered trademark of the Loctite Corporation.
l Spiralock® is a registered trademark of Spiralock of Michigan.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by letter suflix to the publication number. Check with your Allison
Transmission service outlet for the currently applicable publica-
tion. Additional copies of this publication may be purchased from
authorized Allison Transmission service outlets. Look in your tele-
phone directory under the heading of Transmissions - Truck,
Tractor, etc.
Copyright © 1998 General Motors Corp.

ii
IMPORTANT SAFETY NOTICE
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
...
Copyright © 1998 General Motors Corp. 111
LIST OF WARNINGS
This manual contains the following warnings -
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
l If you leave the vehicle and the engine is running, the vehicle can move
suddenly and you or others could be injured. If you must leave the engine
running, do not leave the vehicle until you: Put the transmission in
N (Neutral)...and - Apply the parking brake and emergency brakes and
make sure they are properly engaged...and - Chock the wheels and take any
other steps necessary to keep the vehicle from moving.
l 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.
l While conducting a stall check, the vehicle must be positively prevented from
moving. Apply the parking brake and service brake, and chock the wheels
securely. Warn personnel to keep clear of the vehicle and its travel path.
Failure to do so can cause serious injury.
l Use appropriate safety equipment such as safety glasses, safety shoes, and
gloves.
l Do not burn discarded Teflon® seals; toxic gases are produced by burning
Teflon®.
l Never dry bearings by spinning them with compressed air. A spinning bearing
can disintegrate, allowing halls or rollers to become lethal flying projectiles.
Also, spinning a bearing without lubrication can damage the bearing.
l Transmission dry weights are as follows: MD/B 300/B 400 - 245 kg (535 lb),
MDR/B 300R/B 400R - 275 kg (610 lb), MDP/B 300P/B 400P - 260 kg
(575 lb), MDPR/B 300PR/B 400PR - 300 kg (655 lb), MD 3070PT - 530 kg
(1170 lb). Use proper tools and lifting equipment when installing or removing a
transmission from the repair stand.
l The transfer case module assembly weighs approximately 270 kg (595 lb).
l The control module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personnel injury or control module damage. The control
module assembly used in an MD 3070PT weighs approximately 29 kg (65 lb).
l The retarder module assembly weighs approximately 64 kg (141 lb). Use care
to prevent injury to personnel while handling the retarder module assembly.
l Piston springs are highly compressed. Be extremely careful during removal
and installation. Personal injury can occur if the spring force is not controlled.
l Transmissions installed in overhaul stands must be positioned vertically
before installing control module. Failure to do so could result in personal
injury.
iv Copyright © 1998 General Motors Corp.

TABLE OF CONTENTS
Section 1. GENERAL INFORMATION 1-9. RESTORING TRANSMISSION
TO SERVICE
l-l. SCOPE OF MANUAL a. Transmission Exterior. . . . . . . . . . . . . . . 1-8
a. Content and Organization . . . . . . . . . . . 1-1 b. Sealed Breather and Openings . . . . . . . . 1-8
b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . 1-1 c. New Transmissions. . . . . . . . . . . . . . . . . 1-8
c. Maintenance Information . . . . . . . . . . . 1-1 d. Stored Without Fluid . . . . . . . . . . . . . . 1-8
1-2. SUPPLEMENTARY INFORMATION . . . 1-1 e. Stored With Fluid.. . . . . . . . . . . . . . . . . 1-8
l-10. OPERATING INSTRUCTIONS. . . . . . . . . 1-9
l-3. ORDERING PARTS
a. Transmission Nameplate . . . . . . . . . . . . 1-1 1-11. SPECIFICATIONS AND DATA . . . . . . . . 1-9
b. Parts Catalog.. . . . . . . . . . . . . . . . . . . . . 1-1 1-12. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . . . 1-10
l-4. GENERAL DESCRIPTION
a. Major Modules.. . . . . . . . . . . . . . . . . . . 1-5 Section 2. PREVENTIVE MAINTENANCE
b. Unique Features. . . . . . . . . . . . . . . . . . . 1-5 2 - l . SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-l
1-5. MAJOR MODULES 2-2. PERIODIC INSPECTION
a. Input Module . . . . . . . . . . . . . . . . . . . . . l - 6 AND CARE
b. Torque Converter . . . . . . . . . . . . . . . . . . l - 6 a. Exterior Cleaning and Inspection. . . . . . 2-l
C. Power Takeoff Provision . . . . . . . . . . . . l - 6 2-3. IMPORTANCE OF PROPER
FLUID LEVEL
d. Main Housing and Gear Module. . . . . . l - 6
a. Transmission Fluid. . . . . . . . . . . . . . . . . 2 - l
e. Range Clutches. . . . . . . . . . . . . . . . . . . . l - 6
b. Oil Level Sensor. . . . . . . . . . . . . . . . . . . 2 - l
f. Gearing Ratios . . . . . . . . . . . . . . . . . . . . l - 6
C. Electronic Controls and
g. Control System and Electronic Protection Circuits. . . . . . . . . . . . . . . . 2 - l
Control Unit (ECU). . . . . . . . . . . . . . . l - 6
2-4. ELECTRONIC FLUID LEVEL CHECK
h. Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . l - 6 (WHEN AN OPTIONAL OLS IS
i. Transmission Fluid Coolers . . . . . . . . . . l - 6 PRESENT - FULL-FUNCTION
j Output Configuration. . . . . . . . . . . . . . . l - 6 PUSHBUTTON OR LEVER SHIFT
SELECTORS)
l-6. MODEL DESIGNATION CODE. . . . . . . . l - 6 a. Fluid Level Check Procedure. . . . . . . . . 2-1
l-7. DIAGNOSIS 2-5. ELECTRONIC FLUID LEVEL CHECK
a. Before Starting . . . . . . . . . . . . . . . . . . . . l - 7 (WHEN AN OPTIONAL OLS IS
b. DO NOT SHIFT or CHECK TRANS PRESENT - STRIP TYPE PUSHBUTTON
Light.. . . . . . . . . . . . . . . . . . . . . . . . . . l - 7 SHIFT SELECTORS)
a. Fluid Level Check Procedure
c. Entering Diagnostic Mode. . . . . . . . . . . l - 7
(WTEC II) . . . . . . . . . . . . . . . . . . . . . . 2-3
d. Diagnostic Codes . . . . . . . . . . . . . . . . . . l - 7 b. Fluid Level Check Procedure
e. Displaying Diagnostic Codes. . . . . . . . . l - 7 (WTEC III) . . . . . . . . . . . . . . . . . . . . . 2-3
f. Diagnostic Code Displays . . . . . . . . . . . l - 7 2-6. MANUAL FLUID LEVEL
g. Exiting Diagnostic Mode. . . . . . . . . . . . l - 7 CHECK PROCEDURE
a. Preparation . . . . . . . . . . . . . . . . . . . . . . .2-4
1-8. PRESERVATION AND STORAGE
b. Consistency of Readings . . . . . . . . . . . .2-4
a. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . l - 7
b. Preservation Methods. . . . . . . . . . . . . . . l - 8 2-7. COLD CHECK
c. One Year Storage (Without Fluid) . . . . 1-8 a . Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
d. One Year Storage (With Fluid). . . . . . . . 1-8 b. Cold Check Procedure . . . . . . . . . . . . . .2-4
Copyright © 1998 General Motors Corp. V

I
2-8. HOT CHECK 2-17. FLUID LEAK DIAGNOSIS
a. Procedure . . . . . . . . . . . . . . . . . . . . . . . . 2-5 a. Finding the Leak. . . . . . . . . . . . . . . . . . 2-17
b. Powder Method.. . . . . . . . . . . . . . . . . . 2-17
2-9. KEEPING FLUID CLEAN
c. Black Light and Dye Method. . . . . . . . 2-17
a. Foreign Material. . . . . . . . . . . . . . . . . . . 2-5
d. Possible Points of Fluid Leaks
2-10. FLUID RECOMMENDATIONS . . . . . . . . 2-5 and Their Causes. . . . . . . . . . . . . . . . 2-17
2-11. FLUID AND FILTER CHANGE INTERVAL e. Repairing the Leak . . . . . . . . . . . . . . . . 2-18
a. Fluid and Filter Changes . . , . . . . . . . . . 2-6 2-18. OUTPUT FLANGE/YOKE AND
b. Fluid Analysis. . . . . . . . . . . . . . . . . . . . .2-6 OIL SEAL MAINTENANCE
(All, Except MD 3070PT)
2-12. FLUID CONTAMINATION a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2-18
a. Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 b. Assembly . . . . . . . . . . . . . . . . . . . . . . .2-19
b. Engine Coolant.. . . . . . . . . . . . . . . . . . .2-7 2-19. YOKE AND OIL SEAL MAINTENANCE
c. Metal.. . . . . . . . . . . . . . . . , . . . . . . . . . . 2-7 (MD 3070PT)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2-19
2-13. FLUID AND FILTER
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . .2-20
CHANGE PROCEDURE
a. Drain Fluid.. . . . . . . . . . . . . . . . . . . . . . 2-7 2-20. ON-VEHICLE MAINTENANCE. . . . . . . 2-20
b. Replace Filters - MD 3060/3560/
B 300/B400. . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Section 3. GENERAL OVERHAUL
c. Replace Filters - MD 3070PT. . . . . . . 2-8 INFORMATION
d. Refill Transmission. . . . . . . . . . . . . . . . 2-9 3-l. SCOPE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - l
2-14. BREATHER 3-2. TOOLS AND EQUIPMENT

a. Improvised Tools and Equipment. . . . . . 3 - l
a. Location and Purpose. . . . . . . . . . . . . . . 2-9
b . Special Tools. . . . . . . . . . . . . . . . . . . . . 3-1
b. Maintenance. . . . . . . . . . . . . . . . . . . . . 2-9
c. Mechanic’s Tools and
2-15. CHECKING CLUTCH PRESSURES Shop Equipment. . . . . . . . . . . . . . . . . . 3 - l
a. Transmission and Vehicle 3-3. REPLACEMENT PARTS
Preparation. . . . . . . . . . . . . . . . . . . . . 2-10 a. Ordering Information . . . . . . . . . . . . . . . 3-5
b. Recording Data. . . . . . . . . . . . . . . . . . . 2-10 b. Parts Normally Replaced at Overhaul . . 3-5
c. Comparing Recorded Data
3-4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3-5
to Specifications . . . . . . . . . . . . . . . . 2-11
3-5. CLEANING AND INSPECTION
2-16. TRANSMISSION STALL TEST
a. Dirt Causes Malfunction. . . . . . . . . . . . . 3-5
a. P u r p o s e . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . . 3-6
b. Stall Testing Preparation . . . . . . . . . . . 2-15 c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 3-6
C. Stall Test Procedures -Without d. Keeping Bearings Clean. . . . . . . . . . . . . 3-6
Pro-Link® . . . . . . . . . . . . . . . . . . . . . . 2-15 e. Inspecting Bearings . . . . . . . . . . . . . . . . . 3-6
d. Stall Test Procedures -With f. Inspecting Cast Parts and
Pro-Link®...................... 2-16 Machined Surfaces. . . . . . . . . . . . . . . . 3-6
e. Stall Test Procedures - Smoke g. Inspecting Bushings and Thrust
Controlled Engines . . . . . , . . . . . . . . 2-16 Washers . . . . . . . . . . . . . . . . . . . . . . . . 3-7
f. Neutral Cool-Down Check h. Inspecting Sealrings and Gaskets . . . . . . 3-7
Procedure...................... 2-16 i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 3-8
g. Stall Test Results . . . . . . . . . . . . . . . . . 2-16 j. Inspecting Splined Parts . . . . . . . . . . . . . 3-8
vi Copyright © 1998 General MotorsCorp.

TABLE OF CONTENTS
3-5. CLEANING AND INSPECTION (cont' d) 4-2. DISASSEMBLY OF TRANSMISSION
k. Inspecting Threaded Parts . . . . . . . . . . . 3-8 a. Mounting Transmission on
Repair Stand. . . . . . . . . . . . . . . . . . . . . 4-1
1. Inspecting Retaining Rings. . . . . . . . . . . 3-8
b. Removal of Common Extemally-
m. Inspecting Springs . . . . . . . . . . . . . . . . . 3-8 Mounted Parts . . . . . . . . . . . . . . . . . . . 4-1
n. Inspecting Clutch Plates. . . . . . . . . . . . . 3-8 C. Removal of Speed Sensors. . . . . . . . . . . 4-2
o. Inspecting Swaged and d. Removal of Integral Oil Cooler . . . . . . . 4-3

Interference-Fit Parts. . . . . . . . . . . . . . 3-8 e. Removal of Power Takeoff(s) . . . . . . . . 4-3
p. Inspecting Retainer and Ball Assembly f. Removal of Transfer Case
in Retarder Stator. . . . . . . . . . . . . . . . . 3-9 Module - MD 3070PT. . . . . , . . . . . . 4-3
q. Inspecting Sealing Surfaces . . . . . . . . . . 3-9 g. Removal of Control Module. . . . . . . . . . 4-4
3-6. ASSEMBLY PROCEDURES h. Removal of Torque
Converter Module . . . . . . . . . . . . . . . . 4-4
a. Parts Lubrication. . . . . . . . . . . . . . . . . . . 3-9
i. Removal of Converter
b. Grease Used for Assembly. . . . . . . . . . . 3-9 Housing Module . . . . . . . . . . . . . . . . . 4-5
C. Sealing Compounds and Nonsoluble j Removal of Retarder Module
Greases. . . . . . . . . . . . . . . . . . . . . . . . . 3-9 (Units Built Prior To 1/98) . . . . . . . . . 4-6
d. Clutches and Pistons. . . . . . . . . . . . . . . . 3-9 k. Removal of Retarder Module
e. Threaded Plugs and Hydraulic (Units Built Starting 1/98). . . . . . . . . . 4-7
Fittings. . . . . . . . . . . . . . . . . . . . . . . . . 3-9 1. Removal of Transfer Case Adapter
f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . . 3-9 Housing Module . . . . . . . . . . . . . . . . . 4-7
m. Removal of Rear Cover Module. . . . . . 4-7
g. Butt-Joint Sealrings . . . . . . . . . . . . . . . . 3-9
n. Removal of Main Shaft Module. . . . . . 4-7
h. Bearings.. . . . . . . . . . . . . . . . . . . . . . . 3-10
o. Removal of P2 Module, C5
i. Electrical Components . . . . . . . . . . . . . 3-10 Clutch Plates, and P1 Module . . . . . . 4 - 8
3-7. REMOVING (OR INSTALLING) p. Removal of Front Support/Charging
TRANSMISSION Pump Module and Rotating
Clutch Module. . . . . . . . . . . . . . . . . . 4 - 8
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . 3-10
q. Removal of C3/C4 Clutch Assembly
b. Disconnecting Controls . . . . . . . . . . . . 3-10 From Main Housing Module. . . . . . . 4-9
c. Uncoupling From Driveline, Vehicle,
and Engine. . . . . . . . . . . . . . . . . . . . . 3-11
Section 5. MODULE REBUILD
d. Removing the Transmission. . . . . . . . . 3-12
5-l. SCOPE
3-8. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . 3-12 a. Section. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
3-9. SPRING SPECIFICATIONS. . . . . . . . . . . 3-12 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . 5-1
3-10. TORQUE SPECIFICATIONS. . . . . . . . . . 3-12 5-2. GENERAL INFORMATION FOR
MODULE REBUILD . . . . . . . . . . , . . . . . . 5-l
Section 4. TRANSMISSION DISASSEMBLY 5-3. TORQUE CONVERTER MODULE

a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5-l
4-l. SCOPE
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5-2
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5-4 TORQUE CONVERTER
b. Procedures. . . . . . . . . . . . . . . . . . . . . . . . 4-l
HOUSING MODULE (Models Without
c. Illustrations. . . . . . . . . . . . . . . . . . . . . . . 4-1 PTO Provision)
d. General Information . . . . . . . . . . . . . . . .4-1 a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5-3
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 b. Assembly . . . . , . . . . . . . . . . . . . . . . . . .5-4
Copyright © 1998 General Motors Corp. vii

5-5. TORQUE CONVERTER 5-12. RETARDER MODULE
HOUSING MODULE (Models With a. Disassembly of Retarder Valve Body
PTO Provision) (Units Built Prior To l/98) . . . . . . . . 5-18
a. Module Disassembly . . . . . . . . . . . . . . . 5-4 b. Removal of Wiring Harness
b. Disassembly of the Bearing and Temperature Sensor . . . . . . . . . . 5-19
Retainer. . . . . . . . . . . . . . . . . . . . . . . . 5-4 Disassembly of Retarder Housing . . . . 5-19
C.
c. Disassembly of the PTO
d. Disassembly of P3 Planetary
Gear Assembly . . . . . . . . . . . . . . . . . . 5-4
Carrier Assembly . . . . . . . . . . . . . . . 5-20
d. Assembly of the PTO Gear
e. Disassembly of Retarder
Assembly . . . . . . . . . . . . . . . . . . . . . . 5-4
Stator Assembly . . . . . . . . . . . . . . . . 5-21
e. Assembly of the Bearing
f. Assembly of Retarder Stator . . . . . . . . 5-21
Retainer Assembly . . . . . . . . . . . . . . . 5-5
f. Module Assembly . . . . . . . . . . . . . . . . . 5-5 g. Assembly of P3 Planetary
Carrier Assembly . . . . . . , . . . . . . . . 5-22
5-6. FRONT SUPPORT AND CHARGING OIL h. Assembly of Retarder Housing
PUMP MODULE Assembly . . . . . . . . . . . . , . . . . . . . . 5-22
a. Module Disassembly. . . . . . . . . . . . . . . 5-5
i. Installation of Wiring Harness
b. Assembly of the Front Support . . . . . . . 5-7 Assembly . . . . . . . . . . . . , . . . . . . . . 5-24
c. Assembly of the Pump Housing . . . . . . 5-8 j. Assembly and Installation of Retarder
5-7. ROTATING CLUTCH MODULE Control Body Assembly . . . . . . . . . . 5-24
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5-9 k. Disassembly of Retarder Valve
Body (Units Built Starting l/98) . . . . 5-24
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5-11
1. Disassembly of Retarder Housing . . . . 5-25
5-8. C3/C4 AND MAIN HOUSING MODULE
m. Disassembly of P3 Planetary Carrier
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5-12 Assembly. . . . . . . . . . . . . , . . . . . . . . 5-26
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . 5-14
n. Disassembly of Retarder Stator
5-9. MAIN SHAFT MODULE Assembly. . . . . . . . . . . . . , . . . . . . . . 5-26
a. Disassembly (MD 3060, MD 3066, 0. Assembly of Retarder Stator. . . . . . . . . 5-27
B 300, B 400 Models). . . . . . . . . . . . 5-14
p. Assembly of P3 Planetary Carrier
b. Assembly (MD 3060, MD 3066, B 300, Assembly. . . . . . . . . . . . . . . . . . . . . . 5-27
B 400 Transmission Models) . . . . . . 5-15
q. Assembly of Retarder Housing
C. Module Disassembly Assembly. . . . . . . . . . . . . . . . . . . . . . 5-27
(MD 3560 Transmission Models). . . 5-15 r. Assembly and Installation of Retarder
d. Module Assembly Control Body Assembly . . . . . . . . . . 5-28
(MD 3560 Transmission Models). . . 5-15
5-13. REAR COVER MODULE
e. Module Disassembly
(MD 3070PT Transmission Model) . 5-15 a. Disassembly. . . . . . . . . . . . . . . . . . . . . 5-29
f. Module Assembly b. Disassembly of the P3 Planetary
(MD 3070PT Transmission Model) . 5-15 Carrier Assembly . . . . . . . . . . . . . . . 5-29
c. Disassembly of the Rear Cover
5-10. P1 PLANETARY MODULE
Assembly . . . . . . . . . . . . . . . . . . . . . 5-30
a. Disassembly. . . . . . . . . . . . . . . . . . . . . 5-15
d. Assembly of Rear Cover . . . . . . . . . . .5-30
b. Assembly. . . . . . . . . . . . . . . . . . . . . . 5-16
e. Assembly of the P3 Planetary
5-11. P2 PLANETARY MODULE Carrier Assembly . . . . . . . . . . . . . . . 5-30
a. Disassembly. . . . . . . . . . . . . . . . . . . . . 5-17 f. Completion of the Rear
b. Assembly. . . . . . . . . . . . . . . . . . . . . . .5-18 Cover Module . . . . . . . . . . . . . . . . . . 5-31
...
Vlll Copyright © 1998 General Motors Corn.
TABLE OF CONTENTS
5-14. ADAPTER HOUSING AND P3 OVERHAUL 5-16. CONTROL VALVE MODULE (cont’d)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5-32 h. Assembly of the Channel Plate . . . . . . 5-47
b. Assembly . . . . . . . . . . . . . . . . . . . . . . .5-33 i. Assembly of the Main Valve Body . . . 5-47
5-15. TRANSFER CASE MODULE j Assembly of C6 Control Valve Body . . 5-47
a. Disassembly of Transfer Case k. Assembly of the Stationary Clutch
Module. . . . . . . . . . . . . . . . . . . . . . . . 5-33 Solenoid Body . . . . . . . . . . . . . . . . . 5-48
b. Disassembly of C6 Clutch . . . . . . . . . . 5-35 1. Assembly of the Rotating Clutch
C. Assembly of C6 Clutch . . . . . . . . . . . . 5-36
Solenoid Body . . . . . . . . . . . . . . . . . 5-48
m. Installation of the Wiring Harness
d. Disassembly of C7 Clutch . . . . . . . . . . 5-36
Assembly and Cover Plate . . . . . . . . 5-48
e. Assembly of C7 Clutch Housing . . . . . 5-37
f. Disassembly of Oil Pump. . . . . . . . . . . . 5-37
Section 6. TRANSMISSION ASSEMBLY
g. Assembly of Oil Pump. . . . . . . . . . . . . 5-37
h. Disassembly of P4 Carrier . . . . . . . . . . 5-37 6-1. SCOPE
i. Assembly of P4 Carrier . . . . . . . . . . . . 5-38 a. Section. . . . . . . . . . . . . . . . . . . . . . . . . . 6-l
b. Procedures . . . . . . . . . . . . . . . . . . . . . . .6-l
j Disassembly of Drive, Idler, and
Driven Gears. . . . . . . . . . . . . . . . . . . 5-38 c. Illustrations . . . . . . . . . . . . . . . . . . . . . . 6-l
k. Assembly of Drive, Idler, and d. General Information. . . . . . . . . . . . . . . 6-l
Driven Gears . . . . . . . . . . . . . . . . . . . 5-38 e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . 6-l
1. Disassembly of the Front Output 6-2. ASSEMBLY OF TRANSMISSION
Housing and Front Output Shaft . . . 5-38
a. Assembly of C3/C4 Clutch. . . . . . . . . . . 6-l
m. Assembly of the Front Output
b. Installation of the Rotating
Housing and Front Output Shaft. . . . 5-39
Clutch Module . . . . . . . . . . . . . . . . . . 6-l
n. Disassembly of the Rear Output
C. Installation of the Front Support/
Housing . . . . . . . . . . . . . . . . . . . . . . . 5-39
Charging Pump Module . . . . . . . . . . . 6-l
0 . Assembly of the Rear Output
d. Installation of the P1 Planetary
Housing. . . . . . . . . . . . . . . . . . . . . . . 5-39
Module . . . . . . . . . . . . . . . . . . . . . . . . 6-2
P Output Housing Bearing Preload
e. Installation of the P2 Planetary
Procedures . . . . . . . . . . . . . . . . . . . . . 5-40
Module . . . . . . . . . . . . . . . . . . . . . . . . 6-2
q. Disassembly of C7 Control Valve
f. Installation of the C5 Clutch Pack . . . . . 6-2
Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
r. Assembly of C7 Control Valve g. Installation of the Main Shaft. . . . . . . . . 6-2
Body Assembly . . . . . . . . . . . . . . . . . 5-40 h. Main Shaft Selective Shim
Measurement For Models
S. Assembly of Transfer Case Module . . 5-41
With Retarder . . . . . . . . . . . . . . . . . . . 6-3
5-16. CONTROL VALVE MODULE i. Main Shaft Selective Shim
a. Removal of Filters . . . . . . . . . . . . . . . . 5-44 Measurement For Models Equipped
b. Removal of Electrical Components With Rear Cover. . . . . . . . . . . . . . . . . 6-4
and Sensors. . . . . . . . . . . . . . . . . . . . 5-44 j Selective Shim Measurement For
c. Disassembly of the Rotating Clutch MD 3070PT. . . . . . . . . . . . . . . . . . . . . 6-5
Solenoid Body . . . . . . . . . . . . . . . . . 5-45 k. Installation of Retarder Module
d. Disassembly of the Stationary Clutch (Units Built Prior To 1/98) . . . . . . . . .6-6
Solenoid Body . . . . . . . . . . . . . . . . . 5-45 1. Installation of Retarder Module
e. Disassembly of C6 Control Valve (Units Built Starting 1/98). . . . . . . . . .6-6
Body. . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 m. Installation of Rear Cover Module. . . . . 6-7
f. Disassembly of the Main Valve n. Installation of Transfer Case
Body. . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Adapter Housing. . . . . . . . . . . . . . . . . 6-7
g. Disassembly of the Channel Plate. . . . 5-47 o. Installation of Transfer Case Module. . . 6-7
Copyright © 1998 General Motors Corp. ix

6-2. ASSEMBLY OF TRANSMISSION (cont'd) Section 7. WEAR LIMITS AND
p. Installation of the Converter Housing SPRING DATA
Module . . . . . . . . . . . . . . . . . . . . . . . . 6-8 7-1. WEAR LIMITS DATA
q. Installation of the Torque a. Maximum Variations . . . . . . . . . . . . . 7 - 1
Converter Module . . . . . . . . . . . . . . . . 6-8 b. Cleaning and Inspection . . . . . . . . 7-1
r. Installation of the Control Module. . . . 6-10
7-2. SPRING DATA
s. Installation of Power Takeoff(s). . . . . . 6-11 . . . 7-1
a. Spring Replacement . . . . . . . .
t. Installation of Integral Oil Cooler . . . . 6-11 b. Inspection . . . . . . . . . . . . . . . . . . . . . . 7-1
u. Installation of Speed Sensors . . . . . . . . 6-12
v. Installation of Common Externally- Section 8. CUSTOMER SERVICE
Mounted Parts . . . . . . . . . . . . . . . . . . 6-13
8-1. OWNER ASSISTANCE . . . . . . . . . . . . . . .8-1
w. Removal of Transmission From
Repair Stand . . . . . . . . . . . . . . . . . . . 6-14 8-2. SERVICE LITERATURE . . . . . . . . . . . . . . 8-2
Copyright © 1998 General Motors Corp.

TABLE OF CONTENTS
LIST OF SUPPORTING ILLUSTRATIONS
(Back of Service Manual)
CROSS-SECTION VIEWS
1. Model MD 3060/B 300 Transmission
2. Model MD 3060R/B 300R Transmission (Prior To January 1, 1998)
3. Model MD 3060PR/B 300PR Transmission (Beginning January 1, 1998)
4. Model MD 3066/B 400PR Transmission
5. Model MD 3560PR Transmission
6. Model MD 3070PT Transmission
EXPLODED VIEWS
7. Torque Converter Module
8,A. Converter Housing Module, Without PTO Provision
8,B. Torque Converter Housing Module, With PTO Provision
9,A. Front Support and Oil Pump Module
9,B. Rotating Clutch Module
10,A. Main Housing Module
10,B. Main Shaft Module (MD 3060)
ll,A. Main Shaft Module (MD 3560)
ll,B. Main Shaft Module (MD 3070PT)
12,A. Pl Planetary Module
12,B. P2 Planetary Module
13,A. Retarder and P3 Planetary Module (Prior To 1/98)
13,B. Retarder and P3 Planetary Module (Starting 1/98)
13,C. Rear Cover and P3 Planetary Module
14,A. Transfer Case, Special Tools
14,B. Transfer Case, Special Disassembly/Assembly Instructions
15. Front Main Transfer Case
16. Rear Main Transfer Case
17,A. Control Valve Module (Prior To S/N 6510032369)
17,B. Control Valve Module (S/N 6510032369 To S/N 6510096670)
17,C. Control Valve Module (Starting With S/N 6510096671)
18,A. Output Flange and Yoke
18,B. Transfer Case Adapter Housing
19,A. Oil Cooler
19,B Support Equipment
HYDRAULIC SCHEMATIC
20. MD/B 300/B 400 - Neutral
Copyright © 1998 General Motors Corp. xi

NOTES
xii Copyright © 1998 General Motors Corp.

SECTION 1- GENERAL INFORMATION
1-1. SCOPE OF MANUAL 3. Required tools and fixtures needed are shown
in Figure 3-3 and Table 3-l (Section 3 of this
a. Content and Organization. This Service manual).
Manual describes overhaul procedures for the MD/ 4. Reasonable and prudent maintenance prac-
B 300/B 400 Series automatic transmissions (Figures tices are used.
1-1 through l-7).
l The major transmission components are NOTE:

described and their functions explained. Service organizations and individuals are
l Detailed instructions are provided for encouraged to contact their local ATD Distributor
disassembly, rebuild, and re-assembly. for information and guidance on any task outlined
in this manual.
l Part inspection instructions are in Section 3.
l Wear limits and spring data are in Section 7.
b. Illustrations 1-2. SUPPLEMENTARY

1. The text is supported with line drawings and INFORMATION
cross-sectional views. Overhaul procedures are
Supplementary information will be issued, as required,
illustrated by line drawings. Cross-sections
if any changes occur after publication of this manual.
show the relationship of assembled parts.
Check with your dealer or distributor to be sure you
Cross-sections and exploded views are on fold-
have the latest information.
out pages in the back of the manual.
2. Illustrations show correct procedures for all

models - including models not illustrated. 1-3. ORDERING PARTS
c. Maintenance Information. Each task described a. Transmission Nameplate. The nameplate (Fig-
in this manual has been successfully completed by ure l-8) is located on the right side of the transmis-
service organizations and individuals. Not every sion. The nameplate used prior to April 14, 1998, is
service organization or individual possesses the imprinted with the transmission serial number, part
required special tooling, training, or experience to number (assembly number), and model number. Use
perform all described tasks. However, any task may be all three numbers when ordering replacement parts or
performed if the following conditions are met: requesting service information. The nameplate used
beginning April 14, 1998, is imprinted with the trans-
1. The organization or individual has the required mission model, serial number, date code, TransID
knowledge of the task through: number, and groups. Use all of these numbers when
ordering replacement parts or requesting service infor-
l Formal instruction at Allison Transmission
mation.
Division (ATD) or a Distributor training
facility. b. Parts Catalog. Replacement parts are listed in
l On-the-job instruction by an ATD or Parts Catalog PC2150EN. Do not order by the item
Distributor representative. numbers used on exploded views in this manual. Use
the Parts Catalog to determine the correct part number.
l Experience in performing the task.
Order all replacement parts from your distributor.
2. The work environment is suitable to prevent Check the Yellow Pages for your nearest authorized
contamination or damage to transmission parts service outlet. Listings are under Transmission - Truck,
or assemblies. Tractor, Etc.
Copyright © 1998 General Motors Corp. l-l

1 MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL
FEEDTHROUGH HARNESS CONNECTOR

ASSEMBLY PADS
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
OIL FILL TUBE AND
(AVAILABLE BOTH SIDES)
MAIN-PRESSURE TAP
NOTE: Inch Series Threads S
PTO PROVISION /
(AVAILABLE BOTH SIDES)
V05552
Figure 1-1. Model MD(P) / B 300(R) / B 400(P) Transmission - Left-Front View
ASSEMBLY PADS
OUTPUT SPEED SENSOR

PTO PROVISION
INPUT SPEED SENSOR
FEEDTHROUGH HARNESS CONNECTOR
NOTE: Inch Series Threads OPTIONAL FRONT

COOLER PORTS
FROM COOLER
NOTE: Inch Series Threads
MAIN-PRESSURE TAP
NOTE: Inch Series Threads V01652.02
Figure 1-2. Model MD(P) / B 300(P) / B 400(P) Transmission - Right-Rear View
1-2 Copyright © 1998 General Motors Corp.

GENERAL INFORMATION
ASSEMBLY PADS
(BOTH SIDES)
TORQUE CONVERTER
WITH LOCKUP CLUTCH OUTPUT
AND TORSIONAL DAMPER RETARDER
L TO RETARDER
ACCUMULATOR
MAIN-PRESSURE TAP
.,R.v#Y I--L n__:_ IL____J
NOTE: Inch Series Thread
V05554
Figure 1-3. Model MD(R) / B 300(R) / B 400(R)Transmission (Prior To 1/98)- Left-Front View
BREATHER -
OUTPUT SHAFT -
SPEED SENSOR
- FEEDTHROUGH HARNESSi CONNECTOR
TO
.- I-----.. NAMEPLATE
NOTE: Inch Series Threads
RETARDER CONNECTOR (ON SIDE)
FROM COOLER
NOTE: Inch Series Threads - MAIN-PRESSURE TAP
NOTE: inch Series Threads
V05555
Figure 1-4. Model MD(R) / B 300(R) / B 400(R)Transmission (Prior To 1/98) - Right-Rear View
Copyright © 1998 General Motors Corp. 1-3

&$& r BREATHER
MAIN PRESSURE TAP

NOTE: Inch series threads
TACHOGRAPH PROVISION
NOTE: Metric series threads
SPEEDOMETER PROVISION -/
NOTE: Inch series threads
V05134
Figure 1-5. Model MD(R) / B 300(R) / B 400(R)Transmission (Beginning 1/98) - Left-Rear View
TRANSFER CASE
r FEEDTHROUGH HARNESS CONNECTOR
OIL FILL TUBE AND

(AVAILABLE BOTH SIDES) I/ -WA\’
SCAVENGE PUMP -/
V01953.01
Figure 1-6. Model MD 3070PT Transmission - Right-Front View
l-4 Copyright © 1998 General Motors Corp.

GENERAL INFORMATION
TRANSFER CASE
PTO
V05553
Figure 1-7. Model MD 3070PT Transmission - Left-Rear view
1-4. GENERAL DESCRIPTION

The Allison World Transmission, MD, B 300, and
World Transmissio Manulaciured By
B 400 Series, is a complete transmission system that
-s1on includes all hardware needed for vehicle applications.
Olvlrlon of GmsnlHaton Corpondlon
IndlaMpollr, lndlana
SERIAL NO.
XXXXXXXXXX
0 PART NO.
29509045
a. Major Modules. The MD, B 300, and B 400
Series transmissions contain the following major
modules:
1 YE” x x x x x x J
l Input Module
Prior to 4/l&98
l Main Housing and Gear Module
l Control Module
l Output Module
Indianapolis, Indiana, US
OI-xxx 02-xxx 05-XXX 08-XxX b. Unique Features. Features unique to the MD,
15-XxX 18-XxXx B 300, and B 400 Series transmissions are:
24-XxX 25-XxX
34-XxX 38-XxX . Four, five, or six forward speed configurations
GRO”PS 50-xXx 70-xXx (Mechanically, every MD, B 300, and B 400
RESERVED FOR transmission model is a six speed transmission.
Model XXXXX Options are available to convert it to a four or
s/N X X X X X X X X X X five speed model.) The MD 3070PT has a
\
- DATE TRANS ID - transfer case and seven forward speeds.
Beginning 4/l/&3
L
NUMBER vo5116.ot
l Lockup clutch with torsional damper
Figure 1-8. Transmission Nameplate l Integral retarder (optional)
Copyright © 1998 General Motors Corp. l-5

I MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL
. Integral oil filters, serviceable without the operating limits of the programmed microchip.
complete loss of transmission fluid Some out-of-limit conditions can be corrected by the
. Adaptive, electronic, closed-loop controls with control system. All out-of-limit condition diagnostic
self-diagnostic capabilities codes are stored for later retrieval by a technician.
The Electronic Control System includes:
1-5. MAJOR MODULES
l Electronic Control Unit (ECU)
a. Input Module. The Input Module includes: l Control module
l Engine adaptation l Shift selector
l Torque converter l Sensors
l Power takeoff gearing
l Wiring harness (customer-furnished)
b. Torque Converter
The ECU is a high-speed digital computer that re-
1. The torque converter includes a lockup clutch
ceives information from the sensors and shift selector.
and torsional damper for direct and smooth
This information is processed and shift commands are
transfer of engine power.
sent to the control module for range selection.
2. The available torque converter models are:
h. Oil Filters. Two disposable external-access oil
Torque Converter Model filters are part of the control module. Each filter is in
TC 411 its own separate cavity which permits removal and re-
TC 413 placement without complete loss of transmission fluid.
TC 415
i. Transmission Fluid Coolers. The main housing
TC 417 accepts remote or integral transmission fluid coolers.
TC 418
TC 419 j. Output Configuration. The output module in-
TC 421 cludes either an integral retarder and an output flange,
or a rear cover that includes pads for mounting a park-
c. Power Takeoff Provision. Provision for a direct, ing brake and a flange or yoke. A yoke is not available
engine-driven PTO is available at two positions. with parking brake equipped MD or B Series transmis-
sions. The MD 3070PT has a transfer case and adapter
d. Main Housing and Gear Module. The Main as an output module.
Housing and Gear Module includes:
l Main Housing
1-6. MODEL DESIGNATION CODE
l Oil pump charging system
l Three planetary gear sets The following explains the transmission model desig-
l Two rotating clutches nation code stamped on the transmission nameplate:
l Three stationary clutches
B - Indicates B series transmission
e. Range Clutches. Range clutches are multiple- MD - Indicates MD series transmission
disc, wet-type clutches. Exhaust backfill pressure is
3 or 4 - Indicates model
used to reduce fill time for quick response and smooth
shifts. 0 or 5 - Indicates close or wide ratio (0 = close)
6 or 7 - Indicates six or seven forward speeds
f. Gearing Ratios. MD 3060/MD 3066/B 300/B 400, (not used on B 300/B 400)
MD 3560, and MD 3070PT Series gear ratios are
listed in Table l-l following Paragraph 1-11. 0 - Indicates major revision
P - Indicates power takeoff provision
g. Control System and Electronic Control Unit
R - Indicates integral retarder
(ECU). The control system is capable of recognizing
hydraulic and electronic conditions that are not within T - Indicates transfer case (MD 3070 only)

I GENERAL INFORMATION
1-7. DIAGNOSIS f. Diagnostic Code Displays. The logged position
(dl, d2, d3, d4, and d5) of the following diagnostic
code is the first item of a diagnostic code display. After
NOTE:
two seconds the main code and sub code are displayed
Refer to TS2470EN and/or TS2973EN, WTEC II (example: 25 11). A WTEC III shift selector displays
and/or WTEC III Troubleshooting Manual for in- one character at a time. Each character is displayed for
depth troubleshooting procedures. about one second. The displayed diagnostic code and
the logged position of the code will be displayed se-
a. Before Starting. Before attempting to repair the quentially until the MODE button is pressed. When all
transmission, the faulty condition and its probable codes have been displayed by pressing the MODE
cause should be identified. button, the first code will be re-displayed. Any log po-
sition not containing a diagnostic code will display
b. DO NOT SHIFT or CHECK TRANS Light. “ - - ” at the code and sub code positions. No codes are
Continued illumination of the DO NOT SHIFT or logged after a “- -” display.
CHECK TRANS light during vehicle operation indi-
cates the ECU has signaled a diagnostic code. At start- g. Exiting Diagnostic Mode
up, the DO NOT SHIFT or CHECK TRANS light will
briefly illuminate. 1. Press the same buttons used to enter the diag-
nostic mode.
c. Entering Diagnostic Mode
1. Pushbutton Shift Selector. Begin by pressing 2. Select any range. The transmission will enter
the UP (1‘) and DOWN (J) arrow keys simul- the selected range if the range is not inhibited.
taneously. Diagnostics will be displayed imme-
diately, if no oil level sensor (OLS) is present. 3. Turn off the ignition switch.
Press the UP (1‘) and DOWN (J) arrow keys
simultaneously a second time to enter the Di- 4. The ECU diagnostic mode is exited automati-
agnostic Mode when an OLS is present. The cally after approximately two minutes have
display will list the diagnostic codes logged elapsed without an operator input.
positions (dl, d2, d3, etc.).
2. Lever Shift Selector Begin by pressing the 1-8. PRESERVATION AND STORAGE
DISPLAY MODE button. Diagnostics will be
displayed immediately, if no oil level sensor a. Storage (New Transmissions, Before Installa-
(OLS) is present. Press the DISPLAY MODE tion). New transmissions are filled with transmission
button a second time to enter Diagnostic Mode fluid and drained before shipment. The residual fluid
when an OLS is present. The display will list in the transmission provides adequate protection to
the diagnostic codes logged positions (dl, d2, safely store the transmission without further treatment
d3, etc.). for one full year if stored indoors, in conditions of nor-
mal climate, and with all shipping plugs installed.
d. Diagnostic Codes. Diagnostic codes can be dis-
played on the display portion of the shift selector or on
the Diagnostic Data Reader/Tool (DDR or Pro-Link®).
A diagnostic code is either active or historical. An ac-
tive code is any code that is current in the ECU deci-
sion-making process. Historical codes are codes that
are retained in the ECU memory and will not necessar-
ily affect the ECU decision-making process. Active
codes are indicated on the shift selector by the MODE
ON indicator.
e. Displaying Diagnostic Codes. Press and release
the MODE button to sequentially display the logged
diagnostic codes.
Copyright 0 1998 General Motors Corp. 1-7

b. Preservation Methods. When the transmission is 5. Continue operating the transmission in neutral
stored or inactive for an extended period (one or more at 1500 rpm until normal operating tempera-
years), specific preservation methods are required to ture is reached.
prevent damage from rust, corrosion, and organic
growth in the transmission fluid. Preservation methods
described are for storage with or without transmission
fluid. The methods are the same whether a transmis-
sion is in or out of a vehicle.
c. One Year Storage (Without Fluid) 6. If normal operating temperature is less than
1. Drain the fluid. 107°C (225°F), shift the transmission to for-
ward range and stall the converter. Do not ex-
2. Seal all openings and the breather with mois- ceed 107°C (225°F).
ture-proof tape.
7. As soon as the transmission is cool enough to
3. Coat all exposed, unpainted surfaces with pre- touch, seal all openings and the breather with
servative grease such as petrolatum (MIL-C- moisture-proof tape.
11796, Class 2).
8. Coat all exposed, unpainted surfaces with pre-
4. Remove the breather and spray 30 ml (one servative grease such as petrolatum (MIL-C-
ounce) of VCI #10 (or equivalent) into the trans- 11796), Class 2.
mission through the breather hole. Also, spray
30 ml (one ounce) through the fill tube hole. 9. If additional storage time is required, repeat
Steps 2 through 8 at yearly intervals, except, it
5. If additional storage time is required, repeat is not necessary to drain the transmission each
Steps (3) and (4) at yearly intervals. year. Just add VCI #l0 and Biobor® JF (or
equivalents).
d. One Year Storage (With Fluid)
1. Drain the fluid and replace the oil filter ele-
ments. 1-9. RESTORING TRANSMISSION
TO SERVICE
2. Fill the transmission to operating level with a
mixture of one part VCI #l0 (or equivalent) to a. Transmission Exterior. Wash all external grease
30 parts DEXRON%II transmission fluid. from the transmission with mineral spirits.
Add 1 ml of Biobor® JF (or equivalent) for
every 10 liters (1/4 teaspoon for every 3 gallons) b. Sealed Breather and Openings. Remove all tape
of fluid in the system. from openings and the breather.
c. New Transmissions. If the transmission is new,
NOTE: drain the residual preservative oil. Refill the
transmission to the proper level with DEXRON®-III or
When calculating the amount of Biobor® JF an Allison approved C-4 transmission fluid.
required, use the total volume of the system, not just
the quantity required to fill the transmission. d. Stored Without Fluid. If the transmission was
Include external lines, filters, and the cooler. prepared for storage without fluid, drain the residual
fluid and replace the oil filter elements. Refill the
transmission to the proper level with DEXRON®-III or
3. Operate the transmission for approximately an Allison approved C-4 transmission fluid.
five minutes at 1500 rpm with the transmission
in neutral. e. Stored With Fluid. If the transmission was pre-
pared for storage with fluid, it is not necessary to drain
4. Make sure the transmission shifts through all and refill the transmission with new transmission fluid.
ranges and that the lockup clutch is also acti- Check for proper fluid level. Add or drain transmission
vated. fluid, as required, to obtain the proper level.

GENERAL INFORMATION
1-10. OPERATING INSTRUCTIONS 1-11. SPECIFICATIONS AND DATA
Detailed transmission operation information is in the The following specifications and data provide a quick
MD/HD/B Series Principles of Operation Manual, reference to the major characteristics of the transmis-
P02454EN o r W T E C I I I O p e r a t o r ’ s M a n u a l , sion. More detailed information may be obtained from
OM2995EN. Refer to the latest edition. Sales Tech Data books.
Table 1-1. Specifications And Data Chart*
MD 3060
Range MD 3560** MD 3070PT** B 300/B 400**
MD 3066**
First 3.49:1 4.59:1 6.93:1 3.49:1
Second 1.86:1 2.25:1 4.18:1 1.86:1
Third 1.41:1 1.54:1 2.24:1 1.41:1
Fourth l.00:l l.00:1 1.69:1 1.00: 1
Fifth 0.75:1 0.75:1 1.20:1 0.75:1
Sixth 0.65:1 0.65:1 0.90:1 0.65:1
Seventh N/A N/A 0.78:1 N/A
Reverse -5.03:1 -5.00:1 -6.03:1 -5.03:1
HYDRAULIC SYSTEM:
Fluid type . . . . . . . MIL-L-2104, MIL-L-46167, DEXRON®-III, C-4 (Refer to Section 2,
Preventive Maintenance, for fluid recommendations.)
Filters, main
and cooler. . . . . . . Dual integral, replaceable cartridge type
Cooler . . . . . . . . . . Remote mounted, optional integral
MD 3000 MD 3000P MD 3000R MD 3000PR

B 300/ B 300P/ B 300R/ B 300PR/
SIZE: B 400 B 400P B 400R B 400PR MD 3070PT
Length (transmission 715.2 mm? 826.1 mm? 719.4 mm 826.1 mm 1294.8 mm
mounting face to end (28.16 in.) (32.52 in.) (28.32 in.) (32.52 in.) (50.98 in.)
of output shaft) 719.4 mtntt 821.9 mm+?
(28.32 in.) (32.36 in.)
Depth (centerline to 325.3 mm 325.3 mm 325.3 mm 325.3 mm 555.3 mm
lowest point) (12.81 in.) (12.81 in.) (12.81 in.) (12.81 in.) (21.87 in.)
Dry Weight 245 kg (535 lb) 260 kg (575 lb) 275 kg (610 lb) 300 kg (655 lb) 530 kg (1170 lb)
(Refer to drawings AS66-001 through AS6-005 for more information.)
* All data and specifications are subject to change without notice.

** Gear ratios do not include torque converter multiplication.
t Models prior to 1995
tt 1995 models
Copyright © 1998 General Motors Corp. l-9

1 - 1 2 . ELECTROMAGNETIC/RADIO or adversely affect vehicle operation. Manufacturers
FREQUENCY INTERFERENCE and installers of EMI/RFI emitting equipments are
responsible for adhering to FCC regulations and other
All electrical and electronic systems generate guidelines concerning emitted radio frequency
electromagnetic fields that can interfere with other interference for transportation electronics. Radio or
electronic systems. Allison Transmission’s electronic other two-way communication antenna, power, or
transmission controls comply with Federal ground leads near the transmission wiring harness,
Communications Commission (FCC) regulations and control devices, or power leads may create or be
other guidelines concerning emitted radio frequency subject to electromagnetic interference (EMI). Refer
interference for transportation electronics. Some to the latest edition of WTEC II Troubleshooting
radio-telephone or two-way communications radios Manual, TS2470EN, or WTEC III Troubleshooting
(land-mobile radio), or the manner in which they are Manual, TS2973EN, for detailed instructions
installed, can be affected by other vehicle components regarding EMI problems.

SECTION 2 - PREVENTIVE MAINTENANCE
2-1. SCOPE b. Oil Level Sensor. The optional oil level sensor
(OLS) allows the operator to check the fluid level from
Proper care and regular maintenance ensures the trans- either a full-function pushbutton or a lever shift selec-
mission meets its duty requirements. Perform the tor. Although strip type pushbutton selectors are rarely
maintenance procedures described in this section on a used, the OLS can also give fluid level information on
regular basis to prevent premature transmission or sup- a WTEC II version. There is no fluid level reading ca-
port equipment failure. Allison transmissions are man- pability for a WTEC III strip type pushbutton selector;
ufactured to provide long term, efficient service in use the Pro-Link® 9000 to obtain fluid level data from
their designed applications. the OLS.
2-2. PERIODIC INSPECTION NOTE:

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

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

lubricates, and transmits hydraulic power. Always 1. Park the vehicle on a level surface and shift to
maintain the correct fluid level. If the level is too low, N (Neutral). Apply the parking brake.
the torque converter and clutches do not receive
enough fluid and the transmission overheats. If the 2. On the full-function pushbutton shift selector,
level is too high, the fluid aerates causing the transmis- simultaneously press the UP (?) and DOWN
sion to shift erratically and overheat. (J) arrow buttons once.
Copyright © 1998 General Motors Corp. 2-l

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

I PREVENTIVE MAINTENANCE
10. To exit the oil level display mode (WTEC III 3. Correct fluid level is indicated by a flashing red
selector): LED on the N (Neutral) pushbutton. When this
occurs, the fluid level is within the “OK” zone.
l Pushbutton shift selector - press the The selector display and the transmission dip-
N (Neutral) pushbutton or press UP (?) and stick may not agree exactly because the oil
DOWN (J) arrow pushbuttons simulta- level sensor compensates for fluid temperature.
neously two times.
l Lever shift selector - press the DISPLAY 4. Low fluid level is indicated by a flashing red
MODE pushbutton two times or move the LED on the R (Reverse) pushbutton and a
lever. tone. The number of times the tone sounds is
the number of quarts of fluid which need to be
added to produce an “OK” level. The
2-5. ELECTRONIC FLUID LEVEL N (Neutral) pushbutton red LED will remain
CHECK (WHEN AN OPTIONAL on during this display.
OLS IS PRESENT - STRIP TYPE
PUSHBUTTON SHIFT 5. High fluid level is indicated by a flashing red
LED on the D (Drive) pushbutton and a tone.
SELECTORS) The number of times the tone sounds is the
number of quarts of fluid which need to be
NOTE: drained to produce an “OK” level. The
N (Neutral) pushbutton red LED will remain
The WTEC II strip type pushbutton shift selectors
on during this display.
can give fluid level information. The WTEC III
strip type pushbutton selector can only give fluid
level data by using the Pro-Link® 9000.
a. Fluid Level Check Procedure (WTEC II)

1. Park the vehicle on a level surface and shift to
N (Neutral). Apply the parking brake. 6. An Invalid for Display condition is indicated
by flashing red LEDs in a repeated sequence
2. Activate switch provided by the vehicle manu- from R (Reverse) down through the lowest
facturer to initiate display of fluid level infor- D (Drive) range while the N (Neutral) red LED
mation. remains constantly illuminated. A constant
tone sounds until the fluid level mode is exited.
NOTE: (Reasons for Invalid For Display are the same
The ECU may delay the fluid level check until the as those in the chart in Paragraph 2-4 above.)
following conditions are met:
7. To exit the fluid level display mode, press any
The fluid temperature is above 60°C (140°F) or pushbutton or deactivate the switch provided
below 104°C (220°F). by the vehicle manufacturer that was used to
The transmission is in neutral. enter the fluid level display mode in Step 2.
The vehicle has been stationary for approxi-
mately two minutes to allow the fluid to settle. b. Fluid Level Check Procedure (WTEC III)
The engine is at idle. 1. Connect the DDR (Pro-Link® 9000) to the
The delayed fluid level display signal for a WTEC II DDR connector on the wiring harness.
selector is a flashing indicator under the SELECT
display and a countdown from 8 to 1 under the 2. Scroll (down) the Diagnostic Data List to “OIL
MONITOR display. For a WTEC III selector, the LVL” display.
delayed fluid level display is a countdown from 8 to
1 in the display window. 3. Read the fluid level. Repeat to confirm the first
reading.

4. An Invalid for Display condition is indicated CALIBRATION WITH RESPECT TO SPLIT LINE AND FILL TUBE
by a message on the DDR. (Reasons for Invalid SCALE: NONE
For Display are the same as those in the chart BLADE WIDTH WHEN 6.35 mm REF
CHARACTERS ARE STAMPED (0.256 in.)
in Paragraph 2-4 above under “Cause Of
BLADE WIDTH WHEN A b 4.76 mm REF
Code.”) CHARACTERS ARE DOT-MATRIX m (0.187 in.)
HOT
2-6. MANUAL FLUID LEVEL RUN
BqND
CHECK PROCEDURE
DlMENhON A
sEiEf!ZiRT
DIMENkION B
SEE CHART r-l\ DAND
BELOW
I
j 1 D%~;/Aqj!j~Ej~;
)tTRANShlISSION ~~
CONTROL MODULE
SPLIT LINE (0.23 in.) DETERMINED BY
INSTALLATION
OIL ITRANSMIS~I~N SUMP 1 DIMENSION I DIMENSION 1DIMENSION I
SUMP I DESCRIPTION I A B IC”
4 INCH DEEP SUMP 101.6 mm 63.5 mm 45.7 mm
(4.00 in.) (2.50 in.) (1.80 in.)
2 INCH SHALLOW SUMP 101.6 m m 73.7 m m 50.6 m m
a. Preparation. Clean all dirt from around the end 14.06 in.1 f” 0,
of the fluid fill tube before removing the dipstick. Do I7lNCH 1 STANDARD**
not allow dirt or foreign matter to enter the transmis- ‘Reference only dimension. Actual dimension determined by installation.
sion. Dirt or foreign matter in the hydraulic system “MD 3070PT has 7.00 in. oil sump.
VOlf332
may clog passages and cause undue transmission part
wear or sticking valves. Figure 2-1. Fluid Dipstick Markings
b. Consistency of Readings. Always check the fluid b. Cold Check Procedure

level reading at least twice using the following proce-
1. Park the vehicle on a level surface, chock the
dure. Consistency (repeatable readings) is important to
wheels, and apply the parking brake.
maintaining proper fluid level. If inconsistent readings
persist, check the transmission breather to be sure it is 2. Run the engine at idle (500-800 rpm) for about
not clogged. If readings are still inconsistent, contact one minute. Shift to D (Drive) and then to
your nearest Allison distributor or dealer. R (Reverse) to clear the hydraulic system of
air. Then shift to N (Neutral) and allow the en-
2-7. COLD CHECK (Figure 2-1) gine to remain at idle (500-800 rpm).
3. With the engine running, remove the dipstick

a. Purpose. The purpose of the cold check is to de- from the tube and wipe clean.
termine if the transmission has enough fluid to be op-
erated safely until a hot check can be made. 4. Insert the dipstick into the tube and remove.
Check the fluid level. Repeat the check proce-
dure to verify the reading.
5. If the fluid level is within the “COLD RUN”

band, the transmission can be operated until
the fluid is hot enough to perform a “HOT
RUN” check. If the fluid level is not within the
“COLD RUN” band, add or drain as necessary
2-4 Copyright 0 1998 General Motors Corp.

PREVENTIVE MAINTENANCE
to bring the fluid level to the middle of the 4. Insert the dipstick into the tube and remove.
“COLD RUN” band. Check fluid level. Repeat the check procedure
to verify the reading.
6. Perform a hot check at the first opportunity
after normal operating temperature is 5. If the fluid level is not within the “HOT RUN”
reached - 71-93°C (160-200°F). band, add or drain as necessary to bring the
fluid level to within the band. Safe operating
level is within the “HOT RUN” band on the
2-8. HOT CHECK (Figure 2-1) dipstick (refer to Figure 2-l).
2-9. KEEPING FLUID CLEAN
a. Foreign Material. Prevent foreign material from

entering the transmission by using clean containers,
fillers, etc. Lay the dipstick in a clean place while fill-
ing the transmission.
2-10. FLUID RECOMMENDATIONS

1. The hydraulic fluids (oils) used in Allison
transmissions directly affect transmission per-
formance, reliability, and durability. Use
a. Procedure
DEXRON®-III fluid for regular duty, on-high-
1. Operate the transmission in D (Drive) range way applications. Use Allison Type C-4 fluids
until normal operating temperature is reached: for severe duty and off-highway applications.
l Sump temperature - 2. Some DEXRON®-III fluids are also qualified

71-93°C (160-200°F) as Type C-4 fluid. To ensure your fluid is quali-
fied for use in Allison transmissions, check for
l Converter-out temperature -
a DEXRON®-III or Type C-4 fluid license, or
82-104°C (180-220°F)
approval number on the fluid container, or con-
If a transmission temperature gauge is not sult the lubricant manufacturer. Consult your
present, check fluid level when the engine wa- Allison Transmission dealer or distributor be-
ter temperature gauge has stabilized and the fore using any fluid types except those fluids
transmission has been operated under load for qualified for use in Allison transmissions.
at least one hour.
2. Park the vehicle on a level surface and shift to

N (Neutral). Apply the parking brake and
block the wheels. Allow the engine to idle
(500-800 rpm).
3. With the engine running, remove the dipstick 3. When choosing the optimum viscosity grade of
from the tube and wipe clean. fluid to use, duty cycle, preheat capabilities,

and/or geographical location must be taken
into consideration. Table 2-1 lists the mini-
mum fluid temperatures at which the transmis-
sion may be safely operated. Preheat with
auxiliary heating equipment or by running the
equipment or vehicle with the transmission in
neutral for a minimum of 20 minutes before at-
tempting range operation.
Table 2-1. Transmission Fluid Operating b. Fluid Analysis. Transmission protection and fluid
Temperature Requirements change intervals can be optimized by monitoring fluid
(Ambient Temperature Below Which Preheat Is Required) oxidation according to the tests and limits shown in
Table 2-3. Consult your local telephone directory for
Viscosity Grade Celsius Fahrenheit fluid analysis firms. To ensure consistent and accurate
OW-20* -30 -22 fluid analysis, use only one fluid analysis firm. Refer
DEXRON®-III -27 -17 to the Technician’s Guide for Automatic Transmission
SAE 10W -20 -4 Fluid, GN2055, for additional information,
SAE 15W-40 -15 5
SAE 30 0 32 Table 2-3. Fluid Oxidation Measurement Limits
SAE 40 10 50 Test Limit
* “Arctic” as defined by MIL-L-46167B Viscosity ±25% change from new fluid
Carbonyl Absorbance +0.3 A*/O. 1 mm change from
2-11. FLUID AND FILTER new fluid
CHANGE INTERVAL Total Acid Number +3.0 change from new fluid
Solids 2% by volume maximum
* A= Absorbance Units
2-12. FLUID CONTAMINATION
a. Fluid And Filter Changes. Table 2-2 is given

only as a general guide for fluid and filter change
interval.
Table 2-2. Transmission Fluid and Filter Change a. Water
Transmission Fluid and Filter Change Interval 1. At each fluid change, examine the drained fluid
MD Series After the first 8000 km (5000 for evidence of dirt or water. A normal amount
B 300/B 400 miles); thereafter, 40 000 km of condensation will appear in the fluid during
(On-highway) (25,000 miles) or 18 months* operation.
MD Series After first 500 hours; 2. Obvious water contamination of the transmis-
(Off-highway) thereafter, 1000 hours max, sion fluid requires inspecting and pressure test-
or 18 months* ing the cooler (heat exchanger) for leaks between
* Whichever occurs first. the water and fluid areas. Transmission fluid in

the water side of the cooler (heat exchanger) is 1. Drain the transmission fluid when the fluid is at
another sign of a leak. operating temperature - 71-93°C (160-200°F).
Hot fluid flows quicker and drains more
NOTE: completely.
Cooler water can also be contaminated by engine
oil. Be sure to locate the correct source of cooler wa- 2. For all models except the MD 3070, remove
ter contamination. drain plug assembly 11 (Figure 2-2) from the
control module and allow the fluid to drain into
a suitable container. For an MD 3070, remove
b. Engine Coolant. Engine coolant (ethylene gly-
drain plug assemblies 8 and 11 (Figure 2-3)
col) in the transmission hydraulic system requires im-
from the control module and transfer case. Al-
mediate action to prevent malfunction and possible se-
low the fluid to drain into suitable containers.
rious damage. The transmission must be completely
disassembled, inspected, and cleaned. Remove all
traces of the coolant and varnish deposits resulting 3. Examine the fluid as described in Paragraph
.
from engine coolant contamination. Replace friction 2-12.

clutch plates contaminated with engine coolant.
c. Metal b. Replace Filters - MD 3060/MD 3560/
B 300/B 400 Transmission (Figure 2-2)
,_
Visible metal particles in the transmission fluid (ex-

cept for the minute particles normally trapped in the
oil filter) may indicate internal transmission damage. 1. To replace the oil filters on units prior to
When these particles are found in the sump, the trans- S/N 6510069120, remove twelve bolts 5, two
mission must be disassembled and closely inspected to filter covers 4, two o-rings 2, two square cut
find the source. Metal contamination requires complete seals 3, and two filters 1 from the bottom of the
transmission disassembly. Clean all internal and external control module.
hydraulic circuits, cooler, and all other areas where the
particles could lodge. 2. To replace the oil filters on units beginning
with S/N 6510069120, remove twelve bolts 5,
2-13. FLUID AND FILTER two filter covers 4, two gaskets 8, two
o-rings 7, two o-rings 6 and two filters 1 from
CHANGE PROCEDURE
the bottom of the control module.
NOTE: 3. When reinstalling parts on units prior to

If only filters are being replaced, do not drain the S/N 6510069120, lubricate and install an
fluid. o-ring 2 on each cover 4. Install a square cut
seal 3 on each cover 4. Lubricate filter o-ring
and install filters 1 onto covers 4.
a. Drain Fluid
4. When reinstalling parts on units beginning

with S/N 6510069120, lubricate and install
new o-rings 6 and 7 on each cover 4. Lubricate
o-ring inside filter 1 and push filter onto each
cover 4. Install new gasket 8 on each cover 4
and align holes in gasket with holes in cover.

2. To replace the oil filters on units beginning
with S/N 6510069120, remove 12 bolts 5, two
filter covers 4, two gaskets 14, two o-rings 13,
and two o-rings 12.
5. Install filter 1 and cover 4 assemblies into the 3. When reinstalling parts on units prior to
filter compartment. Index each filter/cover as- S/N 6510069120, lubricate and install an
sembly to the holes in the channel plate/sump. o-ring 2 on each cover 4. Install a square cut
Push the filter/cover assemblies in by hand to seal 3 on each cover 4. Lubricate filter o-ring
seat the seals. and install filters 1 onto covers 4.
6. Install six bolts 5 into each cover 4 and tighten 4. When reinstalling parts on units beginning with
them to 51-61 N•m (38-45 lb ft). S/N 6510069120, lubricate and install new
o-rings 6 and 7 on cover 5. Lubricate o-ring in-
c. Replace Filters - MD 3070PT side filter 1 and push filter onto cover 5. Install
Transmission (Figure 2-3) new gasket and align holes with those in cover 5.
5. Install filter 1 and cover 4 assemblies into the

1. To replace the oil filters on units prior to filter compartment. Index each filter/cover as-
S/N 6510069120, remove twelve bolts 5, two sembly to the holes in the channel plate/sump.
filter covers 4, two o-rings 2, two square cut Push the filter/cover assemblies in by hand to
seals 3, and two filters 1 from the bottom of the seat the seals.
control module.
- ‘BMAIN
V05556 J MAIN V05557
L
Figure 2-2. Filter Change Figure 2-3. MD 3070PT Filter Change

I PREVENTIVE MAINTENANCE I
6. Install six bolts 5 into each cover 4 and tighten Table 2-4. Fluid Fill Quantities (cont’d)
them to 51•61 N m (38-45 lb ft).
d. Refill Transmission
1. For all models except the MD 3070, and if re-
moved, inspect drain plug assembly 11
(Figure 2-2) and replace o-ring 9 or plug 10 as
required. For an MD 3070, remove and inspect
drain plug assemblies 8 and 11 (Figure 2-3)
and replace o-rings or plugs as required.
NOTE:
Whenever metallic particles larger than those nor-
mally found in filters are present on plug 10, the
transfer case must be disassembled to find and re- 2-14. BREATHER
pair the source of the contamination.
a. Location and Purpose. The breather is located
on top of the transmission converter housing. It serves
2. Tighten drain plugs to 25-32 N•m (18-24 lb ft) to prevent air pressure buildup within the transmission
after inspection is completed. and must be kept clean and open.
3. After refill, check the fluid level (refer to Para- b. Maintenance

graphs 2-6 and 2-7).
1. The amount of dust and dirt encountered will
determine the frequency of breather cleaning.
NOTE: Use care when cleaning the transmission exte-
rior. Spraying steam, water, or cleaning solu-
When the transmission is not completely disassem-
tion directly at the breather can force the water
bled or when just filters or fluid is changed, some
or cleaning solution into the transmission.
fluid will remain in the transmission so that refill
quantity will be less than for a dry unit. 2. Always use a wrench of the proper size to
remove or replace the breather. Pliers or a pipe
4. Refer to Table 2-4 for typical initial fill (dry wrench can crush or damage the stem and
unit) and for fluid amounts required to fill cool- produce metal chips which could enter the
ers and the remote retarder accumulator. transmission.
Table 2-4. Fluid Fill Quantities 2-15. CHECKING CLUTCH

Item Being Filled Initial Fill* PRESSURES
MD/B 300/B 400 27.0 liters Checking individual clutch pressures helps to
4.00 inch Sump determine if a transmission malfunction is due to a
Dry Transmission 29.0 quarts
mechanical or an electrical problem. Properly making
MD/B 300/B 400 25.0 liters these pressure checks requires transmission and
2.00 inch Sump
Dry Transmission 26.0 quarts vehicle (or test stand) preparation, recording of data,
and comparing recorded data against specifications
MD 3070PT 37.0 liters provided. These instructions are for all MD, B 300,
7.00 inch Sump
Dry Transmission 39.0 quarts and B 400 Series transmissions.

measured with the vehicle stationary. Consult
NOTE: the Pro-Link® 9000 operating instructions for
Check to see if there are diagnostic codes set which Action Request and select Clutch Test Mode.
are related to the transmission difficulty you are Follow instructions to select individual ranges.
evaluating. Proceed to make mechanical prepara- Record pressures in the desired range(s).
tions for checking clutch pressures after codes have
first been evaluated.
NOTE:
Check lockup clutch pressure by driving the vehicle
a. Transmission and Vehicle Preparation in a range where lockup can be obtained. Record
1. Remove the plugs from the pressure tap loca- the pressure values at the engine speed and sump
tions where measurement is desired (refer to fluid temperature values shown in Table 2-5. The
Figure 2-4). lockup clutch is functioning correctly when engine
speed and turbine speed values are equal as
recorded from the Pro-Link® 9000.
MD 3000/B 300/B 400

C6 (MD 3070PT ONLY) 1
2. Install hydraulic fittings suitable for attaching

pressure gauges or transducers.
3. Connect pressure gauges or transducers, Pres-

sure gauge set J 26417-A is available for this
purpose. See Table 2-6 for pressure levels ex-
pected.
4. Check that engine speed can be monitored BOTTOM VIEW

(Pro-Link® 9000 diagnostic tool may be used
for this purpose).
MD 3070PT TRANSFER CASE
5. Be sure that transmission sump fluid tempera-
ture can be measured. (Pro-Link® 9000 diag-
nostic tool may be used for this purpose.)
6. Be sure that the transmission has enough fluid

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

temperature of 71-93°C (160-200°F). Check
for fluid leaks in the added pressure gauge/
transducer lines. Repair leaks as needed. Be
sure that fluid level is correct. CONNECTOR
b. Recording Data
FRONT VIEW
1. Use the Pro-Link® 9000 diagnostic tool V01834.01
J 38538, which allows selecting of individual

ranges so that clutch pressures can be Figure 2-4. Clutch Pressure Check Points

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

Table 2-6. Main Pressure and Clutch Pressure Specifications
(Sump Fluid Temperature Same as in Table 2-5)
Transmission Main Press. Range Clutch Conv. Out Lube LU Clutch T-Case Main
Model/Test Engine Clutches Spec. Press. Spec.* Press. Spec Press* Qec Press. Spec. Press. Spec.
Type rpm Range Applied kPa / [psi] kPa / [psi] kPa/[psi] kPa/[psi] kPa / [psi]* kPa / [psi]
All (except 580-620 Neutral C5 1400-2000 0-40 (C5) -
MD 3070) [203-2901 [O-5.8]
- Idle
Reverse C3 C5 1400-2000 0-40 (C3 & C5) 3.5 min.
1203-2901 [O-5.8] [0.5 min.]
IC Cl c5 1300-1970 0-70 (C 1) 3.5 min.
[189-2861 [o-101 [0.5 min.]
0-40 (C5)
[o-5.8]
2C C1 C4 1300-1970 0-70 (C 1) 3.5 min.
[ 189-2861 @-101 [0.5 min.]
O-40 (C4)
[O-5.8]
MD 3070 Neutral C5 1400-2000 0-40 (C5) - 1400-2000
- Idle [203-2901 [O-5.8] [203-2901
Reverse C3 C5 1400-2000 040 (C3 & C5) 3.5 min. 1400-2000
[203-2901 [O-5.8] [0.5 min.] [203-2901
LOC C3 C6 1300-1970 0-40 (C3 & C6) 3.5 min. 130&1970
[203-2901 [O-5.8] [0.5 min.] 1203-2901
1c C1 c5 1300-1970 0-70 (Cl) 3.5 min. 1300-1970
[ 189-2861 w-101 [0.5 min.] [203-2901
0-40 (C5)
[O-5.8]
* Subtract clutch pressure from main pressure; the difference must fall within the specifications given (unless a pressure range is supplied).
Table 2-6. Main Pressure and Clutch Pressure Specifications (cont’d)
fiansmission Main Press. Range Clutch Conv. Out Lube LU Clutch r-Case Main
Model/Test Engine Clutches Spec. Press. Spec.* Press. Spec press* SPec Press. Spec. Press. Spec.
All (except 2080-2120 Neutral C5 1825-1965 0-40 (C5) 310-410 150-190
MD 3070) [265-2851 [O-5.8] [45-60] [22-281
- High Speed
Reverse C3 c5 1825-1965 0-40 (C3 & C5) 310-410 150-190
[265-2851 [O-5.8] [45-60] [22-281
1c Cl c5 1550-1690 0-70 (Cl) 310-410 150-190
1225-2451 w-101 [45-60] 122-281
040 (C5)
[O-5.8]
2C C1 C4 1550-1690 0-70 (Cl) 310-410 150-190
[225-2451 [o-101 [45-60] [22-281
0-40 (C4)
[O-5.8]
2L C1 C4 LU 111o1o-1240 0-70 (C 1) 310-410 150-190 0-60
[160-1801 [0-10] [45-601 [22-281 [0-8.7]
0-40 (C4)
[O-5.8]
3L C1 C3 LU 1100-1240 0-70 (Cl) 31WlO 150-190 0-60
[160-1801 w-101 [45-60] [22-281 [O-8.7]
040 (C3)
[O-5.8]
4L C1 C2 LU 1100-1240 0-70 (C 1) 310-410 150-190 0-60
[160-1801 w-101 [45-60] [22-281 [O-8.7]
0-70 (C2)
w101
5L C2 C3 LU 1 loo-1240 0-70 (C2) 310-410 150-190 0-60
[160-1803 w-101 [45-601 [22-281 [O-8.71
040 (C3)
[O-5.8]
6L C2 C4 LU 1 loo-1240 0-70 (C2) 310-410 150-190 0-60
[160-1803 [O-10] [45-601 [22-281 [O-8.7]
0-40 (C4)
[O-5.8]
’ Subtract clutch pressure from main pressure; the difference must fall within the specifications given (unless a pressure range is supplied).
Table 2-6. Main Pressure and Clutch Pressure Specifications (co&d)
Transmission Main Press. Range Clutch Conv. Out Lube LU Clutch T-Case Mair
Model/Test Engine Clutches Spec. Press. Spec.* Press. Spec press* Qec Press. Spec. Press. Spec.
MD 3070 2080-2120 N e u t r a l C5 1825-1965 040 (C5) 310-410 150-190 1440-1700
- High Speed [265-2851 [O-5.8] [45-601 [22-281 [209-2471
Reverse C3 C5 1825-1965 0-40 (C3 & C5) 310-410 150-190 1440-1700
[265-2851 [O-5.8] [45-601 [22-281 [209-2471
LOC C3 C6 1550-1690 o-40 (C3 & C6) 310-410 150-190 1440-1700
[225-2451 [O-5.8] [45-601 [22-281 [209-2471
1c Cl c5 1550-1690 0-70 (C1) 310-410 150-190 1440-1700
[225-2451 w-101 [45-601 [22-281 [209-2471
0-40 (C5)
W-5.81
2C Cl C4 1550-1690 0-70 (Cl) 310-410 150-190 1440-1700
[225-2451 w-101 r45-601 [22-281 [209-2471
0-40 (C4)
[O-5.8]
2L Cl C4 LU 1100-1240 0-70 (C 1) 310-410 150-190 0-60 1440-1700
[ 160-1801 P-lo1 [45-601 [22-281 [0-8.7] [209-2471
0-40 (C4)
[O-5.8]
3L Cl C3 LU 1100-1240 0-70 (Cl) 31OAlO 150-190 0-60 1440-1700
[16&180] ro-101 [45-601 [22-281 [O--8.7] [209-2471
0-40 (C3)
[O-5.8]
4L Cl C2 LU 1100-1240 0-70 (Cl & C2) 310-410 150-190 0-60 1440-1700
[160-1801 N-101 [45-601 [22-281 [0-8.7] [ 209-2471
5L C2 C3 LU 1100-1240 0-70 (C2) 31OAlO 150-190 0-60 1440-1700
[ 160-1801 [0-10] [45-601 [22-281 [0-8.7] [209-2471
o-40 (C3)
P-5.81
6L C2 C4 LU 1100-1240 0-70 (C2) 310-410 150-190 0-60 1440-1700
[160-1801 w-101 [45-601 [22-281 [O-8.7] [209-2471
0-40 (C4)
[O-5.8]
C Subtract clutch pressure from main pressure; the difference must fall within the specifications given (unless a pressure range is supplied).
2-16. TRANSMISSION STALL TEST 7. Start the engine and let the transmission sump
warm to normal operating temperature - 71-93°C
a. Purpose (160-200°F).
1. Stall testing is performed to determine whether 8. Perform a hot check of the transmission fluid
a power complaint is due to an engine problem level and adjust as necessary.
or transmission malfunction. 9. Turn all engine accessories “OFF.”
2. Stall speed is the maximum engine rpm attain- 10. Notify everyone to stay clear of the vehicle.
able when the engine is at full throttle and
when the torque converter turbine is not mov-
ing, or “stalled.”
3. During a stall test, compare actual engine
speed at full throttle stall with established
vehicle manufacturer’s specifications.
NOTE:
Engine stall point data can be obtained from the
vehicle manufacturer or from the equipment dealer
or distributor.
NOTE:
4. Stall tests are used as troubleshooting proce- l For vehicles with engines equipped with smoke
dures only - do not perform them as general controls, skip to Paragraph e.
checks or maintenance. l For vehicles with engines not equipped with
smoke controls, go to the next NOTE.
b. Stall Testing Preparation
1. Make sure the fuel control linkage goes to full
throttle and does not stick when released. NOTE:
2. Check the engine air induction system and ex- l If Pro-Link® (J 38538) diagnostic tool is not
haust system for restrictions. available, proceed with Paragraph c.
l If Pro-Link® (J 38538) diagnostic tool is available,
3. Perform a cold check of the transmission fluid skip Paragraph c, and proceed with Paragraph d.
level and adjust as necessary.
4. Install an accurate tachometer (do not rely on c. Stall Test Procedures - Without Pro-Link®
the vehicle tachometer). 1. Apply the vehicle parking and service brakes.
5. Install a temperature gauge with the probe in
2. Shift to D (Drive).
the transmission converter-out (to cooler) line.
3. Slowly accelerate to full throttle.
4. When the tachometer levels off, record the

maximum engine rpm attained.
5. Slowly release the throttle.
6. Shift to N (Neutral).
7. Skip Paragraph d and e and proceed immedi-
ately with Paragraph f - Neutral Cool-Down
6. Chock the wheels. Check Procedure.

d. Stall Test Procedures -With Pro-Link® 4. Slowly depress the vehicle service brakes
while staying at full throttle.
NOTE:
5. When the vehicle comes to a stop, record the
The Pro-Link® can be used to select a specific
engine rpm - this is stall speed.
range while the vehicle is not moving. This allows
a higher range to be used for stall testing, lower- 6. Proceed immediately with Paragraph f - Neu-
ing the possibility of damage due to excessive out- tral Cool-Down Check Procedure.
put torque.
The Pro-Link® can also be used to monitor f. Neutral Cool-Down Check Procedure
engine rpm. 1. The neutral cool-down check determines if the
transmission fluid cools properly following an
1. Plug the Pro-Link® into the DDL connector. engine load condition. Perform this check im-
mediately after the engine speed has been re-
2. Scroll through the Pro-Link® menus to “AC- corded in the stall test.
TION REQUESTS” and select “Clutch Test.”
3. Apply the vehicle parking and service brakes. 2. Record the converter-out fluid temperature.
4. Place the shift selector in fourth range (for a 3. With the transmission remaining in N (Neu-
pushbutton selector use D (Drive) and the ar- tral), run the engine at 1200-1500 rpm for two
row keys to select fourth). minutes to cool the fluid.
5. Once fourth range is attained, slowly acceler- 4. At the end of two minutes, record the con-
ate to full throttle. verter-out fluid temperature. Converter-out
fluid temperature should return to within the
6. When the Pro-Link® tachometer levels off,
normal operating temperature range.
record maximum rpm attained.
7. Slowly release the throttle. g. Stall Test Results
8. Place the shift selector in N (Neutral).

NOTE:
9. Skip Paragraph e and proceed immediately
with Paragraph f - Cool-Down Check. Environmental conditions, such as ambient temper-
ature, altitude, and engine accessory loss variations,
e. Stall Test Procedures - Smoke affect the power input to the converter. Under such
Controlled Engines conditions, stall speed can vary from specification
by +150 rpm and still be accepted as within normal
range.
NOTE:
Because smoke controls and throttle-delay
mechanisms inhibit engine acceleration, the stall 1. An engine stall speed 150 rpm or more below
testing may need to be performed while the vehicle the stall speed specification, indicates an
is moving. engine problem. An engine stall speed 150 rpm
or more above stall speed specification
indicates a transmission problem. Possible
1. Locate an isolated area to perform the driving transmission problems include slipping
stall test. clutches, improper oil level causing cavitation,
2. Select a hold range that will limit road speed or torque converter failure.
(usually 2nd or 3rd range - do not use Low
because too much torque is produced). 2. An extremely low stall speed (such as 33 per-
cent of the specified engine stall rpm), during
3. Operate the engine at full throttle and maxi- which the engine does not smoke, may indicate
mum governed rpm in the chosen range. a freewheeling torque converter stator.

3. If the fluid does not cool during the two minute c. Black Light and Dye Method
cool-down check, a stuck stator may be the
source of the problem.
NOTE:
4. If the engine stall speed meets the specification A dye and black light kit is available for finding
and the cool-down check shows that transmis- leaks. Refer to the manufacturer’s directions when
sion fluid cools properly, refer to the Allison using the kit. See kit directions for the color of the
Transmission Electronic Control Trouble- fluid and dye mix.
shooting Manual TS2470EN.
1. Pour the specified amount of dye into the trans-
2-17. FLUID LEAK DIAGNOSIS mission fill tube.
Most fluid leaks can be located and repaired by visu- 2. Operate the vehicle under normal operating
ally finding the leak and replacing or repairing the nec- conditions as directed in the kit.
essary parts. On some occasions, a fluid leak may be 3. Direct the black light toward the suspected
difficult to locate or repair. The following procedure area. The dyed fluid will appear as a brightly
may help in locating and repairing most leaks. colored path leading to the source.
d. Possible Points of Fluid Leaks
a. Finding the Leak
and Their Causes
1. Identify the fluid. Determine whether it is en- 1. Transmission mating su$aces:
gine oil, automatic transmission fluid, or hy-
draulic fluid from a specific vehicle system. l Attaching bolts not correctly tightened
l Improperly installed or damaged gasket
2. Operate the vehicle to reach normal operating
temperature and park the vehicle. After a few l Mounting face damaged
minutes look for dripping fluid to identify the 2. Housing leak:
approximate location of the leak.
l Filler pipe or plug seal damaged or missing
3. Visually check around the suspected area. In-
l Filler pipe bracket dislocated
spect all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that l Oil cooler connector fittings loose or
are hard to reach. damaged
4. If the leak still cannot be found, it may be neces- l Output shaft seals worn or damaged
sary to clean the suspected area with a degreaser, l Pressure port plugs loose
steam, or spray solvent. Completely clean and l Porous casting
dry the area. Operate the vehicle for several miles
at normal operating temperature and varying 3. Leak at converter end:
speeds. After operating, visually check the sus- l Converter seal damaged
pected leak area. If the leak is not located, use the l Seal lip cut (check converter hub for damage)
powder or black light and dye methods. l Garter spring missing from seal
b. Powder Method l Converter leak in weld area or o-ring seal
1. Clean the suspected area. l Porous casting
2. Apply an aerosol-type white powder, such as 4. Fluid comes out vent or fill tube:
foot powder, to the suspected area. l Over-filled - incorrect dipstick
3. Operate the vehicle under normal operating l Plugged vent
conditions. l Water or coolant in fluid - fluid will
appear milky
4. Visually inspect the suspected area and trace
the leak path over the white powder surface to l Incorrect electronic fluid level indication
the source. l Drain-back holes plugged

5. Gaskets: e. Repairing the Leak. Once the leak has been lo-
cated and traced back to its source, repair the leaking
l Fluid level/pressure is too high
components. If a gasket is replaced, but the sealing
l Plugged vent or drain-back holes flange is bent, the new gasket will not repair the leak.
The bent flange must be repaired also.
l Improperly tightened fasteners or dirty/
damaged threads
2-18. OUTPUT FLANGE/YOKE AND
l Warped flanges or sealing surface
OIL SEAL MAINTENANCE
l Scratches, burrs, or other damage to a (All, Except MD 3070PT)
sealing surface
l Damaged or worn gasket a. Disassembly (Figure 2-5)
l Cracked or porous casting 1. If installed, remove eight washers 12 and eight

bolts 13 and brake drum 11.
l Improper sealant used (where applicable)
2. Bend down tabs of locktab 6, if present.
6. Seals: 3. Remove two bolts 7 and locktab 6 or two bolts
l Fluid level/pressure is too high 18 and two washers 19 or one bolt 16. Discard
l Plugged vent or drain-back holes locktab 6 and bolts 7.
l Damaged seal bore 4. Remove flange 2 or yoke 8. Remove two
o-rings 4, retainer plug 5, and o-ring 3 or one
l Damaged or worn seal o-ring 14 and retainer plug 15.
l Improper installation 5. If present, remove four bolts 10 and parking
l Cracks in component brake assembly 9.
l Output shaft surface scratched, nicked or 6. Inspect the journal sealing area. Minimum
damaged allowable diameter is 89.78 mm (3.535 inch).
l Loose or worn bearing causing excess seal 7. Remove oil seal 1 using tool J 2417 1 or
wear equivalent.
Figure 2-5. Output Flange and Oil Seal - MD 3000/B 300/B 400

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

2-19. Y O K E A N D O I L S E A L
3. Install o-ring 3 on retainer plug 5 or 15. Lubri- MAINTENANCE (MD3070PT)
cate the o-ring.
a. Disassembly (Figure 2-7)
4. Insert two bolts 18 through belleville
washers 17 and retainer plug 5 or bolt 16 1. Remove output nuts 1 and washers 2 to remove
through retainer plug 15. rear output yoke 5 and front output yoke 3.
2. Remove yoke 5 and yoke 3 by using a slide

NOTE: hammer or a similar tool.
Bolts 18 and washers 17 are available in Service
Bolt Kit P/N 29535910 as described in 3. Remove oil seals 4 using tool J 24171-A.
SIL 15-WT-98. Coned end of belleville washer 17
MUST contact the head of bolt 18 as shown in 4. Inspect the front and rear output yokes and
Figure 2-6. DO NOT use locktab 6 with washer 17 front and rear oil seals for wear and damage.
and bolt 18.
5. Install an o-ring 4 over the threaded end of

each bolt 18 or o-ring 14 over bolt 16 so that
the o-ring seats against the retainer plug.
SERVICE BOLT
P/N 29535534 P/N 29535692
V05151.01
Figure 2-6. Installing Redesigned Two-Bolt

Flange Retention Kit Figure 2-7. Output Flange and Oil Seal - MD 3070PT
Copyright 0 1998 General Motors Corn. 2-19

I
I
MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL I
1
b. Assembly (Figure 2-7) 2-20. ON-VEHICLE MAINTENANCE
1. Inspect front output yoke 3 and rear output The following may be serviced or removed with the
yoke 5 for wear on the output seal journal. No transmission mounted in the vehicle. Refer to the indi-
scoring is permitted and should be removed by cated paragraph for removal instructions.
using a soft stone or crocus cloth. Minimum al-
lowable seal journal diameter is 76.20 mm
(3.000 inch). Item Paragraph
pws) 4-2b
2. Install oil seals 4 using J 38547 and J 35921-1.
Oil Cooler Manifold 4-2c(4)
3. Install rear output yoke 5 and front output
yoke 3 by using a slide hammer or a similar Input and Output Speed 4-2c(9) or (10);
tool. Sensors 4-2c(11) or (12)
4. Apply sealant on both sides of flat washers 2. Scavenge Rump 4-2c(13)
Install flat washers 7.
Control Valve Module 4-2d
5. Install output nuts 1; tighten the nuts to 610-
815 N•m (450-600 lb ft).

. Snapring pliers l Clean, lint-free shop cloths (do not use
waste cloths)
. Micrometer (metric preferred)
l Containers for parts
. Depth micrometer (metric preferred)
l Supply of wood blocks
. Dial indicator set (metric preferred)
. Metric headless guide bolts set

l Petrolatum
. M10 eye bolt l Container of mineral spirits for cleaning

parts
. Ml6 eye bolt
. Suitable hoist - 500 kg (1000 lb) capacity
. A 12 N.m (100 lb in.) torque wrench
. A 350 Nom (250 lb ft) torque wrench
. A press for disassembly and assembly of

spring-loaded clutches and interference-fit
parts
,- J 35926
V05613
Figure 3-2. Overhaul Stand

GENERAL OVERHAUL INFORMATION
MD MAIN TRANSMISSION TOOLS e
NOTE Objects are not shown to scale V05559
Figure 3-3. Special Tools

Table 3-1. Special Tools*
5-12h, q; 5-13e, f;
Piston Spring Compressor (C5)

Table 3-1. Special Tools* (cont’d)
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or tools from these firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066
3-3. REPLACEMENT PARTS
a. Ordering Information. Refer to the latest ver-

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

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

or foreign material to enter the transmission during as- Do not remove the grease in which new
sembly. Even minute particles can cause close-fit bearings are packed until they are to be in-
parts, such as valves, to malfunction. stalled.
b. Cleaning Parts Do not lay bearings on a dirty bench. Place
bearings on clean, lint-free paper.
1. Clean all metallic transmission parts, except
bearings and friction-faced clutch plates, by If a bearing is not installed immediately,
steam-cleaning or with volatile mineral spirits. wrap or cover the lubricated bearing with
Do not use caustic soda solution for steam- clean paper or lint-free cloth to keep out
cleaning. Clean friction-faced clutch plates and dust.
bearings with mineral spirits only. e. Inspecting Bearings
2. Dry all parts, except bearing assemblies, with 1. Inspect bearings for rough rotation. Replace a
compressed air. To prevent rust, lubricate bearing if its rotation is still rough after clean-
steam-cleaned parts as soon as they are dry. ing and lubrication.
2. Inspect bearings for scored, pitted, scratched,
3. Clean fluid passages by working a piece of soft
cracked, or chipped races, and for excessive
wire through the passages and flushing them
roller or ball wear. Replace the bearing if any
with mineral spirits. Dry the passages with
defects are found.
compressed air.
3. Inspect a defective bearing’s bore and mating
4. Examine parts, especially fluid passages, after shaft for grooved, burred, or galled conditions
cleaning to make certain they are entirely that indicate the bearing has been turning in the
clean. Re-clean parts if necessary. bore or on the shaft. If the damage cannot be
repaired with crocus cloth, replace the defec-
c. Cleaning Bearings
tive part.
1. Bearings that have been in service should be
4. When removing a bearing, do not apply pres-
thoroughly cleaned in volatile mineral spirits.
sure across the balls. This can cause brinelling
2. Soak particularly dirty bearings or ones filled and bearing failure.
with hardened grease in mineral spirits before 5. If a bearing must be removed or installed with-
trying to clean them. out the proper tool, press only on the race
which is adjacent to the mounting surface. If a
press is not available, carefully seat the bearing
with a drift and hammer.
f. Inspecting Cast Parts
and Machined Surfaces
1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
3. Before inspection, lubricate the bearings with deeply scratched or grooved.
transmission fluid.
2. Inspect all fluid passages for obstructions. If an
d. Keeping Bearings Clean. Ball or roller bearing obstruction is found, remove it with com-
failures are usually caused by dirt or grit in the bear- pressed air, or by working a soft wire back and
ing. Keep bearings clean during removal and installa- forth through the passage and flushing it out
tion. Observe the following rules to ensure maximum with mineral spirits.
bearing life:
3. Inspect mounting faces for nicks, burrs,
l Do not unwrap new bearings until they are scratches, and foreign matter. Remove any de-
to be installed. fects with crocus cloth or a soft stone. Clean

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

threads. Clean damaged threads with the cor-
rect size tap.
2. Replace bushings that are out-of-round, deeply

scored, or excessively worn. Inspect parts
mated to bushings to ensure they are not dam-
aged or worn beyond use.
3. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace a thrust washer if de-
fective or worn.
h. Inspecting Sealrings and Gaskets
As of this printing, the following parts have 1. Inspect piston sealrings and lip-type seals for
Spiralock threaded holes: nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
l Torque converter cover - flexplate adapter edges in piston grooves or on a mating surface
bolt holes and lockup clutch backplate bolt that could damage a new seal.
holes (starting with S/N 6510024410).
2. Replace all composition gaskets.
l Output shaft with single-bolt flange
retention - starting with S/N 6510184819. 3. Inspect hook-type sealrings for wear, broken
hooks, and distortion.
5. Inspect the ribs inside the main housing for
reaction plate wear grooves in the side of the 4. Install a new hook-type sealring if the old ring
ribs. Replace housings that have wear splines shows any wear on its outside diameter, or if
beyond wear limits. (Refer to Wear Limits, there is excessive side wear.
Table 7-1 in Section 7.)
5. Measure sealring end gap by inserting the seal-
6. Replace housings or other cast parts that are ring into its respective sealing bore. Use a
cracked. feeler gauge to measure end gap. Discard seal-
rings having excessive end gap. (Refer to Wear
7. Inspect all machined surfaces for damage that Limits, Section 7.)
could cause fluid leakage or other malfunction.
Rework or replace defective parts. 6. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
8. Inspect the oil tracks of the control module and could interfere with mating parts or damage
main housing for porosity, broken lands, the piston seal. Remove raised metal, sharp
cracks, dirt, and land surface imperfections. edges, burrs, or nicks with a soft stone and cro-
These imperfections will cause severe fluid cus cloth. Thoroughly clean all residue from
leakage leading to transmission failure. the housing before assembly.
g. Inspecting Bushings and Thrust Washers 7. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
1. Inspect bushings for scores, burrs, sharp edges, the seal. Remove raised metal, sharp edges,
and evidence of overheating. Remove scores burrs, or nicks with a soft stone and crocus
with crocus cloth. Remove burrs and sharp cloth. Thoroughly clean all residue from the
edges with a scraper or knife blade. Before piston before assembly.

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

p. Inspecting Retainer and Ball Assembly in Re- 2. Apply a generous amount of transmission fluid
tarder Stator. Inspect balls in the retarder stator for to the piston cavity before final assembly.
free movement. Inspect the staking that retains the
balls. Any restriction could prevent the ball from seat- 3. Assemble clutch plates so that the cone of each
ing during retarder application. plate faces the same direction.
e. Threaded Plugs and Hydraulic Fittings
q. Inspecting Sealing Surfaces
1. Inspect surfaces in contact with hook-type,

scarf-cut, and butt-joint sealrings for step-
wear, nicks, scratches, and scoring. Use a soft
stone or crocus cloth to remove only the raised
metal portion of these defects. Polishing the
area to remove a defect is neither necessary nor
desirable. If the defects are too severe to cor- Tighten all pipe plugs to the specified torque in the as-
rect, replace the defective part. sembly procedure and on the exploded views. Tighten
other fittings sufficiently to prevent leakage.
2. Inspect surfaces in contact with spring-loaded,
lip-type seals for nicks, scratches, roughness, f. Lip-Type Seals
or other surface irregularities. Inspect for em-
bedded particles, step-wear, and dirt on flanges 1. When replacing lip-type seals, make sure the
or other components exposed to external con- spring-loaded lip is toward the fluid to be
tamination. Remove the defects and restore the sealed (toward the inside of the unit). Coat the
finish. Replace the part if scores or scratches inside of the seal with high temperature grease
permit fluid leakage. (MIL-G-3545A or equivalent) to protect the
seal during shaft installation and to provide lu-
brication during initial operation.
3-6. ASSEMBLY PROCEDURES 2. The circumference of some seals is precoated
with a dry sealant. The sealant is usually col-
a. Parts Lubrication. During final assembly, ored for easy identification, Precoated seals do
lubricate all moving parts with transmission fluid. The not require any additional sealant before instal-
fluid will help protect friction surfaces and ferrous lation.
metals until the unit is in service.
g. Butt-Joint Sealrings
b. Grease Used for Assembly. During assembly use
oil-soluble grease with a low melting point (petrola-
tum) to temporarily retain parts, butt-joint sealrings,
scarf-cut sealrings, and hook-type sealrings.
c. Sealing Compounds and Nonsoluble Greases.

Do not use gasket-type sealing compounds, fibrous
greases, or nonsoluble vegetable-base cooking com-
pounds inside the transmission or where they could be
flushed into the transmission hydraulic system. 1. Butt-joint sealrings require special handling
during assembly. The sealrings contain materi-
d. Clutches and Pistons als that absorb moisture from the atmosphere
causing the sealring to expand. The sealrings
1. Soak each friction-faced clutch plate (two- are shipped in airtight packages. Do not open
minute minimum) in transmission fluid before the sealed package until the butt-joint sealring
final assembly. is ready to be installed into the transmission.

Check sealring end clearance before installa-
tion to ensure the sealring has not expanded.
2. Remove the sealring from its package and

place it in its operational position inside the
bore that it will be sealing.
3. Using a feeler gauge, check the end clearance

of the sealring. The end clearance must not be
less than specifications allow.
4. If the end clearance is less than minimum specifi-

cations, bake the sealring in an oven at 93-149°C
(200-300°F) for 24 hours or get a new seal-
a. Drain Fluid. Drain the transmission fluid before
ring. Repeat Steps (2) and (3).
removing the transmission from the vehicle. The trans-
5. Pack the sealring and its groove with a liberal mission should be warm and the fluid allowed to drain
amount of oil-soluble grease. overnight.
Remove the drain plug from the control mod-

6. Roll up the sealring to about half its free diam-
ule. Examine the drained fluid and magnetic
eter and hold it for about 10 seconds. Being
drain plug for evidence of contamination (refer
careful not to spread the sealring more than
to Paragraph 2-11). Reinstall the drain plug
necessary, slide it onto the hub. Place one end
when fluid draining is completed.
of the sealring into the groove and gradually
work the seal into the groove.
Remove the transmission fill tube if it inter-
h. Bearings. If a bearing must be removed or feres with transmission removal.
installed without an installation sleeve, drive or press
only on the race which is adjacent to the mounting
surface. If a press is not available, carefully seat the NOTE:
bearing with a drift and a hammer, driving against the A significant amount of fluid may drain from a
supported race. hydraulic hose when it is disconnected from the
transmission.
i. Electrical Components. For inspection and re-
pair of electrical components, refer to the Allison
Transmission Electronic Troubleshooting Manual 3. Disconnect all hydraulic hoses from the trans-
TS2470EN (WTEC II Controls) or TS2973EN mission. Remove the hoses from the vehicle if
(WTEC III Controls). they interfere with the transmission removal.
Plug all openings to keep dirt from entering the
hydraulic system.
3-7. REMOVING (OR INSTALLING)
TRANSMISSION (Figures 3-5, 3-6, 4. If an integral cooler is used, drain coolant from
and 3-7) the cooler and disconnect coolant hoses. Re-
move the hoses from the vehicle if they inter-
fere with transmission removal. Plug all
openings to keep dirt from entering the cooling
system.
b. Disconnecting Controls. Disconnect or com-

pletely remove controls. If controls are not removed
from the transmission, position them so that they do
not interfere with transmission removal.

1. For non-retarder models, disconnect the trans- 4. For transfer case models, disconnect the trans-
mission external harness from the feedthrough mission external harness from the feedthrough
harness connector, the input speed sensor, the harness connector, the input speed sensor, the
output speed sensor, and the PTO connector, if transfer case connector, and the PTO connector,
present (see Figure 3-5). Disconnect the ta- if present (see Figure 3-7). Cover the harness
chograph drive, if used. connectors to keep out dirt.
c. Uncoupling From Driveline, Vehicle,
2. For retarder models prior to 1/98, disconnect
And Engine
the transmission external harness from the
feedthrough harness connector, the input speed 1. Disconnect the vehicle drive shaft from the
sensor, the retarder connector, and the PTO transmission output flange or yoke. Position
connector, if present (see Figure 3-5). Cover the disconnected shaft to avoid interference
the harness connectors to keep out dirt. with removing the transmission.
3. For retarder models beginning 1/98, disconnect 2. PTOs, if present, must either have the output
the transmission external harness from the driveline disconnected or be removed from the
transmission feedthrough harness, the input transmission.
speed sensor, the output speed sensor, the re-
tarder temperature sensor, the retarder valve 3. Securely support the transmission with a hoist,
body connector, and the PTO connector, if jack, or other suitable removal equipment.
present (see Figure 3-6). Disconnect the ta-
chograph drive, if used. Cover the harness con- 4. Remove all bolts, nuts, washers, spacers, and
nectors to keep out dirt. supports that attach the transmission to the
vehicle and to the engine.
FEEDTHROUGH -
y COOLER PORTS-- CONNECTOR

NOTE: hch Series Threads TACHOGRAPH PROVISION -/ CONNECTOR
RETARDER (METRIC THREADS)
MAIN PRESSURE TAP CONNECTOR
(ON SIDE) SPEEDOMETER PROVISION
NOTE: Inch Series Threads (INCH SERIES THREADS)
V05560
V05561
Figure 3-5. Disconnect Locations Figure 3-6. Disconnect Locations

(Retarder Models Prior To 1/98) (Retarder Models Beginning 1/98)

MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL-1
MOUNTING d. Removing the Transmission
A PADS FEEDTHROUGH
/- HARNESS 1. Move the transmission away from the engine
approximately 110 mm (4.33 inch) until it is
completely clear of the engine. Remove the
adapter ring (if used).
2. Raise or lower the transmission as necessary to
remove it from the vehicle.
3-8. WEAR LIMITS

Refer to Wear Limits Data Table 7-1, for information
covering parts fits, clearances, and wear limits.
PORTS
SCAVENGE PUMP 3-9. SPRING SPECIFICATIONS
Refer to Spring Data Table 7-2 for spring identifica-
tion and specifications.
3-10. TORQUE SPECIFICATIONS

Assembly procedures in Sections 5 and 6 specify the
torque requirements for all plugs, bolts, and nuts.
Torque values are also presented with the foldout illus-
trations in the back of this manual. Torque values spec-
ified are for dry assembly, except when otherwise
noted. Bolts and washers should be washed and dried
before assembly.
MD 3070PT - V05562
Figure 3-7. Disconnect Locations (MD 3070PT)

I SECTION 4 - TRANSMISSION DISASSEMBLY
4-1. SCOPE balanced, and raise the transmission to the
mounting face of the repair stand.
a. Section. This section covers disassembly of
3. Secure the transmission holding fixture to re-
MD 3000(P)(R)(T), B 300(P)(R), and B 400(P)(R)
pair stand J 29109.
Series transmissions. The disassembly sequence is
continuous and includes all models. 4. For the MD 3070PT transmission model, fol-
low Step (1). In addition, install fixture J 38572
b. Procedures. When a procedure does not apply to
on the transfer case. Connect fixtures J 35926
your specific model, go to the next applicable proce-
and J 38572 by installing four bolts 1 (Figure
dure.
4-1). Secure the transmission holding fixtures
c. Illustrations. Illustrations will not always show to the repair stand.
your model, but when an operation is identical for all
b. Removal of Common Externally-Mounted
models, the correct procedure is shown.
Parts (Figure 4-2)
d. General Information. Refer to Sections 3 and 7 1. Inspect transmission breather 1 for damage or
for general information as follows: obstruction. Remove if necessary for replace-
Paragraph Title ment or cleaning.
3-2 Tools and Equipment
2. Remove screw 22 retaining fill tube bracket 23
3-3 Replacement Parts
to the main housing module. Remove
3-4 Careful Handling bracket 23, fill tube 21, seal 20, and
3-5 Cleaning and Inspection dipstick 24.
3-7 Removing Transmission
7-l Wear Limits Data 3. Remove expander plug 2 from the other fill
7-2 Spring Data tube location on the opposite side of the
main housing module. For transmissions af-
e. Foldouts. Refer to Foldouts 7 through 19 for ex- ter S/N 6510107518, pry under the head of
ploded views. plug 3 and remove plug 3 and seal 4.
4. Remove six bolts 16 retaining remote cooler
4-2. DISASSEMBLY OF manifold 18, or cover 17, to the main housing
module. Remove cooler manifold 18, or
TRANSMISSION cover 17, and gasket 19.
a. Mounting Transmission on Repair Stand
1. Mount holding fixture J 35926 onto the main

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

V05564
Figure 4-2. Common Externally-Mounted Parts Removal
5. If present, remove bolts 8 and brake drum 7. c. Removal of Speed Sensors
NOTE: NOTE:
For MD 3070PT transmission models, do not re- l For models without PTO, proceed to Step (1).
move yokes now. Removal is covered in Section 5-14 . For models with PTO, skip Step (1) and proceed
as part of transfer case disassembly. to Step (2).
6. Bend down edges of locktab 10, if present. Re- 1. Remove bolt 6 (Foldout 8,A), retainer 5, input
move two bolts 9 and locktab 10 or two speed sensor assembly 3, and o-ring 4 from the
bolts 31 and two washers 30, retainer plug 11, converter housing module. Skip to next NOTE.
o-ring 13, and two o-rings 12 or one bolt 29, 2. Remove bolt 22 (Foldout 8,B), retainer 21,
retainer plug 28, and o-ring 27. Discard lock- input speed sensor assembly 19, and o-ring 20
tab 10 and bolts 9. from the converter housing module.
7. Remove flange 14 or yoke 15.
NOTE:
8. Inspect the journal sealing area. Minimum di- l For models without retarder, proceed to Step (3).
ameter allowable is 89.78 mm (3.535 inch).
l For models with retarder (built prior to 1/98),
9. If present, remove four bolts 6 and parking skip Step (3) and proceed to Step (4).
brake assembly 5. l For models with retarder (built starting 1/98),
skip Steps (3) and (4) and proceed to Step (5).
10. If present, remove bolt 25 and harness l For MD 3070PT, proceed to f.
bracket 26.

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

1. Remove eight PTO mounting bolts 7 or 11.
Carefully remove PTO assembly 8 or 12 and
gasket 6 or 10.
2. Inspect two PTO studs 5 or 9 for damage and

remove them if necessary.
f. Removal of Transfer Case

Module - MD 3070PT (Figures 4-4 and 4-5)
1. Remove hose 1 (Figure 4-4), fittings 2 and 3,
o-rings 4 and 5, and screen 6. Remove scav-
enge pump 7 by removing nine bolts 8. Re-
move gasket 9.
2. Separate fixture J 35926 and the transfer case

lifting fixture J 38572 by removing four
bolts 6.
3. Remove nineteen bolts 2 and one bolt 7 to dis-

connect the transfer case from the main trans-
Figure 4-3. Output Speed Sensor mission.

I MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL 1
g. Removal of Control Module (Figure 4-6)
NOTE:
The control module or filters may contain residual
transmission fluid.
Figure 4-4. Scavenge Pump Removal 2. For a four-inch sump, remove seven bolts 3
and twenty-five bolts 4 retaining control mod-
ule 1 to the main housing module, including
the bolts retaining the filter covers.
3. Loosen control module 1 by applying pressure
at the reinforced tabs or use jack bolts. Insert
jack bolts into the control module bolt holes
that bottom against the main housing module.
4. Remove control module assembly 1 and
gasket 2.
h. Removal of Torque Converter Module
(Figure 4-7)
1. Remove any brackets installed to prevent
torque converter movement.
NOTE:
l For units prior to S/N 6510165560, proceed to
Figure 4-5. Transfer Case Module Removal
Step (2).
4. Attach a hoist, making sure that lifting attach- l For units beginning with S/N 6510165560, skip
ments are placed so that the transfer case is Steps (2) and (3) and proceed to Step (4).
properly balanced. Raise the transfer case to
the mounting face of the repair stand.
2. Remove retaining ring 1 using snapring pliers
5. Secure the transfer case holding fixture to the (Figure 4-7, View A).
repair stand.
3. Thread an M6 bolt into converter end plug 2
6. Remove gasket 4 and selective shim 1. The se- and remove plug 2 and o-ring 3. Skip Steps (4)
lective shim is located inside shaft adapter 5. and (5) and proceed to Step (6).

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

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

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

tioning the adapter connections an equal dis-
tance from each other. Using a chain hoist,
carefully lift torque converter module 6 out of
the converter housing (Figure 4-6, View A).
10. Place two wooden blocks on the workbench,

spaced to support the torque converter module
and high enough for the converter hub to clear
the workbench. Lower the converter module,
converter hub down, onto the blocks.
i. Removal of Converter Housing Module

(Figure 4-8)
NOTE:
Three converter housing retaining bolts 3 are re-
moved from inside converter housing 1. After loos-
ening the bolts, use mechanical fingers or a similar
Figure 4-6. Control Module Removal
tool to remove these bolts.
4. Keep the torque converter cover from turning
by using a heel bar, two bolts and a screwdriver
(Figure 4-7, View C). 1. Remove twenty bolts 3 that retain converter
housing 1 to main housing module 4.
5. Remove threaded plug 7 and o-ring 8 using a
¾ inch Allen socket. 2. Lift straight up on converter housing module 1,
6. Hold the turbine and turbine shaft stationary by or remove it using the same sling used for re-
using one of the methods listed below: moving the converter module.
l Insert a screwdriver into the vanes on the
3. Remove main housing gasket 2 from converter
rotating clutch module (Figure 4-7,
housing 1, or from main housing module 4.
View B).
l If the control module is in place, remove the
plug(s), if present, from the fill tube hole or NOTE:
from cooler ports before applying lockup
air pressure. Apply air pressure through the l Proceed to Step j. for units with retarder built
lockup pressure tap (Figure 4-7, View D) prior to 1/98.
and use a heel bar, screwdriver, and bolts. l Proceed to Step k. for units with retarder built
Insert the heel bar into a torque converter starting 1/98.
housing bolt hole. Insert two bolts into the

TCupped end down
ROTATING
CLUTCH
MODULE
LOCKUP -
PRESSURE r
TAP
.
u
BOTTOM VIEW
VIEW D E05568.01
Figure 4-7. Torque Converter Module Removal
V05615
Figure 4-8. Converter Housing Module Removal
j. Removal of Retarder Module (Units Built

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

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

I TRANSMISSION DISASSEMBLY I
3. Attach a suitable sling and lift upward, remov-
ing rear cover module 2.
4. Remove rear cover gasket 1 from main housing
4 or rear cover module 2.
n. Removal of Main Shaft Module
2. Thread an Ml0 eye bolt into the retarder out- (Figure 4-12)
put shaft and lift the retarder module 2 from 1. Remove shim 2 and thrust bearing 3 from the
main housing 3. main shaft module.
3. Remove retarder gasket 1 from main housing 3 2. Lift main shaft module 1 out of the transmis-
or retarder module 2. sion.
k. Removal of Retarder Module (Units Built
Starting 1/98) (Foldout 13,B and Figure 4-9)
1. Remove fourteen bolts 2 (Foldout 13,B), two
bolts 34, four bolts 3, seven bolts 4, and one
bolt 59 that secure retarder module 2 (Figure
4-9) to main housing 3.
2. Thread an M10 eye bolt into the retarder out-

put shaft and lift the retarder module 2 from
main housing 3.
Figure 4-10. Adapter Housing Removal
3. Remove retarder gasket 1 from main housing 3
or retarder module 2.
1. Removal of Transfer Case Adapter
Housing Module (Figure 4-10)
1. Remove adapter housing 3 by removing fifteen
bolts 8, three bolts 6, three bolts 5, four bolts 4,
and two bolts 7.
2. Remove gasket 2.
3. Remove P3 carrier assembly 1 (Foldout 18) by
sliding it up over the main shaft.
m. Removal of Rear Cover Module
(Figure 4-11)
1. Remove nineteen bolts 3.
2. If used, remove the rear support bracket. Figure 4-11. Rear Cover Module Removal

I
I
MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL I I
Figure 4-13. P2 Module and C5 Clutch Plates
Figure 4-12. Main Shaft Module Removal
o. Removal of P2 Module, C5 Clutch Plates,

and P1 Module (Figures 4-13,4-14)
1. Lift P2 planetary module 1 (Figure 4-l 3) from
the main housing module.
2. Lift C5 clutch pack from the main housing

module - seven friction plates 3 and eight
steel reaction plates 2.
3. Measure the thickness of each friction plate 3.

Minimum thickness is 2.90 mm (0.114 inch).
Measure the oil groove depth of each friction Figure 4-14. P1 Module
plate. Minimum groove depth is 0.20 mm
(0.008 inch).
4. Measure thickness of each steel reaction plate

2. Minimum thickness is 2.41 mm (0.095
inch).
5. Measure the cone of each plate. Maximum

cone is 0.41 mm (0.016 inch).
6. Lift P1 planetary module 1 (Figure 4-14) from

the main housing module.
p. Removal of Front Support/Charging Pump

Module and Rotating Clutch Module
(Figures 4-15, 4-16)
1. Remove eleven bolts 1 and 2 (Figure 4-15)
that retain front support and charging pump Figure 4-15. Front Support/Oil Pump
module 3 to the main housing. Module Removal

I TRANSMISSION DISASSEMBLY
2. Lift front support and charging pump module 3 q. Removal of C3/C4 Clutch Assembly From
away from the turbine shaft. Main Housing Module (Figure 4-17)
1. Remove twelve bolts 3 retaining C3/C4 clutch

assembly 1 in main housing module 2.
2. Remove C3/C4 clutch assembly 1 by sliding it
3. Using a hoist and an Ml6 eye bolt, lift turbine out of the input end of main housing module 2.
shaft and rotating clutch module 1 (Figure 4-16)
from the main housing module. 3. Remove the main housing from the repair
stand for cleaning.
4. Inspect the main housing clutch plate splines.
Maximum wear allowed is 1.15 mm
(0.045 inch).
V05621
Figure 4-16. Rotating Clutch Module Removal Figure 4-17. C3/C4 Clutch Module Removal

--- MD/B 300 400 SERIES ON-HIGHWAY SERVICE MANUAL
NOTES

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

3-2 Tools, Equipment
9. Remove bearing 30 and selective shim 29 from
3-3 Replacement Parts the back of the stator.
3-4 Careful Handling
Cleaning, Inspection 10. Remove retaining ring 22.
3-5
3-6 Assembly Procedures 11. Remove thrust plate 23 and measure its thick-
7-l Wear Limits Data ness adjacent to the stator race. Minimum
7-2 Spring Data thickness allowed is 11.68 mm (0.460 inch).
12. Remove thrust washer 24.
5-3. TORQUE CONVERTER MODULE 13. Remove and inspect stator race 25, thirteen
springs 26, and rollers 27.
a. Disassembly (Foldout 7)
14. From converter cover assembly 7, remove
1. Before disassembling the torque converter, twenty (or thirty) bolts 15 retaining lockup
note balance marks or mark a line across the clutch backplate 14 to converter cover 8.
converter cover to the pump assembly with a
scribe. These marks will ensure correct assem- 15. Remove lockup clutch backplate 14. Measure
bly of the torque converter and reduce balance the thickness of the backplate wear surface.
problems. Minimum thickness allowed is 8.58 mm
(0.338 inch).
2. Place converter assembly 4 on a flat surface
with the oil pump drive tangs downward. Sup- 16. Remove lockup clutch/damper 13 from con-
port the converter assembly on wooden blocks verter cover 8. Measure the thickness across
that keep the oil pump drive tangs from con- the lockup clutch friction surfaces. Minimum
tacting the workbench. thickness allowed is 8.05 mm (0.317 inch).
3. Remove thirty-six nuts 5 from the OD of Check for distortion of the lockup clutch fric-
torque converter cover assembly 6. tion surfaces. Maximum distortion allowed is
0.51 mm (0.020 inch). Check spline wear be-
4. Carefully separate cover assembly 6 from tween the turbine and the lockup clutch
pump assembly 32, avoiding damage to their damper. Maximum movement allowed is
sealing surfaces. 0.38 mm (0.015 inch).
Copyright 0 1998 General Motors Corp. 5-l

NOTE: Roller to be installed in

small end of cam pocket
When the lockup clutch and damper assembly must
be replaced, be sure to obtain the correct part for SPRING (End of spring
may be up or down)
your S/N transmission. All transmissions starting
with S/N 6510141464 contained new damper hard-
ware and lockup clutch friction material. This lock-
up c l u t c h a n d d a m p e r a s s e m b l y i s n o t
interchangeable with parts in units prior to the
above SIN.
17. Remove lockup clutch piston 11 by using air

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

I MODULE REBUILD I
SHIM (29) LOCATION
E03214
Figure 5-2. Torque Converter Selective Shim Procedure
Table 5-1. Torque Converter Selective Shims
Dimension C Use P/N Shim Thickness

I
0.08-0.35 mm (0.003-0.014 inch) I - 0.000 mm NO STEP I
0.36-0.06 mm (0.014-0.024 inch) 29502277 0.23-0.28 mm (0.009-0.011 inch)
0.61-0.83 mm (0.024-0.033 inch) 29502276 0.46-0.51 mm (0.018-0.020 inch)
0.84-1.06 mm (0.033-0.042 inch) 29502275 0.69-0.74 mm (0.027-0.029 inch)
17. Install sealring 31 onto converter cover 8. With go back to Paragraph 5-3a and disassemble the
balance marks or scribe mark aligned, place converter and install the correct shim at
converter pump assembly 32 over the top of Step b(15). Repeat Steps b(16)-b(23). If
converter cover assembly 6. dimension C equals the “NO STEP”
dimension, clearance is correct, go on to
18. Install four nuts 5, evenly spaced, onto four bolts Step (24).
35. Tighten the nuts to 30-35 N•m (22-26 lb ft).
19. Using a depth micrometer, measure from the 24. Install the remaining thirty-two nuts 5 onto
top of the converter hub to the thrust surface of converter pump bolts 34. Tighten all the nuts to
turbine assembly 18. This is dimension A (Fig- 30-35 N•m (22-26 lb ft).
ure 5-2).
20. Insert tool J 38548 into the converter cover and 5-4. TORQUE CONVERTER
place on a flat surface. Repeat the same mea-
HOUSING MODULE
surement as in Step (19). This is dimension B.
(Models Without PTO Provision)
21. Subtract dimension B from dimension A to get
dimension C. a. Disassembly (Foldout 8,A)
22. Refer to Table 5-l for correct shim selection.
1. If not previously removed, remove input
23. If dimension C does not equal the “NO STEP” speed sensor retaining bolt 6, sensor retaining
dimension of 0.08-0.35 mm (0.003-0.014 inch), bracket 5, input speed sensor assembly 3, and

o-ring 4. The input speed sensor should have 5. Remove bearing retainer assembly 3 and PTO
a resistance of 300 & 30 Ohms. gear assembly 9. If necessary, use jack bolts to
loosen the bearing retainer assembly.
6. Inspect the bearing bore of converter housing

23 for damage. Measure the bearing bore -
maximum ID permitted is 140.03 mm
(5.513 inch).
2. Remove breather assembly 9.
b. Disassembly of the Bearing Retainer
b. Assembly (Foldout 8,A)
1. Be sure o-ring 4 is in place and install input 1. Remove sealring 8 from bearing retainer 7. Re-
move oil seal 4 using tool J 24171-A.
speed sensor assembly 3. Hold bracket 5 in
place and install retaining bolt 6. Tighten the
2. Inspect bushing 6 for damage or wear and re-
bolt to 24-29 N•m (18-21 lb ft).
move if replacement is necessary. Maximum
bushing ID permitted is 75.23 mm (2.962 inch).
3. Inspect the bearing bore of bearing retainer 7

for damage. Measure the bearing bore - max-
imum ID permitted is 140.06 mm (5.514 inch).
2. Install breather 9. Tighten the breather to 12-
c. Disassembly of the PTO Gear Assembly
16 N•m (9-12 lb ft).
1. Remove retaining ring 16. Remove oil pump
drive hub 14 from PTO gear 13. For units prior
5-5. TORQUE CONVERTER to S/N 24410, remove retaining ring 12 only if
HOUSING MODULE replacement is required.
(Models With PTO Provision)
2. Inspect oil pump drive hub for excessive wear
a. Module Disassembly (Foldout 8, B) on drive tangs. Maximum allowable tang wear
is 0.38 mm (0.015 inch).
1. If not previously removed, remove input
speed sensor retaining bolt 22, sensor re- 3. Remove sealrings 10 and 17. If replacement is
taining bracket 21, input speed sensor as- required, remove bearings 11 and 15 from PTO
sembly 19, and o-ring 20. The input speed gear 13.
sensor should have a resistance of 300
f 30 Ohms. d. Assembly of the PTO Gear Assembly
1. If removed, press bearings 11 and 15 onto PTO

gear 13, using tool J 38565.
2. Remove breather assembly 29 or breather

adapter 30.
3. If present, remove PTO cover(s) 26 by remov-
ing ten bolts 27 for each cover. Remove PTO
cover(s) 26 and gasket(s) 25.
4. Remove ten bolts 2 holding bearing retainer 2. If removed, install retaining ring 12 and then
assembly 3 and PTO gear assembly 9 into install oil pump drive hub 14 into PTO gear 13.
converter housing 23. Install retaining ring 16 onto hub 14.

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

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

ing (Figure 5-4a). Maximum allowable depth
TRANSMISSIONS is 17.93 mm (0.706 inch).
PRIOR TO
S/N 6510005902
8. Measure gear-cavity diameter in the pump
housing (Figure 5-4b). Maximum ID permit-
L TRANSMISSIONS
S/N 6510005902 ted is 127.30 mm (5.012 inch).
THRU
S/N 6510024409 9. On non-PTO models only, inspect bushing 8
inside pump housing 9 (Foldout 9,A) for wear
TRANSMISSIONS or damage. Measure the ID of the pump bush-
AFTER
S/N 6510024409 V01654.01
ing. Maximum allowable ID is 75.23 mm
(2.962 inch). If worn or damaged, remove
Figure 5-3. Oil Pump Drive Hubs bushing 8 from pump housing 9.

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

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

MODULE REBUILD
23. If damaged, remove dowel pin(s) 19 from front
support 21.
24. Measure the OD of ground sleeve 16 or 17 at
the journal for the oil pump gear set bushing.
The minimum allowable OD is 57.04 mm
(2.246 inch).
25. If worn or damaged, remove ground sleeve 16

or 17 by pressing ground sleeve from front
support 21.
b. Assembly of the Front Support
MAX ALLOWABLE
GEAR TOOTH TIP
CLEARANCE 0.20 mm (0.008 in.) V01663.01 NOTE:
Figure 5-6. Measuring Gear Tooth Tip Clearance Prior to S/N 6510024410, if turbine shaft 6 or 9
In The Pump Housing (Foldout 9,B) is being replaced, ground sleeve 16 or
17 must be replaced also.
1. If removed, install ground sleeve 16 or 17

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

MAX GEAR-TO-HOUSING pin(s) to a height of 14.5 mm (0.57 inch) from
CLEARANCE PERMITTED the surface (Figure 5-8, View A).
0.36 mm (0.014 in.) VO1664.01
Figure 5-7. Measuring Driven Gear Clearance 3. Install front support sleeve 20 using a press,
In The Pump Housing and tools J 38565 and J 35921-1.
20. Remove ten bolts 12 (Foldout 9,A) retaining

stiffening plate 13, if present, and wear plate
14 to front support assembly 15. Remove stiff-
ening plate 13, if present, and wear plate 14.
Inspect wear plate 14 for scoring, nicks, or
grooving. Measure the thickness of the wear
plate. Minimum wear plate thickness allowed
is 4.70 mm (0.185 inch).
21. If damaged, remove bearing 22 from front sup- 4. Install stiffening plate 13, if present, and wear
port assembly 15 using tool J 24171-A. plate 14 (Foldout 9,A). Secure with ten bolts 12.
Tighten the bolts to 51-61 N•m (38-45 lb ft).
22. Measure the OD of front support sleeve 20.
Minimum allowable OD is 98.83 mm 5. Install bearing 22 using a press and tools
(3.891 inch). If worn or damaged, remove front J 35922-2 and J 8092. Press bearing 22 flush to
support sleeve 20 from front support 21. 0.25 mm (0.010 inch) below the surface.

FRONT SUPPORT 21
‘IN “\\E
GROUND SLEEVE 7 r~;~&.f;;~ MAX ,D -/ArPlN 17
16or17 1 51.10 mm(2.012 in.) 7/-
INSTALL I) +---I
PIN 17
98.83 mm (3.891 in.)
SECTION EE BOTTOM
VIEW A VIEW B
GROUND SLEEVE
16 or 17
VIEW c
Numbers in this illustration coincide
with callout numbers on foldout 9,A
Figure 5-8. Ground Sleeve Removal And Installation

c. Assembly of the Pump Housing 2. Install oil seal 5 using a press and tools
J 35921-3 and J 35921-1.
NOTE:
3. Install o-ring 4.
l For models without PTO, proceed with Step (1).
l For models with PTO, skip Steps (1), (2), and (3) 4. Install pressure relief ball 27 and pressure re-
and proceed to Step (4). lief spring 26 into pump housing. Using tool
J 41462, compress spring 26. Install pin 25 to
1. If old bushing was removed, install new bush- retain spring and ball.
ing 8 (Foldout 9,A) into pump housing 9 using
5. Lubricate pump gear set 10 to prevent damage
a press and tools J 35922-2 and J 8092.
and install the gear set in pump housing 9.
NOTE: 6. Retain the pump housing to the front support

For transmission models starting with S/N 6510024410, with eight bolts 6. Tighten the bolts to 51-61 N.m
a NEW staked bushing is used along with a NEW (38-45 lb ft).
gear set. You must use a NEW bushing with the 7. Install thrust bearing 24 onto front support 21.
NEW gear set. The later bushing cannot be used
with the earlier gear set. Refer to Figure 5-5. 8. Refer to Paragraph 3-6h. Insert three butt-joint
sealrings 23 into the sealing bore of the

MODULE REBUILD
rotating clutch hub and measure the end gap
with feeler gauges. Maximum sealring end gap NOTE:
allowed is 1.44 mm (0.057 inch). All MD 3066 and B 400 models starting with
S/N 6510142342 have C1 and C2 drive hubs with
9. Remove the three sealrings 23 from the rotat- changed material for increased torque capacity.
ing clutch hub and install them onto the hub of The improved part MUST be used when replacing
front support 21. either of the hubs in MD 3066 or B 400 units with
the S/N shown and above. All other transmis-
sions, including MD 3066 and B 400 units, prior
5-7. ROTATING CLUTCH MODULE to the S/N shown may be serviced with the standard
hubs.
a. Disassembly (Foldout 9, B)
1. Remove retaining ring 43. 12. Remove C1 retaining ring 32 and C1 clutch
pack - two backplates 29, six friction plates
2. Remove PI sun gear assembly 40. 30, and five steel reaction plates 31.
3. Inspect and measure the ID of sun gear 1 3 . Measure the thickness of each friction plate 30.
bushing 42. Maximum ID permitted is Minimum thickness allowed is 2.21 mm
68.22 mm (2.685 inch). Remove the bushing if (0.087 inch). Measure the oil groove depth and
replacement is necessary. cone of each friction plate. Minimum allowable
groove depth is 0.20 mm (0.008 inch). Maxi-
4. Remove C2 retaining ring 39. mum cone permitted is 0.40 mm (0.016 inch).
5. Remove C2 backplate 38. 14. Measure the thickness and cone of each steel
reaction plate 31. Minimum thickness allowed
6. Measure the wear surface thickness of C2
is 2.41 mm (0.095 inch). Maximum allowable
backplate 38. Minimum thickness allowed is
cone is 0.40 mm (0.016 inch).
6.25 mm (0.246 inch). Check flatness of the
backplate. Maximum allowable distortion is 15. Measure the wear surface thickness of the C1
0.45 mm (0.018 inch). backplates 29. Minimum thickness permitted is
6.25 mm (0.246 inch). Check flatness of the
7. Remove C2 clutch pack - six friction plates backplates. Maximum distortion allowed is
37 and six steel reaction plates 36. 0.15 mm (0.006 inch).
8. Measure the thickness of each friction plate 37. 16. Remove thrust bearing 15 from hub assembly 12.
Minimum thickness permitted is 2.21 mm
(0.087 inch). Measure the oil groove depth and 17. Remove retaining ring 16 and turbine shaft as-
cone of each friction plate. Minimum groove sembly 5 or 8.
depth permitted is 0.20 mm (0.008 inch). Max- 18. Inspect bushing 7 inside the end of turbine
imum cone allowed is 0.40 mm (0.016 inch). shaft 5 or 8. Measure the ID of the turbine
shaft bushing. Maximum ID allowed is
9. Measure the thickness and cone of each steel
20.19 mm (0.795 inch).
reaction plate 36. Minimum allowable thick-
ness is 2.41 mm (0.095 inch). Maximum cone 19. Remove three rotating sealrings 10.
permitted is 0.40 mm (0.016 inch).
20. Remove o-ring 4 from turbine shaft assembly 5
10. Remove C2 drive hub 35, including two thrust or 8.
bearings 34. Inspect the splines of the C2 drive
hub. Maximum spline wear permitted is
0.38 mm (0.015 inch).
11. Remove C1 drive hub 33. Inspect the splines of

the C1 drive hub. Maximum allowable spline
wear is 0.38 mm (0.015 inch).

21. Place rotating clutch on tool base J 35923-4 so J 28467-34. Tighten tool and remove retaining
rotating drum is supported by tool tangs (Figure ring 22 (Foldout 9,B). Remove tools J 35923-2
5-9, View C). Install J 35923-1 (Figure 5-9, and J 35923-3.
View A), bearing, washer and handle
J 28467-34. Tighten tool, compressing C1 bal- 24. Remove C2 spring assembly 21.
ance piston 26 (Foldout 9,B) and C1 return
spring 25. Remove retaining ring 28. Remove 25. Lift rotating drum 11 free of hub assembly 12
tool J 35923-1. and C1/C2 pistons 20 and 24. Inspect the
clutch splines of the rotating drum. Maximum
22. Remove balance piston 26, sealring 27, and C1 allowable spline wear is 0.38 mm (0.015 inch).
spring assembly 25.
26. Remove C1 and C2 pistons 20 and 24 from
23. Install tools J 35923-3 and J 35923-2 (Figure hub assembly 12 - rocking the pistons from
5-9, View B), bearing, washer and handle side-to-side.
J 35923-4
-L
J 28467.347
Ii
FLAT FLAT
VIEW A VIEW B
I I
LUBE ORIFICE
VIEW C
SLOTS
V00221.02
Figure 5-9. Rotating Clutch Assembly/Disassembly

MODULE REBUILD
27. Inspect the ID of rotating clutch hub 11. Install Cl/C2 assembly into rotating clutch
bushing 13. Maximum allowable bushing ID is drum 11.
99.25 mm (3.907 inch). Remove the bushing
12. Install C2 clutch spring assembly 21 with the
from hub assembly 12 if replacement is neces-
stepped end down. Make sure the spring as-
sary. Avoid damaging the bushing bore.
sembly properly aligns with the drum and hub
28. Remove piston seals 17 and 18 from hub as- splines.
sembly 12. 13. Place the assembly on tool base J 35923-4 so
29. Separate C1 piston 24 and seal 23 from C2 pis- that the rotating drum is supported by tool
ton 20 and seal 19 by tapping lightly on the C1 tangs (Figure 5-9, View C). Install tools
piston. Remove seals 23 and 19 from the pis- J 35923-3 and J 35923-2 (Figure 5-9,
tons. View B), bearing, washer, and handle.
Compress C2 spring assembly 21 and install
b. Assembly (Foldout 9,B) retaining ring 22 (Foldout 9,B). Remove tools
1. If removed during disassembly, install J 35923-3 and J 35923-2.
bushing 13 into rotating clutch hub 14 using
tools J 35922-2 and J 8092. NOTE:
For units built prior to S/N 6510024410, when tur-
2. Install piston seals 17 and 18 into rotating bine shaft 6 or 9 must be replaced, ground sleeve 16
clutch hub assembly 12. Lube sealrings. or 17 (Foldout 9,A) must also be replaced.
3. Install a new OD sealring 19 in C2 piston 20.
Lube C2 clutch piston inside bore and on OD 14. If removed, install bushing 7 into turbine shaft
sealring. Install C2 piston 20 into the rotating 6 or 9 using tools J 35922-l and J 8092.
clutch hub assembly. Lightly tap until it is fully
seated. 15. Install o-ring 4 onto the forward end of the tur-
bine shaft.
4. Install a new OD sealring 23 into C1 piston 24.
Lube the inside bore and OD sealring on the 16. Refer to Paragraph 3-6h for method and pro-
C1 piston. Aligning slot in C1 clutch piston cedure. Insert three butt-joint sealrings 10 into
with any lube orifice on the rotating clutch hub, the sealing bore of ground sleeve 16 or 17 (Fig-
install C1 clutch piston into the center of C2 ure 5-8) and measure the end gap with feeler
piston 20. With a soft mallet, lightly tap C1 gauges. Maximum sealring gap allowed is
piston until it is fully seated. 0.94 mm (0.037 inch). Remove sealrings from
the ground sleeve bore and install them on tur-
5. Place the assembly on tool base J 35923-4. In- bine shaft assembly 5 or 8 (Foldout 9,B).
stall C1 spring assembly 25.
17. Install turbine shaft assembly 5 or 8. Retain the
6. Install a new sealring 27 on balance piston 26. turbine shaft with retaining ring 16.
Lube the sealring.
18. Install thrust bearing 15 onto the end of rotat-
7. Place balance piston 26 on the assembly, aligning clutch hub assembly 12. Position the as-
ing the notch on the C1 piston with the cast sembly with the turbine shaft downward.
bump in the balance piston.
8. Install tool J 35923-l over the assembly along NOTE:
with bearing, washer, and handle. Thread the Beginning with S/N 6510164169, the two identical
handle down and compress C1 spring assem- C1 pressure plates have been replaced by two dif-
bly 25. ferent plates. The pressure plate 29 which goes next
9. Install retaining ring 28 into the hub of the ro- to the C1 piston is 2 mm (0.157 inch) thinner. The
tating clutch assembly. pressure plate 29 at the opposite end of the C1
clutch pack is 2 mm (0.157 inch) thicker and is re-
10. Carefully release the C1 spring and remove all shaped. See Figure 5-10 for pictorial information.
tools from the assembly.

23. Install C2 backplate 38. Install C2 retaining
ring 39.
24. If removed, install bushing 42 using tools
J 35922-2 and J 8092.
25. Install P1 sun-gear drive hub assembly 40. In-
19. Install Cl clutch pack - two pressure plates stall retaining ring 43.
29, one pressure plate on each side of the
clutch pack, six friction plates 30, and five steel
reaction plates 31. Install clutch plates alter- 5-8. C3/C4 AND MAIN HOUSING
nately, starting with a friction plate 30. Install
MODULE
Cl retaining ring 32.
a. Disassembly (Foldout 10,A)
20. Install Cl drive hub 33.
21. Install a thrust bearing 34 on each side of C2 NOTE:

drive hub 35, and install this assembly over Cl When replacing a nameplate, keep the original
drive hub 33. nameplate. Stamp the information recorded on the
original nameplate onto the replacement name-
plate.
1. If nameplate 28 is damaged, remove nameplate

retaining screw 29 and nameplate 28.
2. If present, remove two bolts 30 and feed-

through connector assembly 32.
3. Inspect the clutch splines in the interior of
main housing 27. Maximum spline wear al-
lowed is 1.15 mm (0.045 inch).
22. Install C2 clutch plates - six friction plates 37
and six steel reaction plates 36. Install clutch 4. Remove twelve bolts 2 retaining C3 clutch
plates alternately, starting with a steel reaction components to C4 clutch housing 24. Remove
plate 36. C3 backplate assembly 3.
Cl Pressure Plate Redesigned Cl Pressure

2 mm thinner than 2 mm thicker than prior
prior pressure plate pressure plate
Figure 5-10. Redesigned C1 Pressure Plates

I MODULE REBUILD
5. Inspect three wear plates 5 and six rivets 6 on 12. Remove C3 housing assembly 14.
clutch backplate 4. Measure the wear plates at
13. Inspect three wear plates 16 and six rivets 15
the contact surface. Minimum thickness al-
on C3 housing 17. Measure the wear plates at
lowed is 2.81 mm (0.111 inch). Check flatness
the contact surface. Maximum allowable wear
of backplate 4 and the wear plates. Maximum
is 2.81 mm (0.111 inch). Check flatness of
allowable distortion is 0.15 mm (0.006 inch). If
clutch housing and the wear plates. Maximum
replacement is necessary remove the wear
distortion permitted is 0.15 mm (0.006 inch). If
plates by drilling out the rivets.
replacement is necessary, remove the wear
6. Remove P1 ring gear 7. Inspect the clutch plates by drilling out the rivets.
splines of the P1 ring gear. Maximum spline
wear permitted is 0.38 mm (0.015 inch). 14. Remove C4 clutch pack - five friction plates
19 and five steel reaction plates 18.
7. Remove C3 clutch pack - five friction
plates 8 and four steel reaction plates 9. 15. Measure the thickness of each friction plate 19.
Minimum thickness allowed is 2.21 mm
8. Measure the thickness of each friction plate 8. (0.087 inch). Measure the oil groove depth of
Minimum thickness allowed is 2.21 mm each friction plate. Minimum groove depth al-
(0.087 inch). Measure the oil groove depth of lowable is 0.20 mm (0.008 inch). Maximum
each friction plate. Minimum allowable groove cone permitted is 0.40 mm (0.016 inch).
depth is 0.20 mm (0.008 inch). Maximum cone
permitted is 0.40 mm (0.016 inch).
NOTE:
NOTE: Beginning with S/N 6510076858, C3 and C4 clutch
Beginning with S/N 6510076858, C3 and C4 clutch friction plates had hardened internal splines. The
friction plates had hardened internal splines. The improved plates are identified by either a missing
improved plates are identified by either a missing spline tooth or by a blue stripe on the OD.
spline tooth or by a blue stripe on the OD.
16. Measure the thickness of each steel reaction

9. Measure the thickness of each steel reaction plate 18. Minimum thickness allowed is
plate 9. Minimum thickness allowed is 2.41 mm (0.095 inch). Maximum allowable
2.41 mm (0.095 inch). Maximum cone allow- cone is 0.40 mm (0.016 inch).
able is 0.40 mm (0.016 inch).
17. Remove piston return plate 21 with four return
10. Remove piston return plate 11 with four return spring assemblies 20 attached. Measure the
spring assemblies 10 attached. Measure the thickness of return plate 21. Minimum thick-
thickness of return plate 11. Minimum thickness permitted is 3.41 mm (0.135 inch). Maxi-
ness permitted is 3.41 mm (0.135 inch). Maxi- mum allowable cone is 0.40 mm (0.016 inch).
mum cone allowed is 0.40 mm (0.016 inch).
18. Remove spring retainer assembly 22 and
11. Only if damaged and replacement is necessary, piston 23 from the C4 housing 24.
remove the return spring assemblies. Remove
spring retainer assembly 12 and piston 13. 19. Inspect C4 clutch housing 24 for damage.

I MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL I
b. Assembly (Foldout 10,A) tool to upset each rivet at the rear of the back-
plate to complete the attachment process. A
1. Install piston 23 into C4 housing 24. Install
correctly formed rivet upset will be 4.00 mm
spring retainer assembly 22.
(0.157 inch) in diameter and no more than
2. If removed, install spring assemblies 20 and 1.00 mm (0.039 inch) above the surface of the
attach them securely. backplate. The wear plate must be tightly at-
tached to the backplate. No movement of the
3. Install piston return plate 21 with four return wear plate is allowed.
spring assemblies 20.
12. Install C3 backplate assembly 3. Backplate 3
4. Install C4 clutch pack. Starting with a friction must be indexed with C3 and C4 housings in
plate, alternately install five friction plates 19 order to insert the assembly into main
and five steel reaction plates 18. housing 27 correctly.
5. To assemble the C3 housing, when wear plates 13. Install twelve retaining bolts 2 through the C3
must be replaced, use six rivets 15 to fasten backplate assembly 3 and into the C4 clutch
three wear plates 16 to the C3 housing 17. Use housing 24. Tighten the bolts to 51-61 N•m
tool J 39354 to cold-form the rivets. Insert the (38-45 lb ft).
rivet so the pre-formed head is below the active
surface of the wear plate. Use the cold-forming 14. If removed, install nameplate 28 and screw 29.
tool to upset each rivet at the rear of the clutch 15. If present and removed, install feedthrough
housing to complete the attachment process. A connector assembly 32 and two bolts 30.
correctly formed rivet upset will be 4.00 mm Tighten the bolts to 5-8 N•m (4-5 lb ft).
(0.157 inch) in diameter and no more than
1.00 mm (0.039 inch) above the surface of the
clutch housing. The wear plate must be tightly 5-9. MAIN SHAFT MODULE
attached to the housing. No movement of the
wear plate is allowed.
NOTE:
6. Lube seal surfaces of C3 clutch piston 13, and
install the C3 clutch piston into C3 clutch l For MD 3060, MD 3066, B 300, and B 400
housing 14. models, proceed to Step a.
l For MD 3560 models, skip Steps a. and b. and
7. Install C3 clutch housing assembly 14 with proceed to c.

clutch piston 13 on top of the assembled C4 l For MD 3070PT model, skip Steps a.-d. and
clutch housing (items 18-24). Ensure the index proceed to e.
tangs on the clutch housings are aligned. In-
stall spring retainer assembly 12.
a. Disassembly (MD 3060, MD 3066, B 300,
8. Install piston return plate 11 and four return B 400 Transmission Models) (Foldout 10B)
spring assemblies 10. If removed, install spring
assemblies and attach them securely. 1. Remove spiral retaining ring 4.
9. Install Pl ring gear 7. 2. Remove P2 sun gear 6.
10. Install C3 clutch pack. Starting with a friction 3. Remove thrust bearing 5.
plate, alternately install five friction plates 8,
and four steel plates 9. 4. Remove bearing spacer 7.
11. To assemble the C3 backplate, when wear 5. Remove selective shim 1, if not previously re-
plates must be replaced, use six rivets 6 to fas- moved.
ten three wear plates 5 to C3 backplate 4. Use 6. Remove thrust bearing 2, if not previously re-
tool J 39354 to cold-form the rivets. Insert the moved.
rivet so the pre-formed head is below the active
surface of the wear plate. Use the cold-forming 7. Remove P3 sun gear 8 from main shaft 9.

© MODULE REBUILD
8. Inspect and measure main shaft pilots. Mini- 2. Install P2 sun gear 5 and spiral retaining ring 4.
mum pilot OD allowed is 19.98 mm Compress the spiral retaining ring to lock it
(0.787 inch). Inspect and measure main shaft into place.
journal OD for the P2 planetary bushing. Mini-
3. Proceed to Paragraph 5-10.
mum permissible main shaft journal OD is
42.97 mm (1.692 inch). e. Module Disassembly (MD 3070PT
Transmission Model) (Foldout 11,B)
b. Assembly (MD 3060, MD 3066, B 300, B 400
Transmission Models) (Foldout 10,B) 1. Remove spiral retaining ring 3.
2. Remove P2 sun gear 5 and thrust bearing 4.

NOTE:
Do not install thrust bearing 2 or selective shim 1 3. Remove spacer 6.
until final transmission assembly. Measurement for 4. Remove P3 sun gear 7.
selective shim 1 is performed during final buildup.
1. Install P3 sun gear 8 onto main shaft 9. 6. Inspect C6 bushing journal OD on main shaft
8. Minimum allowable OD is 35.92 mm
2. Install bearing spacer 7. (1.414 inch). Inspect P3 bushing journal OD.
Minimum OD allowed is 52.98 mm
3. Install thrust bearing 5.
(2.086 inch).
4. Install P2 sun gear 6.
7. Measure the front main shaft pilot. Minimum
5. Install spiral retaining ring 4. Compress the pilot OD permitted is 19.98 mm (0.787 inch).
spiral retaining ring to lock it into place. Inspect and measure main shaft journal OD for
P2 planetary bushing. Minimum journal OD
6. Proceed to Paragraph 5-10. allowed is 42.97 mm (1.692 inch).
c. Module Disassembly (MD 3560 Transmission f. Module Assembly (MD 3070PT Transmission
Models) (Foldout 11,A) Model) (Foldout 11,B)
1. Remove spiral retaining ring 4. 1. Install thrust bearing 1.
2. Remove P2 sun gear 5 and thrust bearing 6. 2. Install P3 sun gear 7.
3. Remove spacer 7. 3. Install spacer 6.
4. Inspect and measure main shaft pilots. 4. Install P2 sun gear 5 and thrust bearing 4.
Minimum pilot OD permitted is 19.98 mm
(0.787 inch). Inspect and measure main shaft 5. Install spiral retaining ring 3. Compress the
journal OD for P2 planetary bushing. spiral retaining ring to lock it into place.
Minimum allowable main shaft journal OD is
42.97 mm (1.692 inch).
5-10. P1 PLANETARY MODULE
d. Module Assembly (MD 3560 Transmission
Models) (Foldout 1 1 , A )
a. Disassembly (Foldout 1 2 , A )
1. Remove retaining ring 2 from P2 ring gear 14.
NOTE:
Do not install thrust bearing 2 or selective shim 1 2. Remove P2 ring gear 14.
until final transmission assembly. Measurement for
3. Check P1 planetary pinion end play in P1 car-
selective shim 1 is performed during final buildup.
rier assembly 4. Pinion end play should not ex-
ceed 0.94 mm (0.037 inch). Check all six
1. Install spacer 7 and thrust bearing 6. pinion gears.
Copyright ©1998 General Motors Corp. 5-15

4. Remove retaining ring 5 and indexing ring 6. 7. Measure the thickness of all thrust washers 9
Inspect indexing ring 6 for abnormal wear and 12. Minimum thrust washer thickness per-
where the spindles 7 contact (Figure 5-11). If mitted is 1.39 mm (0.054 inch).
abnormal wear is present, the planetary
spindle 7 probably has a sharp edge instead of 8. Remove thrust bearings 3 and 13 from each
a radius edge (Figure 5-12). side of Pl planetary carrier 8.
NOTE: 9. Check spline wear of P1 planetary carrier 8

Planetary spindles on transmission S/Ns from and P2 planetary ring gear 14. Maximum
6510063169-6510114718 had sharp edges (Figure spline wear allowed is 0.38 mm (0.015 inch).
5-12). If the index ring 6 is worn and the spindles
have a sharp edge and fall within the S/N range
above, replace the spindles. b. Assembly (Foldout 12,A)
5. Remove six spindles 7 from P1 carrier 8. NOTE:

6. Slide pinion gear 10, thrust washers 9 and 12, Beginning with S/N 6510142342, the Pl carrier was
and two bearing sets 11 from the side of Pl changed to include an oil groove in the ID bore. This
planetary carrier 8. Repeat the procedure with carrier is not interchangeable with former carriers.
the five remaining pinion gears. The new carrier must be used with the new P2 car-
rier which has eliminated two sealring grooves and
INDEXING FLAT sealrings. The former carriers are still available for
service.
NO WEAR
ABNORMAL WEAR
INDEXING RING
V04322
Figure 5-11. Carrier Indexing Ring Wear
SHARP FLAT EDGE (REF)
edge O-25-1.50 mm)
SHARP FLAT EDGE
edge 0.25-1.50 mm)
PLANETARY SPINDLE V04323
Figure 5-12. Sharp Edge vs. Radius Edge On Planetary Spindles

I MODULE REBUILD I
1. Install two bearing sets 11 into the center of
pinion gear 10. Install thrust washers 9 and 12
inside P1 planetary carrier 8. Align thrust
washer tangs with the slots in the carrier and
retain them with oil-soluble grease. Slide the
pinion gear and bearing sets into the side of the
P1 planetary carrier, between the thrust wash-
ers. Repeat the procedure with the five remain-
ing pinion gears.
1. Remove two sealrings 2, if present, from P2
2. Install six spindles 7 so the lower step is posi- carrier.
tioned for proper installation of indexing
ring 6. 2. Remove retaining ring 3.
3. Remove P3 ring gear 15.

4. Check P2 planetary pinion end play. Pinion
end play should not exceed 0.94 mm
(0.037 inch). Check all four pinion gears.
5. Remove retaining ring 14. Remove indexing

ring 13. Remove four pinion spindles 12 from
P2 carrier 6. Inspect indexing ring 13 for ab-
normal wear where the spindles 12 contact
3. Install indexing ring 6 and retaining ring 5. (Figure 5-11). If abnormal wear is present, the
planetary spindle 12 probably has a sharp edge
4. If components were replaced, check pinion end instead of a radius edge (Figure 5-12).
play. Pinion end play should not exceed
0.94 mm (0.037 inch). Check all six pinion
gears. NOTE:
5. Install P1 planetary carrier assembly 4 into P2 Planetary spindles on transmission S/Ns from
ring gear 14. 6510063169-6510114718 had sharp edges (Figure
6. Install retaining ring 2 into P2 ring gear 14, re- have a sharp edge and fall within the S/N range
taining P1 planetary carrier assembly 4 in the above, replace the spindles.
P2 planetary ring gear.
7. Install two thrust bearings 3 and 13 one on
6. Slide a pinion gear 10, thrust washers 8 and 11,
each side of P1 planetary carrier assembly 4.
and two bearing sets 9 from the side of P2
planetary carrier 6. Repeat the procedure with
5-11. P2 PLANETARY MODULE the three remaining pinion gears.
a. Disassembly (Foldout 12,B) 7. Measure the thickness of all thrust washers 8

and 11. Minimum thickness allowed is
1.39 mm (0.054 inch).
NOTE:
Starting with S/N 6510142342, the two sealrings 2 8. Inspect bushing 7 inside P2 planetary carrier 6
on the P2 carrier assembly 4 have been eliminated. for wear or damage. Maximum allowable
The new carrier is not interchangeable with former bushing ID is 43.20 mm (1.701 inch).
carriers. The new carrier must be used with the new
Pl carrier which has an oil groove in the ID bore. 9. Check spline wear between P2 planetary car-
The former carriers are still available for service. rier 6 and P3 planetary ring gear 15. Maximum
movement permitted is 0.38 mm (0.015 inch).

b. Assembly (Foldout 12, B) 5-12. RETARDER MODULE
1. If replacement is necessary, press a new bush-
ing 7 into P2 carrier 6 using a press, installer NOTE:
J 35922-1, and driver J 8092.
l For transmissions with retarder built prior to
2. Install two bearing sets 9 into the center of January, 1998, proceed to Step a.
pinion gear 10. Install thrust washers 8 and 11 l For transmissions with retarder built in
in P2 planetary carrier 6, align thrust washer January, 1998 or later, skip Steps a.-j. and
tangs with slots in the planetary, and retain proceed to Step k.
them with oil-soluble grease. Slide the pinion
gear and two bearing sets into the side of the
P2 planetary carrier between the thrust a. Disassembly of Retarder Valve Body (Units
washers. Repeat the procedure with the three Built Prior To 1/98) (Foldout 13,A)
remaining pinion gears.
1. If not done previously, remove four bolts 71 re-
3. Install four spindles 12 so the lower step is posi- taining wiring harness cover 70 to retarder
tioned for proper installation of indexing ring 13. housing assembly 35 and remove the cover.
2. Remove nine bolts 77 that retain retarder

control body assembly 78 to retarder housing
assembly 35 and remove control body
assembly 78.
3. Remove separator plate gasket 72, solenoid

separator plate 73, separator plate gasket 74,
channel plate 75, and channel plate gasket 76.
4. Remove four bolts 79, solenoid cover 81, and

4. Install indexing ring 13 and retaining ring 14. gasket 95.
5. If components were replaced, check pinion end 5. Remove fluted retaining pin 93 from the re-
play. Pinion end play should not exceed 0.94 mm tarder control body 88. Remove solenoid 82
(0.037 inch). Check all four pinion gears. and o-rings 83 and 84.
6. Install P2 carrier 4 into P3 ring gear 15.
6. Check the resistance of retarder solenoid 82.
7. Install retaining ring 3 into P3 ring gear 15, re- Resistance must be within the range shown on
taining P2 planetary carrier assembly 4. Figure 5-13.
8. Insert two sealrings 2 into the P1 planetary car- 7. Remove solenoid 82 from harness 80.
rier bore and measure their end gap with a
feeler gauge. Maximum sealring end gap al- 8. If repair or replacement of solenoid wiring har-
lowed is 1.20 mm (0.047 inch). Refer to Sec- ness 80 is necessary, remove the external nut
tion 3 if the sealring end gap is incorrect. retaining the harness connector to solenoid
cover 81.
9. Install two sealrings 2 on P2 carrier assembly 4.
9. Remove pressure tap plug 86 and o-ring 87
NOTE: from retarder control body 88.
l For models without retarder and without trans- 10. Remove retaining ring 90, o-ring 91, valve
fer case, skip Paragraph 5-12 and proceed to plug 89, and spring 92 from retarder control
Paragraph 5-13. body 88.
l For models with transfer case, skip Paragraphs
5-12 and 5-13 and proceed to Paragraph 5-14. 11. Remove retarder control valve 94 from retarder
control body 88.

I MODULE REBUILD
3. Check pinion end play. Pinion end play should 2. Compress retainer and spring assembly 23 us-
not exceed 0.94 mm (0.037 inch). Repeat the ing piston spring compressor J 35923-2. Re-
check on the three remaining pinion gears. move retaining ring 22 and slowly release the
spring tension. Remove C5 clutch piston 24
NOTE: from retarder stator 28.
The spindles and pinions do not need to be removed 3. Remove outer sealring 25 from C5 clutch pis-
before removing output shaft assembly 7. ton 24.
4. Remove inner sealring 26 from C5 clutch pis-
4. Remove retaining ring 10. Remove indexing
. ton 24.
ring 11. Remove four pinion spindles 16. In-
spect indexing ring 11 for abnormal wear
where the spindles 16 contact (Figure 5-l1). If NOTE:
abnormal wear is present, the planetary spindle Perform Step (5) only if roller bearing 13 and cup
16 probably has a sharp edge instead of a ra-
27 need to be replaced.
dius edge (Figure 5-12).
NOTE: 5. Remove bearing cup 27 using bearing tool

Planetary spindles on transmission S/Ns from J 3940.
6510063169-6510114718 had sharp edges (Figure
have a sharp edge and fall within the S/N range
above, replace the spindles.
-
6. Inspect e a c h c h e c k b a l l a n d r e t a i n e r
assembly 29 for proper movement. The balls
should move a minimum of 0.50 mm
(0.020 inch) in their respective retainer seats. If
ball movement is less than the specified
amount, use a 1/4-20 UNF tap to remove the
check ball and retainer assembly.
f. Assembly of Retarder Stator (Foldout 13,A)
5. Slide pinion gear 18, thrust washers 17 and 20, 1. If removed, install check ball and retainer as-
and two bearings 19 from the side of P3 plane- semblies 29.
tary carrier 12. Repeat the procedure with three 2. If removed, install bearing cup 27 using bear-
remaining pinion gears. ing tool J 35922-3.
6. Measure the thickness of eight thrust washers 3. Install inner sealring 26 onto C5 clutch piston 24.
17 and 20. Minimum thickness permitted is
1.39 mm (0.054 inch). 4. Install outer sealring 25 onto C5 clutch piston
24. Lube sealrings on the piston and seal bore
e. Disassembly of Retarder Stator Assembly
areas in the retarder stator.
1. Remove o-ring 30 from stator assembly 21.
NOTE:
Align the tang on the back of the C5 clutch piston
with the notch for the piston tang in the retarder
stator before installing C5 clutch piston 24 into re-
tarder stator28.
Copyright ©1998 General Motors Corp. 5-21

5. Install C5 clutch piston 24 into retarder 8. If components were replaced, check pinion end
stator 28. play. Pinion end play should not exceed
0.942 mm (0.037 inch). Check all four pinion
gears.
h. Assembly of Retarder Housing Assembly
1. If removed, install bearing cup 50 using bear-

ing tool J 35922-3.
2. Place P3 carrier assembly 6 on the work table

(output shaft up) and place stator assembly 21
over the output shaft.
3. Install sealrings 31 and 34 onto rotor 33. Install

the rotor assembly over the output shaft.
6. Align the tab on spring retainer 23 with the 4. Install gasket 32 between stator assembly 21
notch in stator housing 28. Compress retainer and retarder housing 51. Place the retarder
and spring assembly 23 using piston spring housing over the output shaft and align the
compressor J 35923-2. Install retaining ring 22 holes of the housing with the holes of the stator
so that the ends clear the tab in the spring reassembly. Install two bolts 57 and bolt 56.
tainer and slowly release the spring force. Re- Tighten the bolts to 51-61 N•m (38-45 lb ft).
move the compressor tool.
5. Install roller bearing 52 using installer
7. Install o-ring seal 30 on retarder stator 28. J 35921-1 and press into retarder housing 51
g. Assembly of P3 Planetary Carrier Assembly while rotating the retarder housing.
1. If removed, install bearing assembly 13. 6. Install locknut retainer 53.
2. If removed, install bushing 8 inside the end of

output shaft 9 using installer J 35922-1, drive
handle J 8092, and a press.
3. If removed, install output shaft assembly 7 into
P3 planetary carrier 12.
4. Install spacer 14 and retaining ring 15.
5. Install two bearings 19 into the center of pinion
gear 18. Install thrust washers 17 and 20 in P3 7. Install and tighten bearing retainer nut 54 using
planetary carrier 12. Align thrust washer tangs special tools J 35925-l and J535925-2. Place
with the slots in the carrier and retain them the torque wrench and a breaker bar as shown
with oil-soluble grease. Slide the pinion gear in Figure 5-l5. Rotate the torque wrench in the
and bearing sets into the side of the P3 plane- counterclockwise direction and tighten the nut
tary carrier between the thrust washers. Repeat to 145-155 N•m (107-114 lb ft). If the retarder
the procedure with the three remaining pinion module is installed on a transmission, see Sec-
gears. tion 6 assembly instructions for correct torque
specifications.
6. Install four pinion spindles 16 so the lower step
is positioned for proper installation of indexing 8. Support retarder housing 51 so that turning
ring 11. torque of P3 carrier assembly 6 can be checked
after installation of bearing retainer nut 54
7. Install indexing ring 11. Install retaining (Figure 5-16). Maximum allowable drag is
ring 10. 3 N•m (26 lb in.).
5-22 Copyright ©1998 General Motors Corp

MODULE REBUILD
SPANNER TOOL SPANNER TOOL

J 35925-1 (MD/B300,8400) J 35925-2 (MDMOO, B400)
TORQUE WRENCH
STATIONARY
FORCE
TOP VIEW
Figure 5-15. Tightening Output Spanner Nut
NOTE:
l For units prior to S/N 6510064183, do Step (10),
skip Steps (11-14), and go to Step (15).
l For units beginning with S/N 6510064183, skip
Step (10) and go to Step (11).
10. Install pin 44 into retarder valve 45 and insert

into the valve bore. Install spring 46, o-ring 47,
plug 48, and retaining ring 49.
NOTE:
Figure 5-16. P3 Carrier Turning Torque Effective S/N 6510044372, a different retarder valve
Check - Retarder Equipped Models spring, separator plate, retarder housing, stator,
and rotor are used. The later parts are not inter-
changeable with the earlier parts. If the parts are
NOTE:
interchanged, retarder capacity will be affected.
Delay bending the retainer tangs on the retainer nut Refer to SIL 28-WT-94, Rev. A.
and the installing of output oil seal 55 until final as-
sembly of the transmission.
11. Thread the J 42048 spring compressor tool into
the accumulator port as far as it will go and
still allow the handle to be aligned with the re-
NOTE: tarder valve bore. Rotate the tool counterclock-
wise to provide clear access to the retarder
Effective S/N 6510021203, a different valve plug is
valve bore.
used which does not require a signal valve. The later
valve plug is not interchangeable with the earlier 12. Install pin 44 into retarder valve 45 and insert
housing. Refer to SIL 31-WT-94. into the valve bore. Install spring 46, o-ring 47,
and plug 48. Spring 46 must remain uncom-
pressed until tool J 42048 is used to safely
9. For transmissions prior to S/N 6510021203, install compress it.
o-ring 43, signal valve 42, plug 41, and retaining
ring 40. For transmissions after S/N 6510021203, 13. Align tool J 42048 with the retarder valve bore
install valve plug 41 and retaining ring 40. and rotate the tool handle clockwise to contact

the center of plug 48. Continue turning the tool
handle clockwise to compress spring 46 until
plug 48 is below the groove for retaining ring
49. Install retaining ring 49.
14. Turn the tool handle counterclockwise to allow

plug 48 to contact retaining ring 49 and to al-
low removal of the tool. Remove the J 42048 6. Install, smooth end first, solenoid retaining
compressor tool from the accumulator bore by pin 93 into retarder control body 88.
rotating it counterclockwise.
7. Install solenoid cover 81 and four bolts 79.
15. Be sure o-ring 37 is in place and install output Tighten bolts to 24-29 N•m (18-21 lb ft).
8. Install two guide pins into the retarder control
place and install retaining bolt 39. Tighten the
body mounting flange bolt holes on retarder
bolt to 24-29 N•m (18-21 lb ft).
housing assembly 35.
i. Installation of Wiring Harness Assembly 9. Install gasket 76, channel plate 75, gasket 74,
solenoid separator plate 73, and gasket 72.
1. If temperature sensor 68 and/or wiring harness
assembly 60 were repaired or replaced, care- 10. Install wiring harness cover 70 and four bolts 71.
fully install the temperature sensor assembly Tighten bolts to 24-29 N•m (18-21 lb ft).
into the retarder housing. Install a new o-ring 69
on the temperature sensor. Install the nut retain- 11. Install retarder control body assembly 78 and
ing the harness connector to the retarder hous- nine bolts 77 that retain it to retarder housing
ing. Tighten the nut to 10-13 N•m (7-10 lb ft). assembly 35. Tighten bolts to 24-29 N•m
(18-21 lb ft).
2. Install temperature sensor retainer 58 and
retainer bolt 59. Tighten bolt to 24-29 N•m NOTE:
(18-21 lb ft).
l For models with retarder built prior to January,
1998, proceed to Paragraph 5-16.
j. Assembly and Installation of Retarder
Control Body Assembly l For models with retarder built January, 1998 or
later, proceed to Step k of this paragraph.
1. Install retarder control valve 94, spring 92,
valve plug 89, o-ring 91, and retaining ring 90
k. Disassembly of Retarder Valve Body (Units
into retarder control body 88.
Built Starting 1/98) (Foldout 1 3 , B )
2. Install o-ring 87 and pressure tap plug 86. 1. Remove three bolts 91 and six bolts 92 that re-
Tighten plug to 10-13 N•m (7-10 lb ft). tain retarder control body assembly 67 to re-
tarder housing assembly 35 and remove control
3. If solenoid wiring harness 80 was repaired or body assembly 67.
replaced, install the nut retaining the harness
connector to solenoid cover 81. Tighten the nut 2. Remove separator plate gasket 64, solenoid
to 2.8-3.4 N•m (25-30 lb in.). separator plate 65, and separator plate
gasket 66.
4. If replaced, connect solenoid 82 to harness 80.
3. Remove plug 82, o-ring 83, valve 84, and
spring 85.
5. Lube o-rings and install gasket 95 and
solenoid 82 into solenoid mounting bore of the 4. Remove plug 80, o-ring 79, spring 78, and
retarder control body 88. valve 77.
5-24 Copyright © 1998 General Motors Corn.

± MODULE REBUILD I
5. Remove spring clip 90. Move connector 69 1. Disassembly of Retarder Housing
partially out of the bore to allow space for sole-
noid removal. 1. If not already removed, remove output speed
sensor bolt 43, bracket 42, output speed sensor
6. Remove retaining pin 81 from retarder control assembly 40, and o-ring 41 from the retarder
body 86. Carefully rotate and wiggle housing. Output speed sensor resistance should
solenoid 74 while exerting force toward con-
be 300 ± 30 Ohms.
nector 69. Remove solenoid 74 and o-rings 75
and 76.
2. If not already removed, remove temperature
7. Disconnect connector assembly 71 from sole- sensor bolt 39, bracket 38, temperature sensor
noid 74. Remove wiring harness 68 from con- assembly 36, and o-ring 37 from the retarder
trol body 86. For repair or replacement of housing. Check the resistance of the tempera-
terminals 73 or connector 72, see TS2973EN, ture sensor and replace the sensor if it is defec-
WTEC III Troubleshooting Manual. tive (Figure 5-17).
8. Check the resistance of retarder solenoid 74.
3. Remove plug 48, o-ring 49, plug 50, and
Resistance must be within the range shown on
washer 51 from retarder housing 52.
Figure 5-13.
9. Remove pressure tap plug 89 and o-ring 88 4. Remove retaining ring 49, plug 48, o-ring 47,
from retarder control-body-86. spring 46, retarder valve 45, and pin 44.
RESISTANCE-TEMPERATURE
CHARACTERISTIC CHART
1,000,000
100,000
10,000
1,000
100
10
1
40 14 S'a 122 li6 2580 2i4 338 362 "F
I I I I I I I I
-40 -10 20 50 80 110 140 170 200 "C
TEMPERATURE
V04641
Figure 5-17. Retarder Temperature Sensor Resistance vs. Temperature (Units Built Starting 1/98)

5. Remove retaining ring 44 and flow valve m. Disassembly of P3 Planetary
plug 45. Carrier Assembly
6. Thread the J 42048 spring compressor tool into 1. Remove retaining ring 15 and spacer 14. Re-
the accumulator port as far as it will go and move output shaft assembly 7. Inspect
still allow the handle to be aligned with bushing 8 inside the end of output shaft 9 for
plug 57. Compress plug 57 to relieve the spring wear or damage. Measure the ID of the output
load on retaining ring 58. Remove retaining shaft bushing. Maximum ID allowed is
ring 57. Carefully release the spring load by 20.19 mm (0.795 inch).
turning the tool handle counterclockwise. Re-
move the J 42048 tool, retaining ring 58, 2. If replacement is necessary, remove bearing as-
plug 57, o-ring 56, spring 55, retarder valve 54, sembly 13.
and pin 53.
3. Check pinion end play. Pinion end play should
7. If not previously removed, remove output seal not exceed 0.94 mm (0.037 inch). Repeat the
63, using seal removal tool J 24171-A. check on the three remaining pinion gears.
8. Flatten the tang(s) of locknut retainer 61 (Fold-
out 13,A) to allow rotation and removal of NOTE:
bearing retainer nut 62. Remove bearing re-
tainer (spanner) nut 62 using special tool The spindles and pinions do not need to be removed
J 35925. Remove locknut retainer 61. before removing output shaft assembly 7.
9. Support retarder housing 52 so that P3

planetary carrier assembly 6 can be removed 4. Remove retaining ring 10. Remove indexing
from the retarder housing. Place special tool ring 11. Remove four pinion spindles 16.
J 35925-l against the threaded shoulder of the
5. Slide pinion gear 18, thrust washers 17 and 20,
P3 planetary carrier. Drive on J 359251 with a
and two bearings 19 from the side of P3 plane-
hydraulic press or a mallet until the P3
tary carrier 12. Repeat the procedure with three
planetary carrier is separated from the retarder
remaining pinion gears.
housing.
6. Measure the thickness of all thrust washers 17
and 20. Minimum thickness permitted is
NOTE:
1.39 mm (0.054 inch).
Perform Steps (10) and (13) only if roller bearing 60
and cup 46 need to be replaced. n. Disassembly of Retarder Stator Assembly
1. Remove o-ring 29 from stator assembly 21.

10. Remove roller bearing 60 from the retarder
housing.
11. Remove two bolts 34 and bolt 59 to allow re-
moval of retarder stator assembly 21 from re-
tarder housing 52. Remove gasket 31 which
seals between stator 28 and the retarder hous-
ing.
12. Remove rotor 32 and sealrings 30 and 33. In- 2. Compress retainer and spring assembly 23 us-
sert hook-type sealrings 30 and 33 into their ing piston spring compressor J 35923-2. Re-
mating bores and measure the ID of each seal- move retaining ring 22 and slowly release the
ring. Replace the sealrings if the ID exceeds spring tension. Remove C5 clutch piston 24
95.67 mm (3.767 inch). from retarder stator 28.
13. Remove bearing cup 46 using bearing tool 3. Remove outer sealring 25 from C5 clutch pis-
J 3940. ton 24.
5-26 Copyright ©1998 General Motors Corp.

MODULE REBUILD
.- 4. Remove inner sealring 26 from C5 clutch pis- p. Assembly of P3 Planetary Carrier Assembly
ton 24.
1. If removed, install bearing assembly 13.
NOTE:
2. If removed, install bushing 8 inside the end of
Perform Step (5) only if roller bearing 13 and cup output shaft 9 using installer J 35922-1, drive
27 need to be replaced. handle J 8092, and a press.
5. Remove bearing cup 27 using bearing tool 3. If removed, install output shaft assembly 7 into
J 3940. P3 planetary carrier 12.
o. Assembly of Retarder Stator (Foldout 13,B) 4. Install spacer 14 and retaining ring 15.
ing tool J 35922-3. 5. Install two bearings 19 into the center of pinion
gear 18. Install thrust washers 17 and 20 in P3
2. Install inner sealring 26 onto C5 clutch planetary carrier 12. Align thrust washer tangs
piston 24. with the slots in the carrier, and retain with
them oil-soluble grease. Slide the pinion gear
3. Install outer sealring 25 onto C5 clutch
and bearing sets into the side of the P3 plane-
piston 24. Lube sealrings on the piston and seal
tary carrier between the thrust washers. Repeat
bore areas in the retarder stator.
the procedure with the three remaining pinion
gears.
NOTE:
Align the tang on the back of the C5 clutch piston 6. Install four pinion spindles 16 so the lower step
with the notch for the piston tang in the retarder is positioned for proper installation of indexing
stator before installing C5 clutch piston 24 into re- ring 11.
tarder stator 28.
7. Install indexing ring 11. Install retaining
4. Install C5 clutch piston 24 into retarder ring 10.
stator 28.
8. If components were replaced, check pinion end
play. Pinion end play should not exceed
0.942 mm (0.037 inch). Check all four pinion
gears.
q. Assembly of Retarder Housing Assembly

ing tool J 35922-3.
2. Place P3 carrier assembly 6 on the work table

(output shaft up) and place stator assembly 21
over the output shaft.
5. Align the tab on spring retainer 23 with the 3. Install sealrings 30 and 33 onto rotor 32. Install
notch in stator housing 28. Compress retainer the rotor assembly over the output shaft.
and spring assembly 23 using piston spring
4. Install gasket 31 between stator assembly 21
compressor J 35923-2. Install retaining ring 22
and retarder housing 52. Place the retarder
so that the ends clear the tab in the spring re-
housing over the output shaft and align the
tainer and slowly release the spring force. Re-
holes of the housing with the holes of the stator
move the compressor tool.
assembly. Install two bolts 34 and bolt 59.
6. Install o-ring seal 29 on retarder stator 28. Tighten the bolts to 51-61 N•m (38-45 lb ft).

5. Install roller bearing 60 using installer 12. Align tool J 42048 with the retarder valve bore
J 35921-1 and press into retarder housing 52 and rotate the tool handle clockwise to contact
while rotating the retarder housing. the center of plug 57. Continue turning the tool
handle clockwise to compress spring 55 until
6. Install locknut retainer 61.
plug 57 is below the groove for retaining ring
58. Install retaining ring 58.
13. Turn the tool handle counterclockwise to allow

plug 57 to contact retaining ring 58 and to al-
low removal of the tool. Remove the J 42048
compressor tool from the accumulator bore by
rotating it counterclockwise.
14. Be sure o-ring 41 is in place and install output

7. Install and tighten bearing retainer nut 62 using place and install retaining bolt 39. Tighten the
special tools J 35925-l and J 35925-2. Place bolt to 24-29 N•m (18-21 lb ft).
the torque wrench and a breaker bar as shown
in Figure 5-15. Rotate the torque wrench in the 15. If temperature sensor assembly 36 was re-
counterclockwise direction and tighten the nut placed, install a new o-ring 37 on the tempera-
to 145-155 N•m (107-114 lb ft). If the retarder ture sensor and install the temperature sensor
module is installed on a transmission, see Sec- assembly into the retarder housing.
tion 6 assembly instructions for correct torque
specifications. If retarder module is installed 16. Install temperature sensor bracket 38 and re-
onto transmission, see Section 6 assembly in- tainer bolt 39. Tighten bolt to 24-29 N•m
structions for correct torque specifications. (18-21 lb ft).
8. Support retarder housing 52 so that turning 17. Install plug 48, o-ring 49, plug 50, and
torque of P3 carrier assembly 6 can be checked washer 51. Tighten plug 48 to 60-67 N•m
after installation of bearing retainer nut 62 (44-49 lb ft). Tighten plug 50 to 60-67 N•m
(Figure 5-15). Maximum allowable drag is (44-49 lb ft).
3 N•m (26 lb in.).
r. Assembly and Installation of Retarder
Control Body Assembly
NOTE:
1. Install and lube o-ring 70 on connector 69.
Delay bending the retainer tangs on the retainer nut Thread connector assembly 71, attached to
and the installing of output oil seal 63 until final as- connector 69, through the bore at the top of
sembly of the transmission. valve body 86 and partially insert
connector 69, l e a v i n g r o o m t o i n s t a l l
9. Install flow valve plug 45 and retaining ring 44. solenoid 74.
10. Thread the J 42048 spring compressor tool into 2. Install and lube o-rings 75 and 76 on
the accumulator port as far as it will go and solenoid 74. Connect connector assembly 72 to
still allow the handle to be aligned with the re- solenoid 74. Place solenoid 74 into position in
tarder valve bore. Rotate the tool counterclock- the valve bore just below connector 69. Rotate
wise to provide clear access to the retarder and wiggle the solenoid while pushing down to
valve bore. seat the o-rings in their bores and to align the
solenoid groove with the hole for retaining
11. Install pin 53 into retarder valve 54 and insert pin 81.
into the valve bore. Install spring 55, o-ring 56,
and plug 57. Spring 55 must remain uncom- 3. Install retaining pin 81. Rotate the solenoid to
pressed until tool J 42048 is used to safely be below the valve body mounting face. Be
compress it. sure the wires connecting to the solenoid are

MODULE REBUILD I
also below the valve body mounting face to 4. Remove bearing retainer (spanner) nut 37 us-
prevent damage during installation of the body. ing special tool J 35925.
4. Push connector 69 completely into the bore 5. Remove locknut retainer 36.
and install spring clip 90.
6. Place blocks under rear cover 28 or 41 so that
5. Install o-ring seal 88 and pressure tap plug 89.
the P3 carrier assembly is above the work sur-
Tighten plug to 10-13 N•m (7-10 lb ft).
face far enough to allow disassembly from the
rear cover. Place special tool J 35925-l against
the threaded shoulder of the P3 carrier assem-
bly. Drive on special tool J 35925-l with a
press or a mallet until the P3 carrier assembly
is separated from the rear cover.
7. Remove roller bearing 35 and output speed

signal wheel 33 from rear cover 28 or 41.
6. Install valve 77, spring 78, lubed o-ring 79, and
plug 80. Tighten plug to 24-29 N•m (18-21 lb ft).
7. Install spring 85, valve 84, lubed o-ring 83, and NOTE:
plug 82. Tighten plug to 24-29 N•m (18-21 lb ft). Perform Step (8) only if replacing roller bearing 35
8. Install two guide pins into the retarder control and cup 34.
body mounting flange bolt holes on retarder
housing assembly 35. 8. Remove bearing cup 34 using bearing tool
9. Install gasket 64, solenoid separator plate 65, J 3940.
and gasket 66.
b. Disassembly of the P3 Planetary
10. Install retarder control body assembly 67, three Carrier Assembly
bolts 91 and six bolts 92 that retain it to re-
tarder housing assembly 35. Tighten bolts to 1. If damaged, or if removing bearing
24-29 N•m (18-21 lb ft). assembly 13, or if replacing output speed sig-
nal wheel 33, remove pin 11.
NOTE: 2. If replacement is necessary, remove bearing

Proceed to Paragraph 5-16 to continue rebuild for assembly 13.
transmission models with retarder.
3. Check pinion end play. Pinion end play should
not exceed 0.94 mm (0.037 inch). Check all
pinion gears.
5-13. REAR COVER MODULE
a. Disassembly (Foldout 13, C) NOTE:
Spindles and pinions do not need to be removed to
1. If not previously removed, remove retaining
remove output shaft assembly 6.
bolt 32, bracket 31, output speed sensor assem-
bly 29, and o-ring 30. The output speed sensor
should have a resistance of 300 + 30 Ohms. 4. Remove retaining ring 9. Remove indexing
2. If not previously removed, remove output ring 10. Remove four pinion spindles 16. In-
seal 38 using seal removal tool J 24171-A. If spect indexing ring 10 for abnormal wear
present, remove plug 39 and washer 40. where the spindles 16 contact (Figure 5-11). If
abnormal wear is present, the planetary
3. Flatten the tang of locknut retainer 36 to allow spindle 16 probably has a sharp edge instead of
rotation and removal of bearing retainer nut 37. a radius edge (Figure 5-12).

d. Assembly of Rear Cover (Foldout 13,C)
NOTE:
1. Install bearing cup 27 using bearing tool
Planetary spindles on transmission S/Ns from
J 35922-l.
6510063169-6510114718 had sharp edges (Figure
5-12). If the index ring 10 is worn and the spindles 2. Install inner sealring 26 onto C5 clutch
have a sharp edge and fall within the S/N range piston 24. Install outer sealring 25 onto C5
above, replace the spindles. clutch piston 24.
5. Slide pinion gear 18, thrust washers 17 and 20, NOTE:

and two bearings 19, from the side of P3 plane- Before installing C5 clutch piston 24 into rear
tary carrier 12. Repeat the procedure with three cover 28 or 41, align the tab on the back of the C5
remaining pinion gears. clutch piston with the notch for the piston tab in the
6. Measure the thickness of thrust washers 17 and rear cover.
20. Minimum thickness allowed is 1.39 mm
(0.054 inch). 3. Install C5 clutch piston 24 into rear cover 28
7. Remove retaining ring 15 and spacer 14. or 41.
8. If not done previously, remove output shaft as-
sembly 6.
9. Inspect bushing 7 inside the end of output
shaft 8 for replacement. Measure the ID of the
output shaft bushing. Maximum allowable ID
is 20.19 mm (0.795 inch).
c. Disassembly of the Rear Cover Assembly
4. Align the tab on the spring retainer with the

notch in the rear cover. Compress retainer and
1. Remove C5 clutch piston 24 from rear cover spring assembly 23 using piston spring com-
28 or 41 by compressing retainer and spring pressor J 35923-2. Install retaining ring 22 so
assembly 23 using piston spring compressor that the ends clear the tab in the spring retainer
J 35923-2. Remove retaining ring 22 with and slowly release the spring force.
snapring pliers and slowly release the spring e. Assembly of the P3 Planetary
force.
Carrier Assembly
2. Remove outer sealring 25 from C5 clutch 1. If removed, install bearing assembly 13.
piston 24.
3. Remove inner sealring 26 from C5 clutch NOTE:
piston 24. If later model output speed signal wheel
P/N 29510781 is to be installed, proceed with
NOTE: Step (2). This P/N is located on the side of the
Perform Step (4) only if replacing roller bearing 13 wheel in recessed characters.
and cup 27. If earlier model output speed signal wheel
P/N 29506608 is to be installed, skip Step (2)
and go to Step (3). This P/N wheel does not have
4. Remove bearing cup 27 using bearing tool a P/N located on the part.
J 3940.

r-- MODULE REBUILD I
2. Install 12 mm (0.47 inch) roll pin 11 (P/N 11512350) f. Completion of the Rear Cover Module
to a height of 2.35-2.95 mm (0.093-0.116 inch)
above the carrier shaft. Skip Step (3) and pro- 1. If removed, install bearing cup 34 using bear-
ceed to Step (4). ing tool J 35922-3.
3. Install 10 mm (0.39inch) roll pin 11 (P/N11512348) 2. Place P3 carrier assembly 5 on the work table
to a height of 2.20-2.80 mm (0.087-0.110 inch) (with the output shaft up) and place rear cover
above the carrier shaft. 28 or 41 over the output shaft.
4. If removed, press bushing 7 inside the end of 3. Using installer J 35921-1 and not exceeding 10
output shaft 8 using installer J 35922-l and 230 N (2300 lbs) of force, press roller bearing
drive handle J 8092. 35 into rear cover 28 or 41, while rotating the
cover assembly.
5. If removed, install output shaft assembly 6 into
P3 planetary carrier 12. 4. Install locknut retainer 36.
6. Install spacer 14 and retaining ring 15.
7. Install two bearings 19 into the center of pinion
gear 18. Install thrust washers 17 and 20 in P3
planetary carrier 12. Align the thrust washer
tangs with the slot in the carrier and retain
them with oil-soluble grease. Slide the pinion
gear and bearing sets into the side of the P3
planetary carrier between the thrust washers.
Repeat the procedure with the three remaining
pinion gears.
NOTE:
8. Install four pinion spindles 16 so the lower step If later model output speed signal wheel
is positioned for proper installation of indexing P/N 29510781 was installed in Paragraph 5-13e(11),
ring 10. proceed with Step (5). Part number will be
shown on side of wheel in recessed numbers.
If earlier model output speed signal wheel
P/N 29506608 was installed in Paragraph 5-13e(11),
skip Step (5) and go to Step (6). Part number is
not shown on this part but there is a 3.0 mm x
0.8 mm raised identification feature on one end
near the gear teeth.
5. Install and tighten bearing retainer nut 37 using

special tools J 35925-l and J 35925-2. Place
9. Install indexing ring 10. Install retaining
the torque wrench and a breaker bar as shown
ring 9.
in Figure 5-15. Rotate the torque wrench in the
10. If components were replaced, check pinion end counterclockwise direction and tighten the nut
play. Pinion end play should not exceed to 74-88 N•.m (55-65 lb ft). Skip Step (6) and
0.942 mm (0.037 inch). Check all four pinion proceed to Step (7).
gears.
6. Install and tighten bearing retainer nut 37 using
11. Align the slot in output speed signal wheel 33 special tools J 35925-l and J 35925-2. Place
with spring pin 11. Using installer J 35921-1 the torque wrench and a breaker bar as shown
and not exceeding 10230 N (2300 lbs) of in Figure 5-15. Rotate the torque wrench in the
force, press output speed signal wheel 33 to counterclockwise direction and tighten the nut
full depth on P3 carrier assembly 5. to 290-340 N•m (214-251 lb ft).

5-14. ADAPTER HOUSING AND
P3 OVERHAUL
a. Disassembly (Foldout 18,B)
1. Place the adapter housing assembly on tool
base J 35923-4 with output end down.
2. Install tool J 35923-2 along with its washer,
bearing, and handle.
3. Thread the handle down to compress spring re-
tainer assembly 16.
4. Remove retaining ring 15.
5. Remove tool J 35923-2, followed by C5 spring
I I
retainer assembly 16.
Figure 5-18. P3 Carrier Turning Torque Check -
Models Without Retarder
7. Support rear cover 28 or 41 so that turning

torque of P3 carrier assembly 5 can be checked
after installation of bearing retainer nut 37 (Fig-
ure 5-18). Maximum allowable drag is 3 N•m
(26 lb in.). Recheck the torque on bearing re- 6. Using a soft face mallet, loosen C5 clutch pis-
tainer nut 37 (Step 5 or 6 above). If torque is ton 17. Remove C5 piston from adapter hous-
correct, recheck drag torque. If both torque val- ing 20.
ues meet specification, proceed to Step 8. 7. Remove square cut outer sealring 18 and inside
lip-type sealring 19 from the piston.
8. Bend up two or more tangs of locknut
retainer 36 to prevent bearing retainer nut 37 8. Inspect seal bore areas in the housing for nicks
from backing off. If only one tang is aligned with and wear.
a spanner nut slot, continue to torque the spanner 9. Remove plug 22 from the lower left side of the
nut (but do not exceed the tightening torque or housing.
drag torque limits) until two or more tangs can
be bent up into slots on the spanner nut. 10. Remove o-ring 23 from the plug.
11. Remove filter screen 24 from housing 20. This
screen filters main sump fluid before it enters
NOTE:
the transfer case lube pump.
DO NOT reuse a tang once it has been bent. Replace
locknut retainer 36, if necessary. NOTE:
P3 carrier disassembly is covered in Steps (12)-(16).
9. Install output shaft oil seal 38 using J 39928
(models with non-drum parking brake) or 12. Check pinion end play. Pinion end play should
J 35921-4 (models with drum parking brake). not exceed 0.94 mm (0.037 inch). Check all
pinion gears.
10. Be sure o-ring 30 is in place and install output
speed sensor assembly 29. Hold bracket 31 in 13. Remove retaining ring 2. Remove indexing
place and install retaining bolt 32. Tighten the ring 3. Remove four pinion spindles 7. Inspect
bolt to 24-29 N•m (18-21 lb ft). indexing ring 3 for abnormal wear where the
spindles 7 contact (Figure 5-11). If abnormal
11. When rear cover 41 is used, be sure to install wear is present, the planetary spindle 7 proba-
plug 39 and washer 40. Torque plug 39 to bly has a sharp edge instead of a radius edge
60-67 N•m (44-50 lb ft). (Figure 5-12).

I ~ MODULE REBUILD I
_I
4. Install indexing ring 3. Install retaining ring 2.
NOTE:
Planetary spindles on transmission S/Ns from 5. If components were replaced, check pinion end
6510063169-6510114718 had sharp edges (Figure play. Pinion end play should not exceed
5-12). If the index ring 3 is worn and the spindles 0.942 mm (0.037 inch). Check all four pinion
have a sharp edge and fall within the S/N range gears.
above, replace the spindles.
6. Install a new filter screen 24. Make sure the
round metal boss properly indexes in the hous-
14. Slide pinion gear 9, thrust washers 8 and 11, ing.
and two bearings 10, from the side of P3 plane-
tary carrier 5. Repeat the procedure with three 7. Install a new o-ring 23 on plug 22, and then in-
remaining pinion gears. stall the plug in the housing. Tighten the plug
to 34-47 N•m (25-35 lb ft).
15. Measure the thickness of thrust washers 8 and
11. Minimum thickness allowed is 1.39 mm 8. Install new inner lip-type sealring 19 and out-
(0.054 inch). side square-cut sealring 18 on the piston. Lube
the sealrings.
16. Inspect bushing 6 inside the end of carrier 5
for replacement. Measure the ID of bushing 6. 9. Lube adapter housing seal bores.
Maximum allowable ID is 53.22 mm
(2.095 inch). Remove bushing 6 if replace- 10. Install C5 piston 17, aligning the cast tab on the
ment is needed. Be careful not to damage the piston with the notch in the housing. Lightly
carrier bore during bushing removal. seat the piston using a soft face mallet.
b. Assembly (Foldout 18, B) 11. Install C5 spring retainer 16, aligning the notch
in the housing with the tab on the retainer.
1. If removed, press bushing 7 inside carrier 5,
using installer J 38569 and drive handle 12. Place adapter housing 20 on the base of tool
J 8092. J 35923-4 with input side up.
2. Install two bearings 10 into the center of pinion 13. Install J 35923-2 along with its washer, bear-
gear 9. Install thrust washers 8 and 11 in P3 ing, and handle. Tighten the handle to com-
planetary carrier 5. Align the thrust washer press spring retainer assembly 16. Make sure
tangs with the slot in the carrier and retain that spring retainer tab indexes with the notch
them with oil-soluble grease. Slide the pinion in the housing.
gear and bearing sets into the side of the P3
planetary carrier between the thrust washers. 14. Install retaining ring 15.
Repeat the procedure with the three remaining
pinion gears. 15. Release spring force and remove tools
J 35923-2 and J 35923-4.
3. Install four pinion spindles 7 so the lower step
is positioned for proper installation of indexing
ring 3. 5-15. TRANSFER CASE MODULE
(Foldouts 14,15,16)
. .
a. Disassembly of Transfer Case Module

11. Remove the bolts securing the rear transfer
NOTE: case to transfer case holding fixture J 38572.
Refer to Foldout 15 for Steps (1) through (4).
NOTE:
1. If not previously done, install transfer case as- Refer to Foldout 14,B for Steps (12) through (14).
sembly 1 on the transmission overhaul stand.
Position the transfer case so that the front out-
put is upward. Begin the transfer case disas- 12. Remove fifteen bolts 17, fastening the rear
sembly by loosening yoke nut 42 installed on transfer case 8 to the front transfer case 7.
front output housing 49. Loosen the nut by in-
stalling a large reaction tool (for leverage) and 13. Thread an eye bolt in the center of rear transfer
case 8, to lift it.
an impact wrench. Leave the nut installed on
the front output shaft. 14. Use a soft face mallet to separate the rear and
front transfer cases. Pry points at opposite ends
2. Remove fifteen bolts 45. Remove front output
of the case halves are also provided to accom-
housing 49 by lifting with a chain hoist and eye
plish separation.
bolts in output yoke 44. Remove gasket 50.
15. Lift and remove the rear transfer case; removal
3. Remove C7 clutch housing assembly 58.
of the rear transfer case exposes drive gear 19
4. Rotate the fixture so that the rear output end is (Foldout 15), idler gear 39, driven gear 80, and
upward. control valve body 29 (Foldout 16). Remove
gasket 16 (Foldout 15) and replace it during as-
sembly.
NOTE:
16. Remove the output speed sensor and solenoid
Refer to Foldout 16 for Steps (5) through (11).
wiring harness connectors. Remove two bolts
46 and output speed sensor 45 (Foldout 16).
5. Loosen rear output yoke nut 81 by following
the same procedure explained in Step (1). 17. Remove control valve assembly 29 after re-
Leave the nut installed on the rear output shaft. moving six bolts 41 holding the control valve
body on the transfer case.
6. Remove six bolts 75 and nine bolts 82. Re-
move rear output housing 74 by lifting with a 18. Remove driven gear 80, idler gear 39, and
chain hoist and eye bolts. Remove gasket 73. drive gear 19 (Foldout 15).
7. Remove P4 carrier assembly 57. 19. Rotate the remaining assembly, front output
end upward.
8. Remove fifteen bolts 23 and two bolts 24. Re-
move C6 clutch housing assembly 17. Remove 20. Remove eight bolts 4, and then remove lube
C6 housing gasket 22. Note where the different charging pump 5.
length bolts were removed so that reassembly 21. Remove shim pack A. Shim pack A is critical
will be correct. to drive gear end play; keep the shim pack in-
9. Remove five bolts 50, holding rear idler cover tact for assembly.
49 on the transfer case. Remove rear idler 22. Remove eight b o l t s 71 a n d m a n i f o l d
cover 49, gasket 47, and o-ring 48. Use small assembly 72.
pry bars at locations provided in order to re-
move the cover. 23. Remove shim pack C and keep it intact for as-
sembly. Shim pack C is used to set up driven
10. Remove controls cover 43 after removing ten gear end play.
bolts 44. Remove gasket 42. Removing the
controls cover provides access to the control 24. Remove five bolts 22, then remove front idler
valve body 29 and its wiring. cover 23, o-ring 24, shim pack B (keeping it

MODULE REBUILD
intact), and gasket 28. Use pry bars as in 35. Install orifice plug and tighten to 12-14 N•m
removal of rear idler cover. (9-10 lb ft). Install lube passage plug and
tighten to 24-29 N•m (18-21 lb ft).
25. Remove nut 88, securing electrical harness
connector 31 to connector plate 29. Remove b. Disassembly of C6 Clutch (Foldout 16)
four bolts 32, holding connector plate 29 to the 1. Remove retaining ring 6 holding C6 clutch
transfer case. Remove connector plate 29, fol- plates and C6 clutch hub in the C6 clutch hous-
lowed by the harness and gasket 30. ing.
26. Remove the suction hose fitting (not shown) 2. Remove C6 clutch hub 7 by lifting it out along
from the transfer case. The fitting is sealed with five C6 clutch friction plates 10, four C6
with an o-ring, and provides a pilot for the clutch steel reaction plates 11, and backplate 9.
screen which filters the fluid returning to the One steel reaction plate 11 will remain in C6
main transmission sump from the transfer case clutch housing 19. Inspect clutch hub splines
sump. Replace the filter screen during the over- for wear and damage. Replace hub if it is dam-
haul. aged.
27. Inspect bearing races 17, 37, and 78 on front 3 . Remove the remaining steel reaction plate 11
transfer case 14 for wear and damage; like- from C6 clutch housing 19.
wise, inspect bearing races 21, 41, and 82 on 4. Separate backplate 9, five friction plates 10,
rear transfer case 2 (Foldout 16). and five reaction plates 11.
28. If the bearing races must be replaced, drive 5. Inspect friction plates 10 for wear, damage,
them out by using a hammer and a drift. and the following specifications: minimum al-
lowable thickness: 3.68 mm (0.145 inch), max-
29. During the race installation, temporarily install imum cone permitted: 0.4 mm (0.016 inch),
the lube charging pump or the manifold with and minimum allowable oil groove depth:
the appropriate shim pack to locate the race in 0.20 mm (0.008 inch); if any of the above
the housing. Since the race does not have an specifications are not met, replace the part.
actual seat in the housing, locating the race
correctly is essential for proper gear end play. 6. Inspect steel reaction plates 11 for wear, dam-
age, and the following specifications: mini-
30. Reinstall the races in the housing. For the drive mum thickness allowed: 2.41 mm (0.095 inch),
and driven gear races, use special tools maximum allowable cone 0 . 4 0 m m
J 38568-l and J 35921-1. For the idler gear (0.016 inch); if any of the above specifications
race, use J 38568-2 and J 8092. is not met, replace the part.
7. Inspect backplate 9 for burrs, wear, damage,
31 Remove two lube passage plugs 33 (Foldout
15); removal of the lube plugs provides access flatness, and the following specifications: mini-
to orifice plugs 34. mum thickness 7.9 mm (0.311 inch), and max-
imum cone 0.40 mm (0.016 inch).
32. Remove two orifice plugs 34. Inspect lube ori-
8. Remove retaining ring 12 after using tool
fices for obstructions. Remove any obstruc-
J 38573 to compress the C6 piston return
tions.
spring assembly.
33. Install orifice plugs 34, and lube passage 9. Release the piston spring force, remove the
plugs 33. Tighten the orifice plugs to 12-14 N•m special tool and check sealring bores in hous-
(9-10 lb ft). Tighten lube passage plugs to ing 19 for wear, nicks, and other damage. Re-
24-29 N•m (18-21 lb ft). move spring retainer assembly 13.
34. Remove lube passage plug 25 (Foldout 16) and 10. Remove piston 14 by firmly striking the hous-
orifice plug 26. Inspect lube orifice for obstruc- ing against a flat surface. Remove sealrings 15
tions and remove any that are found. and 16 from piston 14.

11. Inspect thrust bearing 8 for wear and damage. 7. Inspect spring retainer assembly 13 for missing
If damaged, remove thrust bearing 8 from the or broken springs. Refer to Section 7 for the
C6 housing. spring specifications.
8. Install spring assembly 13.

NOTE:
Bearing 8 must be replaced in any MD 3070 prior to 9. Install retaining ring 12 after using tools
S/N 6510072173. See SIL 29-WT-96. J 38573-l and J 38573-3 to compress spring
assembly 13. Remove special tools.
12. Measure the C6 clutch housing bushing 21 by 10. Install C6 clutch hub 7 hub into the C6
using a telescope gauge and an outside mi- housing.
crometer. The maximum allowable ID is 11. Install five reaction plates 11, and five friction
36.18 mm (1.424 inch). If bushing 21 is worn
plates 10 alternately, starting with a reaction
or damaged, remove it from the C6 housing.
plate 11, and finishing with a friction plate 10.
c. Assembly of C6 Clutch (Foldout 16)
12. Install backplate 9.
1. Inspect C6 clutch housing 19 for groove wear.
Maximum allowable groove wear is 2.29 mm 13. Install retaining ring 6.
(0.090 inch). d. Disassembly of C7 Clutch (Foldout 15)
2. If removed, install bushing 21 using tools 1. Removing retaining ring 60.
J 38569 and J 8092.
2. Remove the C7 clutch hub 59 along with C7
clutch pack. The C7 clutch pack consists of
NOTE:
backplate 61, five friction plates 62, and five
Bearing 8 must be replaced in any MD 3070 prior to steel reaction plates 63 stacked in an altemat-
S/N 6510072173. See SIL 29-WT-96. ing order.
3. Inspect C7 friction plates 62 for minimum al-

3. If removed, install thrust bearing 8 over C6
lowable thickness - 2.21 mm (0.087 inch),
housing sleeve. Machined tangs on the thrust
minimum oil groove depth allowed - 0.20 mm
bearing help ensure that the bearing is installed
(0.008 inch), and maximum cone permitted -
in the proper direction.
0.25 mm (0.010 inch).
4. Inspect piston 14 for sealring groove damage.
Correct the damage with crocus cloth or soft 4. Inspect C7 reaction plate 63 for minimum allow-
stone. Replace the part if damage cannot be able thickness - 2.11 mm (0.083 inch), maxi-
corrected. mum cone permitted - 0.25 mm (0.010 inch).
5. Inspect backplate 61 for minimum thickness

allowed - 8.67 mm (0.341 inch), wear, flat-
ness, and damage.
6. Remove C7 piston 64. Remove internal and ex-

ternal sealrings 66 and 65 from piston 64.
5. Install new external sealring 15 and internal
sealring 1 6 i n p i s t o n 1 4 . F o r i n t e r n a l 7. Measure the C7 clutch housing bushing and re-
sealring 16, use proper lip position. Lube inter- place bushing 68 if required. The maximum al-
nal and external sealring bores in the C6 clutch lowable bushing ID measurement is 47.26 mm
housing, and also lube the sealrings on the pis- (1.861 inch).
ton.
8. Inspect pressure-relief ball 69 and make sure
6. Install piston 14; use soft face mallet to seat the that the ball moves freely; minimum required
piston. movement is 1.00 mm (0.040 inch).

MODULE REBUILD
9. Remove three sealrings 70 from C7 clutch 3. Remove locating pins from front cover 83 by
housing 67. driving them out using a small punch and a
hammer.
e. Assembly of C7 Clutch Housing (Foldout 15)
4. Separate front cover 83 from the rest of the
1. Inspect C7 clutch housing 67 for damage to
pump assembly.
sealring groove and piston seal surfaces, and
housing spline wear, Replace the C7 clutch 5. Remove drive gear 84 from the housing, then
housing if it is damaged. remove driven gear 85 and reversing ring 86.
Note the orientation of drive and driven gears.
2. Install three new sealrings 70 into C7 clutch
housing 67. g. Assembly of Oil Pump (Foldout 15)
3. If bushing 68 was removed, install the bushing 1. Use a depth gauge to measure pump cavity
using tools J 38569 and J 8092. depth in pump rear cover 87.
4. Install ball 69 if it was removed. Make sure 2. Using an outside micrometer, measure the
that it moves freely. driven gear width and the drive gear width.
5. Inspect piston 64 for sealring groove damage 3 . Determine each gear side clearance by sub-
and burrs. tracting the gear width from the pump cavity
depth. The specified side clearance is
0.125 mm (0.005 inch).
4. If not within the specification, replace compo-

nents as required.
6. Install new sealrings 65 and 66 into C7 5. Install reversing gear 86.

piston 64. Be sure that sealring lips are prop-
6. Install driven and drive gears 85 and 84 in the
erly positioned. Lube the sealring areas on the
same orientation as they were removed to
piston, and seal bore areas in C7 clutch hous-
match wear pattern in rear pump cover 87.
ing 67.
7. The groove in reversing ring 86 indexes with
7. Install piston 64 into C7 clutch housing 67. Be
the notch in the pump front cover.
sure it is properly seated.
8. Install pump front cover 83, aligning the holes
8. Inspect C7 clutch hub 59 splines for wear and
with the locating pins in the housing. Drive the
damage. Replace hub if damage is not repair-
locating pins into the cover from the back of
able. Install C7 clutch hub 59 into C7 clutch
the pump housing. Use a small punch to
housing 67.
slightly countersink the pins.
9. Install five friction plates 62 and five reaction
plates 63 into housing 67 in an alternating or- 9. Install pressure relief valve 6, and spring 7 into
der, starting with a reaction plate 63 and finish- bore in the pump housing.
ing with a friction plate 62. 10. Install a NEW washer onto plug 8, then install
10. Install backplate 61 into C7 clutch housing 67. the plug and tighten it to 12-14 N•m (9-10 lb ft).
11. Install retaining ring 60 into C7 clutch h. Disassembly of P4 Carrier (Foldout 16)
housing 67.
1. Remove P4 sun gear 63 by lifting it out of the
f. Disassembly of Oil Pump (Foldout 15) P4 carrier assembly 56.
1. Remove pressure relief valve plug 8. 2. Remove one setscrew 58 by using an Allen
wrench or socket.
2. Remove spring 7, and then remove pressure re-
lief valve 6. 3. Push spindle 59 out from the P4 carrier.

4. Remove pinion gears 61, along with upper and 19, bearings 38 and 40 installed on idler
lower thrust washers 62, and uncaged needle gear 39, or bearings 79 and 81 installed on
bearings 60. driven gear 80 requires replacement, use the
procedure in the next step.
5. Repeat Steps (2) through (4) to remove the re-
maining two pinion gears 61. 2. To remove bearing 18 from drive gear 19, in-
i. Assembly of P4 Carrier (Foldout 16) stall a large split bearing puller on the bearing.
Using appropriate tool(s) and fixture(s), re-
1. Inspect thrust surfaces on each of three pinion move the bearing by pressing the gear out.
gears 61 for wear and damage. Also inspect in-
side bore and gear tooth areas. 3. To remove bearings 20, 38, 40, 79, or 81, fol-
low the procedure in Step (2).
2. Inspect three upper and three lower thrust
washers 62 for wear and damage. k. Assembly of Drive, Idler, and Driven Gears
(Foldout 15)
3. Install three lower thrust washers 62 into each
of three pinion slots in P4 carrier 57. Each 1. Inspect drive gear 19, idler gear 39, and driven
washer has a machined tang which indexes gear 80 for tooth wear and damage. Refer to
with the notch in the P4 carrier housing. Paragraph 3-5i for gear inspection guidelines.
4. Apply a generous amount of lube to the inside 2. If removed, install bearing 18 on drive gear 39
bore of each pinion gear. Install needle bear- using tool J 38579-l and press. Repeat the
ings 60 into each of three pinions 61. Use the same procedure to install bearing 20 on drive
spindle to make sure that the needle bearings gear 39, or bearings 79 and 81 on driven
are properly aligned. gear 80.
5. Install pinion 61 and needle bearing 60 assem- 3. If removed, install bearing 38 on gear 39 using
bly into P4 carrier 57 with bottom thrust tool J 38579-2 and appropriate press. Repeat
washer 62 already in place. the same procedure to install bearing 40 on
gear 39.
6. Install upper thrust washer 62, aligning the
washer indexing tab with the notch in P4 car- 1. Disassembly of the Front Output Housing and
rier 57. Front Output Shaft (Foldout 15)
7. Inspect spindle 59 for wear and damage. Make 1. Remove front output yoke nut 42 and
sure that the fluid holes are free of obstruc- washer 43.
tions.
2. Press front output shaft 57 out of front output
8. Install spindle 59 into P4 carrier 57, aligning housing 49, and remove front output yoke 44.
the setscrew pilot on the spindle with the hole
3. Remove output seal 46 by using a hammer and
in the housing.
a chisel or tool J 24171-A. Be careful not to
9. Install one of three setscrews 58, and tighten to damage the seal bore area.
25-35 N•m (18-26 lb ft). Swage set screw
4. Remove output shaft bearing 47.
bore, using a chisel and a hammer.
10. Repeat Steps (6) through (9) to install the re- 5. Inspect bearing races 48 and 55 for pitting,
scoring, and damage. If the bearing race(s)
maining two pinion gears 61.
needs replacement, remove it by using a ham-
11. Install sun gear 63 into P4 carrier assembly 57. mer and a drift or a hammer and tool J 3940.
j. Disassembly of Drive, Idler, and Driven Gears 6. Remove shims 51, 52, or 53, and output bear-
(Foldout 15) ing spacer 54 from output shaft 57.
1. Inspect bearings 18, 20, 38,40, 79, and 81 per 7. If bearing 56 on output shaft 57 is damaged,
guidelines explained in Paragraph 3-5e. If any remove bearing 56. To remove bearing 56, in-
of bearings 18 and 20 installed on drive gear stall a split bearing puller on the bearing, and

MODULE REBUILD
position the bearing and the puller on a press n. Disassembly of the Rear Output Housing
table. Press the output shaft out using an ap- (Foldout 16)
propriate press.
1. Remove retaining ring 64 to remove P4 ring
m. Assembly of the Front Output Housing gear 65.
and Front Output Shaft (Foldout 15)
2. Remove P4 ring gear 65 from rear output hous-
1. Inspect front output housing 49 for scoring and ing 74.
burrs.
3. Remove output nut 81 and washer 80.
2. If removed, install new bearing races 48 and
4. Remove rear output shaft 66 by pressing it out
55. To install the bearing races, use tool
from rear output housing 74.
J 38568-3 and a press. Press each bearing race
until it bottoms in the output housing. 5. Remove yoke 79. Check yoke sealing area for
nicks, burrs, or damage.
3. Position bearing 47 in output housing 49.
6. Remove output seal 78 by using tool
4. Install output seal 46 in the output housing us- J 24171-A. Be careful not to damage the seal
ing tools J 38547 and J 35921-1.
bore areas.
5. Inspect output yoke 44 for scoring of seal sur- 7. Remove output shaft bearing 77 if it is dam-
face. Minimum seal surface diameter allowed
aged.
is 76.20 mm (3.00 inch). If the yoke does not
meet the required specification, replace the 8. Inspect bearing races 76 and 68 for pitting,
yoke. scoring, and damage. If the bearing races need
replacement, remove each bearing race by us-
6. Inspect output shaft 57 for spline damage and ing tool J 3940 or a hammer and a drift.
scoring. If necessary, replace the output shaft.
Remove shims 70, 71, or 72, and bearing
7. If removed, install bearing 56 on output spacer 69 from output shaft 66.
shaft 57. To install the bearing, use tool
J 38579-2. Position the bearing and tool If bearing 67 on shaft 66 is damaged, replace it.
J 38579-2 on the press table, and then carefully To remove bearing 67, position the bearing on
press the output shaft 57 into the bearing until the press table and install split bearing puller.
it is fully seated. Using a press, press rear output shaft 66 out.
8. Place output yoke 44 on a press table. 0. Assembly of the Rear Output Housing
(Foldout 16)
9. Position output housing 49 on the yoke.
1. Inspect rear output housing 74 for scoring and
10. Place bearing spacer 54 and shims 51, 52, or burrs.
53 on output shaft 57; the number of shims
could be one or more. 2. If removed, install bearing races 76 and 68 into
rear output housing 74 by using tool J 3940 or
11 Install output shaft 57 into front output a hammer and a drift.
housing 49 through bearing 47, output seal 46,
and into yoke 44. Once all the components are 3. Position bearing 77 into the output housing.
properly aligned, press shaft 57. Rotate hous-
ing 49 during this procedure to help the shaft 4. Install output seal 78 into the output housing
and its related components seat properly. by using tool J 38547 and J 35921-1.
12. Install output washer 43 and output nut 42. 5. Inspect output yoke 79 seal area for nicks, burrs,
and damage. Measure yoke seal surface; mini-
13. Perform the bearing preload procedure as ex- mum allowable seal journal OD is 76.20 mm
plained in Paragraph 5-15p which uses the (3.00 inch). If the yoke does not meet the re-
rear output housing as an example. quired specification, replace the yoke.

6. Place output yoke 79 on a press table. 10. Using a chain hoist and a scale, apply an up-
ward force of 734-778 N (165-175 lbs) on the
7. Position output housing 74 on the yoke.
output shaft. While force is applied, slightly
8. Inspect rear output shaft 66 for spline damage rotate the yoke.
and scoring, and if required, replace the rear
output shaft. 11. Check the dial indicator for movement.
9. If removed, install new bearing 67 on output 12. If the indicator readings are not within the spec-
shaft 66. To install bearing 67, use tool ified limits, add or remove shims and check pre-
J 38579-2. Position the bearing and tool load again. End play must be 0.025-0.127 mm
J 38579-2 on the press table, and then carefully (0.001-0.005 inch).
press output shaft 66 into the bearing until it is
13. If the indicator readings are within the speci-
fully seated.
fied limits, coat both sides of washer 80 with
10. Install bearing spacer 69, and shims 70, 71, or sealant and install the washer. Repeat Step (5)
72 onto output shaft 66. from above.
11. Press rear output shaft 66 into the output hous- q. Disassembly of C7 Control Valve Body
ing passing through bearing 77, output seal 78, (Foldout 16)
and yoke 79, making sure that the output hous-
ing spins freely. 1. Begin C7 valve body disassembly by removing
pins 34 and 40 securing the C7 signal valve so-
12. Install washer 80 and output nut 81 but do not lenoid 35 and C7 control valve 31 in body 30.
tighten. Remove the pins by driving them out from the
13. Place P4 ring gear 65 in housing 74. top toward the bottom (machined face).
14. Install retaining ring 64. 2. Remove stop 33, spring 32, and valve 31 from
body 30.
15. Follow bearing preload procedure explained in
Paragraph 5-15p. 3. Remove solenoid 35 and o-rings 36 and 37.
p. Output Housing Bearing Preload Procedure 4. Remove solenoid regulator valve 38.
1. Install rear output housing 74 (Foldout 16) on
5. Check the valves and bores for wear, scoring,
the rear transfer case half 2.
and damage.
2. Remove output yoke nut 8 1.
r. Assembly of C7 Control Valve
3. Install washer 80 on the output shaft after coat- Body Assembly (Foldout 16)
ing both sides with sealant.
1. Insert solenoid regulator valve 38 in the bore of
4. Lube the threads on the output shaft. body 30 and inspect for smooth movement.
5. Install output nut 8 1 and tighten it to 610-815 N•m
2. Inspect solenoid filter screen for damage or de-
(450-600 lb ft).
bris.
6. Install a dial indicator to read up and down
3. Replace solenoid o-rings 36 and 37 during
shaft movements.
overhaul.
7. You may need to place a shim or a smooth
washer on the output shaft to get true readings. 4. Insert solenoid 35 into valve body 30.
8. Bottom the output shaft by applying downward 5. Insert valve 31, followed by spring 32 and
force while slightly rotating the output yoke. valve stop 33.
9. The shaft is bottomed when the dial indicator 6. Push in on stop 33 to compress spring 32 and
shows no more down movement. Zero the dial insert a small cylindrical punch through the top
indicator at this point. hole in body 30 to hold these parts in position.

MODULE REBUILD
7. Install pin 34 by starting it in the hole opposite 12. Install test fixtures where C6 housing and rear
where the punch has been inserted. Tap the pin output housing would normally be installed. A
into position. The punch will be displaced as plate with the same diameter as C6 housing
the pin is installed. and the same hole pattern and size is to be used
as the test fixture and to be installed in the
8. Install pin 40 which retains solenoid 35. Insert place of C6 housing. Likewise, a plate with the
the smooth (not ridged) end of the pin into the same diameter and hole pattern and size as the
mating hole at the bottom face of body 30. Tap rear output housing is to be used in place of the
the pin into position flush with the bottom of rear output housing. When special fixture
body 30. Use a small diameter punch to plates are not available, use washers or spacers
slightly countersink pin 40. under the bolt heads that retain the C6 housing
s. Assembly of Transfer Case Module and rear output housing.
(Foldouts 14, 15, 16)
13. Rotate the assembly so that the front side of the
1. Lube bearing races 17, 37, and 78 (Foldout transfer case is up.
15), installed in front transfer case housing 14.
14. Install guide pins to facilitate installation of
2. One side of drive gear 19 has a shorter shoul- shims 10, 11, and 12 (Foldout 15).
der than the other side. Install drive gear 19 so
15. Install shims 10, 11, and 12 (shim pack A);
that the side with the shorter shoulder is toward
there may be more than or fewer than three
the front of the transmission.
shims.
3. Install idler gear 39 with its threaded hole to-
16. Install lube charging pump 5. Install eight
ward the front of the transmission.
bolts 4 securing the pump to the case. Tighten
4. Install driven gear 80 into front transfer case 14 bolts 4 to 60-75 N•m (44-55 lb ft).
in the same orientation as it was removed.
17. Install guide pins in two manifold bolt holes.
5. Install output speed sensor 45 (Foldout 16).
18. Install manifold shims 75, 76, and 77 (shim
6. Install two bolts 46 and tighten them to pack C).
24-29 N•m (18-21 lb ft).
19. Install manifold 73.
7. Install C7 control valve body assembly 29.
20. Install eight bolts 71 and tighten them to
8. Install six bolts 41, and tighten them to 60-75 N•m (44-55 lb ft) Two bolts will replace
24-29 N•m ( 18-2 1 lb ft). guide pins.
9. Install new transfer case gasket 16
21. Rotate the transfer case assembly so that the
(Foldout 15).
rear side is up.
10. Install rear transfer case 2 (Foldout 16) onto
22. Install special tool J 39623 into drive gear as-
the front transfer case. If necessary, use soft
sembly 19.
face mallet to seat the case half.
11. Install fifteen bolts 17 (Foldout 14). Tighten 23. Install a dial indicator, making sure that the
the bolts to 60-75 N•m (44-55 lb ft). end of the indicator rests squarely on the raised
center area of the tool.
NOTE: 24. Bottom the assembly by applying downward

force and rotating tool J 39623.
Follow Steps (12) through (27) for drive gear bear-
ing preload procedure. The procedure must be per- 25. Zero the dial indicator when there is no more
--
formed with all case-to-case bolts installed, but with downward movement.
the C6 housing and the rear output housing re-
moved. 26. Apply 734-778 N (165-175 lbs) of upward
force using a hoist and a scale.

27. Record the dial indicator reading and add or re- 37. Lube o-ring and install cover 49 over guide
move shims if the reading is not within the pins. Install five bolts 50 and tighten them to
specified limits; the allowable end play is 60-75 N•m (44-55 lb ft). Two bolts replace the
0.025-0.127 mm (0.001-0.005 inch). guide pins.
38. Rotate the transfer case assembly so that the
NOTE: front side is up.
Follow Steps (28) through (34) for driven gear bear- 39. Install guide pins to ease installation of the
ing preload procedure. front idler cover.
40. Install a new gasket 28 (Foldout 15) over the
28. Install special tool J 39623 into driven gear as- guide pins and onto the transfer case.
sembly 80 (Foldout 15).
41. Install shims 25,26, and 27 (shim pack B) over
29. Install a dial indicator, making sure that the the guide pins.
end of the indicator rests on the raised center
area of the tool. 42. Install a new o-ring 24 on cover 23.
30. Bottom the assembly by applying downward 43. Lube the o-ring.
force and rotating tool J 39623.
44. Install idler cover 23 and tap it lightly with a
31. Zero the dial indicator when there is no more soft-faced mallet to seat it in position.
downward movement.
45. Install five bolts 22 and tighten them to 60-75 N•m
32. Apply 734-778 N (165-175 lbs) of upward (44-55 lb ft). Two bolts replace the guide pins.
force using a hoist and a scale.
46. Remove front idler cover bolts 22, cover 23,
33. Record the dial indicator reading and add or re- shim pack B, and gasket 28 to start the idler
move shims if the reading is not within the gear bearing preload check.
specified limits; the allowable end play is
0.025-0.127 mm (0.001-0.005 inch). 47. Install the handle of tool J 39623 into the
threaded hole of idler gear 39.
34. If the preload reading is not within the speci-
48. Mount the dial indicator.
fied limit, add or remove the shims, and re-
check the preload. 49. Bottom the idler gear assembly by slightly ro-
tating tool J 39623 while applying downward
force.
NOTE:
Follow Steps (35) through (53) for idler gear bear- 50. Zero the dial indicator.
ing preload procedure.
51. Use a chain hoist and apply 734-778 N
(165-175 lbs) of upward force.
NOTE: 52. Read dial indicator to determine bearing pre-

load.
Both idler covers must be installed and tightened to
establish the idler gear position before bearing pre- 53. If preload is not within the specified limits, add
load is checked. or remove shims and repeat Steps (41)-(53).
The allowable end play is 0.025-0.127 mm
(0.00l-0.005 inch).
35. Install guide pins in two rear idler cover bolt
holes. 54. When preload is within the specified limits, re-
move the special tools.
36. Install new gasket 47 (Foldout 16) over guide
pins. Install new o-ring 48 on rear idler 55. Install guide pins to ease installation of the
cover 49. front idler cover.

MODULE REBUILD
56. Install a new gasket 28 over the guide pins, and
onto the transfer case.
57. Install shims 25,26, and 27 (shim pack B).
58. Install a new idler cover o-ring 24.
59. Lube the o-ring.
60. Install idler cover 23, and tap it lightly for in-
stallation.
61. Install five bolts 22 and tighten them to 60-75 N•m

(44-55 lb ft). Two bolts replace the guide pins.
62. Install a new o-ring on main wiring harness

connector 31.
63. Install harness connector assembly 31 on connec-

tor plate 29 and tighten nut 88 to 2.73–4.09 N•m
(24-36 lb in.).
Figure 5-19. Transfer Case Fitting And Screen
64. Place a new gasket 30 on the connector plate, Installation
carefully rotating wiring harness through the
gasket. 75. Install bolts 45 and tighten them to 60-75 N•m
(44-55 lb ft).
65. Position the harness connector through the
transfer case, and the connector plate. 76. Rotate the assembly so that the rear side is up.
66. Install four bolts 32 and tighten them to 5-8 N•m 77. Reconnect main wiring harness connector 31
(4-6 lb ft). to speed sensor 45 (Foldout 16) and solenoid
35, making sure that each connector locks in
67. Install a new o-ring 2 (Figure 5-19) on suction place.
hose fitting 3. Lube the o-ring.
78. Install a new control cover gasket 42.
68. Lube the metal boss of filter screen 1 and posi-
tion it in fitting 3. 79. Install control cover 43.
80. Install ten bolts 44, and tighten them to 24-29 N•m
69. Carefully thread the fitting into the transfer
(18-21 lb ft).
case.
81. If not previously done, remove test fixtures
70. Tighten the jam nut on fitting 3 to 100-120 N•m which were installed during drive and driven
(74-89 lb ft). gear bearing preload.
71. Install C7 clutch assembly 58 (Foldout 15) into 82. Position P4 carrier assembly 56 on the transfer
the transfer case. case.
72. Install guide pins in two front output housing 83. Install two guide bolts to facilitate installation
bolt holes. of rear output housing 74.
-
73. Install a new output housing gasket 50. 84. Install a new gasket 73.
74. Position front output housing 49 on the transfer 85. Carefully install rear output housing assembly
case. 74 onto the transfer case.

86. Install six bolts 75 and nine bolts 82. Tighten a. Removal of Filters
them to 60-75 N•m (44-55 lb ft) Two bolts
will replace guide bolts.
NOTE:
87. Install guide bolts in two C6 cover bolt holes. l For units prior to S/N 6510069120, proceed to
Step (1).
88. Install a new gasket 22. l For units beginning with S/N 6510069120, skip
Steps (1) and (2) and proceed to Step (3).
89. Position C6 clutch housing assembly 5 on the
transfer case.
1. If not previously removed, remove two filter
90. Install fifteen bolts 23 and two bolts 24. covers 178 (Foldout 17,A), two square cut
Tighten them to 60-75 N•m (44-55 lb ft). seals 179, two o-rings 180, and two filters 181.
91. Perform selective shim measurement before in- 2. Remove bolt 5 and two bolts 7. Remove suc-
stalling transfer case into the main transmis- tion housing 4, seal 6, suction filter assembly
sion as explained in Paragraph 6-21. 3, and gasket 2. Clean suction filter 3 and dis-
card it, if damaged.
3. If not previously removed, remove two filter
5-16. CONTROL VALVE MODULE covers 183 (Foldout 17,B), two gaskets 184,
(Foldouts I7,A; 17,B; and 17,C) two o-rings 185, two o-rings 186, and two fil-
ters 187.
4. Remove bolt 8 and two bolts 10. Remove suc-
tion housing 7, seal 9, suction filter
assembly 6, and gasket 5. Clean suction filter 6
and discard it, if damaged.
b. Removal of Electrical
Components and Sensors
NOTE:
Refer to Troubleshooting Manual TS2470EN
(WTEC II Controls) or TS2973EN (WTEC III
Controls) for inspection and repair procedures.
NOTE:
Step (1).
l For units with S/Ns between 6510032369 and
NOTE: 6510096670, skip Steps (1)-(4) and proceed to
Step (5).
The following SILs affect the control module and l For units beginning with S/N 6510096671, skip
should be consulted for detail service and parts in- Steps (1)-(8) and proceed to Step (9).
formation:
27-WT-93 - 1991-1992 Controls Differences and 1. Remove four bolts 9 (Foldout 17,A) and wiring
Serviceability harness cover plate 8.
9-WT-96 - Filter Cover Seal Change
7-WT-98 - TransID 2. Disconnect all connectors. Remove three
bolts 10 and internal harness assembly 11.

MODULE REBUILD
3. Remove two bolts 104 and turbine speed sen- 4. Remove two solenoids 55, each with
sor 105. The turbine speed sensor should have o-rings 56 and 57. Remove one solenoid 58
a resistance of 300 ± 30 Ohms. with o-rings 59 and 60. Remove three valves
54, and three springs 53. Check resistance of
4. If present, remove two bolts 147 and oil level
each solenoid by using chart in Figure 5-13.
sensor assembly 148. Clean the oil level sensor
with a soft clean cloth. Refer to Troubleshoot- 5. If present, remove valve retention pin 67,
ing Manual TS2470EN for proper sensor oper- stop 66, spring 65, and valve 64.
ation. Proceed to Step c.
6. Remove two bolts 52 and pressure switch as-
5. Remove four bolts 11 (Foldout 17,B) and wir- sembly 48. Maximum resistance of pressure
ing harness cover plate 12. switch assembly 48 (closed) must not exceed
2 Ohms. Minimum resistance of pressure
6. Disconnect all connectors. Remove three
switch assembly 48 (open) must be at least
bolts 13 and feedthrough harness assembly 14.
20,000 Ohms. The switch should close be-
7. Remove two bolts 112 and turbine speed sen- tween 159-255 kPa (23-37 psi).
sor 113. The turbine speed sensor should have
7. If present, remove three screens 62 from
a resistance of 300 ± 30 Ohms.
body 63.
8. If present, remove two bolts 155 and oil level
d. Disassembly of the Stationary Clutch
Solenoid Body (Foldout I7,A)
with a soft clean cloth. Refer to Troubleshoot-
ing Manual TS2470EN or TS2973EN for 1. Remove eight bolts 68 and stationary clutch
proper sensor operation. Proceed to Step c. solenoid body assembly 70.
9. Disconnect all connectors. Remove three 2. Remove two seals 69.
bolts 12 (Foldout 17,C) and feedthrough har-
ness assembly 13. 3. Remove three solenoid retention pins 81 from
bottom of solenoid body 71.
10. Remove two bolts 113 and turbine speed sen-
sor 114. The turbine speed sensor should have 4. Remove solenoids 75, small o-rings 77, large
a resistance of 300 ± 30 Ohms. o-rings 76, valves 78, and springs 79. Check
resistance of each solenoid by using the chart
11 If present, remove two bolts 156 and oil level in Figure 5-13.
with a soft clean cloth. Refer to Troubleshoot- 5. Remove valve retention pin 80.
ing Manual TS2470EN or TS2973EN for 6. Remove stop 74, spring 73, and valve 72.
proper sensor operation.
7. Remove solenoid separator plate 107.
c. Disassembly of the Rotating Clutch
Solenoid Body (Foldout I7,A) 8. If present, remove three screens 82 from
body 71.
1. Remove seal 46.
e. Disassembly of C6 Control Valve Body
2. Remove three bolts 45 and rotating clutch sole- (Foldout 17,A)
noid body assembly 47.
NOTE:
NOTE:
C6 control valve body is only in MD 3070PT trans-
Solenoid retention pins 61,81, and 125 must be re- mission models.
moved from the BOTTOM of the solenoid bodies.
Note the grooved end of pin for positive retention.
1. Remove five bolts 84 to remove C6 valve body
cover plate 85.
3. Remove three solenoid retention pins 61 from
bottom of solenoid body. 2. Remove C6 valve body cover plate 84.

3. Remove C6 valve body 87. 10. Remove stop 120, spring 119, and main regula-
tor valve 118.
4. Remove retaining pin 95, holding C6 regulator
valve solenoid 90. 11. Remove valve retention pin 121.
5. Remove regulator valve solenoid 90 with 12. Remove stop 124, spring 123, and control
o-rings 91 and 92. Remove regulator valve 89 main valve 122.
and spring 88. Check valve and bore for dam-
age. 13. Remove valve retention pin 130.
6. Remove retaining pin 95, holding C6 interlock 14. Remove stop 134, spring 133, and C2 latch
valve solenoid 99. valve 132.
7. Remove interlock valve solenoid 99 with
15. Remove valve retention pin 135.
o-rings 100 and 101. Remove interlock valve
102 and spring 103. 16. Remove stop 138, spring 137, and exhaust
8. Inspect interlock valve 102 and its bore for back valve 136.
nicks, wear, and damage.
f. Disassembly of Main Valve Body
18. Remove stop 142, spring 141, and Cl latching
1. Remove two bolts 106 and main valve body as- valve 140.
sembly 108.
2. If damaged, remove indexing pin 130.
20. Remove stop 146, spring 145, and converter
3. Remove solenoid retention pin 125 from bot- regulator valve 144. Inspect stop 146 for bat-
tom of solenoid body. tering. Replace the stop if it is battered. For
transmission S/Ns between 6510004324 and
4. Remove solenoid 126 with o-rings 127 and
6510058500, also replace separator plate 157
128. Check resistance of the solenoid by using and gasket 156 using part numbers specified in
the chart in Figure 5-13. SIL 24-WT-95.
21. Remove gasket 156, separator plate 157, and
6. Remove stop 112, spring 111, and lockup relay gasket 158.
valve 110.
8. Remove stop 116, spring 115, and lube regula-

tor valve 114.
9. Install spring compressor J 35924 (Figure 5-20).

Compress spring 119, remove valve retention
pin 117, and carefully remove compressor
w E00224
J 35924 after turning handle counter-clockwise Figure 5-20. Use of Tool to Release Main-Pressure
to release spring force. Valve Spring Force

MODULE REBUILD
g. Disassembly of the Channel Plate 9. Install control main valve 122, spring 123, and
(Foldout 17,A) stop 124.
1. If damaged, remove two pins 161 or 169. 10. Install valve retention pin 121.
2. Remove drain plug 163 and o-ring 164 or drain 11. Install main regulator valve 118, spring 119,
plug 174 and o-ring 175. and stop 120.
3. Remove eight pressure tap plug assemblies 12. Install spring compressor J 35924 (Figure 5-20).
165 with o-ring 166 or nine plugs 171 with Compress spring 119, install valve retention
o-ring 172. pin 117, and remove J 35924 after turning han-
dle counter-clockwise until the tool clears pin
4. Remove o-rings from all plugs.
117.
h. Assembly of the Channel Plate
13. Install lube regulator valve 114, spring 115,
1. Install new o-rings on all plugs. and stop 116.
2. Install eight pressure tap plugs 165 or nine plugs 14. Install valve retention pin 113.
171. Tighten plugs to 10-13 N•m (7-10 lb ft).
15. Install lockup relay valve 110, spring 111, and
stop 112.
NOTE:
16. Install valve retention pin 109.
A new, longer drain plug is available for improved
clamp load distribution and as a repair for channel 17. Install o-rings 127 and 128 on solenoid 126
plates with damaged threads. See SIL 5-WT-98 for and install solenoid.
details.
18. Install solenoid retention pin 125 from bottom
of main valve body assembly.
3. Install drain plug 163 or 174. Tighten plug to
25-32 N•m (18-24 lb ft). 19. Install indexing pin 130, if removed.
4. If removed, install two pins 161 or 169. 20. Install main valve body assembly 108 and two
bolts 106 until finger tight.
5. Install gasket 158, separator plate 157, and
gasket 156. 21. Install solenoid separator plate 107.
i. Assembly of the Main Valve Body j. Assembly of C6 Control Valve Body

(Foldout 17,A) (Foldout 17,A)
1. Install converter regulator valve 144, 1. Insert interlock valve 102 in the bore and check
spring 145, and stop 146. it for free movement. After ensuring that
valve 102 moves freely, install spring 103.
2. Inspect solenoid filter screen 96, if present, for
3. Install C1 latching valve 140, spring 141, and debris and damage. Replace it if necessary.
stop 142.
3. Install new o-rings 100 and 101 on interlock
valve solenoid 99, and install the solenoid.
5. Install exhaust-back valve 136, spring 137, and
4. Insert regulator valve 89 in the bore and check
stop 138.
it for free movement. After ensuring that
6. Install valve retention pin 135. valve 89 moves freely, install spring 88.
7. Install C2 latch valve 132, spring 133, and 5. Install new o-rings 91 and 92 on regulator
stop 134. valve solenoid 90.
8. Install valve retention pin 131. 6. Install regulator valve solenoid 90 in its bore.

7. Insert solenoid retention pins 95, smooth end 8. Install turbine speed sensor 105 and two bolts
first, from the bottom (separator plate side) of 104. Tighten bolts to 10-13 N•m (7-10 lb ft).
body 87 into body 87. Seat pins using hammer
and countersink the pins. m. Installation of the Wiring Harness
Assembly and Cover Plate (Foldout 17,A)
8. Place the valve body on the control module.
9. Install C6 valve body cover plate 85. NOTE:
10. Install five bolts 84. Tighten the bolts to l For units prior to S/N 6510032369, proceed to
10-13 N•m (7-10 lb ft). Step(l).
l For units with S/Ns between 6510032369 and
k. Assembly of the Stationary 6510096670, skip Steps (l)-(8) and proceed to
Clutch Solenoid Body (Foldout 17,A) Step (9).
1. Install valve 72, spring 73, and stop 74. Install l For units beginning with S/N 6510096671, skip
valve retention pin 80. Steps (1)-(15) and proceed to Step (16).
2. Install three each of springs 79, solenoid

1 Install 24-way internal connector 16 (Fold-
regulator valve 78, small o-rings 76 and 77,
out 17,A), two internal seals 15 and bolt 17
and solenoids 75.
onto standoff bracket 12. Tighten bolt 17 to
3. As valve bores are filled, install solenoid reten- 1.3-2.7 N•m (12-24 lb in.).
tion pins 81 from bottom of solenoid body.
2. Install wiring harness assembly 11 and three
4. Install two seals 69. bolts 10. Tighten bolts to 2-3 N•m (18-27 lb in.).
5. Install stationary clutch solenoid body assem- 3. If present, install oil level assembly 148 and
bly 70 and eight bolts 68. Tighten bolts 68 to two bolts 147. Tighten bolts to lo-13 N•m
l0-13 N•m (7-10 lb ft). (7-10 lb ft).
I. Assembly of the Rotating 4. Reconnect all connectors.
Clutch Solenoid Body (Foldout 17,A)
5. Install wiring harness cover plate 8 and four
1. Install valve 64 with stem toward the outside. bolts 9. Tighten bolts finger tight.
Then install spring 65 and stop 66. Install valve
retention pin 67. 6. Install gasket 2, seal 6, suction filter 3, filter
housing 4, bolt 5 and two bolts 7. Tighten bolts
2. Install three springs 53, three solenoid regula- finger tight.
tor valves 54, two solenoids 55 with o-rings 56
and 57, and one solenoid 58 with o-rings 59 7. Evenly tighten cover plate bolts 9, suction filter
and 60. bolts 5 and 7, and main valve body bolts 106.
Tighten all bolts to l0-13 N•m (7-10 lb ft).
3. Install solenoid retention pins 61 from bottom
of rotating clutch solenoid body. 8. Proceed to Section 6.
4. Install pressure switch assembly 48 and two 9. Install feedthrough harness assembly 14 (Fold-
bolts 52. Tighten bolts to 5-8 N•m (4-6 lb ft). out 17,B) and three bolts 13. Tighten bolts to
2-3 N•m (18-27 lb in.).
5. Install seal 46.
10. If present, install oil level assembly 156 and
6. Install rotating clutch solenoid body two bolts 155. Tighten bolts to l0-13 N•m
assembly 47 and three bolts 45. Tighten bolts (7-10 lb ft).
45 to 10-13 N•m (7-10 lb ft).
11. Reconnect all connectors.
7. Install oil level sensor assembly 148 and
two bolts 147. Tighten bolts to l0-13 N•m 12. Install wiring harness cover plate 12 and four
(7-10 lb ft). bolts 11. Tighten bolts finger tight.

I MODULE REBUILD
13. Install gasket 5, seal 9, suction filter 6, filter 17. If present, install oil level assembly 157 and
housing 7, bolt 8 and two bolts 10. Tighten two bolts 156. Tighten bolts to l0-13 N•m
bolts finger tight. (7-10 lb ft).
18. Reconnect all connectors.

14. Evenly tighten cover plate bolts 11, suction fil-
ter bolts 8 and 10, and main valve body bolts 19. Install four bolts 11. Tighten bolts finger tight.
114. Tighten all bolts to 10-13 N•m (7-10 lb ft).
20. Install gasket 5, seal 9, suction filter 6, filter
housing 7, bolt 8 and two bolts 10. Tighten
15. Proceed to Section 6.
bolts finger tight.
16. Install feedthrough harness assembly 13 (Fold- 21. Evenly tighten bolts 11, suction filter bolts 8
out 17,C) and three bolts 12. Tighten bolts to and 10, and main valve body bolts 115. Tighten
2-3 N•m (18-27 lb in.). all bolts to 10-13 N•m (7-10 lb ft).

NOTES

SECTION 6 - TRANSMISSION ASSEMBLY
6-1. SCOPE 6. Rotate the repair stand so the transmission
housing output end is up and install the remain-
a. Section. This section covers the assembly of ing ten bolts 3. Tighten all bolts to 51-61 N•m
MD 3000(P)(R)(T), B 300(P)(R), and B 400(P)(R) (38–45 lb ft).
Series transmissions. The assembly sequence is
b. Installation of the Rotating Clutch Module
continuous and includes all models.
(Figure 6-2)
b. Procedures. When a procedure does not apply to
1. Rotate the repair stand so the input end of the
your specific model, go to the next applicable proce-
main housing is up.
dure.
c. Illustrations. Illustrations will not always show 2. Using a hoist and an Ml6 eye bolt, insert rotat-
your model, but when an operation is identical for all ing clutch module 1 in the front of the main
models, the correct procedure is shown. housing.
d. General Information. Refer to Section 3 for c. Installation of the Front Support/Charging

general information as follows: Pump Module (Figure 6-3)
Paragraph Description 1. Lower front support and charging pump mod-

ule 3 over the top of the turbine shaft.
3-2 Tools, Equipment
3-3 Replacement Parts
3-4 Careful Handling
3-6 Assembly Procedures
e. Foldouts. Refer to Foldouts 7 through 19 for dis-

assembled views and torque specifications.
NOTE:
All parts must be cleaned and lubricated before
assembly.
VO5621
6-2. ASSEMBLY OF TRANSMISSION
Figure 6-1. P2 Planetary Module and
a. Assembly of C3/C4 Clutch C5 Clutch Installation
1. Mount holding fixture J 35926 onto the main I

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

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

housing is up.
2. Install P1 planetary module 1 - consisting of

the P1 carrier and P2 ring gear. I VO5618
3. Mesh the P1 pinion gears with the P1 ring gear Figure 6-4. P1 Planetary Module Installation
inside the C3/C4 clutch assembly.
e. Installation of the P2 Planetary Module
(Figure 6-5)
1. Install P2 planetary module 1 - consisting of
the P2 carrier and the P3 ring gear.
2. Mesh the P2 pinions with the P2 ring gear dur-
ing installation.
f. Installation of the C5 Clutch Pack (Figure 6-5).
Install the C5 clutch pack in the main housing - eight
steel reaction plates 2 and seven friction plates 3,
stacked alternately, starting with a steel reaction plate.
Stack all plates so plate cone faces the same direction.
Steel plates mesh with the main housing and reaction
plates mesh with the P3 ring gear.
g. Installation of the Main Shaft (Figure 6-6). In- Figure 6-5. P2 Planetary Module and
stall main shaft 1 as assembled in Section 5, without C5 Clutch Installation
r
selective shim 2 and thrust bearing 3 (does not apply
to MD 3070PT models).
l(MD3060
V05565
Figure 6-3. Front Support/Charging Pump

Module Installation Figure 6-6. Main Shaft Installation

I TRANSMISSION ASSEMBLY
h. Main Shaft Selective Shim Measurement For face and place a straight edge across the P3
Models With Retarder (Figure 6-7) planetary carrier.
1. Place a straight edge across the retarder mount- 5. Measure dimension D, from top of the straight
ing surface of the main housing. edge to the retarder mounting gasket.
6. Measure dimension E, from top of the straight
2. Measure dimension A, from top of the straight
edge to the thrust bearing contact surface on
edge to the selective shim thrust surface on the
the P3 planetary carrier. Subtract dimension E
main shaft bearing spacer. from dimension D - the remainder is dimen-
3. Measure dimension B, thickness of straight sion F.
edge. Subtract dimension B from dimension A 7. Dimension G is the remainder of C minus F
- the remainder is dimension C. and determines the thickness of the selective
shim.
4. Place the retarder module output end down
(facing the bench top). Install an uncom- 8. Install the proper thickness selective shim and
pressed gasket on the retarder mounting sur- the thrust bearing.
BEARING AND
STRAIGHT EDGE SHIM REMOVED STRAIGHT EDGE
DIM. E
- / l-
-_I-
t t
DIM. DIM,
MAIN SHAFT MODULE RETARDER MODULE

PROCEDURE:
*FORMULA(C)-(F)=G
1 DIM. G 1 USE PIN 1 SHIM ID 1
;I;; ;I” 29503226 1 NOTCH

I
-5.113 mm
0.201 in. 29503227 2 NOTCHES
;;; .;” . 29503228 3 NOTCHES
;$;”* . 29503229 4 NOTCHES
;;;;.1” . 29503230 5 NOTCHES
&lg3
0.244 in.
mm 29503231 6 NOTCHES
6.463 mm
29503232 7 NOTCHES
0.254 in. E00211.05
Figure 6-7. Main Shaft Selective Shim Measurement With Retarder Module - MD 3060/MD 3066/B 300/B 400

i. Main Shaft Selective Shim Measurement For the rear cover mounting surface and place a
Models Equipped With Rear Cover straight edge across the P3 planetary carrier.
(Figure 6-8)
5. Measure dimension D from top of the straight
1. Place a straight edge across the rear cover edge to the rear cover mounting gasket.
mounting surface of the main housing. 6. Measure dimension E from top of the straight
edge to the thrust bearing contact surface on
2. Measure dimension A, from top of the straight the P3 planetary carrier. Subtract dimension E
edge to the selective shim thrust surface on the from dimension D - the remainder is dimen-
main shaft bearing spacer.
sion F.
3. Measure dimension B, thickness of straight 7. Dimension G is the remainder of C minus F
edge. Subtract dimension B from dimension A and determines the thickness of the selective
- the remainder is dimension C. shim.
4. Place rear cover output end down (facing the 8. Install the proper thickness selective shim and
bench top). Install an uncompressed gasket on the thrust bearing.
STRAIGHT EDGE
7 DIM. E1
MAIN SHAFT MODULE REAR COVER MODULE

PROCEDURE:
* FORMULA (C) -(F) q G
DIM. G USE PIN SHIM ID
4.5744043 mm 295032,8
1 NOTCH
0.180-0.190 in.
4.844-5.113 mm
0.192-0.201 in. 29503219 2 NOTCHES
;‘;;;-‘f; .z”
. . 29503220 3 NOTCHES
;;yz;; .Em
. . 29503221 4 NOTCHES
;;;z;; .I”
. . 29503222 5 NOTCHES
;;;z;i; .1”
. . 29503223 6 NOTCHES
6.194-6.463 mm
0.245-0.254 in. 29503224 7 NOTCHES
E00212.03
Figure 6-8. Main Shaft Selective Shim Measurement With Rear Cover Module

j. Selective Shim Measurement For MD 3070PT 4. Place transfer case rear output end down (fac-
(Figure 6-9) ing the bench top). Install a NEW gasket on the
front main transfer case mounting surface and
1. Place a straight edge across the transfer case place straight edge across the transmission
mounting surface of the adapter housing (gas- shaft adapter.
ket removed). Also, be sure that there is no se-
lective shim in place at this time. 5. Measure dimension D from the top of the
straight edge to the transfer case mounting gas-
ket.
2. Measure dimension A from the top of the
straight edge to the shoulder where the selec- 6. Measure dimension E from the top of the
tive shim will rest. straight edge. Subtract dimension E from di-
mension D - the remainder is dimension F.
3. Measure dimension B, from the top of the
straight edge to the face where the gasket rests. 7. Dimension G is the remainder of C minus F,
Subtract dimension B from dimension A - the and determines the thickness of the selective
remainder is dimension C. shim.
STRAIGHT EDGE
I 17
DIM. E
1
TRANSMISSION ASSEMBLY PROCEDURE: TRANSFER CASE MODULE

* FORMULA (C)-(F) = G
1 DIM. G 1 USE PIN SHIM ID 1
0.899-1.169 mm
29503226 1 NOTCH
0.035-0.046 in.
1.169-1.439 mm
0.046-0.057 in. 29503227 2 NOTCHES
mm
;;y-;;; 29503228 3 NOTCHES
( in
1
;;;y--;; .;”. . 29503229 4 NOTCHES
(
1
;i;z;;; .8” . . 29503230 5 NOTCHES
(
:!.249-2.519 mm
29503231 6 NOTCHES
(LO894099 in.
:2.519-2.674 mm
(0.099-0.113 in. 29503232 7 NOTCHES E01843.01
Figure 6-9. Selective Shim Measurement For MD 3070PT

8. Coat the selected shim with a generous coating
of lube (petrolatum) and insert shim inside the
transmission shaft adapter.
NOTE:
l Proceed to Step k. for units with retarder built
prior to 1/98.
• Proceed to Step 1. for units with retarder built
starting 1/98. BOLT(6),M12 x1.75xlWm
k. Installation of Retarder Module (Units Built

Prior To 1/98) (Foldout 13,A) BOLT(7), HlOxl.5 xl
MARKED B
1. Install a NEW retarder gasket 1 on the trans- V01644.01
mission main housing.

Figure 6-10. Retarder Module Bolts
2. Install guide bolts to ease the installation of re- (Units Built Prior To 1/98)
tarder module 5 and to keep gasket 1 in place.
6. Install output shaft oil seal 55 using tool
J 39928.
1. Installation of Retarder Module (Units Built

Starting l/98) (Foldout 13,B)
1. Install a NEW retarder gasket 1 on the trans-
3. Place retarder module 5 on the transmission mission main housing.
main housing using a hoist and sling as a lift-
ing fixture. If used, install the rear support 2. Install guide bolts to ease the installation of re-
bracket. tarder module 5 and to keep gasket 1 in place.
4. Install twelve Ml2 x 1.75 x 165 mm bolts at

locations marked A (Figure 6-10). Install six
Ml2 x 1.75 x 190 mm bolts marked C. Tighten
the eighteen Ml2 bolts to 90-l10 N•m
(66-81 lb ft). Install seven Ml0 x 1.5 x 180 mm
bolts at locations marked B. Tighten the Ml0
bolts to 51-61 N•m (38-45 lb ft). Three bolts
not mentioned were installed and tightened in
3. Place retarder module 5 on the transmission
Section 5.
main housing using a hoist and sling as a lift-
5. Retighten spanner nut 54 (Foldout 13,A) to ing fixture. If used, install the rear support
74-88 N•m (55-65 lb ft). If only one tang is bracket.
aligned with a bearing retainer nut slot, con-
tinue to torque the bearing retainer nut (but do 4. Install fourteen Ml2 x 1.75 x 130 mm bolts at
not exceed the tightening torque or drag torque locations marked A (Figure 6-l 1). Install four
limits) until two or more tangs can be bent up Ml2 x 1.75 x 190 mm bolts marked C. Tighten
into slots on the bearing retainer nut. the eighteen Ml2 bolts to 90-110 N•m
(66-81 lb ft). Install seven Ml0 x 1.5 x 180 mm
NOTE: bolts at locations marked B. Tighten the Ml0
DO NOT reuse a tang once it has been bent. Replace bolts to 51-61 N.m (38-45 lb ft). Three bolts
locknut retainer 53, if necessary. not mentioned were installed and tightened in
Section 5.

BOLT(14),M12x1.75x13Omm
MARKED A
BOLT (4), Ml2 x 1.75 x 190 mm

MARKED C
BOLT (7), Ml0 x 1.5 x 180 mm
MARKED B
VO5638
Figure 6-11. Retarder Module Bolts

(Units Built Starting 1/98) Figure 6-12. Rear Cover Module Installation
5. Retighten spanner nut 62 (Foldout 13,B) to n. Installation of Transfer Case Adapter Housing
74-88 N•m (55-65 lb ft). If only one tang is (Figure 6-13)
aligned with a bearing retainer nut slot, con- 1. Install a new adapter housing gasket 2.
tinue to torque the bearing retainer nut (but do
not exceed the tightening torque or drag torque 2. Inspect adapter housing 3 for cracks, nicks, or
limits) until two or more tangs can be bent up burrs. Remove the burrs and nicks with crocus
into slots on the bearing retainer nut. cloth or light stone.
3. Install adapter housing 3 by installing fifteen
NOTE: bolts 8 and three bolts 5. Torque to 90-110 N•m
(66-81 lb ft).
DO NOT reuse a tang once it has been bent. Replace
locknut retainer 61, if necessary. 4. Install three bolts 6, two bolts 7, and four bolts
4. Torque them to 51-61 N•m (38-45 lb ft).
6. Install output shaft oil seal 63 using tool o. Installation of Transfer Case Module
J 39928. (Figure 6-14)
1. Install a NEW gasket 4.
m. Installation of Rear Cover Module
(Figure 6-12) 2. Be sure that selective shim 1 is located inside
shaft adapter 5.
1. Install a NEW rear cover gasket 1 on main 3. Mount J 38572 on transfer case 3.
housing 4.
2. Install guide bolts to ease rear cover 2 installa-

tion and keep gasket 1 in place.
3. Place rear cover module 2 on main housing 4

using a hoist and sling as a lifting fixture. In-
4. Use hoist and J 38572 to lift transfer case 3.
stall rear support bracket, if used.
5. Install transmission shaft adapter 5 into trans-
4. Install nineteen bolts 3. Tighten bolts to fer case 3.
90-110 N•m (66-81 lb ft).
6. Install transfer case 3 into the main transmis-
5. Install output shaft oil seal 5. sion, and install bolts 2.

7. Install bolt 7, passing through C6 housing into 2. Install guide bolts to ease converter housing 1
the adapter housing. installation and keep gasket 2 in place.
8. Torque bolts 2 and bolt 7 to 51-61 N•m 3. Lower converter housing 1 onto main
(38-45 lb ft). housing 4. If the transmission is PTO
equipped, rotate the PTO drive gear to align
p. Installation of the Converter Housing Module the gear tangs with the charging pump.
(Figure 6-15)
4. Install three bolts 3 into the inside of converter
1. Place transmission input end up. Install a new housing 1. Use mechanical fingers, or a similar
converter housing gasket 2 on main housing tool, when installing these bolts.
module 4.
5. Remove the two guide bolts and install the re-
maining seventeen bolts 3. Tighten all bolts to
62-72 N•m (46-53 lb ft).
q. Installation of the Torque Converter Module

(Figure 6-16)
1. The torque converter is installed over the tur-
bine shaft which rotates inside the stator shaft
or ground sleeve. The splines on the ground
sleeve engage the converter stator. The splines
on the turbine shaft engage the converter tur-
bine. The end of the turbine shaft is threaded
and machined to accept the converter retaining
bolt and lockup sealring.
2. The splines of the ground sleeve and turbine

7 6 VO5569 shaft must engage with their respective splines
in the torque converter module. The tangs on
Figure 6-13. Transfer Case Adapter Housing the converter-pump hub must engage the
Installation charging pump tangs or the PTO oil pump
drive hub.
3. Using hoist and sling, install torque converter
module 6 into the converter housing module
(Figure 6-16, View A).
V05908
Figure 6-14. Transfer Case Module Installation Figure 6-15. Converter Housing Module Installation

TRANSMISSION ASSEMBLY
,-Cupped end down

ROTATING
CLUTCH
MODULE
J 38548
r TOOL HEIGHT
(CONSTANT)
VIEW C EO5623.01
Figure 6-16. Torque Converter Module Installation and Selective Shim Measurement
Table 6-1. Torque Converter Selective Shims
Dimension “C” Use P/N Shim Thickness

0.4093-0.6597 mm (0.0161-0.0260 in.) 29505688 0.000 mm; NO STEP
0.6598-0.8377 mm (0.0261-0.0330 in.) 29505681 0.178-0.228 mm (0.007-0.009 in.)
0.8378-1.0157 mm (0.0331-0.0400 in.) 29505682 0.356-0.406 mm (0.014-0.016 in.)
) 1.0158-1.1937 mm (0.0401-0.0470 in.) 1 29505683 I 0.534-0.584 mm (0.021-0.023 in.)
1.1938-l .3707 mm (0.047 l-0.0540 in.) 29505684 I 0.71 l-0.761 mm (0.028-0.030 in.)
1.3708-l .5487 mm (0.0541-0.0610 in.) 29505685 0.889-0.939 mm (0.035-0.037 in.)
1.5488-l .6823 mm (0.0611-0.0662 in.) 29505686 1.067-l.117 mm (0.042-0.044 in.)

I
I
MD/B 300/B 400 SERIES ON-HIGHWAY SERVICE MANUAL 1
4. Ensure the torque converter is properly seated. 9. Install selective shim 5 with the shim step side
If PTO equipped, rotate the PTO gear to en- toward the turbine shaft. Install bolt 4, con-
gage the pump hub with the charging pump. verter bolt tightening tool J 38564, and retain-
Proceed with the selective shim measurement. ing ring 1 (Figure 6-16, View A).
5. Hold the turbine and turbine shaft stationary by 10. Prevent turbine shaft rotation as in Step (5).
using one of the methods listed below: Tighten bolt 4 to 100-120 N•m (74-89 lb ft).
l Insert a screwdriver into the vanes on the
11. If present, remove retaining ring 1 and tool
rotating clutch module (Figure 6-16,
J 38564. Install o-ring 3 on converter end
View B).
plug 2. Install the end plug. Aligning retaining
l If the control module is in place, remove the ring 1 so that the sharp edge faces outward, in-
plug(s), if present, from the fill tube hole or stall the retaining ring.
from cooler ports before applying lockup
air pressure. Apply air pressure through the 12. Install selective shim 5 with the shim step side
lockup pressure tap (Figure 4-7, View D) toward the turbine shaft. Install bolt 4 and con-
and use a heel bar, screwdriver, and bolts. verter bolt tightening tool J 38564 (Figure 6-17,
Insert the heel bar into a torque converter View A).
housing bolt hole. Insert two bolts into the
flexplate adapter bolt holes. Then place a 13. Prevent turbine shaft rotation as in Step (5).
Tighten bolt 4 to 100-120 N•m (74-89 lb ft).
screwdriver at an angle to prevent converter
rotation (Figure 6-16, View C). 14. Remove tool J 38564. Install o-ring 8 on
6. Install converter end play gauge J 38548 threaded converter end plug 7. Use a 3/4 inch
and tighten the attaching bolt to 27-34 N•m Allen socket to install end plug 7 and tighten it
(20-25 lb ft). to 50-60 N•m (37-44 lb ft).
15. Install converter shipping brackets (Foldout

NOTE: lO,A), or equivalent, to retain the torque con-
Dimension C shown in Table 6-l includes a correction verter to the transmission. Tighten the shipping
due to internal deflection caused by the 27-34 N•m bracket bolts to 51-61 N•m (38-45 lb ft).
(20-25 lb ft) bolt torque applied to gauge J 38548.
Accurate torque value is critical to selection of the r. Installation of the Control Module
(Figure 6-17
proper shim.
7. Measure from top of tool J 38548 to face of

turbine shaft and record it as dimension B.
Subtract dimension B from dimension A — di-
mension A is the height of tool J 38548,
100.00 mm (3.937 inch) to determine dimen-
sion C (Figure 6-16, View D).
1. Position transmission in overhaul stand verti-
8. Use Dimension C and Table 6-l to determine cally.
proper selective shim part number. Remove
tool J 38548 and continue with installation of
the torque converter.
NOTE:
Step (9).
l For units beginning with S/N 6510165560, skip
2. Install a new control module gasket 2 over the
Steps (9-11) and proceed to Step (12). dowel pins on control module 1.

thirty-one bolts 176 and 177. Tighten all bolts
to 51-61 N•m (38-45 lb ft).
5. Install two filter covers 183 (Foldout 17,B),
two gaskets 184, two o-rings 185, two o-rings
186, and two filters 187. Install remaining
thirty-one bolts 188 and 189. Tighten all bolts
to 51-61 N•m (38-45 lb ft).
s. Installation of Power Takeoff(s)
(Figure 6-18)
1. If removed, install PI’0 studs 4.
2. Install PTO gasket 3 and PTO assembly 2. In-
sert bolt 1 into each of the 6 o’clock and
12 o’clock positions. Install the remaining six
bolts. Tighten bolts to 51-61 N•m (3845 lb ft).
t. Installation of Integral Oil Cooler
(Foldout 19,A)
NOTE:
l For models without retarder, proceed to Step (1).
l For models with retarder, skip Steps(l)-(5) and
proceed to Step (6).
1. Install two M10 guide bolts at rear of main hous-
ing where cooler housing attaches. Slide gasket 5
V05614 and cooler housing 7 onto the guide bolts. Be
sure the housing and gasket are properly aligned.
Figure 6-17. Control Module Installation
2. Install nine bolts 15 and nine washers 16 (two
3. Guide control module 1 onto the main housing will replace the guide bolts) which fasten the
using the dowel pins. Install one bolt 176 cooler housing to the main housing. Tighten
(Foldout 17,A) in the top center bolt hole. the bolts to 51-61 N•m (3845 lb ft).
3. Install plate assembly 27 with four lubed
NOTE: o-rings 28 in place. Push the plate assembly in
until the o-rings are seated in their mating
Main and lube filters are interchangeable. However,
bores in the cooler housing.
the filters for a two inch sump are a different length
than those for a four inch sump. The filters in the 4. Install two o-rings 26. Install two guide bolts at
seven inch sump are the same as in the two inch sump. rear of cooler housing where cover 23 attaches.
Slide gasket 22 and cover 23 into position over
the guide bolts.
NOTE: 5. Install two bolts 24 and seventeen bolts 25 (two
l For units prior to S/N 6510032369, proceed to will replace the guide bolts). Tighten the two
Step (4). bolts 24 to 90-110 N•m (66-81 lb ft) and the
l For units starting with S/N 6510032369, and seventeen bolts 25 to 51-61 N•m (38-45 lb ft).
later, skip Step (4) and go to Step (5). 6. Install two M10 guide bolts at rear of retarder
housing where cooler housing attaches. Slide
4. Install two square cut seals 179 (Foldout gasket 6 and cooler housing 7 onto the guide
17,A), two o-rings 180, two filters 181, and bolts. Be sure the housing and gasket are prop-
two filter covers 178. Install remaining erly aligned.

Figure 6-18. Power Takeoff(s) Installation
7. Install bolt 12, washer 11, six bolts 15 and six bolts 24 to 90-110 N•m (66-81 lb ft) and the
washers 16 which fasten the cooler housing to the seventeen bolts 25 to 51-61 N•m (38-45 lb ft).
retarder housing. Tighten the bolts to 51-61 N•m
(38-45 lb ft). Install three bolts 13 and three u. Installation of Speed Sensors
washers 14. Tighten the three bolts 13 to
l00-120 N•m (74-88 lb ft).
NOTE:
8. Install plate assembly 27 with four lubed l For models without retarder, proceed to Step (1).
o-rings 28 in place. Push the plate assembly in l For models with retarder (built prior to l/98),
until the o-rings are seated in their mating skip Step (1) and proceed to Step (2).
bores in the cooler housing.
l For models with retarder (built starting l/98),
9. Install two o-rings 26. Install two guide bolts at skip Steps (1) and (2) and proceed to Step (3).
rear of cooler housing where cover 23 attaches.
Slide gasket 22 and cover 23 into position over 1. Install output speed sensor assembly 29 (Fold-
the guide bolts. out 13,C), o-ring 30, retainer 31, and bolt 32
into the rear cover assembly 21. Tighten
10. Install two bolts 24 and seventeen bolts 25 (two bolt 32 to 24-29 N•m (18-21 lb ft). Skip to
will replace the guide bolts). Tighten the two next NOTE.

I TRANSMISSION ASSEMBLY I
2. Install output speed sensor assembly 36 (Fold- 5. Install input speed sensor assembly 19 (Fold-
out 13,A), o-ring 37, retainer 38 and bolt 39. out 8,B), o-ring 20, retainer 21, and bolt 22
Tighten bolt 39 to 24-29 N•m
•m (18-21 lb ft). In- into the converter housing module. Tighten
stall cover 70 and four bolts 71. Tighten bolts bolt 22 to 24-29 N•m (18-21 lb ft).
71 to 39 to 24-29 N•m (18-21 lb ft). Skip to
next NOTE. v. Installation of Common Externally-Mounted
Parts (Figure 6-19)
3. Install output speed sensor assembly 40 (Fold- 1. Install transmission breather 1, if not previ-
out 13,B), o-ring 41, retainer 42, and bolt 43
ously installed. Tighten breather to 12-16 N•m
into the retarder housing. Tighten bolt 43 to
(9-12 lb ft).
24-29 N•m (18-21 lb ft).
2. Install fill tube seal 20, fill tube 21, bracket 23,
and screw 22. Tighten screw to 24-29 N•m
NOTE: (18-21 lb ft). Install dipstick 24.
l For models without PTO, proceed to Step (4).
3. If reusable, install expander plug 2 in the op-
l For models with PTO, skip Step (4) and proceed tional fill tube location on the opposite side of
to Step (5). the main housing module. Tighten the plug to
1-2 N•m (9-18 lb in.). If plug 2 is not reusable
4. Install input speed sensor assembly 3 (Foldout and for transmissions after S/N 6510107518,
8,A), o-ring 4, retainer 5, and bolt 6 into the install seal 4 and plug 3. Plug 3 is fully seated
converter housing. module. Tighten bolt 6 to when the underside of the plug head contacts
24-29 N•m (18-21 lb ft). seal 4.
Figure 6-19. Externally-Mounted Parts Installation

4. If transmission has rear cooler ports, install
new cooler port gasket 19. Install remote
cooler port manifold 18 and six bolts 16.
Tighten bolts to 51-61 N•m (38-45 lb ft).
5. For a transmission which uses front cooler

ports, install gasket 19, cover plate 17, and
six bolts 16. Tighten the bolts to 51-61 N•m
(38-45 lb ft).
6. Install parking brake assembly 5. Install four

bolts 6. Tighten the bolts to 228-266 N•m
V01837
(168-196 lb ft).
Figure 6-20. MD 3070PT - Scavenge Pump Installation
7. Install output flange 14 or yoke 15.
8. Install lubricated o-ring 13 on retainer plug 11. NOTE:

If you have an MD 3070PT transmission model,
complete Steps (14) through (15). Refer to Figure 620.
NOTE:
A service kit is recommended which improves the
13. Replace gasket 9 (thin coated metal type), and
clamp load on parts retained by the two output
install scavenge pump 7. Install nine bolts 8.
flange bolts. The kit contains Allen-Head bolts,
belleville washers, o-rings and an instruction sheet. Tighten bolts 8 to 51-61 N•m (38-45 lb ft).
14. Install hose 1, fittings 2 and 3, o-rings 4 and 5,

and screen 6. Tighten fittings to 100-120 N•m
9. Insert two bolts 9 through belleville washers 10 (74-88 lb ft).
and retainer plug 11 or one bolt 29 through re-
tainer plug 28. w. Removal of Transmission From Repair Stand
(Figure 6-21). Using a hoist, remove the transmission
10. Install an o-ring 12 over the threaded end of
and holding fixture from the repair stand and prepare
each bolt 9 or o-ring 27 over bolt 29, so that the
for vehicle installation.
o-ring seats against the retainer plug.
11. Install retainer plug 11 or 28 into the yoke or NOTE:

flange. Tighten bolts 9 to 30-35 N•m (22-26 lb ft). Refer to Mechanic’s Tips MT2159EN or
Tighten bolt 29 to 70-80 N•m (5l-60 lb ft.) MT3004EN for preparing the transmission for in-
stallation and installing the transmission onto the
12. If used, install brake drum 7 and two bolts 8. vehicle.
Tighten bolts to 56-66 N•m (41-49 lb ft).

VIEW A
MD/B300/B400 MD 3070PT
Figure 6-21. Removing Transmission From Repair Stand

NOTES

I SECTION 7 - WEAR LIMITS AND SPRING DATA I
7-1. WEAR LIMITS DATA adjacent parts, or permanent set. Discard springs
which do not meet the load height specifications ac-
a. Maximum Variations. Wear limits information cording to Table 7-2, Spring Data.
in this Section shows the maximum wear at which
components are expected to function satisfactorily. Ta- b. Inspection. Inspection criteria (load vs. height)
ble 7-l lists the Wear Limits Data and is referenced to and identification characteristics of the springs are pre-
the exploded views (Foldouts 7 through 19) in the sented in Table 7-2. The Spring Data are keyed to the
back of this manual. exploded views (Foldouts 7 through 19) in the back of
this manual.
b. Cleaning and Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Section 3.
NOTE:
When more than one spring part number is listed
7-2. SPRING DATA for the same location, refer to the latest edition of
Parts Catalog PC2150EN to determine which
a. Spring Replacement. Springs should be replaced spring is used in your specific assembly number.
if there are signs of overheating, wear due to rubbing
Table 7-1. Wear Limits Data

Wear Limit
-
Illustration Description mm (inches)
Foldout 7 TORQUE CONVERTER MODULE
9 Cover Bushing, Maximum ID 61.51 2.422
11 Piston, Minimum Thickness 5.71 0.225
13 Lockup Clutch Friction Plate Flatness, Maximum Distortion 0.51 0.020
13 Lockup Clutch Friction Plate, Minimum Thickness 8.05 0.317
13,18 Turbine-To-Damper Spline Wear, Maximum Movement 0.38 0.015
14 Backing Plate Wear Surface, Minimum Thickness 8.58 0.338
16 Turbine Hub Hook-Type Sealring, Maximum ID When Installed In 56.75 1.441
Cover 7 Bore
18 Turbine Hub, Minimum OD 61.34 2.415
23 Stator Thrust Plate, Minimum Thickness 11.68 0.460
34 Converter Pump Hub, Minimum OD 74.999 2.9527
Foldout 8,B TORQUE CONVERTER HOUSING MODULE -WITH PTO
6 Bearing Retainer Bushing, Maximum ID 75.23 2.962
7 Bearing Retainer Bearing Bore, Maximum ID 140.06 5.514
10,17 Oil Pump Drive Hub Seals, When Installed in Sealing Bore, 1.15 0.045
Maximum End Gap
14 Oil Pump Drive Hub, Maximum Tang Wear 0.38 0.015
23 Converter Housing Bearing Bore, Maximum ID 140.03 5.513

Table 7-1. Wear Limits Data (cont’d)
Wear Limit
Foldout 9,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 75.23 2.962
9 Pump Housing Gear Cavity, Maximum Depth 17.93 0.706
9 Pump Housing Gear Cavity, Maximum ID 127.30 5.012
9, 10 Driven Gear-To-Pump Housing, Maximum Diametral Clearance 0.36 0.014
10 Drive/Driven Gear, Maximum Gear Tooth Tip Clearance 0.20 0.008
10 Driven Gear, Minimum OD 126.95 4.998
10 Drive/Driven Gear, Minimum Width 17.81 0.701
10,14 Gear-To-Plate Maximum Side Clearance 0.13 0.005
11 Pump Drive Gear Bushing, Maximum ID 57.30 2.256
14 Wear Plate, Minimum Thickness 4.70 0.185
16,17 Ground Sleeve Oil Pump Bushing Journal, Minimum OD 57.04 2.246
20 Front Support Sleeve, Minimum Dimension 98.83 3.891
23 Front Support Seal, Maximum End Gap 1.44 0.057
Foldout 9,B ROTATING CLUTCH MODULE
7 Turbine Shaft Bushing ID, Maximum 20.19 0.795
10 Turbine Shaft Seal, Maximum End Gap 0.94 0.037
11 Drum, Maximum Spline Wear 0.38 0.015
13 Rotating Clutch Hub Bushing, Maximum ID 99.25 3.907
29 C 1 Clutch Pressure Plate Flatness, Maximum Distortion 0.15 0.006
29 Cl Clutch Pressure Plate, Minimum Wear Surface Thickness 6.25 0.246
30,37 C 1, C2 Friction Plate, Maximum Cone 0.40 0.016
30,37 Cl, C2 Friction Plate, Minimum Thickness 2.21 0.087
30,37 C 1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31,36 Cl, C2 Steel Reaction Plate, Maximum Cone 0.40 0.016
31,36 Cl, C2 Steel Reaction Plate, Minimum Thickness 2.41 0.095 *
33,35 Cl, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
38 C2 Clutch Pressure Plate, Maximum Cone 0.45 0.018
38 C2 Clutch Pressure Plate, Minimum Thickness 6.25 0.246
42 PI Sun Gear Drive Hub Bushing, Maximum ID 68.22 2.685
* 0.0965 For MD 307OF’T Model

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

Wear Limit
Foldout 12,B P2 PLANETARY MODULE
2 P2 Carrier Seal, Maximum End Gap 1.20 0.047
7 P2 Carrier Bushing, Maximum ID 43.20 1.701
16 P3 Ring Gear, Maximum Spline Wear 0.38 0.015
Foldout 13,A
RETARDER AND P3 PLANETARYMODULE
And 13,B
8 Output Shaft Bushing, Maximum ID 20.19 0.795
17,20 P3 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
29 Retainer Ball, Minimum Movement (N/A To Foldout 13 B 0.50 0.020
Foldout 13,C REAR COVER AND P3 PLANETARY MODULE
7 Output Shaft Bushing, Maximum ID 20.19 0.795
17,20 P3 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
Foldout 15 C7 CLUTCH HOUSING
44 Yoke Journal Seal Wear, Minimum Diameter 76.20 3.000
61 C7 Backplate, Minimum Thickness 8.67 0.341
62 C7 Friction Plate, Maximum Cone 0.25 0.010
63 C7 Reaction Plate, Minimum Thickness 2.11 0.083
63 C7 Reaction Plate, Maximum Cone 0.25 0.010
68 Bushing, Maximum ID 47.26 1.861
69 Ball, Free Movement 1.00 0.040

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

Table 7-2. Spring Data
Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
25 Stator 29500064 No Code N/A N/A N/A 17.8 3.3 0.7-1.6
Convoluted (0.70) (0.13) (0.16-0.36)
9,B C2 Return 29503215 No Code 12” 2.04* 13.00* 45.3** 37.0 4823-5379**
(0.080) (0.512) (1.78) (1.46) (1084-1209)
9,B 25 Cl Return 23045586 No Code 10* 2.19* 16.00* 45.2** 27.5 5763-6369**
(0.086) (0.630) (1.78) (1.08) (1296-1432)
10,A 10 C3 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232-256**
(0.067) (0.472) (1.53) (0.96) (52.2-57.6)
10,A 12 C3 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310-14610**
(0.102) (0.522) (0.50) (0.43) (2543-3284)
10,A C4 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232-256**
(0.067) (0.472) (1.53) (0.96) (52.2-57.6)
10.A C4 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310-14610**
(0.102) (0.522) (0.50) (0.43) (2543-3284)
13,A/13,B 23123 C5 Retainer 29507780 No Code 9.5* 1.83* 14.35* 39.2** 25.0 3044-3364**
(0.072) (0.565) (1.54) (0.98) (684-756)
13.A 46 Retarder 6880775 Yellow/ 12 1.93 16.61 53.85 35.31 73-89
Red Stripe (0.076) (0.654) (2.12) (1.39) (16.5-20.1)
13,A 46 Retarder 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 177.5-196.3
(0.085) (0.75) (2.42) (1.02) (39.944.1)
13,A 46 Retarder 29515101 Green 16.0 3.78 36.6 106.7 73.66 120.1-146.7
(0.149) (1.44) (4.20) (2.90) (27.0-33.0)
13,A/13,B 46155 Retarder 29515692 None 11.4 4.12 36.17 114.3 91.1 200.0-226.6
(0.162) (1.42) (4.50) (3.59) (44.96-50.94)
13,A 92 Retarder Control 29510494 Solid Orange 7 1.60 15.50 27.8 18.0 44-50.9
Low, 27 psi (0.063) (0.610) (1.09) (0.71) (9.9–11.4)
* Individual Springs
** For the complete Spring Assembly
Table 7-2. Spring Data (cont'd)
Spring Approx. Free
Length Under Load
13,A 92 Retarder Control 29510495 Solid Silver 7.5 1.40 15.09 30.8 18.0 32.5-35.9
Medium, 36 psi (0.055) (0.594) (1.21) (0.71) (7.3-8.05)
13,A 92 Retarder Control 29510496 Solid Blue 8 1.14 14.59 36.0 18.0 19.8-21.9
High, 45 psi (0.045) (0.574) (1.42) (0.7 1) (4.5-4.9)
13,B 78 Retarder Control 29529300 White/ 8.52 1.27 13.46 33.02 16.51 34.22-37.86
Low, 54 psi Black Stripe (0.050) (0.530) (1.30) (0.650) (7.69-8.51)
13,B 78 Retarder Control 29529299 Yellow/ 9.25 1.04 12.19 37.8 16.51 23.44-25.94
Medium, 64 psi Red Stripe (0.04 1) (0.480) (1.49) (0.650) (5.27-5.83)
13,B 78 Retarder Control 29529298 Pink/ 8.23 0.94 12.19 31.47 16.51 9.39-10.37
High, 76 psi White Ends (0.037) (0.480) (1.24) (0.650) (2.1 l-2.33)
13$/l 8,B 23/l 6 C5 Retainer 29500867 No Code 11.5* 2.16* 16.00* 52.1** 33.0 3034-3498*‘”
(0.085) (0.630) (2.05) (1.30) (682.1-786.4)
16 13 C6 Spring Retainer 29501191 No 10 1.84 12.70 35.10 26.20 2109-
Code 2331**
Assembly (0.072) (0.500) (1.382) (1.032)
(474-524)
17,A 53,79, Solenoid Regulator 29502195 No Code 4 0.67 11.05 t 6.5 3.45 3.2-4.2
88,103 (0.026) (0.435) (0.26) (0.14) (0.72-0.94)
17,B 60,75 Solenoid Regulator 29502195 No Code 4 0.67 11.05 t 6.5 3.45 3.2-4.2
84,109 (0.026) (0.435) (0.26) (0.14) (0.72-0.94)
17,C 61,76 Solenoid Regulator 29502195 No Code 4 0.67 11.05 t 6.5 3.45 3.2-4.2
89,110 (0.026) (0.435) (0.26) (0.14) (0.72-0.94)
17+4/l 7,B 65/96 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 47.3-52.3
17,C 97 (0.050) (0.460) (1.72) (0.79) (10.6-11.8)
17,A/17,B 73/103 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.4-15.2
17,C 104 (0.030) (0.305) (1.05) (0.49) (2.79-3.42)
* Individual Springs
-4 ** For the complete Spring Assembly
L t OD at larger end
Table 7-2. Spring Data (cont’d)
2
Spring Approx. Free
Length Under Load
17,A/17,B 111/119 Lockup Relay 23049326 No Code 10 1.37 14.10 42.1 17.0 49.2-60.2
17,C 120 (0.054) (0.555) (1.66) (0.67) (11.06-13.53)
17,A/17,B 5/123 Lube Regulator 23049327 Red 13 1.22 11.10 46.3 23.5 46.5-51.3
17,C 124 (0.048) (0.437) (1.82) (0.93) (10.5-11.5)
17,A/17,B 119/127 Main Regulator 29500963 Lt. Blue 15 2.87 22.0 98.5 54.6 305-337
17,C 128 (0.113) (0.866) (3.88) (2.15) (68.G75.8)
17,A/17,B 123/131 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.2 131-145
6 17,C 132 (0.072) (0.583) (1.76) (0.95) (29.5-32.6)

33. 17,A/17,B 133/141 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 64.1-78.3
09
z 17,C 142 (0.052) (0.450) (1.63) (0.75) (14.4-17.6)
0 23049391 No Code 17 0.61 7.80 29.2 18.2 2.40-2.94
17,A/17,B 137/145 Exhaust Back
s 17,C 146 (0.024) (0.307) (1.15) (0.72) (0.54-0.66)
00
Q 17,A/17,B 141/149 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 16.7-18.9
g
5 17,C 150 (0.054) (0.640) (1.82) (1.15) (3.754.25)
17,A/17,B 145/153 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 53.7-59.3
i
17,C 154 (0.060) (0.433) (1.19) (0.90) (12.1-13.3)
5
s
3
SECTION 8 - CUSTOMER SERVICE
8-1. OWNER ASSISTANCE Step Two - If your problem cannot be readily re-
solved at the distributor level without additional assis-
The satisfaction and goodwill of the owners of Allison tance, contact the Allison Transmission Regional
transmissions are of primary concern to Allison Trans- Office responsible for your local distributor (see
mission Division (ATD), its distributors, and their maps in Warranty Manual). You will be assisted by a
dealers. member of the Regional Service Manager’s staff.
As an owner of an Allison transmission, you have ser- For prompt assistance, please have the following infor-
vice locations throughout the world eager to meet your mation available.
parts and service needs with:
Name and location of authorized distributor
l Expert service by trained personnel or dealer
l Emergency service 24 hours a day in many Type and make of equipment
areas
Transmission model number, serial number,
l Complete parts support
and assembly number - if equipped with
l Sales teams to help determine your trans- electronic controls, also provide the ECU
mission requirements assembly number
l Product information and literature Transmission delivery date and accumu-

lated miles and/or hours of operation
Refer to a current North American Parts and Service
Directory SA2229 or the International Parts and Ser- Nature of problem
vice Directory SA2338 for a listing of Allison Trans-
mission authorized distributors and service dealers. Chronological summary of unit’s history
Normally, any situation that arises in connection with Step Three - If you contacted a regional office and
the sale, operation, or service of your transmission will you are still not satisfied, present the entire matter in
be handled by the distributor or dealer in your area. writing or by phone to the Home Office:
(Check the telephone directory for the Allison Trans-
mission service outlet nearest you.) Manager Warranty Administration - PF9
Allison Transmission
We recognize, however, that despite the best intentions P. O. Box 894
of all concerned, misunderstandings may occur. To Indianapolis, Indiana 46206-0894
further assure your complete satisfaction, we have de- Phone: (317) 242-3538
veloped the following three-step procedure in the
event you have a problem that has not been handled The inclusion of all pertinent information will assist
satisfactorily. the Home Office in expediting the matter. If an addi-
tional review by the Home Office of all the facts in-
Step One - Discuss your problem with a member volved indicates that some further action can be taken,
of management from the distributorship or dealer- the Regional Office will be advised.
ship. Complaints are frequently the result of a break-
down in communication and can be quickly resolved When contacting the Regional or Home Office, please
by a member of management. If you have already dis- keep in mind that ultimately your problem will likely
cussed the problem with the Sales or Service Manager, be resolved at the distributorship or dealership - us-
contact the General Manager. All ATD dealers are as- ing their facilities, equipment, and personnel. There-
sociated with an ATD distributor. If your problems fore, we suggest you follow the above steps, in se-
originate with a dealer, explain the matter to a distribu- quence, when experiencing a problem.
torship member of management with whom the dealer
has his service agreement. The dealer will provide his Your purchase of an Allison Transmission product is
ATD distributor’s name, address, and telephone num- greatly appreciated, and it is our sincere desire to as-
ber on request. sure complete satisfaction.

8-2. SERVICE LITERATURE maximum performance and service life from your
transmission, you may order publications from:
Additional service literature is available. This service SGI, Inc.
literature provides fully illustrated instructions for Attn: Allison Literature Fulfillment Desk
operation, maintenance, service, overhaul, and parts 8350 Allison Avenue
support for your transmission. To ensure that you get Indianapolis, IN 46268
Toll Free: 888-666-5799
International: 317-47l-4995
Table 8-1. Service Literature

Literature Type MD/B 300/B 400 MD 3070PT
Mechanic’s Tips (WTEC III Controls) MT3004EN -
Mechanic’s Tips (WTEC II Controls) MT2159EN MT2923EN
Operator’s Manual (WTEC III Controls) OM2995EN -
Operator’s Manual (WTEC II Controls) OM2157EN OM2683EN
Parts Catalog PC2150EN PC2150EN
Parts Catalog on CD-ROM CD2150EN CD2150EN
Principles of Operation PO2454EN PO2454EN
Retail Literature Catalog GM2798EN GM2798EN
Service Manual SM2148EN SM2148EN
Troubleshooting Manual (WTEC III Controls) TS2973EN TS2973EN
Troubleshooting Manual (WTEC II Controls) TS2470EN TS2470EN

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SM2148EN

Printed in the U.S.A. Copyright 0 1998 General Motors Corp.

ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL

The following trademarks are the property of the companies indicated:

l Pro-Link® is a registered trademark of Micro Processor Systems, Inc.

Copyright © 1998 General Motors Corp.

WARNINGS, CAUTIONS, AND NOTES

iv Copyright © 1998 General Motors Corp.

Copyright © 1998 General Motors Corp. V

2-14. BREATHER 3-2. TOOLS AND EQUIPMENT

vi Copyright © 1998 General MotorsCorp.

o. Inspecting Swaged and d. Removal of Integral Oil Cooler . . . . . . . 4-3

Section 4. TRANSMISSION DISASSEMBLY 5-3. TORQUE CONVERTER MODULE

Copyright © 1998 General Motors Corp. vii

Copyright © 1998 General Motors Corp. ix

Copyright © 1998 General Motors Corp.

Copyright © 1998 General Motors Corp. xi

xii Copyright © 1998 General Motors Corp.

l The major transmission components are NOTE:

b. Illustrations 1-2. SUPPLEMENTARY

2. Illustrations show correct procedures for all

Copyright © 1998 General Motors Corp. l-l

FEEDTHROUGH HARNESS CONNECTOR

OIL FILL TUBE AND

(AVAILABLE BOTH SIDES)

Figure 1-1. Model MD(P) / B 300(R) / B 400(P) Transmission - Left-Front View

OUTPUT SPEED SENSOR

INPUT SPEED SENSOR

FEEDTHROUGH HARNESS CONNECTOR

NOTE: Inch Series Threads OPTIONAL FRONT

Figure 1-2. Model MD(P) / B 300(P) / B 400(P) Transmission - Right-Rear View

1-2 Copyright © 1998 General Motors Corp.

- FEEDTHROUGH HARNESSi CONNECTOR

Copyright © 1998 General Motors Corp. 1-3

MAIN PRESSURE TAP

OIL FILL TUBE AND

Figure 1-6. Model MD 3070PT Transmission - Right-Front View

l-4 Copyright © 1998 General Motors Corp.

Figure 1-7. Model MD 3070PT Transmission - Left-Rear view

1-4. GENERAL DESCRIPTION

Copyright © 1998 General Motors Corp. l-5

l-6 Copyright © 1998 General Motors Corp.

Copyright 0 1998 General Motors Corp. 1-7

l-8 Copyright © 1998 General Motors Corp.

Table 1-1. Specifications And Data Chart*

MD 3000 MD 3000P MD 3000R MD 3000PR

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

Copyright © 1998 General Motors Corp. l-9

l-10 Copyright © 1998 General Motors Corp.

2-2. PERIODIC INSPECTION NOTE:

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

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

Copyright © 1998 General Motors Corp. 2-l

2-2 Copyright © 1998 General Motors Corp.

a. Fluid Level Check Procedure (WTEC II)

Copyright © 1998 General Motors Corp. 2-3

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

3. With the engine running, remove the dipstick

5. If the fluid level is within the “COLD RUN”