Service Manual

Procision
TRSM0990 EN-US
June 2023
TRSM0990 Table of Contents

General Information Disassembly/Assembly

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . .1 Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . .3 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535
Serial Tag Information and Model Nomenclature . . . . .4 Interface Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . .550
Service Kits and Parts Index . . . . . . . . . . . . . . . . . . . . .5 Lower Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
Main Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .712
Service Procedures Rear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767
3-Rail Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . .9 Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .793
74-Way Connector Retainer . . . . . . . . . . . . . . . . . . . .38 Upper Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
90-Degree Connector . . . . . . . . . . . . . . . . . . . . . . . . .43
Actuation Control Manifold (ACM) . . . . . . . . . . . . . . .73 Service Parts and Kits
Cartridge Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 OEM and Engine Specific Transmission Kits . . . . . . .870
Clutch Cooling Module . . . . . . . . . . . . . . . . . . . . . . . .92 Main Housing Service Kits . . . . . . . . . . . . . . . . . . . .878
Cooler Temperature Sensor (CTS) . . . . . . . . . . . . . .140 Rear Housing Service Kits . . . . . . . . . . . . . . . . . . . . .887
Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Dual Clutch Module (DCM) . . . . . . . . . . . . . . . . . . . .153 Appendix
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .167 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . .892
Input Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 Oil Leak Inspection Process . . . . . . . . . . . . . . . . . . .893
Lower Shaft Rear Bearing Cover . . . . . . . . . . . . . . . .189 Oil Level Inspection Procedure . . . . . . . . . . . . . . . . .894
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 Inspection Precautions . . . . . . . . . . . . . . . . . . . . . . .895
Output Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 Handling, Inspection and Cleaning of Parts . . . . . . . .898
Output Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 Recycling Parts and Oil . . . . . . . . . . . . . . . . . . . . . . .899
Primary and Secondary Input . . . . . . . . . . . . . . . . . .204 Roadranger Specialty Tools . . . . . . . . . . . . . . . . . . .900
PTO Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 4th and 6th Gear Needle Bearing Service Procedure .901
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 Change Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926
Shift Rail D Magnet . . . . . . . . . . . . . . . . . . . . . . . . . .322
Rail D Position Sensor . . . . . . . . . . . . . . . . . . . . . . .380
Sump Pan and Filter . . . . . . . . . . . . . . . . . . . . . . . . .397
Transmission Control Module (TCM) . . . . . . . . . . . .402
Transmission Harness . . . . . . . . . . . . . . . . . . . . . . . .408
Transmission Range Sensor (TRS) . . . . . . . . . . . . . .427
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431
Triple Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . .434

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. i
 Warnings and Cautions | General Information TRSM0990

Warnings and Cautions

The alert symbols, signal words (DANGER, WARNING: When working on vehicle components, keep
! body parts clear of sharp objects and pinch points. Failure
WARNING and CAUTION) and statements
to keep clear of sharp objects and pinch points may result
throughout this manual indicate the potential
in severe injury or death.
severity of a situation. Ensure to read, under-
stand and follow each statement to avoid vehi- WARNING: Use appropriate lifting devices and equipment
! when working with heavy vehicle components. Failure to do
cle damage, component damage, personal
so may result in major vehicle component damage, severe
injury, severe injury and/or death. injury or death.
DANGER: Indicates an immediate hazard. Failure to follow
! the indicated procedures will cause major vehicle compo- !
CAUTION: Do not work on the vehicle immediately after
operation. Working on a hot vehicle component could result
nent damage, severe injury or death. in personal injury.
WARNING: Indicates an immediate hazard. Failure to follow
! the indicated procedures may result in major vehicle com- Compressed Air System
ponent damage, severe injury or death.
WARNING: The vehicle air system operates approximately
CAUTION: Indicates a potential hazard. Failure to follow the ! between 60 - 140 PSI. Refer to OEM guidelines regarding
! indicated procedures could result in minor or moderate vehicle system operation and service. Failure to follow OEM
component damage and/or personal injury. guidelines may result in major vehicle component damage,
severe injury or death.
The NOTICE and Note statements through out this manual
provide additional details required to avoid damaging a
component or incorrectly completing a repair. Ensure to Before starting a vehicle:
read, understand and follow each statement to properly
• Sit in the driver’s seat.
complete a repair.
• Confirm vehicle parking brake is applied.
NOTICE: Indicates component or property damage could
result if you do not follow the indicated procedure. • Confirm Neutral (Push Button) or Park (Shift Lever)
is selected on the Transmission Driver Interface
Note: Indicates additional detail that will aid in the repair of Device.
a component.
• Ensure vehicle has adequate fuel level.
NOTICE: Always reference the latest electronic version of
• Do not operate the vehicle if the Alternator lamp is
this document to ensure accurate service information.
on or if gauge indicates low voltage with the engine
running.
While working on a vehicle:
WARNING: Do not modify transmission components or When parking the vehicle or leaving the cab:
! systems. Modification (altering, substituting, relocating) of
1. Safely come to a complete stop.
transmission components may result in major vehicle com-
ponent damage, severe injury or death. 2. Continue to depress and hold service brake.
WARNING: Do not modify transmission service tools. Mod- 3. Select Neutral (Push Button) or Park (Shift Lever)
! ification (altering, substituting, relocating) of transmission on the Transmission Driver Interface Device.
service tools may result in major vehicle component dam-
4. Apply vehicle parking brake.
age, severe injury or death.
WARNING: Apply vehicle parking brake and follow
WARNING: Read, understand and follow each statement !
! regarding cap screw installation and torque specification
vehicle manufacturer parking instructions. Failure to follow
these instructions could cause unintended vehicle move-
requirements. Failure to install and torque cap screws to
ment and may result in major vehicle component damage,
specification may result in major vehicle component dam-
severe injury or death.
age, severe injury or death.

1 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 General Information | Warnings and Cautions

5. Turn ignition key Off and allow the engine to shut to

down.

Before working on a vehicle or leaving the cab

with engine running:
1. Safely come to a complete stop.
2. Continue to depress and hold service brake.
3. Select Neutral (Push Button) or Park (Shift Lever)
on the Transmission Driver Interface Device.
4. Apply vehicle parking brake.
WARNING: Apply vehicle parking brake and follow
! vehicle manufacture parking instructions. Failure to follow
these instructions could cause unintended vehicle move-
ment and may result in major vehicle component damage,
severe injury or death.
5. Chock wheels.

To avoid damage to the transmission during

towing:
When towing a vehicle equipped with the Procision Trans-
mission, do not allow the output shaft of the transmission
to rotate. If the vehicle is towed with the drive wheels still in
contact with the road surface, the vehicle axle shafts or
driveline must be removed or disconnected prior to towing
vehicle.

NOTICE: Internal transmission damage can result from

improper vehicle towing.
Preferred

Must remove vehicle axle shafts or driveline prior to towing

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2
How to Use This Manual | General Information TRSM0990

How to Use This Manual

This publication is divided into three sections: General
Information, Service Procedures and Appendix.

General Information
This section contains basic chapters such as Transmission
Overview, How to Use This Manual and Serial Tag and
Model Nomenclature.

Service Procedures
To find the information you need, simply locate the proce-
dure in the Table of Contents, turn to the page specified and
follow the procedure.

The Service Procedures are divided in three sections;

Removal, Disassembly/Assembly and Installation. Removal
instructs how to remove the part or assembly from the
transmission. Disassembly instructs how to take an assem-
bly apart. Assembly instructs how to put together an
assembly. Installation instructs how to install the part or
assembly in the transmission. Not all parts have a disas-
sembly/assembly section.

A Component Identification diagram is included at the

beginning of each procedure for Removal, Disassem-
bly/Assembly and Installation. Below the Component
Identification diagram is a numerical listing for each part
with the part name.

Appendix
This section contains information such as Lubrication
Specifications, Inspection, Tool Specifications, and Torque
Specifications.

3 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 General Information | Serial Tag Information and Model Nomenclature

Serial Tag Information and Model Nomenclature

Transmission model designation and other transmission Serial Number
identification information are stamped on the serial tag. To The serial number is the sequential identification number of
identify the transmission model and serial number, locate the transmission. Before calling for service assistance,
the tag on the lower right side of the clutch housing. write the number down as it may be needed.
When calling for service assistance or parts, have the
model and serial numbers handy.

NOTICE: Do not remove or destroy the transmission identi-

fication tag.

Model

Serial Assembled In

Eaton ® Transmissions
Fuller ® Transmissions Eaton Corporation
Kalamazoo, MI USA

Model Number
The model number gives basic information about the trans-
mission and is explained below. Use this number when call-
ing for service assistance or replacement parts.
E DC O - 6F 1 07 A No transmission pa

Eaton
ual Clutch Ratio Set
Overdrive
Forward Speeds
city (ft-lb)
Design Level
# x 100

E DC O - 6F 1 07 A - M No transmission p
Non-Park Pawl w/T
Eaton
ual Clutch Ratio Set
Overdrive
Forward Speeds
acity (ft-lb)
Design Level
# x 100

E DC O - 6F 1 07 A - B
Park Brake (externally m
aton
utch Ratio Set
rive
Forward Speeds
t-lb)
Design Level
100

E DC O - 6F 1 07 A - P
Park Pawl (interna
Eaton
ual Clutch Ratio Set
Overdrive Forward Speeds
acity (ft-lb)
Design Level
# x 100

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TRPB0990 General Information | Service Kits and Parts Index

Service Kits and Parts Index

OEM and Engine Specific Transmission Kits
Description Page

Damper page 8

Transmission Driver Interface page 8

Transmission Service Units page 8

Clutch Housing
Description Part Number Page

Breather X2014210 page 15

Cap Screw, Clutch Support Manifold and Pump Drive Gear - X-8C-839M page 15
M8x1.25X20 (7)

Cap Screw, Front Cover to Clutch Hsg - M8X1.25x35 (16) X-8-0833M page 15

Cap Screw, Harness Bracket and Seal Plate - M6x1.0x16 (22) X-8-0625M page 15

Cartridge Filter Service Kit K-4273 page 9

Clutch Cooling Module Assembly Kit K-4435 page 11

Complete Clutch Housing Kit K-4411 page 11

Dual Clutch Module Assembly Kit K-4265 page 9

Front Cover Seal & Bearing Kit K-4410 page 10

Harness Bracket 4307676 page 15

Heat Exchanger Relief Valve Kit K-4414 page 10

HPTO Orifice 4307840 page 15

Complete Interface Manifold Assembly Kit K-4420 page 14

Interface Manifold to Clutch Housing Gasket Kit K-4412 page 12

Lifting Eye 20815 page 15

Lower Shaft Front Bearing Kit K-4429 page 15

Plug, Clutch Housing Lower (2) 4308229 page 15

Plug, HPTO/LPTO (2) 4308231 page 15

Pump Assembly Kit K-4472 page 12

Rail D Detent Kit K-4413 page 14

Rail D Magnet Kit K-4408 page 13

Rail D Shift Yoke Kit K-4400 page 13

Shift Rail Detent Kit K-4425 page 15

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Service Kits and Parts Index | General Information TRPB0990

Clutch Housing
Description Part Number Page

Shift Rail Piston Kit K-4426 page 15

Main Housing
Description Part Number Page

1st/2nd Gear A-8553 page 24

1st/2nd Gear Needle Bearing (2) 3315703 page 24

3rd Gear A-8515 page 24

3rd Gear Needle Bearing (2) 4124075 page 24

5th/7th Clutch Teeth Gear 4307762 page 24

74-Way Connector Retainer Kit K-4276 page 19

Actuation Control Manifold Complete Kit K-4277 page 20

Actuation Control Manifold Gasket Kit K-4439 page 19

Actuation Control Manifold Retainer Tab 4307877 page 20

Cap Screw, Actuation Control Manifold X-8-0633M page 24

Cap Screw, Transmission Harness X-8-0625M page 24

Cluster Gear Kit K-4436 page 22

Cooler Oil Temp Sensor 4307775 page 20

Drain Plug Kit K-4270 page 17

Engine Speed Sensor Kit K-4281 page 21

Complete Filter Kit K-4272 page 18

Primary and Secondary Input Shaft Kit K-4415 page 22

Lower Shaft Assembly A-8507 page 24

Lower Shaft Mid-Wall Bearing Kit K-4405 page 23

Lower Shaft Mid-Wall Bearing Shim Kit K-4431 page 24

Lower Shaft Snap Ring Kit K-4283 page 24

Rail A Synchro Assembly S-8563 page 24

Rail A Synchro Hub Snap Ring 4307980 page 24

Rail B Synchro Assembly A-8555 page 24

Rail D Position Sensor Kit K-4280 page 21

Rail D Synchronizer and Cluster Gear Kit K-4404 page 22

Reverse Gear A-8554 page 24

5 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 General Information | Service Kits and Parts Index

Main Housing
Description Part Number Page

Reverse Idler Bearing 4307822 page 24

Reverse Idler Gear 4307666 page 24

Reverse Idler Shaft 4307708 page 24

Reverse Idler Shaft Cap Screw X-8-0833M page 24

Reverse Idler Thrust Washer 4308951 page 24

Secondary Driven Gear 4307647 page 24

Sump Pan Replacement Kit K-4271 page 17

TCM Cover 4307675 page 17

TCM Mounting Stud (M6x50.0) 5577511-MP4 page 17

Transmission Control Module (TCM) Kits K-4266 (EDCO-xx107A) page 16

Transmission Control Module (TCM) Kits K-4266 page 16

(EDCO-xx107A-P)

Transmission Control Module (TCM) Kits K-4274 page 16

Transmission Harness Kit K-4275 page 18

Triple Pressure / Temp Sensor Kit K-4279 page 20

Upper Shaft 4308250 page 24

Upper Shaft Assembly Complete A-8556 page 24

Upper Shaft Front Bearing Kit K-4417 page 22

Upper Shaft Mid-Wall Baring Spacer 4307979 page 24

Upper Shaft Mid-Wall Bearing Kit K-4419 page 23

Upper Shaft Mid-Wall Bearing Shim Kit K-4430 page 23

Rear Housing
Description Part Number Page

3 Rail Magnet Kit K-4474 page 25

3 Rail Position Sensor Assembly Kit K-4475 page 26

4th Drive Gear Kit K-4478 page 28

4th Driven Gear 4307891 page 29

6/4 Drive Gear Set with Rail C Synchronizer Kit K-4407 page 29

6th Drive Gear Mid-Wall Bearing Spacer 4307755 page 29

6th Drive Gr Mid-Wall Bearing Spacer Alignment Ball (5mm) X-14-0500M page 29

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Service Kits and Parts Index | General Information TRPB0990

Rear Housing
Description Part Number Page

6th Driven Gear 4307659 page 29

Cap Scew, Lower Shaft Rear Cover M12x1.75x25 (4) X-8-1212M page 29

Cap Screw, Long Rear Housing to Main Housing - M10x1.5x90 (3) X-8-1047M page 29

Cap Screw, Rear Housing Spray Bar and Oil Trough - M6x1.0x16 (4) X-8-0625M page 29

Cap Screw, Short Rear Housing to Main Housing - M10x1.5x35 (15) X-8-1046M page 29

Lower Shaft Rear Bearing Kit K-4424 page 28

Output Seal 4307882 page 29

Output Shaft Slinger Shield 4307669 page 29

Output Yoke/Flange Retainer Kit K-4291 page 25

Rear Bearing Spacer 4307972 page 29

Rear Housing Cover Kit - Non Park Pawl K-4268 page 27

Rear Housing Cover Kit - Park Pawl K-4422 page 27

Rear Housing Spray Bar A-8536 page 29

Speed Sensor Plug Kit K-4267 page 28

Transmission Range Sensor Assembly 4307605 page 29

Upper Shaft Rear Bearing Kit K-4423 page 28

Lubricant, PS-386 HD Synthetic Transmission

Description Part Number Page

5 Gallon Pail 5564547 page 29

7 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
3-Rail Position Sensor | Service Procedures TRSM0990

3-Rail Position Sensor

Special Instructions Special Tools
3-Rail Position Sensor and Magnets procedure can be per- None
formed with transmission in chassis.

Component Identification

1
4
2

1. Rail A Magnet
2. Rail B Magnet
3. Rail C Magnet
4. 3-Rail Position Sensor

9 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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3-Rail Position Sensor | Service Procedures TRSM0990

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

11 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

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3-Rail Position Sensor | Service Procedures TRSM0990

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

13 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

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 3-Rail Position Sensor | Service Procedures TRSM0990

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

15 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

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 3-Rail Position Sensor | Service Procedures TRSM0990

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

17 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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3-Rail Position Sensor | Service Procedures TRSM0990

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

19 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

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3-Rail Position Sensor | Service Procedures TRSM0990

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

21 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 22
3-Rail Position Sensor | Service Procedures TRSM0990

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

23 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 24
3-Rail Position Sensor | Service Procedures TRSM0990

2. Install Shift Rail Magnets A, B and C on Shift Rails A, B, 4. Install 4, 3-Rail Position Sensor T30 torx head screws
and C with T20 torx head screws and torque to and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1.55-1.85 Nm (13.7-16.3 lb-in).

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

25 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

Assemble Rear Housing with/without Park Pawl 3. Install Mid-Wall Bearing Spacer Alignment Ball on
Lower Shaft.
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission. Note: Assembly Grease should be used to hold Ball in
place.
! CAUTION: Ensure the raised side of gear faces rear of
transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing

Spacer Alignment Ball locating hole is in 12 o'clock
position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 26
3-Rail Position Sensor | Service Procedures TRSM0990

4. Install 6th Gear Mid-Wall Bearing Spacer on Lower 5. Install 6th Gear Bearing on Lower Shaft.
Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main

Housing and Reverse Idler Shaft.

27 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

7. Install 2 Rear Lube Bar 10 mm cap screws and torque 9. Install Rail C Synchronizer Blocking Ring onto 6th
to 8.8-10.4 Nm (77.9-92 lb-in). Gear.

8. Install 6th Gear on Lower Shaft. 10. Assemble Rail C Synchronizer assembly.

Note: Raised side of gear faces rear of transmission. NOTICE: Ensure all 3 Rail C Synchronizer Keys and
Proper orientation is critical to final assembly. Springs are in Synchronizer Hub Key Slots.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 28
3-Rail Position Sensor | Service Procedures TRSM0990

11. Position Rail C Shift Yoke onto Rail C Synchronizer 14. Install remaining Rail C Synchronizer Blocking Ring
assembly. onto Rail C Synchronizer Hub.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces NOTICE: Ensure Blocking Ring tabs align with Hub Key
rear of transmission. Slots.

12. Install Rail C Synchronizer assembly with Rail C Shift 15. Install 4th Gear Bearing and Captured Inner Race into
Yoke on Lower Shaft and Shift Rail C. 4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

29 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

16. Place 4th Gear assembly onto Lower Shaft. 18. Drive 4th Gear assembly onto Lower Shaft.

NOTICE: Ensure Rail C Synchronizer Blocking Ring

tabs stay aligned with Hub Key Slots during 4th Gear
installation.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
19. Install Spacer onto Lower Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 30
3-Rail Position Sensor | Service Procedures TRSM0990

20. Place Lower Shaft Rear Bearing Inner Race onto end of 22. Install new Snap Ring on Lower Shaft.
Lower Shaft.
NOTICE: If Snap Ring cannot be properly installed into
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer
installation orientation (Step 4). Raised side of Spacer
must face front of transmission. Proper orientation is
critical to final assembly.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.

Note: Ensure Rear Bearing Inner Race is fully seated.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

31 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and 26. Install 4th Driven Gear and Park Pawl Gear assembly
Shift Rail C into the 4th Gear position then remove on Upper Shaft.
Shift Rail Actuation Tool (RR1039TR).
NOTICE: Align Park Pawl Gear tooth gap with Lower
Note: Ensure Rail C is fully extended rearward. Roll Pin Shaft Bearing Race or damage may occur.
hole in Rail must be aligned with Roll Pin hole in Shift
Yoke. Note: For transmissions without a Park Pawl, install
4th Driven Gear on Upper Shaft.

25. Install Rail C Shift Yoke Roll Pin.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Note: Roll Pin must be driven from the inside of hous- Upper Shaft.
ing outward.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 32
3-Rail Position Sensor | Service Procedures TRSM0990

28. Use Upper Shaft Rear Bearing Inner Race Driver 3. Apply Gasket Sealant in an 1/8" bead inward of all cap
(RR1041TR) to drive Upper Shaft Rear Bearing Inner screw holes to the Main Housing sealing surface fol-
Race onto Upper Shaft. lowing the pattern below.

NOTICE: Ensure Park Pawl Gear tooth gap stays CAUTION: Ensure there is no Gasket Sealant in Main
aligned with Lower Shaft Bearing Race or damage may ! Housing Rear Bearing Oil Passage. Failure to keep oil
occur. passage clear of sealant results in component damage.

Install the Rear Housing Cover

1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

33 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

4. Install Rear Housing Cover onto Upper Shaft, Lower 6. Install 18 Rear Housing Cover 16 mm cap screws
Shaft and Main Housing Dowel Pins. torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern.
NOTICE: If transmission is equipped with a park pawl
confirm the Internal Shift Shaft has remained in the Note: Three Rear Housing Cover cap screws are a dif-
Neutral position as shown prior to installing the Rear ferent length than the rest. Refer to Rear Housing
Housing Cover or damage to the internal Park Pawl Cover removal notes for proper location.
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

Install the Transmission Range Sensor (TRS)

1. Install TRS assembly on Internal Shift Shaft and push
flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 34
3-Rail Position Sensor | Service Procedures TRSM0990

2. Install 5 TRS Harness Bracket to T30 torx head screws 4. Use hand tools to install the Transmission Cable Shift
and torque to 8.8-10.4 Nm (77.9-92 lb-in). Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft).

NOTICE: Retain TRS Internal Shift Shaft position by

holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
cause gear selection problems.
Connect Shift Lever Cable Linkage
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever.

NOTICE: See OEM Service Manual for shift selector

cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

35 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 3-Rail Position Sensor

2. Slide the Output Yoke over the output shaft. 1. Park vehicle in a safe area on level ground.

Note: The Output Yoke may require to be driven on due • Select Park if equipped with a Shift Lever and
to an interference fit. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

3. Install new Retainer Plate, Retainer Plate O-ring, and level.
two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105 9. Repeat steps 7 and 8 to confirm oil level.
Nm (70.1-77.4 lb-ft).
10. Add or drain transmission oil if oil level is not within
WARNING: Reusing previously removed Retainer the Transmission Oil Level Operating Range based on
! Bolts, Retainer Plate and Retainer O-ring could result in transmission oil temperature.
major vehicle component damage, severe injury or
death. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate Rail and TRS Shift Device

4. Install the driveline. Refer to OEM guidelines for drive-
line Installation. 1. Key on with engine running.

Fill Oil 2. Connect ServiceRanger.

Note: For a list of Eaton Approved Synthetic Lubricants, see 3. Go To “Service Routines”.
Eaton TCMT0021 Lubrication guide on Roadranger.com or 4. Select “Start” Rail Calibration and follow on-screen
call 1-800-826-HELP (4357). prompts.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 36
3-Rail Position Sensor | Service Procedures TRSM0990

5. Key off and wait 1 minute.

6. Key on with engine off.

7. Select “Start” TRS Shift Device Calibration and follow

on-screen prompts.

Note: If transmission is not equipped with a Transmis-

sion Range Sensor (TRS) go to Step 9.
8. Go To “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
9. Disconnect ServiceRanger.

10. Key off.

37 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 74-Way Connector Retainer

74-Way Connector Retainer

Special Instructions Special Tools
74-Way Connector Retainer procedure can be performed • M6x1.0x70 cap screw
with transmission in chassis.

Component Identification

1. 74-Way Connector Retainer

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 38
74-Way Connector Retainer | Service Procedures TRSM0990

Disconnect the Transmission Control Module Remove the Transmission Control Module
(TCM) (TCM) Horizontally
1. Disconnect the negative battery cable. 1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

NOTICE: Leaving battery cable connected may damage Note: TCM Cover nuts are 10 or 13 mm.
the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

39 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 74-Way Connector Retainer

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Unlatch 74-Way Connector Retainer from 74-Way
Transmission Harness Connector. Transmission Harness Connector.

Remove the 74-Way Connector Retainer 3. Remove the 5 remaining 74-Way Connector Retainer 8
mm cap screws.
1. Remove the 8 mm cap screw at the top of the 74-Way
Connector Retainer.

4. Remove 74-Way Connector Retainer.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 40
74-Way Connector Retainer | Service Procedures TRSM0990

Install the 74-Way Connector Retainer 5. Install six 74-Way Connector Retainer 8 mm cap
screws and torque to 5.3-6.3 Nm (46.8-55.2 lb-in) in a
NOTICE: Do not allow contamination into the TCM or har- crisscross pattern.
ness connectors.
1. Clean Main Housing sealing surface of old oil and
debris.

2. Align 74-Way Connector Retainer to 74-Way Transmis-

sion Harness Connector.

Note: An M6x1.0x70 cap screw can be used to aid in

alignment.

Install the Transmission Control Module (TCM)

Horizontally
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

3. Latch 74-Way Connector Retainer to 74-Way Trans-

mission Harness Connector.

Note: Remove M6x1.0x70 cap screw if used to aid in

alignment.

4. Use 74-Way Connector Retainer locating pins to cor-

rectly position 74-Way Connector Retainer to Main
Housing.

41 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 74-Way Connector Retainer

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). Connect the Transmission Control Module
(TCM)
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.

Note: TCM Cover nuts are 10 or 13 mm.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 42
90-Degree Connector | Service Procedures TRSM0990

90-Degree Connector
Special Instructions Special Tools
90-Degree Connector procedure can be performed with None
transmission in chassis.

Component Identification

1. 90-Degree Connector

43 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 44
90-Degree Connector | Service Procedures TRSM0990

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

45 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 46
90-Degree Connector | Service Procedures TRSM0990

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

47 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 48
 90-Degree Connector | Service Procedures TRSM0990

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

49 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 50
 90-Degree Connector | Service Procedures TRSM0990

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

51 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 52
90-Degree Connector | Service Procedures TRSM0990

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

53 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 54
90-Degree Connector | Service Procedures TRSM0990

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

55 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 56
90-Degree Connector | Service Procedures TRSM0990

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

57 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

Secure Transmission (Vertical) 2. Remove Sump Pan.

1. Securely place transmission in the vertical position

with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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90-Degree Connector | Service Procedures TRSM0990

Remove the 90-Degree Connector 3. Remove 90-Degree Connector.

1. Locate and disconnect 8-Way Transmission Harness

Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

Install the 90-Degree Connector

1. Locate and position 90-Degree Connector in Main
Housing.

2. Remove 2 90-Degree Connector 10 mm cap screws.

59 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

2. Install 2 90-Degree Connector 10 mm cap screws and 4. Install Sump Pan Filter.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
5. Install Sump Pan Seal into Main Housing recess if pre-
viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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90-Degree Connector | Service Procedures TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.

61 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

Assemble Rear Housing with/without Park Pawl 3. Install Mid-Wall Bearing Spacer Alignment Ball on
Lower Shaft.
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission. Note: Assembly Grease should be used to hold Ball in
place.
! CAUTION: Ensure the raised side of gear faces rear of
transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing

Spacer Alignment Ball locating hole is in 12 o'clock
position.

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90-Degree Connector | Service Procedures TRSM0990

4. Install 6th Gear Mid-Wall Bearing Spacer on Lower 5. Install 6th Gear Bearing on Lower Shaft.
Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main

Housing and Reverse Idler Shaft.

63 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

7. Install 2 Rear Lube Bar 10 mm cap screws and torque 9. Install Rail C Synchronizer Blocking Ring onto 6th
to 8.8-10.4 Nm (77.9-92 lb-in). Gear.

8. Install 6th Gear on Lower Shaft. 10. Assemble Rail C Synchronizer assembly.

Note: Raised side of gear faces rear of transmission. NOTICE: Ensure all 3 Rail C Synchronizer Keys and
Proper orientation is critical to final assembly. Springs are in Synchronizer Hub Key Slots.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

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90-Degree Connector | Service Procedures TRSM0990

11. Position Rail C Shift Yoke onto Rail C Synchronizer 14. Install remaining Rail C Synchronizer Blocking Ring
assembly. onto Rail C Synchronizer Hub.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces NOTICE: Ensure Blocking Ring tabs align with Hub Key
rear of transmission. Slots.

12. Install Rail C Synchronizer assembly with Rail C Shift 15. Install 4th Gear Bearing and Captured Inner Race into
Yoke on Lower Shaft and Shift Rail C. 4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

65 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

16. Place 4th Gear assembly onto Lower Shaft. 18. Drive 4th Gear assembly onto Lower Shaft.

NOTICE: Ensure Rail C Synchronizer Blocking Ring

tabs stay aligned with Hub Key Slots during 4th Gear
installation.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
19. Install Spacer onto Lower Shaft.

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90-Degree Connector | Service Procedures TRSM0990

20. Place Lower Shaft Rear Bearing Inner Race onto end of 22. Install new Snap Ring on Lower Shaft.
Lower Shaft.
NOTICE: If Snap Ring cannot be properly installed into
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer
installation orientation (Step 4). Raised side of Spacer
must face front of transmission. Proper orientation is
critical to final assembly.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.

Note: Ensure Rear Bearing Inner Race is fully seated.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

67 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and 26. Install 4th Driven Gear and Park Pawl Gear assembly
Shift Rail C into the 4th Gear position then remove on Upper Shaft.
Shift Rail Actuation Tool (RR1039TR).
NOTICE: Align Park Pawl Gear tooth gap with Lower
Note: Ensure Rail C is fully extended rearward. Roll Pin Shaft Bearing Race or damage may occur.
hole in Rail must be aligned with Roll Pin hole in Shift
Yoke. Note: For transmissions without a Park Pawl, install
4th Driven Gear on Upper Shaft.

25. Install Rail C Shift Yoke Roll Pin.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Note: Roll Pin must be driven from the inside of hous- Upper Shaft.
ing outward.

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90-Degree Connector | Service Procedures TRSM0990

28. Use Upper Shaft Rear Bearing Inner Race Driver 3. Apply Gasket Sealant in an 1/8" bead inward of all cap
(RR1041TR) to drive Upper Shaft Rear Bearing Inner screw holes to the Main Housing sealing surface fol-
Race onto Upper Shaft. lowing the pattern below.

NOTICE: Ensure Park Pawl Gear tooth gap stays CAUTION: Ensure there is no Gasket Sealant in Main
aligned with Lower Shaft Bearing Race or damage may ! Housing Rear Bearing Oil Passage. Failure to keep oil
occur. passage clear of sealant results in component damage.

Install the Rear Housing Cover

1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

69 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

4. Install Rear Housing Cover onto Upper Shaft, Lower 6. Install 18 Rear Housing Cover 16 mm cap screws
Shaft and Main Housing Dowel Pins. torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern.
NOTICE: If transmission is equipped with a park pawl
confirm the Internal Shift Shaft has remained in the Note: Three Rear Housing Cover cap screws are a dif-
Neutral position as shown prior to installing the Rear ferent length than the rest. Refer to Rear Housing
Housing Cover or damage to the internal Park Pawl Cover removal notes for proper location.
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

Install the Transmission Range Sensor (TRS)

1. Install TRS assembly on Internal Shift Shaft and push
flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

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90-Degree Connector | Service Procedures TRSM0990

2. Install 5 TRS Harness Bracket to T30 torx head screws 4. Use hand tools to install the Transmission Cable Shift
and torque to 8.8-10.4 Nm (77.9-92 lb-in). Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft).

NOTICE: Retain TRS Internal Shift Shaft position by

holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
cause gear selection problems.
Connect Shift Lever Cable Linkage
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever.

NOTICE: See OEM Service Manual for shift selector

cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

71 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | 90-Degree Connector

2. Slide the Output Yoke over the output shaft. 1. Park vehicle in a safe area on level ground.

Note: The Output Yoke may require to be driven on due • Select Park if equipped with a Shift Lever and
to an interference fit. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

3. Install new Retainer Plate, Retainer Plate O-ring, and level.
two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105 9. Repeat steps 7 and 8 to confirm oil level.
Nm (70.1-77.4 lb-ft).
10. Add or drain transmission oil if oil level is not within
WARNING: Reusing previously removed Retainer the Transmission Oil Level Operating Range based on
! Bolts, Retainer Plate and Retainer O-ring could result in transmission oil temperature.
major vehicle component damage, severe injury or
death. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).

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TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

Actuation Control Manifold (ACM)

Special Instructions Special Tools
Actuation Control Manifold (ACM) procedure can be per- None
formed with transmission in chassis.

Component Identification

2
3

1. Actuation Control Manifold (ACM)

2. ACM Retainer Tab
3. O-ring
4. ACM to Interface Manifold Gasket

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TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure Transmission (Vertical)

1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.
6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

Disconnect the Transmission Control Module Remove the Transmission Control Module
(TCM) (TCM) Vertically
1. Disconnect the negative battery cable. 1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

NOTICE: Leaving battery cable connected may damage Note: TCM Cover nuts are 10 or 13 mm.
the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

75 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

77 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

9. Remove ACM rear lubrication O-ring. Install the Actuation Control Module (ACM)
Note: If O-ring is missing it may be located on ACM. 1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

10. Remove ACM to Interface Manifold Gasket.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

79 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing. 7. Position ACM onto ACM Alignment Pins (RR1036TR).

Note: Ensure Engine Speed Sensor Connector remains

accessible after ACM installation.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.
8. Push ACM flush to Interface Manifold and Main Hous-
ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

9. Install 4 ACM 10 mm cap screws and hand tighten. 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
Interface Manifold outermost threaded mounting
holes.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

cap screw and hand tighten.
12. Install the 2 remaining ACM to Interface Manifold 10
Note: Assembly grease may be used to hold O-ring in mm cap screws into Interface Manifold outermost
place. threaded mounting holes and hand tighten.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

81 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

13. Torque all 6 ACM to Interface Manifold 10 mm cap 15. Install Output Speed Sensor and 10 mm cap screw into
screws to 8.8-10.4 Nm (77.9-92 lb-in). Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

14. Torque ACM Retainer Tab 13 mm cap screw to

20.5-25.5 Nm (15.14-18 lb-ft).

Note: Ensure that ACM Retainer Tab is square with

Main Housing and completely covers O-ring isolator.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.
2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

83 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

3. Install TCM Cover with 4 nuts over TCM studs and Connect the Transmission Control Module
torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross (TCM)
pattern.
1. Connect the 20-Way Vehicle and Body Harness Con-
Note: TCM Cover nuts are 10 or 13 mm.
nectors to the TCM Connectors by pressing levers into
the locked position.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

4. Install Sump Pan Filter. 6. Position Sump Pan on Main Housing.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

85 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Actuation Control Manifold (ACM)

8. Ensure Oil Drain Plug is installed. If not, Install the Oil 10. Add or drain transmission oil if oil level is not within
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft) the Transmission Oil Level Operating Range based on
transmission oil temperature.
NOTICE: Do not over-torque Oil Drain Plug or damage
to threads may occur. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

Fill Oil
1. Key on with engine running.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or 2. Complete engine warm-up by running engine at idle
call 1-800-826-HELP (4357). speed for 15 minutes.
1. Park vehicle in a safe area on level ground. Note: If Engine Idle Shutdown engine setting is pre-
venting 15-minute idle time requirement, restart engine
• Select Park if equipped with a Shift Lever and
immediately after shutdown as needed to complete.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Connect ServiceRanger.
2. Set vehicle parking brake and chock wheels. 4. Go To “Service Routines”.
3. Locate the transmission oil level dipstick and tube in 5. Use engine high-idle switch or cruise control switch in
the engine compartment and clean any dirt or debris cab to raise engine idle speed to 950 RPM.
from dipstick handle and tube.
Note: If vehicle is not equipped with high-idle switch or
4. Remove transmission oil level dipstick. cruise control switch, go to Step 6.
5. Fill transmission with 12 liters of Eaton Procision DCT 6. Select “Start” Rail Calibration and follow on-screen
transmission oil through the dipstick tube. prompts.
6. Key on, engine running at low idle RPM. 7. Select “Start” Line Pressure Calibration and follow
on-screen prompts.
7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. 8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.
8. Remove transmission oil level dipstick and check oil
level. Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 9.
9. Repeat steps 7 and 8 to confirm oil level.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

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Actuation Control Manifold (ACM) | Service Procedures TRSM0990

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

87 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cartridge Filter

Cartridge Filter
Special Instructions Special Tools
Cartridge Filter procedure can be performed with transmis- None
sion in chassis.

Component Identification

1. Cartridge Filter
2. Cartridge Filter Cover with O-ring

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Cartridge Filter | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

89 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cartridge Filter

Remove the Cartridge Filter 3. Inspect the Cartridge Filter Cover O-ring for damage.

1. Remove Cartridge Filter Cover with O-ring. NOTICE: Replace the O-ring if damaged.
Note: If replacing the Cartridge Filter the Cartridge Fil-
NOTICE: Use hand tools to remove Cartridge Filter
Cover or damage to threads may occur. ter Cover O-ring must be replaced.
4. Pull down to remove Cartridge Filter.
Note: Cartridge Filter Cover hex end size is 15/16”.

Install the Cartridge Filter

1. Clean Cartridge Filter sealing surface in Clutch Housing
of old oil and debris.

2. Lightly lubricate Cartridge Filter O-ring with Eaton®

Procision DCT transmission oil.

3. Install Cartridge Filter.

2. Remove Cartridge Filter Cover O-ring.

4. Clean Cartridge Filter Cover of old oil and debris.

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Cartridge Filter | Service Procedures TRSM0990

5. Install Cartridge Filter Cover O-ring and lightly lubricate 3. Locate the transmission oil level dipstick and tube in
with Eaton® Procision DCT transmission oil. the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
6. Install Cartridge Filter Cover then torque to 27.5-32.5 transmission oil temperature.
Nm (20.3-24 lb-ft)
! CAUTION: Use only Eaton® approved lubricant
NOTICE: Use hand tools to install Cartridge Filter Cover PS-278. Failure to use specified lubricant results in
or damage to threads may occur. component damage.
Note: Cartridge Filter Cover hex end size is 15/16”. NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

91 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Clutch Cooling Module

Special Instructions Special Tools
None • Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Clutch Cooling Module

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Clutch Cooling Module | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

93 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Remove the OEM Harness Bracket 2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.
1. Remove 4 OEM Harness Bracket 10 mm cap screws;
remove OEM Harness Bracket. Note: New Retainer Bolts, Retainer Plate and Retainer
O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

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Clutch Cooling Module | Service Procedures TRSM0990

3. Remove the Output Yoke Remove the Transmission Range Sensor (TRS)
Note: There is an interference fit between the Output 1. Place the Transmission Cable Shift Lever in the Neutral
Yoke and output shaft splines that may require an out- (N) position.
put yoke puller.

2. Use hand tools to remove 15 mm Transmission Cable

Disconnect Shift Lever Cable Linkage Shift Lever Retaining Nut.
1. Unlock and disconnect Vehicle 4-Way Harness Con- NOTICE: Retain TRS Internal Shift Shaft position by
nector from 4-Way TRS Harness Connector. holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

95 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

3. Remove Transmission Cable Shift Lever. Remove the Rear Housing Cover
1. Remove Output Seal Slinger Shield.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

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 Clutch Cooling Module | Service Procedures TRSM0990

3. Separate Rear Housing Cover from Main Housing at 2 Disassemble Rear Housing with Park Pawl
pry points.
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
CAUTION: Do not pry on sealing surfaces. Failure to Rail C and place Shift Rail C in the Neutral position;
! avoid prying on sealing surface results in component remove Shift Rail Actuation Tool (RR1039TR).
damage.
Note: Confirm Rail C Synchronizer is in Neutral posi-
NOTICE: If transmission is equipped with a Park Pawl,
tion.
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Install puller Medium Jaws (CJ105-6) or equivalent

into puller crossarm as shown.

4. Remove Rear Housing Cover.

97 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

3. For gear pulling clearance, rotate and align Park Pawl 5. Pull off 4th Driven Gear, Park Pawl Gear and Upper
Gear tooth gap with Lower Shaft Bearing Inner Race as Shaft Rear Bearing Inner Race.
shown.
CAUTION: Ensure a Park Pawl Gear tooth gap is
CAUTION: Ensure a Park Pawl Gear tooth gap is ! aligned with the Lower Shaft Bearing Inner Race. Fail-
! aligned with the Lower Shaft Bearing Inner Race. Fail- ure to align a gear tooth with the race results in com-
ure to align a gear tooth with the race results in com- ponent damage.
ponent damage.

4. Install puller assembly onto Upper Shaft and under

Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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Clutch Cooling Module | Service Procedures TRSM0990

7. Remove Rear Housing Spray Bar from Main Housing 9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
and end of Reverse Idler Shaft. onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C. 10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

99 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

11. Remove Lower Shaft Rear Bearing Inner Race Snap 13. Install puller assembly onto Lower Shaft and under 6th
Ring from Lower Shaft and discard. Gear with puller jaws in the 10 and 4 o'clock positions
as shown.
Note: New Snap Ring is required when reinstalling.
CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
component damage.

12. Install puller Large Jaws (CJ105-7) or equivalent into

puller crossarm as shown.

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Clutch Cooling Module | Service Procedures TRSM0990

14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 15. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
Bearing Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

101 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

17. Remove 6th Gear Mid-Wall Bearing Spacer. 19. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disassemble Rear Housing without Park Pawl

1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR).
18. Use a magnet to remove 6th Gear Mid-Wall Spacer
Note: Confirm Rail C Synchronizer is in Neutral posi-
Alignment Ball.
tion.

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 Clutch Cooling Module | Service Procedures TRSM0990

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing
into puller crossarm as shown. Inner Race.

3. Install puller assembly onto Upper Shaft and under 4th 5. Remove 2 Rear Lube Bar 10 mm cap screws.
Driven Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

103 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

7. Install Shift Rail Actuation Tool (RR1039TR) into Shift 9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
Rail C. mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve

onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).
10. Remove Lower Shaft Rear Bearing Inner Race Snap
Ring from Lower Shaft and discard.

Note: New Snap Ring is required when reinstalling.

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 Clutch Cooling Module | Service Procedures TRSM0990

11. Install puller Large Jaws (CJ105-7) or equivalent into 13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
puller crossarm as shown. Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

105 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

14. Remove 6th Gear Bearing from Lower Shaft. 16. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

17. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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Clutch Cooling Module | Service Procedures TRSM0990

18. Remove 6th Driven Gear from Upper Shaft. Remove the 3-Rail Position Sensor and Mag-
nets
1. Remove 4, 3-Rail Position Sensor T30 torx head
screws.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector. 2. Remove 3-Rail Position Sensor.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

107 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

3. Remove the 3 Shift Rail Magnet T20 torx head screws Secure Transmission (Vertical)
from Shift Rails A, B and C.
1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

4. Remove Shift Rail Magnets A, B and C.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

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Clutch Cooling Module | Service Procedures TRSM0990

2. Disconnect the 20-Way Vehicle and Body Harness Con- Remove the Transmission Control Module
nectors from the TCM by depressing the lock tab and (TCM) Vertically
lifting up on the levers.
1. Unscrew 4 TCM Cover nuts and remove TCM Cover.
NOTICE: Do not allow contamination into the TCM or
harness connectors. Note: TCM Cover nuts are 10 or 13 mm.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

109 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Clutch Cooling Module | Service Procedures TRSM0990

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

111 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

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Clutch Cooling Module | Service Procedures TRSM0990

9. Remove ACM rear lubrication O-ring. Remove the Reverse Idler Gear
Note: If O-ring is missing it may be located on ACM. 1. Remove Reverse Idler Shaft 13 mm cap screw.

10. Remove ACM to Interface Manifold Gasket.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft
and lift to remove Reverse Idler Shaft from Main Hous-
ing.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

113 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

3. Remove Reverse Idler Gear, Bearings, and Thrust Remove the Main Housing
Washers.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

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Clutch Cooling Module | Service Procedures TRSM0990

2. Separate Main Housing from Clutch Housing at 3 pry 3. Lift and remove Main Housing from Clutch Housing.
points.
CAUTION: Main Housing assembly weighs approxi-
NOTICE: Do not pry on sealing surfaces. Failure to ! mately 30 lbs. Dropping Main Housing assembly could
avoid prying on sealing surface results in component result in component damage and/or personal injury.
damage.

115 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Remove the Clutch Cooling Module Install the Clutch Cooling Module
1. Remove 5 Clutch Cooling Module Assembly 13 mm 1. Position Clutch Cooling Module with attached gasket
cap screws. on Interface Manifold.

NOTICE: Inspect Clutch Cooling Module gasket

(in-place) for damage. If damaged, replace Clutch
Cooling Module Assembly.

2. Remove Clutch Cooling Module with attached gasket.

2. Install 5 Clutch Cooling Module Assembly 13 mm cap

screws and torque 20.5-25.5 Nm (15.1-18.8 lb-ft) in a
crisscross pattern.

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Clutch Cooling Module | Service Procedures TRSM0990

3. Clean Rail D Position Sensor Magnet (in place) of any 2. Push Main Housing flush to Clutch Housing.
metal shavings or debris.
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.

Install Main Housing without Gasket Sealant

1. Lower Main Housing onto Upper Shaft, Lower Shaft,
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.
3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
Main Housing to Clutch Housing.

117 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

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Clutch Cooling Module | Service Procedures TRSM0990

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

119 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.

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Clutch Cooling Module | Service Procedures TRSM0990

6. Latch 74-Way Connector Retainer to 74-Way Trans- 9. Install 4 ACM 10 mm cap screws and hand tighten.
mission Harness Connector.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

7. Position ACM onto ACM Alignment Pins (RR1036TR). cap screw and hand tighten.

Note: Ensure Engine Speed Sensor Connector remains Note: Assembly grease may be used to hold O-ring in
accessible after ACM installation. place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

121 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

11. Remove the 2 ACM Alignment Pins (RR1036TR) from 13. Torque all 6 ACM to Interface Manifold 10 mm cap
Interface Manifold outermost threaded mounting screws to 8.8-10.4 Nm (77.9-92 lb-in).
holes.

14. Torque ACM Retainer Tab 13 mm cap screw to

12. Install the 2 remaining ACM to Interface Manifold 10 20.5-25.5 Nm (15.14-18 lb-ft).
mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten. Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

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Clutch Cooling Module | Service Procedures TRSM0990

15. Install Output Speed Sensor and 10 mm cap screw into 17. Connect 2-Way Transmission Harness Connector to
Main Housing and torque screw to 8.8-10.4 Nm Engine Speed Sensor Connector.
(77.9-92 lb-in).

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

123 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Install the Transmission Control Module (TCM) 3. Install TCM Cover with 4 nuts over TCM studs and
Vertically torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
1. Align the TCM to the 74-Way Transmission Harness
Note: TCM Cover nuts are 10 or 13 mm.
Connector and TCM studs.

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

Install the Sump Pan and Filter
1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

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Clutch Cooling Module | Service Procedures TRSM0990

5. Install Sump Pan Seal into Main Housing recess if pre- 7. Install 20 Sump Pan 13 mm cap screws and torque to
viously removed. 20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

8. Ensure Oil Drain Plug is installed. If not, Install the Oil

Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

6. Position Sump Pan on Main Housing. to threads may occur.

125 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

Calibrate and Clear Faults Secure the Transmission (Horizontal)

1. Key on with engine running. 1. Securely place transmission in the horizontal position.

2. Complete engine warm-up by running engine at idle WARNING: Transmission weighs approximately 375
speed for 15 minutes. ! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
Note: If Engine Idle Shutdown engine setting is pre- may result in major component damage, severe injury
venting 15-minute idle time requirement, restart engine or death.
immediately after shutdown as needed to complete.
NOTICE: Use an appropriate lifting device to safely lift
3. Connect ServiceRanger. component.
4. Go To “Service Routines”. Install the 3-Rail Position Sensor and Magnets
5. Use engine high-idle switch or cruise control switch in
cab to raise engine idle speed to 950 RPM. 1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.
Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 6. 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
and C with T20 torx head screws and torque to
6. Select “Start” Rail Calibration and follow on-screen 1.55-1.85 Nm (13.7-16.3 lb-in).
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

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Clutch Cooling Module | Service Procedures TRSM0990

3. Position 3-Rail Position Sensor on Main Housing Connect the 3-Rail Position Sensor and Mag-
Mid-Wall. nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.

4. Install 4, 3-Rail Position Sensor T30 torx head screws

and torque to 8.8-10.4 Nm (77.9-92 lb-in).

Assemble Rear Housing with/without Park Pawl

1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

127 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Spacer Alignment Ball locating hole is in 12 o'clock Shaft with raised side facing the front of transmission
position. and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

3. Install Mid-Wall Bearing Spacer Alignment Ball on

Lower Shaft.

Note: Assembly Grease should be used to hold Ball in

place.

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Clutch Cooling Module | Service Procedures TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

129 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Clutch Cooling Module | Service Procedures TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

131 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

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Clutch Cooling Module | Service Procedures TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

133 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

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 Clutch Cooling Module | Service Procedures TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

135 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Install 5 TRS Harness Bracket to T30 torx head screws
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss- and torque to 8.8-10.4 Nm (77.9-92 lb-in).
cross pattern.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
Install the Transmission Range Sensor (TRS) cause gear selection problems.

1. Install TRS assembly on Internal Shift Shaft and push

flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

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Clutch Cooling Module | Service Procedures TRSM0990

4. Use hand tools to install the Transmission Cable Shift 2. Slide the Output Yoke over the output shaft.
Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft). Note: The Output Yoke may require to be driven on due
to an interference fit.
NOTICE: Retain TRS Internal Shift Shaft position by
holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Nm (70.1-77.4 lb-ft).
Connect Shift Lever Cable Linkage
WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever. major vehicle component damage, severe injury or
death.
NOTICE: See OEM Service Manual for shift selector
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke 1. Position OEM Harness Bracket to Clutch Housing.

1. Clean the mating surfaces and splines on the output

shaft and Output Yoke.

137 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Clutch Cooling Module

2. Install 4 OEM Harness Bracket 10 mm cap screws and 9. Repeat steps 7 and 8 to confirm oil level.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

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Clutch Cooling Module | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

139 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cooler Temperature Sensor (CTS)

Cooler Temperature Sensor (CTS)

Special Instructions Special Tools
Cooler Temperature Sensor (CTS) procedure can be per- None
formed with transmission in chassis.

Component Identification

1. Cooler Temperature Sensor (CTS)

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Cooler Temperature Sensor (CTS) | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

141 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cooler Temperature Sensor (CTS)

2. Remove Sump Pan. Remove the Cooler Temperature Sensor (CTS)

1. Locate CTS on the Actuation Control Manifold (ACM).

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached. 2. To access CTS, locate and disconnect 2-Way Engine
If not attached, inspect Pump inlet and remove. Speed Sensor Connector from Transmission Harness
NOTICE: If O-ring must be removed from Pump inlet, Connector.
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Cooler Temperature Sensor (CTS) | Service Procedures TRSM0990

3. Disconnect the 2-Way Transmission Harness Connec- 4. Remove CTS by lifting the lock tab, rotating sensor
tor from CTS. 90-degree counterclockwise, and pulling out from
ACM.

Note: A small flat blade screwdriver may be used to aid

in sensor removal.

143 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cooler Temperature Sensor (CTS)

Install the Cooler Temperature Sensor (CTS) 3. Insert CTS in mounting hole and rotate 90-degrees
clockwise to lock into place.
1. Locate CTS position on Actuation Control Manifold
(ACM). NOTICE: Ensure sensor lock tab is in the latched posi-
tion.

2. Align bottom tabs on Cooler Temperature Sensor with

slots in mounting hole.

4. Connect 2-Way Transmission Harness connector to Oil

Cooler Temperature Sensor.

NOTICE: Ensure connector is fully seated and latched.

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Cooler Temperature Sensor (CTS) | Service Procedures TRSM0990

5. Connect 2-Way Engine Speed Sensor Connector to 5. Install Sump Pan Seal into Main Housing recess if pre-
Transmission Harness Connector. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.
6. Position Sump Pan on Main Housing.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

145 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Cooler Temperature Sensor (CTS)

7. Install 20 Sump Pan 13 mm cap screws and torque to 3. Locate the transmission oil level dipstick and tube in
20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern. the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
8. Ensure Oil Drain Plug is installed. If not, Install the Oil transmission oil temperature.
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)
! CAUTION: Use only Eaton® approved lubricant
NOTICE: Do not over-torque Oil Drain Plug or damage PS-278. Failure to use specified lubricant results in
to threads may occur. component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

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TRSM0990 Service Procedures | Damper

Damper
Special Instructions Special Tools
Ensure to install the correct Damper based on the vehicle • Damper Alignment Tool (RR1037TR)
manufacturer (OEM) and engine type (4 or 6 cylinder).

Component Identification

1. Damper

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TRSM0990 Service Procedures | Damper

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Damper | Service Procedures TRSM0990

Remove the Damper 3. Slide and remove Damper from Damper Alignment
Tool (RR1037TR).
1. Install Damper Alignment Tool (RR1037TR) into Fly-
wheel Pilot Bearing.

4. Remove Damper Alignment Tool (RR1037TR) from

Flywheel Pilot Bearing.
2. Remove 12 Damper to Flywheel cap screws with split
lock washers. Install the Damper
WARNING: Damper weights approximately 20 lbs. Fail- CAUTION: Ensure to install the correct Damper based on
! ure to properly secure the Damper to the Flywheel with !the vehicle manufacturer (OEM) and engine type (4 or 6 cyl-
the Damper Alignment Tool may result in component inder). Failure to install the correct Damper results in trans-
damage, severe injury or death. mission component damage.
1. Ensure Flywheel Pilot Bearing is installed per OEM
guidelines.

2. Install Damper Alignment Tool (RR1037TR) into Fly-

wheel Pilot Bearing.

149 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Damper

3. Slide Damper onto Damper Alignment Tool 5. Install 12 Damper to Flywheel cap screws with split
(RR1037TR) and push flush to Flywheel. lock washers and torque to 47.5-54.2 Nm (35-40 lb-ft)
in a crisscross pattern.
WARNING: Damper weighs approximately 20 lbs. Fail-
! ure to properly secure the Damper to the Flywheel with
the Damper Alignment Tool may result in component
damage, severe injury or death.

6. Remove Damper Alignment Tool (RR1037TR) from

Flywheel Pilot Bearing.

4. Rotate Damper to align bolt holes with threaded holes

in Flywheel.

7. Install the transmission. Refer to OEM guidelines for

transmission installation.

Install the Transmission

1. Refer to OEM guidelines for transmission installation.

2. Reconnect the negativ

3. e battery cable.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).

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Damper | Service Procedures TRSM0990

1. Park vehicle in a safe area on level ground. 1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. • Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels. 2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris the engine compartment and clean any dirt or debris
from dipstick handle and tube. from dipstick handle and tube.

4. Remove transmission oil level dipstick. 4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM. 6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. install in dipstick tube.

8. Remove transmission oil level dipstick and check oil 8. Remove transmission oil level dipstick and check oil
level. level.

9. Repeat steps 7 and 8 to confirm oil level. 9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within 10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on the Transmission Oil Level Operating Range based on
transmission oil temperature. transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in PS-278. Failure to use specified lubricant results in
component damage. component damage.
NOTICE: Do not overfill transmission oil. NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required. Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick. 11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after Note: Reference the Oil Leak Inspection Process after
performing the steps to Fill Oil. performing the steps to Fill Oil.

Fill Oil Calibrate Transmission

Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Key on with engine off.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). 2. Connect ServiceRanger.

3. Go To “Fault Codes”.

4. Select “Clear Eaton Faults” and follow on screen

prompts.

151 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Damper

5. Select “Service Activity Report” and create a Service

Activity Report.

6. Select “Go To” menu.

7. Go To “Programming” and update software if available.

8. Go To “Configuration”.

9. Select “Options”.

10. Enter the transmission serial number in the “New

Value” Serial Number option.

11. Select “Apply” and follow on-screen prompts.

12. Select the “Calibration” tab.

13. Select the appropriate OEM vehicle application calibra-

tion.

14. Select “Apply” and follow on-screen prompts.

15. Go To “Service Routines”.

16. Select “Start” Grade Sensor Calibration and follow

on-screen prompts.

Note: If vehicle is equipped with a T-Handle shift

device, select “Start” TRS Shift Device Calibration and
follow on-screen prompts.
17. Key on with engine running.

18. Select “Start” Rail Calibration and follow on-screen

prompts.

19. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

20. Select “Start” Clutch Pressure (PI) Calibration and fol-

low on-screen prompts.

21. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

22. Key off and wait 1 minute.

23. Key on with engine off.

24. Go To “Fault Codes”.

Note: If active fault code(s) is set, refer to TRTS0990

Procision Troubleshooting Guide.
Note: If no active fault code(s) is set, select “Clear
Eaton Faults” and follow on-screen prompts.
25. Disconnect ServiceRanger.

26. Key off.

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TRSM0990 Service Procedures | Dual Clutch Module (DCM)

Dual Clutch Module (DCM)

Special Instructions Special Tools
None • Front Cover Input Bearing Driver (RR1055TR)
• Universal Driver Handle (OE8044-T0)
• Front Cover Puller Kit (RR1033TR)
• Slide Hammer Seal Puller
• Input Bearing Driver (RR1049TR)
• Input Seal Driver (RR1032TR)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)
• Input Seal Installer (RR1038TR)

Component Identification

9
7 8

2 6
5
4
1 3

1. Front Cover Cap Screws

2. Front Cover 6. DCM Input Shaft Bearing
3. DCM Input Shaft Seal 7. DCM
4. DCM Input Shaft Bearing Snap Ring 8. Clutch Support Manifold
5. DCM Input Shaft Bearing to Front Cover Spiral Retaining 9. Clutch Support Manifold Cap Screws
Ring

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TRSM0990 Service Procedures | Dual Clutch Module (DCM)

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

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Dual Clutch Module (DCM) | Service Procedures TRSM0990

Remove the Input Seal 3. Use Slide Hammer Seal Puller to remove Input Seal.

1. Drill 1/8 in. hole in Input Seal at an “indentation”

around outer edge at approximately the 6 o'clock posi-
tion.

NOTICE: Do not penetrate Input Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Input Seal or sealing surface
damage may occur.

4. Discard Input Seal.

Note: New Input Seal is required when reinstalling.

Remove Front Cover/Dual Clutch Module (DCM)

Assembly
1. Remove 16 Front Cover 13 mm cap screws.

2. Thread Slide Hammer Seal Puller screw into drilled

hole 1/4 in. deep.

NOTICE: Do not thread screw more than 6.35 mm (1/4

in.) in depth or sealing surface damage may occur.

155 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

2. Locate 2 jackscrew threaded holes in Front Cover at the 4. Use hand tools to tighten jackscrews equally in an
2 & 8 o'clock positions. alternating pattern until Front Cover separates from
Clutch Housing, then remove jackscrews.

3. Install 2 Front Cover 13 mm cap screws into jackscrew

holes. 5. Carefully pull and remove Front Cover/DCM assembly
from Clutch Housing.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.
Note: Ensure proper support for Front Cover/DCM
assembly when removing to avoid dropping.

Remove the Dual Clutch Module (DCM)

1. If replacing DCM and Clutch Support Manifold, go to
next step.

Note: If not replacing DCM and only removing to gain

access for another procedure, procedure complete. Do
not perform remaining steps.

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Dual Clutch Module (DCM) | Service Procedures TRSM0990

2. Remove 6 Clutch Support Manifold 13 mm cap screws. 5. Position Front Cover Puller (RR1033TR) assembly on
DCM Input Shaft.

3. Remove Clutch Support Manifold.

6. Hand tighten 2 Front Cover Puller (RR1033TR) 15 mm
cap screws into Front Cover until fully seated.

4. Remove Front Cover Input Bearing Snap Ring from

DCM Input Shaft.

157 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

7. Tighten Front Cover Puller (RR1033TR) forcing screw 10. Position Front Cover Input Bearing Driver (RR1055TR)
to remove Front Cover from DCM Input Shaft. with Universal Driver Handle (OE8044-T0) on Input
Bearing.

8. Remove Input Bearing Spiral Retaining Ring.

11. Drive Input Bearing from Front Cover.

9. Turn Front Cover face down on bench.

Install the Dual Clutch Module (DCM)
1. Place Front Cover face up on bench.

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Dual Clutch Module (DCM) | Service Procedures TRSM0990

2. Position Input Bearing on Front Cover. 5. Support DCM on bench by setting it on Input Seal
Driver (RR1032TR).

3. Use Front Cover Input Bearing Driver (RR1055TR) with

Universal Driver Handle (OE8044-T0) to drive Input
Bearing into Front Cover.

6. Place Front Cover on DCM Input Shaft.

4. Install Input Bearing Spiral Retaining Ring.

7. Place Input Bearing Driver (RR1049TR) on Input Bear-

ing.

159 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

8. Drive Input Bearing and Front Cover onto DCM Input 11. Position CSM to Clutch Housing.
Shaft until fully seated.
Note: Do not use sealant.

9. Install Input Shaft Ring.

12. Install 6 CSM 13 mm cap screws and torque to
20.5-25.5 Nm (15.1-18.8 lb-ft).

10. Clean Clutch Support Manifold (CSM) sealing surfaces

of old oil and debris.
13. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
14. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

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Dual Clutch Module (DCM) | Service Procedures TRSM0990

15. Apply Gasket Sealant in an 1/8” bead inward of all cap 3. Apply Gasket Sealant in an 1/8” bead inward of all cap
screw holes to the Clutch Housing sealing surface fol- screw holes to the Clutch Housing sealing surface fol-
lowing the pattern below. lowing the pattern below.

Install Front Cover/Dual Clutch Module (DCM) 4. Install Front Cover/DCM assembly onto Clutch Support
Assembly Manifold.

CAUTION: Front Cover/DCM assembly weighs approxi-

1. Clean sealing surfaces on Front Cover and Clutch ! mately 45 lbs. Keep fingers clear of pinch point
Housing with Gasket Remover.
between Front Cover and Clutch Housing. Dropping
NOTICE: Do not use abrasive scrapers or power tools Front Cover/DCM assembly could result in component
to clean sealing surfaces. damage and/or personal injury.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

161 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

5. Rotate and push DCM Input Shaft to align DCM onto 8. Install 16 Front Cover 13 mm cap screws and torque to
both transmission Input Shafts and the Pump Driven 20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
Gear.

Install the Input Seal

6. Rotate Front Cover so “TOP” is at the 12 o'clock posi-
tion. 1. Clean Dual Clutch Module (DCM) Input Shaft and Front
Cover sealing surfaces of old oil and debris.
Note: Ensure Front Cover dowel holes are aligned with
Clutch Housing Dowel pins. 2. Lightly lubricate Input Seal lip with Eaton® Procision
DCT transmission oil.

7. Push Front Cover flush to Clutch Housing.

NOTICE: Front Cover should not be forced onto Clutch

Housing. If Cover and Housings do not meet flush,
check internal assembly.
NOTICE: Do not use cap screws to pull Front Cover to
Clutch Housing or damage may occur.

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Dual Clutch Module (DCM) | Service Procedures TRSM0990

3. Install Input Seal on Input Seal Installer (RR1038TR) 5. With seal lip facing the transmission, place Input Seal
with a rotating and pushing motion until seal is 1/2 in. Installer (RR1038TR) with Input Seal on DCM input
from the end. shaft.

4. Inspect Input Seal installation on Input Seal Installer 6. Position Input Seal Driver (RR1032TR) over DCM
(RR1038TR) to ensure seal lip has not flipped. Input Shaft onto Input Seal.

163 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

7. Drive Input Seal into Front Cover until fully seated. 1. Park vehicle in a safe area on level ground.

Note: Front of seal will be flush with Front Cover when • Select Park if equipped with a Shift Lever and
fully seated. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

8. Remove Input Seal Installer (RR1038TR) level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

Install the Transmission

1. Refer to OEM guidelines for transmission installation. 11. Re-install transmission oil level dipstick.
2. Reconnect the negativ Note: Reference the Oil Leak Inspection Process after
3. e battery cable. performing the steps to Fill Oil.

Fill Oil Fill Oil

Note: For a list of Eaton Approved Synthetic Lubricants, see Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). call 1-800-826-HELP (4357).

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 164
Dual Clutch Module (DCM) | Service Procedures TRSM0990

1. Park vehicle in a safe area on level ground. 3. Confirm engine is running at low idle RPM.

• Select Park if equipped with a Shift Lever and 4. Locate the transmission oil level dipstick and tube in
slowly release service brake to engage park pawl. the engine compartment and clean any dirt or debris
• Select Neutral if equipped with a Push Button. from dipstick and tube.

2. Set vehicle parking brake and chock wheels. 5. Remove the transmission oil level dipstick.

3. Locate the transmission oil level dipstick and tube in 6. Wipe transmission oil dipstick clean and reinstall into
the engine compartment and clean any dirt or debris tube.
from dipstick handle and tube.
7. Remove the transmission oil level dipstick and inspect
4. Remove transmission oil level dipstick. oil level.

5. Fill transmission with 12 liters of Eaton Procision DCT 8. Repeat Steps 6 and 7 to confirm oil level.
transmission oil through the dipstick tube.
9. Add or drain transmission oil if oil level is not within
6. Key on, engine running at low idle RPM. the Transmission Oil Level Operating Range based on
transmission oil temperature.
7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
8. Remove transmission oil level dipstick and check oil component damage.
level.
NOTICE: Do not overfill transmission oil.
9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
10. Re-install the transmission oil level dipstick.
component damage.
NOTICE: Do not overfill transmission oil. Calibrate and Clear Faults
Note: If PTO-equipped additional oil will be required. 1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
11. Re-install transmission oil level dipstick. 3. Connect ServiceRanger.
Note: Reference the Oil Leak Inspection Process after 4. Go To “Service Routines”.
performing the steps to Fill Oil.
5. Use engine high-idle switch or cruise control switch in
Inspect Oil Level cab to raise engine idle speed to 950 RPM.
1. Park vehicle in a safe area on level ground. Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 6.
• Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. 6. Select “Start” Rail Calibration and follow on-screen
• Select Neutral if equipped with a Push Button. prompts.

2. Set vehicle parking brake and chock wheels. 7. Select “Start” Line Pressure Calibration and follow
on-screen prompts.

165 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Dual Clutch Module (DCM)

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

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Engine Speed Sensor | Service Procedures TRSM0990

Engine Speed Sensor

Special Instructions Special Tools
Engine Speed Sensor procedure can be performed with • 1/4” Swivel Adapter
transmission in chassis.

Component Identification

1. Engine Speed Sensor

2. Engine Speed Sensor to Pump Cap Screw
3. Engine Speed Sensor Harness Clip to Pump Cap Screws

167 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure Transmission (Vertical)

1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.
6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Engine Speed Sensor | Service Procedures TRSM0990

Disconnect the Transmission Control Module Remove the Transmission Control Module
(TCM) (TCM) Vertically
1. Disconnect the negative battery cable. 1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

NOTICE: Leaving battery cable connected may damage Note: TCM Cover nuts are 10 or 13 mm.
the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

169 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Engine Speed Sensor | Service Procedures TRSM0990

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

171 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

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Engine Speed Sensor | Service Procedures TRSM0990

9. Remove ACM rear lubrication O-ring. Remove the Engine Speed Sensor
Note: If O-ring is missing it may be located on ACM. 1. Locate Engine Speed Sensor near Pump inlet.

10. Remove ACM to Interface Manifold Gasket.

2. Remove 2 Engine Speed Sensor harness retainer T20
torx head screws.

Note: A 1/4” swivel adapter may be used to aid in

screw removal.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

173 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

3. Remove Engine Speed Sensor 10 mm cap screw. Install the Engine Speed Sensor
1. Locate Engine Speed Sensor mounting hole on Pump.

4. Remove Engine Speed Sensor from Pump mounting

hole.
2. Install Engine Speed Sensor in Pump mounting hole.

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Engine Speed Sensor | Service Procedures TRSM0990

3. Install Engine Speed Sensor to Pump 10 mm cap 6. Install outermost Engine Speed Sensor harness
screw and torque to 8.8-10.4 Nm (77.9-92.0 lb-in). retainer T20 torx head screw and torque to 2.25-2.85
Nm (19.9-25.2 lb-in).

Note: A 1/4” swivel adapter may be used to aid screw

in installation.

4. Place T20 Torx Head into Engine Speed Sensor har-

ness retainer clip

7. Install innermost Engine Speed Sensor harness

retainer T20 torx head screw and torque to 2.25-2.85
Nm (19.9-25.2 lb-in).

5. Route Engine Speed Sensor harness into position

around Pump inlet.

175 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.

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Engine Speed Sensor | Service Procedures TRSM0990

6. Latch 74-Way Connector Retainer to 74-Way Trans- 9. Install 4 ACM 10 mm cap screws and hand tighten.
mission Harness Connector.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

7. Position ACM onto ACM Alignment Pins (RR1036TR). cap screw and hand tighten.

Note: Ensure Engine Speed Sensor Connector remains Note: Assembly grease may be used to hold O-ring in
accessible after ACM installation. place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

177 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

11. Remove the 2 ACM Alignment Pins (RR1036TR) from 13. Torque all 6 ACM to Interface Manifold 10 mm cap
Interface Manifold outermost threaded mounting screws to 8.8-10.4 Nm (77.9-92 lb-in).
holes.

14. Torque ACM Retainer Tab 13 mm cap screw to

12. Install the 2 remaining ACM to Interface Manifold 10 20.5-25.5 Nm (15.14-18 lb-ft).
mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten. Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

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Engine Speed Sensor | Service Procedures TRSM0990

15. Install Output Speed Sensor and 10 mm cap screw into 17. Connect 2-Way Transmission Harness Connector to
Main Housing and torque screw to 8.8-10.4 Nm Engine Speed Sensor Connector.
(77.9-92 lb-in).

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

179 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

Install the Transmission Control Module (TCM) 3. Install TCM Cover with 4 nuts over TCM studs and
Vertically torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
1. Align the TCM to the 74-Way Transmission Harness
Note: TCM Cover nuts are 10 or 13 mm.
Connector and TCM studs.

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

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Engine Speed Sensor | Service Procedures TRSM0990

Connect the Transmission Control Module 4. Install Sump Pan Filter.

(TCM) Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

5. Install Sump Pan Seal into Main Housing recess if pre-

viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

181 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Engine Speed Sensor

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 182
Engine Speed Sensor | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

183 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Input Seal

Input Seal
Special Instructions Special Tools
None • Slide Hammer Seal Puller
• Input Seal Installer (RR1038TR)
• Input Seal Driver (RR1032TR)

Component Identification

1. Input Seal

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 184
Input Seal | Service Procedures TRSM0990

Remove the Transmission 2. Thread Slide Hammer Seal Puller screw into drilled
hole 1/4 in. deep.
1. Key on with engine off.
NOTICE: Do not thread screw more than 6.35 mm (1/4
2. Connect ServiceRanger. in.) in depth or sealing surface damage may occur.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.

7. Refer to OEM guidelines for transmission removal.

Remove the Input Seal

1. Drill 1/8 in. hole in Input Seal at an “indentation”
around outer edge at approximately the 6 o'clock posi-
tion.

NOTICE: Do not penetrate Input Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may 3. Use Slide Hammer Seal Puller to remove Input Seal.
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Input Seal or sealing surface
damage may occur.

4. Discard Input Seal.

Note: New Input Seal is required when reinstalling.

Install the Input Seal

1. Clean Dual Clutch Module (DCM) Input Shaft and Front
Cover sealing surfaces of old oil and debris.

185 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Input Seal

2. Lightly lubricate Input Seal lip with Eaton® Procision 4. Inspect Input Seal installation on Input Seal Installer
DCT transmission oil. (RR1038TR) to ensure seal lip has not flipped.

3. Install Input Seal on Input Seal Installer (RR1038TR) 5. With seal lip facing the transmission, place Input Seal
with a rotating and pushing motion until seal is 1/2 in. Installer (RR1038TR) with Input Seal on DCM input
from the end. shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 186
Input Seal | Service Procedures TRSM0990

6. Position Input Seal Driver (RR1032TR) over DCM 8. Remove Input Seal Installer (RR1038TR)
Input Shaft onto Input Seal.

Install the Transmission

7. Drive Input Seal into Front Cover until fully seated.
1. Refer to OEM guidelines for transmission installation.
Note: Front of seal will be flush with Front Cover when
fully seated. 2. Reconnect the negativ

3. e battery cable.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

187 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Input Seal

10. Add or drain transmission oil if oil level is not within 9. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on the Transmission Oil Level Operating Range based on
transmission oil temperature. transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in PS-278. Failure to use specified lubricant results in
component damage. component damage.
NOTICE: Do not overfill transmission oil. NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

10. Re-install the transmission oil level dipstick.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Inspect Oil Level

1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Confirm engine is running at low idle RPM.

4. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick and tube.

5. Remove the transmission oil level dipstick.

6. Wipe transmission oil dipstick clean and reinstall into

tube.

7. Remove the transmission oil level dipstick and inspect

oil level.

8. Repeat Steps 6 and 7 to confirm oil level.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 188
TRSM0990 Service Procedures | Lower Shaft Rear Bearing Cover

Lower Shaft Rear Bearing Cover

Special Instructions Special Tools
Lower Shaft Rear Bearing Cover procedure can be per- • Gasket Sealant (Loctite 5188)
formed with transmission in chassis.
• Gasket Remover (Loctite SF 7631)

Component Identification

2
1

1. Lower Shaft Rear Bearing Cover

2. Rear Bearing Cover Cap Screws

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 189
TRSM0990 Service Procedures | Lower Shaft Rear Bearing Cover

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Lower Shaft Rear Bearing Cover

1. Remove 4 Rear Bearing Cover 18 mm cap screws.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Lower Shaft Rear Bearing Cover | Service Procedures TRSM0990

2. Remove Rear Bearing Cover. 4. Install the Rear Bearing Cover and four 18 mm cap
screws and torque to 69–81 Nm (50.9–59.7 lb.–ft.) in a
crisscross pattern.

Install the Lower Shaft Rear Bearing Cover

1. Clean sealing surfaces on the Rear Bearing Cover and
Rear Housing Cover with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Rear Housing Cover may be damaged
when cap screws are tightened.
3. Apply Gasket Sealant in a 1/8" bead to the Rear Hous-
ing Cover sealing surface following the pattern below.
Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

191 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Lower Shaft Rear Bearing Cover

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 192
TRSM0990 Service Procedures | Oil

Oil
Special Instructions Special Tools
None None

Component Identification

1. Oil Drain Plug

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 193
TRSM0990 Service Procedures | Oil

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.
6. If PTO-equipped, remove PTO and drain oil. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
from dipstick handle and tube.
damage. If damaged, replace the Oil Drain Plug.
4. Remove transmission oil level dipstick.
Note: O-ring is serviced with plug.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 194
Oil | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

195 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Output Seal

Output Seal
Special Instructions Special Tools
Output Seal procedure can be performed with transmission • Slide Hammer Seal Puller
in chassis.
• Output Seal Installer (RR1034TR)
• Output Seal Driver Handle (RR1001TR-2)

Component Identification

1
2
3

1. Output Seal
2. Output Seal Slinger Shield
3. Output Yoke
4. Retainer Plate
5. Retainer Bolts

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Output Seal | Service Procedures TRSM0990

Remove the Output Yoke 3. Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for Note: There is an interference fit between the Output
driveline removal. Yoke and output shaft splines that may require an out-
put yoke puller.
2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.

Note: New Retainer Bolts, Retainer Plate and Retainer

O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Remove the Output Seal

1. Remove Output Seal Slinger Shield.

197 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Output Seal

2. Drill 1/8 in. hole in Output Seal at an “indentation” 4. Use Slide Hammer Seal Puller to remove Output Seal.
around the outer edge at approximately the 6 o'clock
position.

NOTICE: Do not penetrate Output Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Output Seal or sealing surface
damage may occur.

5. Discard Output Seal.

Note: New Output Seal is required when reinstalling.

Install the Output Seal

1. Clean Upper Shaft and Rear Housing Cover sealing
surfaces of old oil and debris.

2. Place Output Seal Installer (RR1034TR) onto Output

3. Thread Slide Hammer Seal Puller screw into drilled Seal Driver Handle (RR1001TR-2).
hole 1/4 in. deep.

NOTICE: Do not thread screw more than 6.35 mm (1/4

in.) in depth or sealing surface damage may occur.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 198
Output Seal | Service Procedures TRSM0990

3. Place Output Seal onto Output Seal Installer 5. Drive the Output Seal into Rear Housing Cover until
(RR1034TR). fully seated.

4. Position Output Seal in Rear Housing Cover seal open- 6. Install Output Seal Slinger Shield.
ing.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

199 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Output Seal

2. Slide the Output Yoke over the output shaft. Inspect Oil Level
Note: The Output Yoke may require to be driven on due 1. Park vehicle in a safe area on level ground.
to an interference fit.
• Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Confirm engine is running at low idle RPM.

4. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick and tube.

5. Remove the transmission oil level dipstick.

6. Wipe transmission oil dipstick clean and reinstall into

tube.

7. Remove the transmission oil level dipstick and inspect

oil level.
3. Install new Retainer Plate, Retainer Plate O-ring, and
two 15 mm Retainer Bolts and torque to 75-85 Nm 8. Repeat Steps 6 and 7 to confirm oil level.
(55.3-62.7 lb-ft), then perform final torque to 95-105
Nm (70.1-77.4 lb-ft). 9. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
WARNING: Reusing previously removed Retainer transmission oil temperature.
! Bolts, Retainer Plate and Retainer O-ring could result in
major vehicle component damage, severe injury or ! CAUTION: Use only Eaton® approved lubricant
death. PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.

10. Re-install the transmission oil level dipstick.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

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TRSM0990 Service Procedures | Output Yoke

Output Yoke
Special Instructions Special Tools
Output Yoke procedure can be performed with transmission None
in chassis.

Component Identification

1. Output Yoke
2. Retainer Plate
3. Retainer Bolts

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 201
TRSM0990 Service Procedures | Output Yoke

Remove the Output Yoke 3. Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for Note: There is an interference fit between the Output
driveline removal. Yoke and output shaft splines that may require an out-
put yoke puller.
2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.

Note: New Retainer Bolts, Retainer Plate and Retainer

O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

2. Slide the Output Yoke over the output shaft.

Note: The Output Yoke may require to be driven on due

to an interference fit.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 202
Output Yoke | Service Procedures TRSM0990

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Nm (70.1-77.4 lb-ft).

WARNING: Reusing previously removed Retainer

! Bolts, Retainer Plate and Retainer O-ring could result in
major vehicle component damage, severe injury or
death.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

203 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Primary and Secondary Input

Special Instructions Special Tools
None • Shift Rail Actuation Tool (RR1039TR)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1050TR)
• Upper Shaft Bearing Outer Race Driver
(RR1048TR)
• Universal Driver Handle (OE8044-T0)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Primary Input Shaft Assembly

2. Secondary Input Shaft Assembly

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Primary and Secondary Input | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

6. If PTO-equipped, remove PTO and drain oil. Remove the Output Yoke

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for 1. Remove the driveline. Refer to OEM guidelines for
damage. If damaged, replace the Oil Drain Plug. driveline removal.

Note: O-ring is serviced with plug.

205 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 206
Primary and Secondary Input | Service Procedures TRSM0990

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

207 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

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Primary and Secondary Input | Service Procedures TRSM0990

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

209 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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Primary and Secondary Input | Service Procedures TRSM0990

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

211 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

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Primary and Secondary Input | Service Procedures TRSM0990

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

213 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

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Primary and Secondary Input | Service Procedures TRSM0990

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

215 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

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Primary and Secondary Input | Service Procedures TRSM0990

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

217 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

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Primary and Secondary Input | Service Procedures TRSM0990

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

219 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Secure Transmission (Vertical) 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
1. Securely place transmission in the vertical position lifting up on the levers.
with front side down.
NOTICE: Do not allow contamination into the TCM or
WARNING: Transmission weighs approximately 375 harness connectors.
! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

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Primary and Secondary Input | Service Procedures TRSM0990

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Vertically Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

221 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Primary and Secondary Input | Service Procedures TRSM0990

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

223 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

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Primary and Secondary Input | Service Procedures TRSM0990

Remove the Reverse Idler Gear 3. Remove Reverse Idler Gear, Bearings, and Thrust
Washers.
1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft

and lift to remove Reverse Idler Shaft from Main Hous-
ing.

225 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Remove the Main Housing 2. Separate Main Housing from Clutch Housing at 3 pry
points.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws. NOTICE: Do not pry on sealing surfaces. Failure to
avoid prying on sealing surface results in component
NOTICE: To avoid internal transmission contamination, damage.
keep Main Housing cap screws separated.

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Primary and Secondary Input | Service Procedures TRSM0990

3. Lift and remove Main Housing from Clutch Housing. 2. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail B.
CAUTION: Main Housing assembly weighs approxi-
! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

3. Push Shift Rail B downward to engage Rail B Synchro-

nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift
Rail Actuation Tool (RR1039TR).
Remove the Upper Shaft
Note: Place a rag over the Interface Manifold flange to
1. Lift and remove Main Housing Spray Bar from Pump capture any oil spray.
Outlet.

227 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5 6. Separate Upper and Lower Shafts to create clearance
mm) roll pin punch. between Reverse Gear and Lower Shaft Mid-Wall Bear-
ing when removing Upper Shaft.

5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

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Primary and Secondary Input | Service Procedures TRSM0990

7. Lift and remove Upper Shaft assembly. Remove the Lower Shaft
CAUTION: Upper Shaft assembly weighs approxi- 1. Remove Rail A Shift Yoke from Shift Rail A.
! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

2. Remove Rail B Shift Yoke and Rail B Synchronizer

Sleeve from Shift Rail B.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

229 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

3. Remove Rail B Synchronizer Blocking Ring and Clutch- 5. Remove 3 Primary Input Shaft Retainer 13 mm cap
ing Teeth Gear. screws.

4. Remove Rail D Shift Yoke 13 mm cap screw and 6. To create clearance when removing Lower Shaft pry on
washer. Secondary Driven Gear to release Primary Input Shaft
from Interface Manifold.

Note: Place a rag over the Interface Manifold flange to

capture any oil spray.

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Primary and Secondary Input | Service Procedures TRSM0990

7. Lift and remove Lower Shaft assembly with Rail D Shift Remove Primary and Secondary Input Shaft
Yoke.
1. Remove Primary Input Shaft, Primary Input Shaft
CAUTION: Lower Shaft assembly weighs approxi- Retainer, and Primary Input Shaft Lube Elbow assem-
! mately 50 lbs. Dropping Lower Shaft assembly could bly.
result in component damage and/or personal injury.

2. Remove Secondary Input Shaft assembly.

231 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Install the Primary and Secondary Input Shaft 3. Install Primary Input Shaft, Primary Input Shaft
Retainer, and Primary Input Shaft Lube Elbow assem-
1. Ensure Clutch Housing assembly is securely placed in bly into Secondary Input Shaft. Do not install Primary
the vertical position with front side down. Input Shaft Retainer cap screws at this time.

2. Install Secondary Input Shaft assembly. NOTICE: Ensure Lube Elbow aligns with oil passage
holes in the Input Shaft assembly and Interface Mani-
fold. Improper installation will result in gear failure
when run.

Install the Upper Shaft

1. Mark the position of Rail B Synchronizer Sleeve detent
grooves to aid in installing the Upper Shaft assembly.

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Primary and Secondary Input | Service Procedures TRSM0990

2. Install Rail A Shift Yoke onto Rail A Synchronizer 3. Separate the Upper and Lower Shafts to create clear-
Sleeve. ance between the Reverse Gear and Lower Shaft
Mid-Wall Bearing when installing Upper Shaft assem-
NOTICE: Ensure “REAR” indicated on Shift Yoke faces bly.
rear of transmission.
NOTICE: Ensure all 3 Rail B Synchronizer Keys and
Springs are in Synchronizer Hub Key Slots.

233 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

4. Lower and install Upper Shaft assembly with Rail A 5. Install 2 Rail A Shift Yoke Roll Pins.
Shift Yoke onto Rail B Synchronizer Sleeve and Shift
Rail A.

CAUTION: Upper Shaft assembly weighs approxi-

! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Synchronizer Hub Key Slots align with
detent grooves and marks on Synchronizer Sleeve.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in installation.

6. Install 2 Rail B Shift Yoke Roll Pins.

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Primary and Secondary Input | Service Procedures TRSM0990

7. Install Main Housing Spray Bar into Pump outlet align- Remove the Upper and Lower Mid-Wall Bearing
ing molded-in cap over Pump cap screw head. Outer Race
NOTICE: The Spray Bar molded-in cap ensures proper
1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm
Spray Bar position for gear lubrication. Improper
cap screws.
installation will result in gear failure when run.

2. Remove Upper Shaft Bearing Retainer Plate and shims.

8. Clean Rail D Position Sensor Magnet (in place) of any
metal shavings or debris. Note: Keep bearing shims. Do not discard.

235 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm 5. Position Upper Shaft Mid Bearing Outer Race Driver
cap screws. (RR1048TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race.

4. Remove Lower Shaft Bearing Retainer Plate and shims.

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from
Note: Keep bearing shims. Do not discard. Main Housing.

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Primary and Secondary Input | Service Procedures TRSM0990

7. Position Lower Shaft Mid Bearing Outer Race Driver 3. Install Upper Shaft Mid-Wall Bearing Outer Race into
(RR1050TR) and Universal Driver Handle (OE8044-T0) Main Housing bore approximately 1/2 way.
onto Lower Shaft Mid-Wall Bearing Outer Race.

4. Install Lower Shaft Mid-Wall Bearing Outer Race into

8. Drive Lower Shaft Mid-Wall Bearing Outer Race from Main Housing approximately 1/2 way.
Main Housing.

Install the Upper and Lower Mid-Wall Bearing

Outer Race
1. Clean Upper and Lower Shaft Mid-Wall Bearing Race
bores of old oil and debris.

2. Clean mating sealing surfaces on Main Housing and

Clutch Housing with Gasket Remover.

237 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

Install Main Housing without Gasket Sealant 3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
1. Lower Main Housing onto Upper Shaft, Lower Shaft, Main Housing to Clutch Housing.
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Measure and Adjust End-Play

1. Create table as shown.

Original Bearing Shims thickness

2. Push Main Housing flush to Clutch Housing.
Add: + 0.010
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check Baseline Total: =
internal assembly.
End-play measurement:
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing. Upper Shaft: + 0.002

Note: A rubber hammer may be used to gently tap New Shim Thickness: =
Main Housing onto Clutch Housing Dowel Pins.
2. Measure Upper Shaft Original Bearing Shim Thickness
and record in table.

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Primary and Secondary Input | Service Procedures TRSM0990

3. Add a 0.010 shim to the original Upper Shaft bearing 6. Position a dial indicator plunger against end of Upper
shim set then place shims and Upper Shaft Bearing Shaft.
Retainer Plate on Main Housing.

7. Set dial indicator to zero.

8. Use a pry bar to move the Upper Shaft rearward.

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness.

11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm

cap screws and Upper Shaft Bearing Retainer Plate
from Main Housing.

12. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

5. Rotate Upper Shaft 8 times to center shaft.

239 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

13. Place Upper Shaft Bearing Retainer Plate and shims on 16. Position the dial indicator and pry on Upper Shaft to
Main Housing. verify zero end play. If zero end play exists go to Step
25. If end play exists record measurement in table
NOTICE: Ensure shims are aligned with Main Housing below.
oil passage. Improper installation will result in bearing
failure when run.

End play measurement:

Preload + 0.002
14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a Total: =
crisscross pattern.
17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: =

15. Rotate shaft 8 times to seat bearing to bearing race. 19. Measure Lower Shaft Original Bearing Shim Thickness
and record in table.

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Primary and Secondary Input | Service Procedures TRSM0990

20. Add a 0.010 shim to the original Lower Shaft bearing 23. Remove 6 PTO cover (right side) 16 mm cap screws.
shim set then place shims and Lower Shaft Bearing
Retainer Plate on Main Housing.

24. Remove PTO cover.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern.

25. Position dial indicator plunger against end of Lower

Shaft.

22. Rotate Lower Shaft 8 times to center shaft.

241 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

26. Set dial indicator to zero. 33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
27. Use a pry bar through PTO opening to move the Lower a crisscross pattern.
Shaft rearward.

34. Rotate shaft 8 times to seat bearing to bearing race.

28. Record end-play reading in a table.
35. Position the dial indicator and pry on Lower Shaft to
29. Use table to calculate New Shim Thickness. verify zero end play. If zero end play go to Step 44. If
30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm end play exists record measurement in table below.
cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End-play measurement:

Preload + 0.002

Total: =

36. Remove the Lower Shaft Bearing Retainer Plate and

the “Total” number amount of shims calculated in the
table above then repeat Steps 32-35.

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Primary and Secondary Input | Service Procedures TRSM0990

Remove the Main Housing 2. Inspect threaded bolt holes for debris and clean if nec-
essary.
1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing. NOTICE: Ensure there is nothing in the threaded bolt
holes or the Clutch Housing may be damaged when
cap screws are tightened.
3. Apply Gasket Sealant in an 1/8" bead to the Clutch
Housing sealing surface following the pattern below.

2. Lift and remove Main Housing from Clutch Housing.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

4. Lower Main Housing onto Upper Shaft, Lower Shaft,

and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.

243 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

5. Push Main Housing flush to Clutch Housing. Install the PTO Cover
Note: A rubber hammer may be used to gently tap 1. Clean sealing surfaces on the PTO Cover and Main
Main Housing onto Clutch Housing Dowel Pins. Housing with Gasket Remover.
NOTICE: Main Housing should not be forced onto
NOTICE: Do not use abrasive scrapers or power tools
Clutch Housing. If Housings do not meet flush check
to clean sealing surfaces.
internal assembly.
2. Inspect threaded bolt holes for debris and clean if nec-
NOTICE: Do not use cap screws to pull Main Housing
essary.
to Clutch Housing.
NOTICE: Ensure there is nothing in the threaded bolt
holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

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Primary and Secondary Input | Service Procedures TRSM0990

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

245 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

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Primary and Secondary Input | Service Procedures TRSM0990

Install the 90-Degree Connector 3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
1. Locate and position 90-Degree Connector in Main
Housing.

Install the Actuation Control Module (ACM)

2. Install 2 90-Degree Connector 10 mm cap screws and 1. Install ACM rear lubrication O-ring.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: Assembly grease can be used to hold O-ring in
place.

247 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

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Primary and Secondary Input | Service Procedures TRSM0990

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

249 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

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Primary and Secondary Input | Service Procedures TRSM0990

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

251 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). 4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
Note: TCM Cover nuts are 10 or 13 mm. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Primary and Secondary Input | Service Procedures TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

253 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

7. Select “Start” Line Pressure Calibration and follow 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

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Primary and Secondary Input | Service Procedures TRSM0990

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

255 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 256
Primary and Secondary Input | Service Procedures TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

257 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Primary and Secondary Input | Service Procedures TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

259 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 260
Primary and Secondary Input | Service Procedures TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

261 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

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 Primary and Secondary Input | Service Procedures TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

263 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Slide the Output Yoke over the output shaft.
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern. Note: The Output Yoke may require to be driven on due
to an interference fit.
Note: Three Rear Housing Cover cap screws are a dif-
ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Connect Shift Lever Cable Linkage Nm (70.1-77.4 lb-ft).

1. Install transmission shift selector cable linkage to WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
Transmission Cable Shift Lever.
major vehicle component damage, severe injury or
NOTICE: See OEM Service Manual for shift selector death.
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke
1. Position OEM Harness Bracket to Clutch Housing.
1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

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Primary and Secondary Input | Service Procedures TRSM0990

2. Install 4 OEM Harness Bracket 10 mm cap screws and 9. Repeat steps 7 and 8 to confirm oil level.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

265 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Primary and Secondary Input

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 266
PTO Cover | Service Procedures TRSM0990

PTO Cover
Special Instructions Special Tools
PTO Cover procedure can be performed with transmission • Gasket Remover (Loctite SF 7631)
in chassis.
• Gasket Sealant (Loctite 5188)

Component Identification

1
2

1. PTO Cover
2. PTO Cover Cap Screws

267 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | PTO Cover

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the PTO Cover

1. Remove the 6 PTO Cover 16 mm cap screws.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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PTO Cover | Service Procedures TRSM0990

2. Remove PTO Cover. 4. Install the PTO Cover and 6 PTO Cover 16 mm cap
screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

Install the PTO Cover

1. Clean sealing surfaces on the PTO Cover and Main Fill Oil
Housing with Gasket Remover.
Note: For a list of Eaton Approved Synthetic Lubricants, see
NOTICE: Do not use abrasive scrapers or power tools Eaton TCMT0021 Lubrication guide on Roadranger.com or
to clean sealing surfaces. call 1-800-826-HELP (4357).
2. Inspect threaded bolt holes for debris and clean if nec- 1. Park vehicle in a safe area on level ground.
essary.
• Select Park if equipped with a Shift Lever and
NOTICE: Ensure there is nothing in the threaded bolt slowly release service brake to engage park pawl.
holes or the Main Housing may be damaged when cap
screws are tightened. • Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

269 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | PTO Cover

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 270
Pump | Service Procedures TRSM0990

Pump
Special Instructions Special Tools
Refer to OEM guidelines for transmission removal. • Shift Rail Actuation Tool (RR1039TR)
• Snap-on CJ85-1 Puller or equivalent
• Snap-on CJ105-6 Medium Jaw (Qty 2) or
equivalent
• Snap-on CJ105-7 Large Jaw (Qty 2) or equivalent
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)
• ACM Alignment Pins (RR1036TR)
• Shift Rail Actuation Tool (RR1039TR)
• Lower Shaft Rear Bearing Inner Race & 4th Gear
Inner Sleeve Driver (RR1040TR)
• Inner Race Driver (RR1041TR)

Component Identification

1. Pump Cap Screws

2. Pump
3. Pump Gasket

271 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Pump

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

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Pump | Service Procedures TRSM0990

Remove Front Cover/Dual Clutch Module (DCM) 3. Install 2 Front Cover 13 mm cap screws into jackscrew
Assembly holes.

1. Remove 16 Front Cover 13 mm cap screws.

4. Use hand tools to tighten jackscrews equally in an

alternating pattern until Front Cover separates from
2. Locate 2 jackscrew threaded holes in Front Cover at the Clutch Housing, then remove jackscrews.
2 & 8 o'clock positions.

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TRSM0990 Service Procedures | Pump

5. Carefully pull and remove Front Cover/DCM assembly 3. Remove Pump Driven Gear 13 mm cap screw.
from Clutch Housing.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.
Note: Ensure proper support for Front Cover/DCM
assembly when removing to avoid dropping.

4. Remove Pump Driven Gear.

Remove the Pump Driven Gear

1. Install drift into Pump Driven Gear.

2. Hold drift securely against Clutch Housing to hold

Pump Driven Gear stationary.

CAUTION: Failure to hold Pump Driven Gear stationary

! during cap screw removal could result in component
damage and/or personal injury.

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Pump | Service Procedures TRSM0990

Remove the OEM Harness Bracket 2. Use hand tools to remove 15 mm Transmission Cable
Shift Lever Retaining Nut.
1. Remove 4 OEM Harness Bracket 10 mm cap screws;
remove OEM Harness Bracket. NOTICE: Retain TRS Internal Shift Shaft position by
holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

Remove the Transmission Range Sensor (TRS)

1. Place the Transmission Cable Shift Lever in the Neutral
(N) position. 3. Remove Transmission Cable Shift Lever.

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TRSM0990 Service Procedures | Pump

4. Remove 5 TRS Harness Bracket T30 torx head screws. 2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.

Note: New Retainer Bolts, Retainer Plate and Retainer

O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

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Pump | Service Procedures TRSM0990

3. Remove the Output Yoke 2. Remove 18 Rear Housing Cover cap screws.

Note: There is an interference fit between the Output Note: Three Rear Housing Cover cap screws are a dif-
Yoke and output shaft splines that may require an out- ferent length than the rest. Note their proper position
put yoke puller. for re-installation.

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

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TRSM0990 Service Procedures | Pump

4. Remove Rear Housing Cover. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing with Park Pawl

3. For gear pulling clearance, rotate and align Park Pawl
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Gear tooth gap with Lower Shaft Bearing Inner Race as
Rail C and place Shift Rail C in the Neutral position; shown.
remove Shift Rail Actuation Tool (RR1039TR).
CAUTION: Ensure a Park Pawl Gear tooth gap is
Note: Confirm Rail C Synchronizer is in Neutral posi- ! aligned with the Lower Shaft Bearing Inner Race. Fail-
tion. ure to align a gear tooth with the race results in com-
ponent damage.

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 Pump | Service Procedures TRSM0990

4. Install puller assembly onto Upper Shaft and under 5. Pull off 4th Driven Gear, Park Pawl Gear and Upper
Park Pawl Gear as shown. Shaft Rear Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under CAUTION: Ensure a Park Pawl Gear tooth gap is
! gear. Failure to fully seat jaws under gear results in ! aligned with the Lower Shaft Bearing Inner Race. Fail-
component damage. ure to align a gear tooth with the race results in com-
ponent damage.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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TRSM0990 Service Procedures | Pump

7. Remove Rear Housing Spray Bar from Main Housing 9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
and end of Reverse Idler Shaft. onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C. 10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

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Pump | Service Procedures TRSM0990

11. Remove Lower Shaft Rear Bearing Inner Race Snap 13. Install puller assembly onto Lower Shaft and under 6th
Ring from Lower Shaft and discard. Gear with puller jaws in the 10 and 4 o'clock positions
as shown.
Note: New Snap Ring is required when reinstalling.
CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
component damage.

12. Install puller Large Jaws (CJ105-7) or equivalent into

puller crossarm as shown.

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TRSM0990 Service Procedures | Pump

14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 15. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
Bearing Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

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Pump | Service Procedures TRSM0990

17. Remove 6th Gear Mid-Wall Bearing Spacer. 19. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disassemble Rear Housing without Park Pawl

1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR).
18. Use a magnet to remove 6th Gear Mid-Wall Spacer
Note: Confirm Rail C Synchronizer is in Neutral posi-
Alignment Ball.
tion.

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TRSM0990 Service Procedures | Pump

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing
into puller crossarm as shown. Inner Race.

3. Install puller assembly onto Upper Shaft and under 4th 5. Remove 2 Rear Lube Bar 10 mm cap screws.
Driven Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

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Pump | Service Procedures TRSM0990

7. Install Shift Rail Actuation Tool (RR1039TR) into Shift 9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
Rail C. mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve

onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).
10. Remove Lower Shaft Rear Bearing Inner Race Snap
Ring from Lower Shaft and discard.

Note: New Snap Ring is required when reinstalling.

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TRSM0990 Service Procedures | Pump

11. Install puller Large Jaws (CJ105-7) or equivalent into 13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
puller crossarm as shown. Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

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Pump | Service Procedures TRSM0990

14. Remove 6th Gear Bearing from Lower Shaft. 16. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

17. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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TRSM0990 Service Procedures | Pump

18. Remove 6th Driven Gear from Upper Shaft. Remove the 3-Rail Position Sensor and Mag-
nets
1. Remove 4, 3-Rail Position Sensor T30 torx head
screws.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector. 2. Remove 3-Rail Position Sensor.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

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Pump | Service Procedures TRSM0990

3. Remove the 3 Shift Rail Magnet T20 torx head screws Secure Transmission (Vertical)
from Shift Rails A, B and C.
1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

4. Remove Shift Rail Magnets A, B and C.

Remove the Transmission Control Module

(TCM) Vertically
1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

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TRSM0990 Service Procedures | Pump

2. Unscrew the 7 mm jackscrew and remove TCM from Remove the Sump Pan and Filter
transmission.
1. Remove 20 Sump Pan 13 mm cap screws.

2. Remove Sump Pan.

3. Unlatch 74-Way Connector Retainer from 74-Way

Transmission Harness Connector.

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Pump | Service Procedures TRSM0990

3. Remove Sump Pan Filter 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.
Note: Ensure Sump Pan Filter neck O-ring is attached.
If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

3. Remove the 2 Transmission Harness to Main Housing

10 mm cap screws.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

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TRSM0990 Service Procedures | Pump

4. Remove Output Speed Sensor 10 mm cap screw and 6. Remove ACM Retainer Tab and O-ring isolator.
pull Output Speed Sensor free from Main Housing.
Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

7. Remove 6 ACM to Interface Manifold 10 mm cap

screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

5. Remove the ACM Retainer Tab 13 mm cap screw.

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Pump | Service Procedures TRSM0990

8. Remove ACM/Transmission Harness assembly from 10. Remove ACM to Interface Manifold Gasket.
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.
9. Remove ACM rear lubrication O-ring.
Remove the Reverse Idler Gear
Note: If O-ring is missing it may be located on ACM.
1. Remove Reverse Idler Shaft 13 mm cap screw.

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TRSM0990 Service Procedures | Pump

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft Remove the Main Housing
and lift to remove Reverse Idler Shaft from Main Hous-
ing. 1. Remove 16 external and 5 internal Main Housing 16
mm cap screws.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

3. Remove Reverse Idler Gear, Bearings, and Thrust

Washers.

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Pump | Service Procedures TRSM0990

2. Separate Main Housing from Clutch Housing at 3 pry 3. Lift and remove Main Housing from Clutch Housing.
points.
CAUTION: Main Housing assembly weighs approxi-
NOTICE: Do not pry on sealing surfaces. Failure to ! mately 30 lbs. Dropping Main Housing assembly could
avoid prying on sealing surface results in component result in component damage and/or personal injury.
damage.

Remove the Pump

1. Lift and remove Main Housing Spray Bar from Pump
Outlet.

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TRSM0990 Service Procedures | Pump

2. Remove 10 Pump 8 mm cap screws. Install the Pump

Note: Pump cap screws are 3 different lengths. Note 1. Position and install Pump Gasket on Clutch Housing.
their proper position for re-installation.
Note: Use small Clutch Housing Dowel Pins to ensure
proper alignment.

2. Align Pump with small Clutch Housing Dowel Pins and

install Pump.

3. Remove Pump and Gasket.

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Pump | Service Procedures TRSM0990

3. Install 10 Pump 8 mm cap screws and torque to 5. Clean Rail D Position Sensor Magnet (in place) of any
8.8-10.4 Nm (77.9-92 lb-in) in a crisscross pattern. metal shavings or debris.

Note: Pump cap screws are 3 different lengths. Refer

to Pump Removal notes for proper location.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
4. Install Main Housing Spray Bar into Pump outlet align- Housing with Gasket Remover.
ing molded-in cap over Pump cap screw head.
NOTICE: Do not use abrasive scrapers or power tools
NOTICE: The Spray Bar molded-in cap ensures proper
to clean sealing surfaces.
Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run. 2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

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TRSM0990 Service Procedures | Pump

3. Apply Gasket Sealant in an 1/8" bead to the Clutch 5. Push Main Housing flush to Clutch Housing.
Housing sealing surface following the pattern below.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.

4. Lower Main Housing onto Upper Shaft, Lower Shaft, 6. Install 16 external and 5 internal Main Housing 16 mm
and Clutch Housing Dowel Pins. cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.
CAUTION: Main Housing assembly weighs approxi-
! mately 30 lbs. Dropping Main Housing assembly could NOTICE: To avoid internal transmission contamination,
result in component damage and/or personal injury. keep Main Housing cap screws separated.

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Pump | Service Procedures TRSM0990

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

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TRSM0990 Service Procedures | Pump

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

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Pump | Service Procedures TRSM0990

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.

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TRSM0990 Service Procedures | Pump

6. Latch 74-Way Connector Retainer to 74-Way Trans- 9. Install 4 ACM 10 mm cap screws and hand tighten.
mission Harness Connector.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

7. Position ACM onto ACM Alignment Pins (RR1036TR). cap screw and hand tighten.

Note: Ensure Engine Speed Sensor Connector remains Note: Assembly grease may be used to hold O-ring in
accessible after ACM installation. place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

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Pump | Service Procedures TRSM0990

11. Remove the 2 ACM Alignment Pins (RR1036TR) from 13. Torque all 6 ACM to Interface Manifold 10 mm cap
Interface Manifold outermost threaded mounting screws to 8.8-10.4 Nm (77.9-92 lb-in).
holes.

14. Torque ACM Retainer Tab 13 mm cap screw to

12. Install the 2 remaining ACM to Interface Manifold 10 20.5-25.5 Nm (15.14-18 lb-ft).
mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten. Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

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TRSM0990 Service Procedures | Pump

15. Install Output Speed Sensor and 10 mm cap screw into 17. Connect 2-Way Transmission Harness Connector to
Main Housing and torque screw to 8.8-10.4 Nm Engine Speed Sensor Connector.
(77.9-92 lb-in).

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Pump | Service Procedures TRSM0990

4. Install Sump Pan Filter. 6. Position Sump Pan on Main Housing.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

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TRSM0990 Service Procedures | Pump

8. Ensure Oil Drain Plug is installed. If not, Install the Oil 2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.

Install the Transmission Control Module (TCM) Note: TCM Cover nuts are 10 or 13 mm.
Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

Secure Transmission (Horizontal)

1. Securely place the transmission in the horizontal posi-
tion.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

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Pump | Service Procedures TRSM0990

Install the 3-Rail Position Sensor and Magnets 3. Position 3-Rail Position Sensor on Main Housing
Mid-Wall.
1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,

and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).

4. Install 4, 3-Rail Position Sensor T30 torx head screws

and torque to 8.8-10.4 Nm (77.9-92 lb-in).

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TRSM0990 Service Procedures | Pump

Connect the 3-Rail Position Sensor and Mag- 2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
nets Spacer Alignment Ball locating hole is in 12 o'clock
position.
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.

3. Install Mid-Wall Bearing Spacer Alignment Ball on

Lower Shaft.
Assemble Rear Housing with/without Park Pawl Note: Assembly Grease should be used to hold Ball in
place.
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

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Pump | Service Procedures TRSM0990

4. Install 6th Gear Mid-Wall Bearing Spacer on Lower 5. Install 6th Gear Bearing on Lower Shaft.
Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main

Housing and Reverse Idler Shaft.

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TRSM0990 Service Procedures | Pump

7. Install 2 Rear Lube Bar 10 mm cap screws and torque 9. Install Rail C Synchronizer Blocking Ring onto 6th
to 8.8-10.4 Nm (77.9-92 lb-in). Gear.

8. Install 6th Gear on Lower Shaft. 10. Assemble Rail C Synchronizer assembly.

Note: Raised side of gear faces rear of transmission. NOTICE: Ensure all 3 Rail C Synchronizer Keys and
Proper orientation is critical to final assembly. Springs are in Synchronizer Hub Key Slots.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

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Pump | Service Procedures TRSM0990

11. Position Rail C Shift Yoke onto Rail C Synchronizer 14. Install remaining Rail C Synchronizer Blocking Ring
assembly. onto Rail C Synchronizer Hub.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces NOTICE: Ensure Blocking Ring tabs align with Hub Key
rear of transmission. Slots.

12. Install Rail C Synchronizer assembly with Rail C Shift 15. Install 4th Gear Bearing and Captured Inner Race into
Yoke on Lower Shaft and Shift Rail C. 4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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TRSM0990 Service Procedures | Pump

16. Place 4th Gear assembly onto Lower Shaft. 18. Drive 4th Gear assembly onto Lower Shaft.

NOTICE: Ensure Rail C Synchronizer Blocking Ring

tabs stay aligned with Hub Key Slots during 4th Gear
installation.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
19. Install Spacer onto Lower Shaft.

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Pump | Service Procedures TRSM0990

20. Place Lower Shaft Rear Bearing Inner Race onto end of 22. Install new Snap Ring on Lower Shaft.
Lower Shaft.
NOTICE: If Snap Ring cannot be properly installed into
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer
installation orientation (Step 4). Raised side of Spacer
must face front of transmission. Proper orientation is
critical to final assembly.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.

Note: Ensure Rear Bearing Inner Race is fully seated.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

313 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Pump

24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and 26. Install 4th Driven Gear and Park Pawl Gear assembly
Shift Rail C into the 4th Gear position then remove on Upper Shaft.
Shift Rail Actuation Tool (RR1039TR).
NOTICE: Align Park Pawl Gear tooth gap with Lower
Note: Ensure Rail C is fully extended rearward. Roll Pin Shaft Bearing Race or damage may occur.
hole in Rail must be aligned with Roll Pin hole in Shift
Yoke. Note: For transmissions without a Park Pawl, install
4th Driven Gear on Upper Shaft.

25. Install Rail C Shift Yoke Roll Pin.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Note: Roll Pin must be driven from the inside of hous- Upper Shaft.
ing outward.

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Pump | Service Procedures TRSM0990

28. Use Upper Shaft Rear Bearing Inner Race Driver 3. Apply Gasket Sealant in an 1/8" bead inward of all cap
(RR1041TR) to drive Upper Shaft Rear Bearing Inner screw holes to the Main Housing sealing surface fol-
Race onto Upper Shaft. lowing the pattern below.

NOTICE: Ensure Park Pawl Gear tooth gap stays CAUTION: Ensure there is no Gasket Sealant in Main
aligned with Lower Shaft Bearing Race or damage may ! Housing Rear Bearing Oil Passage. Failure to keep oil
occur. passage clear of sealant results in component damage.

Install the Rear Housing Cover

1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

315 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Pump

4. Install Rear Housing Cover onto Upper Shaft, Lower 6. Install 18 Rear Housing Cover 16 mm cap screws
Shaft and Main Housing Dowel Pins. torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern.
NOTICE: If transmission is equipped with a park pawl
confirm the Internal Shift Shaft has remained in the Note: Three Rear Housing Cover cap screws are a dif-
Neutral position as shown prior to installing the Rear ferent length than the rest. Refer to Rear Housing
Housing Cover or damage to the internal Park Pawl Cover removal notes for proper location.
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

Install the Transmission Range Sensor (TRS)

1. Install TRS assembly on Internal Shift Shaft and push
flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

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Pump | Service Procedures TRSM0990

2. Install 5 TRS Harness Bracket to T30 torx head screws 4. Use hand tools to install the Transmission Cable Shift
and torque to 8.8-10.4 Nm (77.9-92 lb-in). Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft).

NOTICE: Retain TRS Internal Shift Shaft position by

holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
cause gear selection problems.
Install OEM Harness Bracket
1. Position OEM Harness Bracket to Clutch Housing.

2. Install 4 OEM Harness Bracket 10 mm cap screws and

torque to 8.8-10.4 Nm (77.9-92 lb-in).

317 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Pump

Install Pump Driven Gear 4. Hold drift securely against Clutch Housing to hold
Pump Driven Gear stationary and torque Pump Driven
1. Align and install Pump Driven Gear onto Pump Drive- Gear 13 mm cap screw to 32.5-39.5 Nm (24.0-29.1
shaft with raised side toward Pump Driveshaft. lb-ft).

Note: Ensure proper alignment of Gear square opening CAUTION: Failure to hold Pump Driven Gear stationary
onto Driveshaft. ! during cap screw installation could result in compo-
nent damage and/or personal injury.

2. Install Pump Driven Gear 13 mm cap screw and hand

tighten. Install Front Cover/Dual Clutch Module (DCM)
Note: Do not torque cap screw yet. Assembly
3. Install drift into Pump Driven Gear. 1. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

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Pump | Service Procedures TRSM0990

3. Apply Gasket Sealant in an 1/8” bead inward of all cap 5. Rotate and push DCM Input Shaft to align DCM onto
screw holes to the Clutch Housing sealing surface fol- both transmission Input Shafts and the Pump Driven
lowing the pattern below. Gear.

6. Rotate Front Cover so “TOP” is at the 12 o'clock posi-

tion.

Note: Ensure Front Cover dowel holes are aligned with

Clutch Housing Dowel pins.
4. Install Front Cover/DCM assembly onto Clutch Support
Manifold.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.

7. Push Front Cover flush to Clutch Housing.

NOTICE: Front Cover should not be forced onto Clutch

Housing. If Cover and Housings do not meet flush,
check internal assembly.
NOTICE: Do not use cap screws to pull Front Cover to
Clutch Housing or damage may occur.

319 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Pump

8. Install 16 Front Cover 13 mm cap screws and torque to 9. Repeat steps 7 and 8 to confirm oil level.
20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

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Pump | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

321 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

Shift Rail D Magnet

Special Instructions Special Tools
None • Shift Rail Actuation Tool (RR1039TR)
• Gasket Sealant (Loctite 5188)
• Gasket Remover (Loctite SF 7631)

Component Identification

1. Ring Retainer
2. Rail D Magnet
3. Rail D Shift Yoke
4. Rail D Shift Yoke Cap Screw and Washer

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Shift Rail D Magnet | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

323 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

Remove the OEM Harness Bracket 2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.
1. Remove 4 OEM Harness Bracket 10 mm cap screws;
remove OEM Harness Bracket. Note: New Retainer Bolts, Retainer Plate and Retainer
O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

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Shift Rail D Magnet | Service Procedures TRSM0990

3. Remove the Output Yoke Remove the Transmission Range Sensor (TRS)
Note: There is an interference fit between the Output 1. Place the Transmission Cable Shift Lever in the Neutral
Yoke and output shaft splines that may require an out- (N) position.
put yoke puller.

2. Use hand tools to remove 15 mm Transmission Cable

Disconnect Shift Lever Cable Linkage Shift Lever Retaining Nut.
1. Unlock and disconnect Vehicle 4-Way Harness Con- NOTICE: Retain TRS Internal Shift Shaft position by
nector from 4-Way TRS Harness Connector. holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

325 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Remove Transmission Cable Shift Lever. Remove the Rear Housing Cover
1. Remove Output Seal Slinger Shield.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

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 Shift Rail D Magnet | Service Procedures TRSM0990

3. Separate Rear Housing Cover from Main Housing at 2 Disassemble Rear Housing with Park Pawl
pry points.
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
CAUTION: Do not pry on sealing surfaces. Failure to Rail C and place Shift Rail C in the Neutral position;
! avoid prying on sealing surface results in component remove Shift Rail Actuation Tool (RR1039TR).
damage.
Note: Confirm Rail C Synchronizer is in Neutral posi-
NOTICE: If transmission is equipped with a Park Pawl,
tion.
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Install puller Medium Jaws (CJ105-6) or equivalent

into puller crossarm as shown.

4. Remove Rear Housing Cover.

327 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. For gear pulling clearance, rotate and align Park Pawl 5. Pull off 4th Driven Gear, Park Pawl Gear and Upper
Gear tooth gap with Lower Shaft Bearing Inner Race as Shaft Rear Bearing Inner Race.
shown.
CAUTION: Ensure a Park Pawl Gear tooth gap is
CAUTION: Ensure a Park Pawl Gear tooth gap is ! aligned with the Lower Shaft Bearing Inner Race. Fail-
! aligned with the Lower Shaft Bearing Inner Race. Fail- ure to align a gear tooth with the race results in com-
ure to align a gear tooth with the race results in com- ponent damage.
ponent damage.

4. Install puller assembly onto Upper Shaft and under

Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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Shift Rail D Magnet | Service Procedures TRSM0990

7. Remove Rear Housing Spray Bar from Main Housing 9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
and end of Reverse Idler Shaft. onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C. 10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

329 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

11. Remove Lower Shaft Rear Bearing Inner Race Snap 13. Install puller assembly onto Lower Shaft and under 6th
Ring from Lower Shaft and discard. Gear with puller jaws in the 10 and 4 o'clock positions
as shown.
Note: New Snap Ring is required when reinstalling.
CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
component damage.

12. Install puller Large Jaws (CJ105-7) or equivalent into

puller crossarm as shown.

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Shift Rail D Magnet | Service Procedures TRSM0990

14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 15. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
Bearing Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

331 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

17. Remove 6th Gear Mid-Wall Bearing Spacer. 19. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disassemble Rear Housing without Park Pawl

1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR).
18. Use a magnet to remove 6th Gear Mid-Wall Spacer
Note: Confirm Rail C Synchronizer is in Neutral posi-
Alignment Ball.
tion.

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 Shift Rail D Magnet | Service Procedures TRSM0990

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing
into puller crossarm as shown. Inner Race.

3. Install puller assembly onto Upper Shaft and under 4th 5. Remove 2 Rear Lube Bar 10 mm cap screws.
Driven Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

333 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

7. Install Shift Rail Actuation Tool (RR1039TR) into Shift 9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
Rail C. mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve

onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).
10. Remove Lower Shaft Rear Bearing Inner Race Snap
Ring from Lower Shaft and discard.

Note: New Snap Ring is required when reinstalling.

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 Shift Rail D Magnet | Service Procedures TRSM0990

11. Install puller Large Jaws (CJ105-7) or equivalent into 13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
puller crossarm as shown. Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

335 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

14. Remove 6th Gear Bearing from Lower Shaft. 16. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

17. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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Shift Rail D Magnet | Service Procedures TRSM0990

18. Remove 6th Driven Gear from Upper Shaft. Remove the 3-Rail Position Sensor and Mag-
nets
1. Remove 4, 3-Rail Position Sensor T30 torx head
screws.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector. 2. Remove 3-Rail Position Sensor.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

337 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Remove the 3 Shift Rail Magnet T20 torx head screws Secure Transmission (Vertical)
from Shift Rails A, B and C.
1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

4. Remove Shift Rail Magnets A, B and C.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

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Shift Rail D Magnet | Service Procedures TRSM0990

2. Disconnect the 20-Way Vehicle and Body Harness Con- Remove the Transmission Control Module
nectors from the TCM by depressing the lock tab and (TCM) Vertically
lifting up on the levers.
1. Unscrew 4 TCM Cover nuts and remove TCM Cover.
NOTICE: Do not allow contamination into the TCM or
harness connectors. Note: TCM Cover nuts are 10 or 13 mm.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

339 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Shift Rail D Magnet | Service Procedures TRSM0990

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

341 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

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Shift Rail D Magnet | Service Procedures TRSM0990

9. Remove ACM rear lubrication O-ring. Remove the Reverse Idler Gear
Note: If O-ring is missing it may be located on ACM. 1. Remove Reverse Idler Shaft 13 mm cap screw.

10. Remove ACM to Interface Manifold Gasket.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft
and lift to remove Reverse Idler Shaft from Main Hous-
ing.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

343 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Remove Reverse Idler Gear, Bearings, and Thrust Remove the Main Housing
Washers.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

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Shift Rail D Magnet | Service Procedures TRSM0990

2. Separate Main Housing from Clutch Housing at 3 pry 3. Lift and remove Main Housing from Clutch Housing.
points.
CAUTION: Main Housing assembly weighs approxi-
NOTICE: Do not pry on sealing surfaces. Failure to ! mately 30 lbs. Dropping Main Housing assembly could
avoid prying on sealing surface results in component result in component damage and/or personal injury.
damage.

Remove the Upper Shaft

1. Lift and remove Main Housing Spray Bar from Pump
Outlet.

345 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

2. Install Shift Rail Actuation Tool (RR1039TR) into Shift 4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5
Rail B. mm) roll pin punch.

3. Push Shift Rail B downward to engage Rail B Synchro- 5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift mm) roll pin punch.
Rail Actuation Tool (RR1039TR).
Note: Roll Pins will contact Shift Rail A when remov-
Note: Place a rag over the Interface Manifold flange to ing; this is okay.
capture any oil spray.

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Shift Rail D Magnet | Service Procedures TRSM0990

6. Separate Upper and Lower Shafts to create clearance 7. Lift and remove Upper Shaft assembly.
between Reverse Gear and Lower Shaft Mid-Wall Bear-
ing when removing Upper Shaft. CAUTION: Upper Shaft assembly weighs approxi-
! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

347 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

Remove the Lower Shaft 3. Remove Rail B Synchronizer Blocking Ring and Clutch-
ing Teeth Gear.
1. Remove Rail A Shift Yoke from Shift Rail A.

4. Remove Rail D Shift Yoke 13 mm cap screw and

2. Remove Rail B Shift Yoke and Rail B Synchronizer washer.
Sleeve from Shift Rail B.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

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Shift Rail D Magnet | Service Procedures TRSM0990

5. Remove 3 Primary Input Shaft Retainer 13 mm cap 7. Lift and remove Lower Shaft assembly with Rail D Shift
screws. Yoke.

CAUTION: Lower Shaft assembly weighs approxi-

! mately 50 lbs. Dropping Lower Shaft assembly could
result in component damage and/or personal injury.

6. To create clearance when removing Lower Shaft pry on

Secondary Driven Gear to release Primary Input Shaft
from Interface Manifold.

Note: Place a rag over the Interface Manifold flange to

capture any oil spray.

349 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

Remove the Shift Rail D Magnet Install the Shift Rail D Magnet
1. Push Rail D Magnet into Rail D Shift Yoke to release 1. Align Rail D Magnet with slot in Rail D Shift Yoke.
Ring Retainer.

2. While holding Rail D Magnet in place install Magnet

Ring Retainer.

Note: Rail D Shift Yoke may be temporarily installed on

Shift Rail D to aid in Ring Retainer installation.

2. Remove Rail D Magnet from Rail D Shift Yoke.

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Shift Rail D Magnet | Service Procedures TRSM0990

Assemble the Lower Shaft 5. Install Cluster Gear assembly.

1. Place Lower Shaft Mid-Wall Bearing on Lower Shaft.

6. Install Rail D Synchronizer Blocking Ring.

2. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

7. Place Rail D Synchronizer Hub on Lower Shaft.

Note: Raised side of Synchronizer Hub faces down

3. Press on Lower Shaft Mid-Wall Bearing. toward Cluster Gear.

4. Secure Lower Shaft in the vertical position.

CAUTION: Dropping Lower Shaft assembly could

! result in component damage and/or personal injury.

351 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

8. Align Synchronizer Hub Key Slots with Synchronizer 10. Install Synchronizer Hub Key Retainer Plate.
Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

11. Place Secondary Driven Gear on Lower Shaft.

9. Align Rail D Synchronizer Hub Key Slots with detent

grooves in Rail D Synchronizer Sleeve and install
Sleeve.

NOTICE: Ensure beveled edge of Synchronizer Sleeve

faces front of transmission.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.

12. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

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Shift Rail D Magnet | Service Procedures TRSM0990

13. Press on Secondary Driven Gear. 17. Install Lower Shaft Front Ring.

14. Place Lower Shaft Front Bearing on Lower Shaft.

Install the Upper Shaft

15. Position Lower Shaft and Lower Shaft Front Bearing 1. Mark the position of Rail B Synchronizer Sleeve detent
Driver (RR1046TR) in Press. grooves to aid in installing the Upper Shaft assembly.

2. Install Rail A Shift Yoke onto Rail A Synchronizer

Sleeve.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

16. Press on Lower Shaft Front Bearing.

353 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Separate the Upper and Lower Shafts to create clear- 4. Lower and install Upper Shaft assembly with Rail A
ance between the Reverse Gear and Lower Shaft Shift Yoke onto Rail B Synchronizer Sleeve and Shift
Mid-Wall Bearing when installing Upper Shaft assem- Rail A.
bly.
CAUTION: Upper Shaft assembly weighs approxi-
NOTICE: Ensure all 3 Rail B Synchronizer Keys and ! mately 60 lbs. Dropping Upper Shaft assembly could
Springs are in Synchronizer Hub Key Slots. result in component damage and/or personal injury.
NOTICE: Ensure Synchronizer Hub Key Slots align with
detent grooves and marks on Synchronizer Sleeve.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in installation.

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Shift Rail D Magnet | Service Procedures TRSM0990

5. Install 2 Rail A Shift Yoke Roll Pins. 7. Install Main Housing Spray Bar into Pump outlet align-
ing molded-in cap over Pump cap screw head.

NOTICE: The Spray Bar molded-in cap ensures proper

Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run.

6. Install 2 Rail B Shift Yoke Roll Pins.

8. Clean Rail D Position Sensor Magnet (in place) of any

metal shavings or debris.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

355 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Apply Gasket Sealant in an 1/8" bead to the Clutch 5. Push Main Housing flush to Clutch Housing.
Housing sealing surface following the pattern below.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.

4. Lower Main Housing onto Upper Shaft, Lower Shaft, 6. Install 16 external and 5 internal Main Housing 16 mm
and Clutch Housing Dowel Pins. cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.
CAUTION: Main Housing assembly weighs approxi-
! mately 30 lbs. Dropping Main Housing assembly could NOTICE: To avoid internal transmission contamination,
result in component damage and/or personal injury. keep Main Housing cap screws separated.

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Shift Rail D Magnet | Service Procedures TRSM0990

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

357 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

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Shift Rail D Magnet | Service Procedures TRSM0990

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.

359 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

6. Latch 74-Way Connector Retainer to 74-Way Trans- 9. Install 4 ACM 10 mm cap screws and hand tighten.
mission Harness Connector.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

7. Position ACM onto ACM Alignment Pins (RR1036TR). cap screw and hand tighten.

Note: Ensure Engine Speed Sensor Connector remains Note: Assembly grease may be used to hold O-ring in
accessible after ACM installation. place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

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Shift Rail D Magnet | Service Procedures TRSM0990

11. Remove the 2 ACM Alignment Pins (RR1036TR) from 13. Torque all 6 ACM to Interface Manifold 10 mm cap
Interface Manifold outermost threaded mounting screws to 8.8-10.4 Nm (77.9-92 lb-in).
holes.

14. Torque ACM Retainer Tab 13 mm cap screw to

12. Install the 2 remaining ACM to Interface Manifold 10 20.5-25.5 Nm (15.14-18 lb-ft).
mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten. Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

361 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

15. Install Output Speed Sensor and 10 mm cap screw into 17. Connect 2-Way Transmission Harness Connector to
Main Housing and torque screw to 8.8-10.4 Nm Engine Speed Sensor Connector.
(77.9-92 lb-in).

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

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Shift Rail D Magnet | Service Procedures TRSM0990

Install the Transmission Control Module (TCM) 3. Install TCM Cover with 4 nuts over TCM studs and
Vertically torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
1. Align the TCM to the 74-Way Transmission Harness
Note: TCM Cover nuts are 10 or 13 mm.
Connector and TCM studs.

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

363 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

Connect the Transmission Control Module 4. Install Sump Pan Filter.

(TCM) Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

5. Install Sump Pan Seal into Main Housing recess if pre-

viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Shift Rail D Magnet | Service Procedures TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

365 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

10. Select “Start” Clutch Touch Point (PTP) Calibration and 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
follow on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

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Shift Rail D Magnet | Service Procedures TRSM0990

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

367 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

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Shift Rail D Magnet | Service Procedures TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

369 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Shift Rail D Magnet | Service Procedures TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

371 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

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Shift Rail D Magnet | Service Procedures TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

373 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

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 Shift Rail D Magnet | Service Procedures TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

375 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Install 5 TRS Harness Bracket to T30 torx head screws
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss- and torque to 8.8-10.4 Nm (77.9-92 lb-in).
cross pattern.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
Install the Transmission Range Sensor (TRS) cause gear selection problems.

1. Install TRS assembly on Internal Shift Shaft and push

flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

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Shift Rail D Magnet | Service Procedures TRSM0990

4. Use hand tools to install the Transmission Cable Shift 2. Slide the Output Yoke over the output shaft.
Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft). Note: The Output Yoke may require to be driven on due
to an interference fit.
NOTICE: Retain TRS Internal Shift Shaft position by
holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Nm (70.1-77.4 lb-ft).
Connect Shift Lever Cable Linkage
WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever. major vehicle component damage, severe injury or
death.
NOTICE: See OEM Service Manual for shift selector
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke 1. Position OEM Harness Bracket to Clutch Housing.

1. Clean the mating surfaces and splines on the output

shaft and Output Yoke.

377 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Shift Rail D Magnet

2. Install 4 OEM Harness Bracket 10 mm cap screws and 9. Repeat steps 7 and 8 to confirm oil level.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

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Shift Rail D Magnet | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate Rail
1. Key on with engine running.

2. Connect ServiceRanger.

3. Go To “Service Routines”.

4. Select “Start” Rail Calibration and follow on-screen

prompts.

5. Key off and wait 1 minute.

6. Key on with engine off.

7. Go To “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
8. Disconnect ServiceRanger.

9. Key off.

379 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

Rail D Position Sensor

Special Instructions Special Tools
Rail D Position Sensor procedure can be performed with None
transmission in chassis.

Component Identification

1. Retainer Clip Cap Screw

2. Retainer Clip
3. 3-Way Rail D Position Sensor Connector

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Rail D Position Sensor | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure Transmission (Vertical)

1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.
6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

381 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

Disconnect the Transmission Control Module Remove the Transmission Control Module
(TCM) (TCM) Vertically
1. Disconnect the negative battery cable. 1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

NOTICE: Leaving battery cable connected may damage Note: TCM Cover nuts are 10 or 13 mm.
the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

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Rail D Position Sensor | Service Procedures TRSM0990

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

383 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

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Rail D Position Sensor | Service Procedures TRSM0990

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

385 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

9. Remove ACM rear lubrication O-ring. Remove the Rail D Position Sensor
Note: If O-ring is missing it may be located on ACM. 1. Place Actuation Control Manifold (ACM) on bench with
Transmission Harness facing upward.

10. Remove ACM to Interface Manifold Gasket.

2. Locate 3-Way Rail D Position Sensor Connector.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

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Rail D Position Sensor | Service Procedures TRSM0990

3. Disconnect 3-Way Rail D Position Sensor Connector 5. Turn ACM over and locate Rail D Position Sensor.
from 3-Way Transmission Harness Connector.

Note: Connector gray lock tab must be unlatched and

the top of the connector depressed to remove.

6. Remove remaining Rail D Position Sensor wire retainer

clip 10 mm cap screw.

4. Remove Rail D Position Sensor wire retainer clip 10

mm cap screw.

7. Remove Rail D Position Sensor T30 torx head screw.

387 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

8. Remove Rail D Position Sensor. 3. Align Rail D Position Sensor locating pin to mounting
hole in ACM and place Rail D Position Sensor on ACM.

Install the Rail D Position Sensor

1. Place Actuation Control Manifold (ACM) on bench with
Transmission Harness facing down.

2. Locate Rail D Position Sensor position.

4. Install Rail D Position Sensor T30 torx head screw and

torque to 8.8-10.4 Nm (77.9-92 lb-in).

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Rail D Position Sensor | Service Procedures TRSM0990

5. Install Rail D Position Sensor Wire Retainer Clip 10 7. Connect 3-Way Rail D Position Sensor Connector to
mm cap screw and torque to 5.3-6.3 Nm (46.9-55.8 Transmission Harness 3-Way connector.
lb-in).
NOTICE: Ensure connector is fully seated and gray lock
tab is latched.

6. Turn ACM over and install remaining Rail D Position

Sensor Wire Retainer Clip 10 mm cap screw and
torque to 5.3-6.3 Nm (46.9-55.8 lb-in). Install the Actuation Control Module (ACM)
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

389 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

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Rail D Position Sensor | Service Procedures TRSM0990

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

391 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

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Rail D Position Sensor | Service Procedures TRSM0990

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

393 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). Connect the Transmission Control Module
(TCM)
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.

Note: TCM Cover nuts are 10 or 13 mm.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Rail D Position Sensor | Service Procedures TRSM0990

4. Install Sump Pan Filter. 6. Position Sump Pan on Main Housing.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

395 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Rail D Position Sensor

8. Ensure Oil Drain Plug is installed. If not, Install the Oil 10. Add or drain transmission oil if oil level is not within
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft) the Transmission Oil Level Operating Range based on
transmission oil temperature.
NOTICE: Do not over-torque Oil Drain Plug or damage
to threads may occur. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate Rail
Fill Oil
1. Key on with engine running.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or 2. Connect ServiceRanger.
call 1-800-826-HELP (4357).
3. Go To “Service Routines”.
1. Park vehicle in a safe area on level ground.
4. Select “Start” Rail Calibration and follow on-screen
• Select Park if equipped with a Shift Lever and prompts.
slowly release service brake to engage park pawl.
5. Key off and wait 1 minute.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels. 6. Key on with engine off.

3. Locate the transmission oil level dipstick and tube in 7. Go To “Fault Codes”.
the engine compartment and clean any dirt or debris
• If active fault code(s) is set, refer to TRTS0990 Pro-
from dipstick handle and tube.
cision Troubleshooting Guide.
4. Remove transmission oil level dipstick. • If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 8. Disconnect ServiceRanger.

6. Key on, engine running at low idle RPM. 9. Key off.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 396
TRSM0990 Service Procedures | Sump Pan and Filter

Sump Pan and Filter

Special Instructions Special Tools
Sump Pan Filter procedure can be performed with trans- None
mission in chassis.

Component Identification

1. Sump Pan Filter

2. Sump Pan
3. Sump Pan Cap Screws

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 397
TRSM0990 Service Procedures | Sump Pan and Filter

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Sump Pan and Filter | Service Procedures TRSM0990

2. Remove Sump Pan. 2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

5. Install Sump Pan Seal into Main Housing recess if pre-

viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

399 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Sump Pan and Filter

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

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Sump Pan and Filter | Service Procedures TRSM0990

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

401 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
Transmission Control Module (TCM) | Service Procedures TRSM0990

Transmission Control Module (TCM)

Special Instructions Special Tools
Transmission Control Module (TCM) procedure can be per- None
formed with transmission in chassis.

Component Identification

1. Transmission Control Module (TCM)

2. TCM Cover
3. TCM Cover Nuts

402 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
Transmission Control Module (TCM) | Service Procedures TRSM0990

Create a Service Activity Report Remove the Transmission Control Module

(TCM) Horizontally
1. Key on with engine off.
1. Unscrew 4 TCM Cover nuts and remove TCM Cover.
2. Connect ServiceRanger and create a Service Activity
Report. Note: TCM Cover nuts are 10 or 13 mm.
3. Disconnect ServiceRanger.

4. Key off.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.
2. Unscrew the 7 mm jackscrew and remove TCM from
transmission.

403 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Control Module (TCM)

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Unscrew the 7 mm jackscrew and remove TCM from
Transmission Harness Connector. transmission.

Remove the Transmission Control Module

(TCM) Vertically
1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

3. Unlatch 74-Way Connector Retainer from 74-Way

Transmission Harness Connector.

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Transmission Control Module (TCM) | Service Procedures TRSM0990

Install the Transmission Control Module (TCM) 3. Install TCM Cover with 4 nuts over TCM studs and
Vertically torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
1. Align the TCM to the 74-Way Transmission Harness
Note: TCM Cover nuts are 10 or 13 mm.
Connector and TCM studs.

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

Install the Transmission Control Module (TCM)
Horizontally
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

405 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Control Module (TCM)

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). Connect the Transmission Control Module
(TCM)
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.

Note: TCM Cover nuts are 10 or 13 mm.

Calibrate Transmission Control Module (TCM)

1. Key on with engine off.

2. Connect ServiceRanger.

3. Go To “Fault Codes”.

4. Select “Clear Eaton Faults” and follow on screen

prompts.

5. Select “Service Activity Report” and create a Service

Activity Report.

6. From the “Viewing” drop-down list select “Snapshot”.

7. Select “Clear Snapshot”.

8. Go To “Programming” and update software if available.

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Transmission Control Module (TCM) | Service Procedures TRSM0990

9. Go To “Configuration”.

10. Select “Options”.

11. In the Serial Number parameter “New Value” field enter

the transmission serial number.

12. Select “Apply” and follow on-screen prompts.

13. Select the “Calibration” tab.

14. Select the appropriate OEM vehicle application calibra-

tion.

15. Select “Apply” and follow on-screen prompts.

16. Go To “Service Routines”.

17. Select “Start” Grade Sensor Calibration and follow

on-screen prompts.

18. If vehicle is equipped with a T-Handle shift device,

select “Start” TRS Shift Device Calibration and follow
on-screen prompts.

19. Key on with engine running.

20. Select “Start” Rail Calibration and follow on-screen

prompts.

21. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

22. Select “Start” Clutch Pressure (PI) Calibration and fol-

low on-screen prompts.

23. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

24. Key off and wait 1 minute.

25. Key on with engine off.

26. Go To “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault code(s) is set, select “Clear Eaton
Faults” and follow on-screen prompts.
27. Disconnect ServiceRanger.

28. Key off.

407 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

Transmission Harness
Special Instructions Special Tools
Transmission Harness procedure can be performed with None
transmission in chassis.

Component Identification

1. Transmission Harness

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Transmission Harness | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure Transmission (Vertical)

1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.
6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

409 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

Disconnect the Transmission Control Module Remove the Transmission Control Module
(TCM) (TCM) Vertically
1. Disconnect the negative battery cable. 1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

NOTICE: Leaving battery cable connected may damage Note: TCM Cover nuts are 10 or 13 mm.
the TCM.
2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
lifting up on the levers.

NOTICE: Do not allow contamination into the TCM or

harness connectors.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

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Transmission Harness | Service Procedures TRSM0990

3. Unlatch 74-Way Connector Retainer from 74-Way 2. Remove Sump Pan.

Transmission Harness Connector.

3. Remove Sump Pan Filter

Remove the Sump Pan and Filter
Note: Ensure Sump Pan Filter neck O-ring is attached.
1. Remove 20 Sump Pan 13 mm cap screws. If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

411 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

Remove the Actuation Control Manifold (ACM) 3. Remove the 2 Transmission Harness to Main Housing
10 mm cap screws.
1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Remove Output Speed Sensor 10 mm cap screw and

pull Output Speed Sensor free from Main Housing.

2. Disconnect 2-Way Engine Speed Sensor Connector

from Transmission Harness Connector.

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Transmission Harness | Service Procedures TRSM0990

5. Remove the ACM Retainer Tab 13 mm cap screw. 7. Remove 6 ACM to Interface Manifold 10 mm cap
screws.

CAUTION: Support ACM when removing cap screws.

! Dropping ACM could result in component damage
and/or personal injury.

6. Remove ACM Retainer Tab and O-ring isolator.

Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.
8. Remove ACM/Transmission Harness assembly from
Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

413 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

9. Remove ACM rear lubrication O-ring. Remove the Transmission Harness

Note: If O-ring is missing it may be located on ACM. 1. Remove 4 Transmission Harness 10 mm cap screws.

10. Remove ACM to Interface Manifold Gasket.

2. Remove Primary Input Speed Sensor 10 mm cap
screw.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

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Transmission Harness | Service Procedures TRSM0990

3. Remove Secondary Input Speed Sensor 10 mm cap 5. Disconnect 8-Way Transmission Harness Connector
screw. from Triple Pressure Sensor.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

4. Disconnect 2-Way Transmission Harness Connector

from Oil Cooler Temperature Sensor.
6. Disconnect 3-Way Rail D Position Sensor Connector
from 3-Way Transmission Harness Connector.

Note: Connector gray lock tab must be unlatched and

the top of the connector depressed to remove.

415 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

7. Disconnect 2-Way Transmission Harness Connectors Install the Transmission Harness

from all 11 Solenoids.
1. Place the Transmission Harness on Actuation Control
Manifold (ACM).

8. Lift and remove Transmission Harness from ACM.

2. Insert Primary and Secondary Input Speed Sensors in

ACM.

Note: Do not secure Sensors with cap screws at this

time.

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Transmission Harness | Service Procedures TRSM0990

3. Connect 2-Way Transmission Harness Connectors to 5. If required, install Rail D Position Sensor wire retainer
the 11 Solenoids. clip 10 mm cap screw and torque to 5.3-6.3 Nm
(46.9-55.8 lb-in).
NOTICE: Ensure connectors are fully seated and
latched.

6. Connect 8-Way Transmission Harness Connector to

Triple Pressure Sensor (TPS).
4. Connect 3-Way Rail D Position Sensor Connector to
3-Way Transmission Harness Connector. NOTICE: Ensure connector is fully seated and red lock
tab is latched.
NOTICE: Ensure connector is fully seated and gray lock
tab is latched.

417 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

7. Connect 2-Way Transmission Harness Connector to Oil 9. Install Primary Input Speed Sensor 10 mm cap screw
Cooler Temperature Sensor. and torque to 8.8-10.4 Nm (77.9-92.0 lb-in).

NOTICE: Ensure connector is fully seated and latched.

10. Install Secondary Input Speed Sensor 10 mm cap

screw and torque to 8.8-10.4 Nm (77.9-92.0 lb-in).
8. Install 4 Transmission Harness 10 mm cap screws and
torque to 8.8-10.4 Nm (77.9-92.0 lb-in). Note: Ensure Secondary Input Speed Sensor wire is
routed under the TPS Connector.

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Transmission Harness | Service Procedures TRSM0990

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-

face Manifold outermost threaded mounting holes.

5. Route 74-Way Transmission Harness Connector into

74-Way Connector Retainer.

419 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

6. Latch 74-Way Connector Retainer to 74-Way Trans- 9. Install 4 ACM 10 mm cap screws and hand tighten.
mission Harness Connector.

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm

7. Position ACM onto ACM Alignment Pins (RR1036TR). cap screw and hand tighten.

Note: Ensure Engine Speed Sensor Connector remains Note: Assembly grease may be used to hold O-ring in
accessible after ACM installation. place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.

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Transmission Harness | Service Procedures TRSM0990

11. Remove the 2 ACM Alignment Pins (RR1036TR) from 13. Torque all 6 ACM to Interface Manifold 10 mm cap
Interface Manifold outermost threaded mounting screws to 8.8-10.4 Nm (77.9-92 lb-in).
holes.

14. Torque ACM Retainer Tab 13 mm cap screw to

12. Install the 2 remaining ACM to Interface Manifold 10 20.5-25.5 Nm (15.14-18 lb-ft).
mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten. Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

421 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

15. Install Output Speed Sensor and 10 mm cap screw into 17. Connect 2-Way Transmission Harness Connector to
Main Housing and torque screw to 8.8-10.4 Nm Engine Speed Sensor Connector.
(77.9-92 lb-in).

18. Connect 8-Way Transmission Harness Connector to

90-degree pass-through connector and latch red lock
tab.

16. Install 2 Transmission Harness to Main Housing 10

mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).

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Transmission Harness | Service Procedures TRSM0990

Install the Transmission Control Module (TCM) 3. Install TCM Cover with 4 nuts over TCM studs and
Vertically torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
1. Align the TCM to the 74-Way Transmission Harness
Note: TCM Cover nuts are 10 or 13 mm.
Connector and TCM studs.

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).

423 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

Connect the Transmission Control Module 4. Install Sump Pan Filter.

(TCM) Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.
1. Connect the 20-Way Vehicle and Body Harness Con-
nectors to the TCM Connectors by pressing levers into
the locked position.

5. Install Sump Pan Seal into Main Housing recess if pre-

viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Transmission Harness | Service Procedures TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

425 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Harness

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 426
TRSM0990 Service Procedures | Transmission Range Sensor (TRS)

Transmission Range Sensor (TRS)

Special Instructions Special Tools
Transmission Range Sensor (TRS) procedure can be per- None
formed with transmission in chassis.

Component Identification

2
1

1. Transmission Cable Shift Lever

2. Transmission Range Sensor (TRS) Assembly

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TRSM0990 Service Procedures | Transmission Range Sensor (TRS)

Disconnect Shift Lever Cable Linkage 2. Use hand tools to remove 15 mm Transmission Cable
Shift Lever Retaining Nut.
1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector. NOTICE: Retain TRS Internal Shift Shaft position by
holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

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Transmission Range Sensor (TRS) | Service Procedures TRSM0990

4. Remove 5 TRS Harness Bracket T30 torx head screws. Install the Transmission Range Sensor (TRS)
1. Install TRS assembly on Internal Shift Shaft and push
flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

2. Install 5 TRS Harness Bracket to T30 torx head screws

and torque to 8.8-10.4 Nm (77.9-92 lb-in).

429 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Transmission Range Sensor (TRS)

3. Install Transmission Cable Shift Lever on Internal Shift 2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Shaft. Harness Connector.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
cause gear selection problems.

Calibrate TRS Shift Device

1. Key on with engine off.
4. Use hand tools to install the Transmission Cable Shift 2. Connect ServiceRanger.
Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft). 3. Go To “Service Routines”.

NOTICE: Retain TRS Internal Shift Shaft position by 4. Select “Start” TRS Shift Device Calibration and follow
holding Cable Shift Lever in the Neutral (N) position on-screen prompts.
while tightening the retaining nut to prevent internal
5. Go to “Fault Codes”.
TRS damage. Do not use power tools.
• If active fault code(s) is set, refer to TRTS0990 Pro-
cision Troubleshooting Guide.
• If no active code(s) is set, select “Clear Eaton
Faults” and follow on-screen prompts.
6. Disconnect ServiceRanger.

7. Key off.

Connect Shift Lever Cable Linkage

1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever.

NOTICE: See OEM Service Manual for shift selector

cable linkage adjustment procedure.

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TRSM0990 Service Procedures | Transmission

Transmission
Special Instructions 7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
None damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

Special Tools
None

Drain Oil
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris. 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil. NOTICE: Do not over-torque Oil Drain Plug or damage
to threads may occur.

6. If PTO-equipped, remove PTO and drain oil.

Remove the Transmission
1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

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TRSM0990 Service Procedures | Transmission

5. Disconnect ServiceRanger. 10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
6. Key off. transmission oil temperature.
7. Refer to OEM guidelines for transmission removal.
! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
Install the Transmission
component damage.
1. Refer to OEM guidelines for transmission installation. NOTICE: Do not overfill transmission oil.
2. Reconnect the negativ Note: If PTO-equipped additional oil will be required.
3. e battery cable.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). 11. Re-install transmission oil level dipstick.
1. Park vehicle in a safe area on level ground.
Note: Reference the Oil Leak Inspection Process after
• Select Park if equipped with a Shift Lever and performing the steps to Fill Oil.
slowly release service brake to engage park pawl.
Calibrate Transmission
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels. 1. Key on with engine off.

3. Locate the transmission oil level dipstick and tube in 2. Connect ServiceRanger.
the engine compartment and clean any dirt or debris 3. Go To “Fault Codes”.
from dipstick handle and tube.
4. Select “Clear Eaton Faults” and follow on screen
4. Remove transmission oil level dipstick. prompts.
5. Fill transmission with 12 liters of Eaton Procision DCT 5. Select “Service Activity Report” and create a Service
transmission oil through the dipstick tube. Activity Report.
6. Key on, engine running at low idle RPM. 6. Select “Go To” menu.
7. Wipe clean the transmission oil level dipstick and 7. Go To “Programming” and update software if available.
install in dipstick tube.
8. Go To “Configuration”.
8. Remove transmission oil level dipstick and check oil
level. 9. Select “Options”.
9. Repeat steps 7 and 8 to confirm oil level. 10. Enter the transmission serial number in the “New
Value” Serial Number option.

11. Select “Apply” and follow on-screen prompts.

12. Select the “Calibration” tab.

13. Select the appropriate OEM vehicle application calibra-

tion.

14. Select “Apply” and follow on-screen prompts.

15. Go To “Service Routines”.

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Transmission | Service Procedures TRSM0990

16. Select “Start” Grade Sensor Calibration and follow

on-screen prompts.

Note: If vehicle is equipped with a T-Handle shift

device, select “Start” TRS Shift Device Calibration and
follow on-screen prompts.
17. Key on with engine running.

18. Select “Start” Rail Calibration and follow on-screen

prompts.

19. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

20. Select “Start” Clutch Pressure (PI) Calibration and fol-

low on-screen prompts.

21. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

22. Key off and wait 1 minute.

23. Key on with engine off.

24. Go To “Fault Codes”.

Note: If active fault code(s) is set, refer to TRTS0990

Procision Troubleshooting Guide.
Note: If no active fault code(s) is set, select “Clear
Eaton Faults” and follow on-screen prompts.
25. Disconnect ServiceRanger.

26. Key off.

433 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Triple Pressure Sensor

Triple Pressure Sensor

Special Instructions Special Tools
Triple Pressure Sensor (TPS) procedure can be performed None
with transmission in chassis.

Component Identification

1. Triple Pressure Sensor

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Triple Pressure Sensor | Service Procedures TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

435 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Triple Pressure Sensor

2. Remove Sump Pan. Remove the Triple Pressure Sensor

1. Locate TPS on Actuation Control Manifold (ACM).

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached. 2. Disconnect 8-Way Transmission Harness Connector
If not attached, inspect Pump inlet and remove. from Triple Pressure Sensor.
NOTICE: If O-ring must be removed from Pump inlet,
Note: Connector red lock tab must be unlatched and
do not damage Pump inlet sealing surface.
the top of the connector depressed to remove.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Triple Pressure Sensor | Service Procedures TRSM0990

3. Remove Primary Input Speed Sensor to ACM 10 mm 6. Lift Primary and Secondary Input Speed Sensors from
cap screw. ACM.

4. Remove Secondary Input Speed Sensor 10 mm cap 7. Move section of Transmission Harness above TPS
screw. slightly away from ACM to access TPS.

5. Remove 4 Transmission Harness 10 mm cap screws. 8. Remove 2 TPS 8 mm cap screws.

437 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Triple Pressure Sensor

9. Pull and remove TPS. 4. Install 2 TPS 8 mm cap screws and torque to 6.8-7.9
Nm (60.2-69.9 lb-in).

Install the Triple Pressure Sensor

5. Move section of Transmission Harness above TPS back
1. Locate TPS position on Actuation Control Manifold toward ACM and into final position.
(ACM).

2. Lightly lubricate TPS O-rings with Eaton® Procision

DCT transmission oil.

3. Install TPS into ACM.

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Triple Pressure Sensor | Service Procedures TRSM0990

6. Insert Primary and Secondary Input Speed Sensors 8. Install Primary Input Speed Sensor 10 mm cap screws
into ACM. and torque to 8.8-10.4 Nm (77.9-92 lb-in).

Note: Ensure Secondary Input Speed Sensor wire is

routed under the TPS Connector.

9. Install Secondary Input Speed Sensor 10 mm cap

screws and torque to 8.8-10.4 Nm (77.9-92 lb-in).
7. Install 4 Transmission Harness 10 mm cap screws and
torque to 8.8-10.4 Nm (77.9-92 lb-in).

439 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Triple Pressure Sensor

10. Connect 8-Way Transmission Harness Connector to 5. Install Sump Pan Seal into Main Housing recess if pre-
TPS. viously removed.

NOTICE: Ensure connector is fully seated and red lock Note: The Sump Pan Seal can only go in the Main
tab is latched. Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

6. Position Sump Pan on Main Housing.
1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

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Triple Pressure Sensor | Service Procedures TRSM0990

7. Install 20 Sump Pan 13 mm cap screws and torque to 3. Locate the transmission oil level dipstick and tube in
20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern. the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
8. Ensure Oil Drain Plug is installed. If not, Install the Oil transmission oil temperature.
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)
! CAUTION: Use only Eaton® approved lubricant
NOTICE: Do not over-torque Oil Drain Plug or damage PS-278. Failure to use specified lubricant results in
to threads may occur. component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.
Fill Oil
2. Complete engine warm-up by running engine at idle
Note: For a list of Eaton Approved Synthetic Lubricants, see speed for 15 minutes.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). Note: If Engine Idle Shutdown engine setting is pre-
venting 15-minute idle time requirement, restart engine
1. Park vehicle in a safe area on level ground. immediately after shutdown as needed to complete.
• Select Park if equipped with a Shift Lever and 3. Connect ServiceRanger.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 4. Go To “Service Routines”.

2. Set vehicle parking brake and chock wheels.

441 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Service Procedures | Triple Pressure Sensor

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

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TRSM0990 Disassembly/Assembly | Clutch Housing

Clutch Housing
Special Instructions Special Tools
None • Shift Rail Actuation Tool (RR1039TR)
• Clutch Housing Rod Seal Installer (RR1056TR)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1050TR)
• Upper Shaft Bearing Outer Race Driver
(RR1048TR)
• Universal Driver Handle (OE8044-T0)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Secondary Input Shaft

2. Primary Input Shaft
3. Primary Input Shaft Retainer Cap Screws

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TRSM0990 Disassembly/Assembly | Clutch Housing

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the Input Seal 3. Use Slide Hammer Seal Puller to remove Input Seal.

1. Drill 1/8 in. hole in Input Seal at an “indentation”

around outer edge at approximately the 6 o'clock posi-
tion.

NOTICE: Do not penetrate Input Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Input Seal or sealing surface
damage may occur.

4. Discard Input Seal.

Note: New Input Seal is required when reinstalling.

Remove Front Cover/Dual Clutch Module (DCM)

Assembly
1. Remove 16 Front Cover 13 mm cap screws.

2. Thread Slide Hammer Seal Puller screw into drilled

hole 1/4 in. deep.

NOTICE: Do not thread screw more than 6.35 mm (1/4

in.) in depth or sealing surface damage may occur.

445 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

2. Locate 2 jackscrew threaded holes in Front Cover at the 4. Use hand tools to tighten jackscrews equally in an
2 & 8 o'clock positions. alternating pattern until Front Cover separates from
Clutch Housing, then remove jackscrews.

3. Install 2 Front Cover 13 mm cap screws into jackscrew

holes. 5. Carefully pull and remove Front Cover/DCM assembly
from Clutch Housing.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.
Note: Ensure proper support for Front Cover/DCM
assembly when removing to avoid dropping.

Remove the Dual Clutch Module (DCM)

1. If replacing DCM and Clutch Support Manifold, go to
next step.

Note: If not replacing DCM and only removing to gain

access for another procedure, procedure complete. Do
not perform remaining steps.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Remove 6 Clutch Support Manifold 13 mm cap screws. 5. Position Front Cover Puller (RR1033TR) assembly on
DCM Input Shaft.

3. Remove Clutch Support Manifold.

6. Hand tighten 2 Front Cover Puller (RR1033TR) 15 mm
cap screws into Front Cover until fully seated.

4. Remove Front Cover Input Bearing Snap Ring from

DCM Input Shaft.

447 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Tighten Front Cover Puller (RR1033TR) forcing screw 10. Position Front Cover Input Bearing Driver (RR1055TR)
to remove Front Cover from DCM Input Shaft. with Universal Driver Handle (OE8044-T0) on Input
Bearing.

8. Remove Input Bearing Spiral Retaining Ring.

11. Drive Input Bearing from Front Cover.

9. Turn Front Cover face down on bench.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the Pump Driven Gear 4. Remove Pump Driven Gear.

1. Install drift into Pump Driven Gear.

Remove the OEM Harness Bracket

2. Hold drift securely against Clutch Housing to hold 1. Remove 4 OEM Harness Bracket 10 mm cap screws;
Pump Driven Gear stationary. remove OEM Harness Bracket.

CAUTION: Failure to hold Pump Driven Gear stationary

! during cap screw removal could result in component
damage and/or personal injury.
3. Remove Pump Driven Gear 13 mm cap screw.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

449 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

451 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

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Clutch Housing | Disassembly/Assembly TRSM0990

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

453 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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Clutch Housing | Disassembly/Assembly TRSM0990

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

455 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

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Clutch Housing | Disassembly/Assembly TRSM0990

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

457 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

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Clutch Housing | Disassembly/Assembly TRSM0990

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

459 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

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Clutch Housing | Disassembly/Assembly TRSM0990

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

461 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

463 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Secure Transmission (Vertical) 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
1. Securely place transmission in the vertical position lifting up on the levers.
with front side down.
NOTICE: Do not allow contamination into the TCM or
WARNING: Transmission weighs approximately 375 harness connectors.
! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Vertically Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

465 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

467 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

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Clutch Housing | Disassembly/Assembly TRSM0990

Remove the Reverse Idler Gear 3. Remove Reverse Idler Gear, Bearings, and Thrust
Washers.
1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft

and lift to remove Reverse Idler Shaft from Main Hous-
ing.

469 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Remove the Main Housing 2. Separate Main Housing from Clutch Housing at 3 pry
points.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws. NOTICE: Do not pry on sealing surfaces. Failure to
avoid prying on sealing surface results in component
NOTICE: To avoid internal transmission contamination, damage.
keep Main Housing cap screws separated.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Lift and remove Main Housing from Clutch Housing. 2. Remove 10 Pump 8 mm cap screws.

CAUTION: Main Housing assembly weighs approxi- Note: Pump cap screws are 3 different lengths. Note
! mately 30 lbs. Dropping Main Housing assembly could their proper position for re-installation.
result in component damage and/or personal injury.

Remove the Pump

1. Lift and remove Main Housing Spray Bar from Pump
Outlet.

3. Remove Pump and Gasket.

471 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Remove the Clutch Cooling Module Remove the Upper Shaft

1. Remove 5 Clutch Cooling Module Assembly 13 mm 1. Lift and remove Main Housing Spray Bar from Pump
cap screws. Outlet.

2. Remove Clutch Cooling Module with attached gasket. 2. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail B.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Push Shift Rail B downward to engage Rail B Synchro- 5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift mm) roll pin punch.
Rail Actuation Tool (RR1039TR).
Note: Roll Pins will contact Shift Rail A when remov-
Note: Place a rag over the Interface Manifold flange to ing; this is okay.
capture any oil spray.

6. Separate Upper and Lower Shafts to create clearance

4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5 between Reverse Gear and Lower Shaft Mid-Wall Bear-
mm) roll pin punch. ing when removing Upper Shaft.

473 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Lift and remove Upper Shaft assembly. Remove the Lower Shaft
CAUTION: Upper Shaft assembly weighs approxi- 1. Remove Rail A Shift Yoke from Shift Rail A.
! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

2. Remove Rail B Shift Yoke and Rail B Synchronizer

Sleeve from Shift Rail B.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Remove Rail B Synchronizer Blocking Ring and Clutch- 5. Remove 3 Primary Input Shaft Retainer 13 mm cap
ing Teeth Gear. screws.

4. Remove Rail D Shift Yoke 13 mm cap screw and 6. To create clearance when removing Lower Shaft pry on
washer. Secondary Driven Gear to release Primary Input Shaft
from Interface Manifold.

Note: Place a rag over the Interface Manifold flange to

capture any oil spray.

475 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Lift and remove Lower Shaft assembly with Rail D Shift 2. Remove Secondary Input Shaft assembly.
Yoke.

CAUTION: Lower Shaft assembly weighs approxi-

! mately 50 lbs. Dropping Lower Shaft assembly could
result in component damage and/or personal injury.

Remove the Interface Manifold

1. Remove 23 Interface Manifold 13 mm cap screws.

Note: Interface Manifold cap screws are 4 different

Remove Primary and Secondary Input Shaft lengths. Note their proper position for re-installation.

1. Remove Primary Input Shaft, Primary Input Shaft

Retainer, and Primary Input Shaft Lube Elbow assem-
bly.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Separate Interface Manifold from Clutch Housing at 3 Remove the Cartridge Filter
pry points.
1. Remove Cartridge Filter Cover with O-ring.
NOTICE: Do not pry on sealing surfaces of damage
may occur. NOTICE: Use hand tools to remove Cartridge Filter
Cover or damage to threads may occur.
Note: Cartridge Filter Cover hex end size is 15/16”.

3. Remove Interface Manifold from Clutch Housing.

2. Remove Cartridge Filter Cover O-ring.

477 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

3. Inspect the Cartridge Filter Cover O-ring for damage. Remove Shift Rail D
NOTICE: Replace the O-ring if damaged. 1. Remove Shift Rail D Detent 6 mm hex hole plug.
Note: If replacing the Cartridge Filter the Cartridge Fil-
ter Cover O-ring must be replaced.
4. Pull down to remove Cartridge Filter.

2. Remove Shift Rail D Spring and Detent.

Note: Observe and record Detent orientation for proper

re-installation.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Remove Shift Rail D. 2. Remove Interface Manifold Spacer Seal Plate and Gas-
kets.
Note: Retain O-ring on the end of the shift rail so it
does not become lost.

3. Use a small flat blade screwdriver to remove Shift Rail

(A, B. and D) Seals from Clutch Housing bores.
Disassemble the Clutch Housing
Note: Shift Rail C does not have a seal in the Clutch
1. Remove Low Pressure (LP) and High Pressure (HP) Housing.
port 6 mm hex hole plugs.

4. Turn Clutch Housing Over.

479 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

5. Remove 6 Clutch Support Manifold 13 mm cap screws. 8. Remove Seal Plate and Gasket.

6. Remove Clutch Support Manifold.

7. Remove 18 Seal Plate 10 mm cap screws.

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Clutch Housing | Disassembly/Assembly TRSM0990

Assemble the Clutch Housing 4. Position CSM on Clutch Housing.

1. Clean Clutch Housing Front Seal Plate and Clutch Sup- Note: Do not use sealant.
port Manifold (CSM) sealing surfaces of old oil and
debris.

2. Position Front Seal Plate and gasket on Clutch Hous-

ing.

5. Install 6 CSM 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft).

3. Install 18 Front Seal Plate 10 mm cap screws and

torque from the center out to 8.8-10.4 Nm ((77.9-92
lb-in).

6. Securely place Clutch Housing in the vertical position.

7. Lightly lubricate Clutch Housing Shift Rails Seals with

Eaton® Procision DCT transmission oil to aid in instal-
lation.

Note: Shift Rail C does not have a seal in the Clutch

Housing.

481 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

8. Position Shift Rail A Seal into Rail A Clutch Housing 10. Position Shift Rail B Seal into Rail B Clutch Housing
bore. bore.

9. Use Clutch Housing Rod Seal Installer (RR1056TR) to 11. Use Clutch Housing Rod Seal Installer (RR1056TR) to
seat Shift Rail A Seal into bore. seat Shift Rail B Seal into bore.

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Clutch Housing | Disassembly/Assembly TRSM0990

12. Position Shift Rail D Seal into Rail D Clutch Housing 14. Install High Pressure (HP) and Low Pressure (LP) port
bore. 6 mm hex hole plugs and torque to 19-23 Nm (14-17
lb-ft).

13. Use Clutch Housing Rod Seal Installer (RR1056TR) to

seat Shift Rail D Seal into bore. 15. Install first Spacer Seal Plate Gasket, Spacer Seal Plate
and second gasket onto Clutch Housing.

Note: Use Clutch Housing dowel pins to align.

483 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Install Shift Rail D 3. Install Shift Rail D Detent 6 mm hex hole plug and
torque to 24.5-29.5 Nm (18.1-21.8 lb-ft).
1. Install Shift Rail D while aligning Rail detent notches
with detent hole in the side of Clutch Housing.

NOTICE: Proper Rail D installation is critical to Rail D

shift operation.

Install the Cartridge Filter

1. Clean Cartridge Filter sealing surface in Clutch Housing
of old oil and debris.
2. Install Shift Rail D Detent and Spring. 2. Lightly lubricate Cartridge Filter O-ring with Eaton®
Procision DCT transmission oil.
NOTICE: Proper Detent installation orientation is criti-
cal to Rail D shift operation. 3. Install Cartridge Filter.
Note: Refer to removal notes to ensure proper orienta-
tion for Shift Rail D Detent notch engagement.

4. Clean Cartridge Filter Cover of old oil and debris.

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Clutch Housing | Disassembly/Assembly TRSM0990

5. Install Cartridge Filter Cover O-ring and lightly lubricate 2. Place the Upper Shaft Outer Bearing Race on IM bore.
with Eaton® Procision DCT transmission oil.

3. Use the Upper Shaft Mid Bearing Outer Race Driver

6. Install Cartridge Filter Cover then torque to 27.5-32.5 (RR1042TR) and Universal Driver Handle (OE8044-T0)
Nm (20.3-24 lb-ft) to drive the Upper Shaft Outer Bearing Race into bore.

NOTICE: Use hand tools to install Cartridge Filter Cover Note: Ensure Bearing Race is fully seated.
or damage to threads may occur.
Note: Cartridge Filter Cover hex end size is 15/16”.

Assemble the Interface Manifold

1. Clean Interface Manifold (IM) Upper and Lower Shaft
Bearing Race bores of old oil and debris.

485 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

4. Place the Lower Shaft Outer Bearing Race on IM bore. 7. Position Shift Rail A Seal in bottom of Interface Mani-
fold (IM) cylinder bore.

5. Use the Lower Shaft Mid Bearing Outer Race Driver

(RR1045TR) and Universal Driver Handle (OE8044-T0) 8. Use IM Housing Rod Seal Installer (RR1051TR) to seat
to drive the Upper Shaft Outer Bearing Race into bore. Shift Rail A Seal into bore.

Note: Ensure Bearing Race is fully seated.

6. Lightly lubricate Shift Rail Seals with Eaton® Procision

DCT transmission oil to aid in installation.

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Clutch Housing | Disassembly/Assembly TRSM0990

9. Position Shift Rail B Seal into bottom of IM cylinder 11. Position Shift Rail C Seal into bottom of Interface Man-
bore. ifold (IM) cylinder bore.

10. Use IM Housing Rod Seal Installer (RR1051TR) to seat 12. Use IM Housing Rod Seal Installer (RR1051TR) to seat
Shift Rail B Seal into bore. Shift Rail C Seal into bore.

487 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

13. Position Shift Rail D Seal into bottom of IM cylinder 15. Push Shift Rails A, B and C into Interface Manifold (IM)
bore. cylinders from back to front until pistons are flush with
IM surface.

14. Use IM Housing Rod Seal Installer (RR1051TR) to seat

Shift Rail D Seal into bore. 16. Loosen Shift Rail Detent Retainer (RR1057TR) pin
locking screws and pull retainer pins upward to disen-
gage shift rail detents.

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Clutch Housing | Disassembly/Assembly TRSM0990

17. Remove Shift Rail Detent Retainer (RR1057TR). 2. Install Secondary Input Shaft assembly.

18. To lock shift rail detents in correct position rotate Shift

Rails A, B, and C until rail letters, etched on shafts, are
visible in the IM rail access openings.

19. Ensure Clutch Housing is securely placed in the vertical

position with front side down.

20. Ensure IM to Clutch Housing Spacer Sealing Plate,

Gaskets and Shift Rail D are installed on Clutch Hous-
ing.

Install the Primary and Secondary Input Shaft

1. Ensure Clutch Housing assembly is securely placed in
the vertical position with front side down.

489 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

3. Install Primary Input Shaft, Primary Input Shaft Assemble the Lower Shaft
Retainer, and Primary Input Shaft Lube Elbow assem-
bly into Secondary Input Shaft. Do not install Primary 1. Place Lower Shaft Mid-Wall Bearing on Lower Shaft.
Input Shaft Retainer cap screws at this time.

NOTICE: Ensure Lube Elbow aligns with oil passage

holes in the Input Shaft assembly and Interface Mani-
fold. Improper installation will result in gear failure
when run.

2. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

3. Press on Lower Shaft Mid-Wall Bearing.

4. Secure Lower Shaft in the vertical position.

CAUTION: Dropping Lower Shaft assembly could

! result in component damage and/or personal injury.

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Clutch Housing | Disassembly/Assembly TRSM0990

5. Install Cluster Gear assembly. 8. Align Synchronizer Hub Key Slots with Synchronizer
Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

6. Install Rail D Synchronizer Blocking Ring.

9. Align Rail D Synchronizer Hub Key Slots with detent

grooves in Rail D Synchronizer Sleeve and install
Sleeve.

NOTICE: Ensure beveled edge of Synchronizer Sleeve

faces front of transmission.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.

7. Place Rail D Synchronizer Hub on Lower Shaft.

Note: Raised side of Synchronizer Hub faces down

toward Cluster Gear.

491 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

10. Install Synchronizer Hub Key Retainer Plate. 13. Press on Secondary Driven Gear.

14. Place Lower Shaft Front Bearing on Lower Shaft.

11. Place Secondary Driven Gear on Lower Shaft.

15. Position Lower Shaft and Lower Shaft Front Bearing

Driver (RR1046TR) in Press.

12. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

16. Press on Lower Shaft Front Bearing.

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Clutch Housing | Disassembly/Assembly TRSM0990

17. Install Lower Shaft Front Ring. 3. Separate the Upper and Lower Shafts to create clear-
ance between the Reverse Gear and Lower Shaft
Mid-Wall Bearing when installing Upper Shaft assem-
bly.

NOTICE: Ensure all 3 Rail B Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots.

Install the Upper Shaft

1. Mark the position of Rail B Synchronizer Sleeve detent
grooves to aid in installing the Upper Shaft assembly.

2. Install Rail A Shift Yoke onto Rail A Synchronizer

Sleeve.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

493 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

4. Lower and install Upper Shaft assembly with Rail A 5. Install 2 Rail A Shift Yoke Roll Pins.
Shift Yoke onto Rail B Synchronizer Sleeve and Shift
Rail A.

CAUTION: Upper Shaft assembly weighs approxi-

! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Synchronizer Hub Key Slots align with
detent grooves and marks on Synchronizer Sleeve.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in installation.

6. Install 2 Rail B Shift Yoke Roll Pins.

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Clutch Housing | Disassembly/Assembly TRSM0990

7. Install Main Housing Spray Bar into Pump outlet align- Install the Pump
ing molded-in cap over Pump cap screw head.
1. Position and install Pump Gasket on Clutch Housing.
NOTICE: The Spray Bar molded-in cap ensures proper
Spray Bar position for gear lubrication. Improper Note: Use small Clutch Housing Dowel Pins to ensure
installation will result in gear failure when run. proper alignment.

8. Clean Rail D Position Sensor Magnet (in place) of any 2. Align Pump with small Clutch Housing Dowel Pins and
metal shavings or debris. install Pump.

495 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

3. Install 10 Pump 8 mm cap screws and torque to 5. Clean Rail D Position Sensor Magnet (in place) of any
8.8-10.4 Nm (77.9-92 lb-in) in a crisscross pattern. metal shavings or debris.

Note: Pump cap screws are 3 different lengths. Refer

to Pump Removal notes for proper location.

Remove the Upper and Lower Mid-Wall Bearing

Outer Race
4. Install Main Housing Spray Bar into Pump outlet align-
1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm
ing molded-in cap over Pump cap screw head.
cap screws.
NOTICE: The Spray Bar molded-in cap ensures proper
Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Remove Upper Shaft Bearing Retainer Plate and shims. 4. Remove Lower Shaft Bearing Retainer Plate and shims.

Note: Keep bearing shims. Do not discard. Note: Keep bearing shims. Do not discard.

3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm 5. Position Upper Shaft Mid Bearing Outer Race Driver
cap screws. (RR1048TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race.

497 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from 8. Drive Lower Shaft Mid-Wall Bearing Outer Race from
Main Housing. Main Housing.

7. Position Lower Shaft Mid Bearing Outer Race Driver Install the Upper and Lower Mid-Wall Bearing
(RR1050TR) and Universal Driver Handle (OE8044-T0) Outer Race
onto Lower Shaft Mid-Wall Bearing Outer Race.
1. Clean Upper and Lower Shaft Mid-Wall Bearing Race
bores of old oil and debris.

2. Clean mating sealing surfaces on Main Housing and

Clutch Housing with Gasket Remover.

3. Install Upper Shaft Mid-Wall Bearing Outer Race into

Main Housing bore approximately 1/2 way.

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Clutch Housing | Disassembly/Assembly TRSM0990

4. Install Lower Shaft Mid-Wall Bearing Outer Race into 2. Push Main Housing flush to Clutch Housing.
Main Housing approximately 1/2 way.
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.

Install Main Housing without Gasket Sealant

1. Lower Main Housing onto Upper Shaft, Lower Shaft,
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.
3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
Main Housing to Clutch Housing.

Measure and Adjust End-Play

1. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

499 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

Baseline Total: =
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
End-play measurement: crisscross pattern.

Upper Shaft: + 0.002

New Shim Thickness: =

2. Measure Upper Shaft Original Bearing Shim Thickness

and record in table.

3. Add a 0.010 shim to the original Upper Shaft bearing

shim set then place shims and Upper Shaft Bearing
Retainer Plate on Main Housing.

5. Rotate Upper Shaft 8 times to center shaft.

6. Position a dial indicator plunger against end of Upper

Shaft.

7. Set dial indicator to zero.

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Clutch Housing | Disassembly/Assembly TRSM0990

8. Use a pry bar to move the Upper Shaft rearward. 14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness. 15. Rotate shaft 8 times to seat bearing to bearing race.
11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm 16. Position the dial indicator and pry on Upper Shaft to
cap screws and Upper Shaft Bearing Retainer Plate verify zero end play. If zero end play exists go to Step
from Main Housing. 25. If end play exists record measurement in table
12. Select shims to meet New Shim Thickness. below.

Note: Allowable preload is 0.000"-0.002".

13. Place Upper Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End play measurement:

Preload + 0.002

Total: =

17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

501 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

23. Remove 6 PTO cover (right side) 16 mm cap screws.

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: =

19. Measure Lower Shaft Original Bearing Shim Thickness

and record in table.

20. Add a 0.010 shim to the original Lower Shaft bearing

shim set then place shims and Lower Shaft Bearing
Retainer Plate on Main Housing.

24. Remove PTO cover.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern.

25. Position dial indicator plunger against end of Lower

Shaft.

22. Rotate Lower Shaft 8 times to center shaft.

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Clutch Housing | Disassembly/Assembly TRSM0990

26. Set dial indicator to zero. 33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
27. Use a pry bar through PTO opening to move the Lower a crisscross pattern.
Shaft rearward.

34. Rotate shaft 8 times to seat bearing to bearing race.

28. Record end-play reading in a table.
35. Position the dial indicator and pry on Lower Shaft to
29. Use table to calculate New Shim Thickness. verify zero end play. If zero end play go to Step 44. If
30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm end play exists record measurement in table below.
cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End-play measurement:

Preload + 0.002

Total: =

36. Remove the Lower Shaft Bearing Retainer Plate and

the “Total” number amount of shims calculated in the
table above then repeat Steps 32-35.

503 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Remove the Main Housing 2. Inspect threaded bolt holes for debris and clean if nec-
essary.
1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing. NOTICE: Ensure there is nothing in the threaded bolt
holes or the Clutch Housing may be damaged when
cap screws are tightened.
3. Apply Gasket Sealant in an 1/8" bead to the Clutch
Housing sealing surface following the pattern below.

2. Lift and remove Main Housing from Clutch Housing.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

4. Lower Main Housing onto Upper Shaft, Lower Shaft,

and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.

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Clutch Housing | Disassembly/Assembly TRSM0990

5. Push Main Housing flush to Clutch Housing. Install the PTO Cover
Note: A rubber hammer may be used to gently tap 1. Clean sealing surfaces on the PTO Cover and Main
Main Housing onto Clutch Housing Dowel Pins. Housing with Gasket Remover.
NOTICE: Main Housing should not be forced onto
NOTICE: Do not use abrasive scrapers or power tools
Clutch Housing. If Housings do not meet flush check
to clean sealing surfaces.
internal assembly.
2. Inspect threaded bolt holes for debris and clean if nec-
NOTICE: Do not use cap screws to pull Main Housing
essary.
to Clutch Housing.
NOTICE: Ensure there is nothing in the threaded bolt
holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

505 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

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Clutch Housing | Disassembly/Assembly TRSM0990

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

507 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

Install the 90-Degree Connector 3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
1. Locate and position 90-Degree Connector in Main
Housing.

Install the Actuation Control Module (ACM)

2. Install 2 90-Degree Connector 10 mm cap screws and 1. Install ACM rear lubrication O-ring.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: Assembly grease can be used to hold O-ring in
place.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

509 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

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Clutch Housing | Disassembly/Assembly TRSM0990

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

511 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Horizontally
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). 4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
Note: TCM Cover nuts are 10 or 13 mm. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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TRSM0990 Disassembly/Assembly | Clutch Housing

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

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Clutch Housing | Disassembly/Assembly TRSM0990

7. Select “Start” Line Pressure Calibration and follow 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

515 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

517 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

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Clutch Housing | Disassembly/Assembly TRSM0990

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

519 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

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Clutch Housing | Disassembly/Assembly TRSM0990

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

521 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

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Clutch Housing | Disassembly/Assembly TRSM0990

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

523 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

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Clutch Housing | Disassembly/Assembly TRSM0990

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Slide the Output Yoke over the output shaft.
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern. Note: The Output Yoke may require to be driven on due
to an interference fit.
Note: Three Rear Housing Cover cap screws are a dif-
ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Connect Shift Lever Cable Linkage Nm (70.1-77.4 lb-ft).

1. Install transmission shift selector cable linkage to WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
Transmission Cable Shift Lever.
major vehicle component damage, severe injury or
NOTICE: See OEM Service Manual for shift selector death.
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke
1. Position OEM Harness Bracket to Clutch Housing.
1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

525 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

2. Install 4 OEM Harness Bracket 10 mm cap screws and 3. Install drift into Pump Driven Gear.
torque to 8.8-10.4 Nm (77.9-92 lb-in).

4. Hold drift securely against Clutch Housing to hold

Install Pump Driven Gear Pump Driven Gear stationary and torque Pump Driven
Gear 13 mm cap screw to 32.5-39.5 Nm (24.0-29.1
1. Align and install Pump Driven Gear onto Pump Drive- lb-ft).
shaft with raised side toward Pump Driveshaft.
CAUTION: Failure to hold Pump Driven Gear stationary
Note: Ensure proper alignment of Gear square opening ! during cap screw installation could result in compo-
onto Driveshaft. nent damage and/or personal injury.

2. Install Pump Driven Gear 13 mm cap screw and hand Install the Dual Clutch Module (DCM)
tighten.
1. Place Front Cover face up on bench.
Note: Do not torque cap screw yet.

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Clutch Housing | Disassembly/Assembly TRSM0990

2. Position Input Bearing on Front Cover. 5. Support DCM on bench by setting it on Input Seal
Driver (RR1032TR).

3. Use Front Cover Input Bearing Driver (RR1055TR) with

Universal Driver Handle (OE8044-T0) to drive Input
Bearing into Front Cover.

6. Place Front Cover on DCM Input Shaft.

4. Install Input Bearing Spiral Retaining Ring.

7. Place Input Bearing Driver (RR1049TR) on Input Bear-

ing.

527 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

8. Drive Input Bearing and Front Cover onto DCM Input 11. Position CSM to Clutch Housing.
Shaft until fully seated.
Note: Do not use sealant.

9. Install Input Shaft Ring.

12. Install 6 CSM 13 mm cap screws and torque to
20.5-25.5 Nm (15.1-18.8 lb-ft).

10. Clean Clutch Support Manifold (CSM) sealing surfaces

of old oil and debris.
13. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
14. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

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Clutch Housing | Disassembly/Assembly TRSM0990

15. Apply Gasket Sealant in an 1/8” bead inward of all cap 3. Apply Gasket Sealant in an 1/8” bead inward of all cap
screw holes to the Clutch Housing sealing surface fol- screw holes to the Clutch Housing sealing surface fol-
lowing the pattern below. lowing the pattern below.

Install Front Cover/Dual Clutch Module (DCM) 4. Install Front Cover/DCM assembly onto Clutch Support
Assembly Manifold.

CAUTION: Front Cover/DCM assembly weighs approxi-

1. Clean sealing surfaces on Front Cover and Clutch ! mately 45 lbs. Keep fingers clear of pinch point
Housing with Gasket Remover.
between Front Cover and Clutch Housing. Dropping
NOTICE: Do not use abrasive scrapers or power tools Front Cover/DCM assembly could result in component
to clean sealing surfaces. damage and/or personal injury.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

529 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

5. Rotate and push DCM Input Shaft to align DCM onto 8. Install 16 Front Cover 13 mm cap screws and torque to
both transmission Input Shafts and the Pump Driven 20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
Gear.

Install the Input Seal

6. Rotate Front Cover so “TOP” is at the 12 o'clock posi-
tion. 1. Clean Dual Clutch Module (DCM) Input Shaft and Front
Cover sealing surfaces of old oil and debris.
Note: Ensure Front Cover dowel holes are aligned with
Clutch Housing Dowel pins. 2. Lightly lubricate Input Seal lip with Eaton® Procision
DCT transmission oil.

7. Push Front Cover flush to Clutch Housing.

NOTICE: Front Cover should not be forced onto Clutch

Housing. If Cover and Housings do not meet flush,
check internal assembly.
NOTICE: Do not use cap screws to pull Front Cover to
Clutch Housing or damage may occur.

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Clutch Housing | Disassembly/Assembly TRSM0990

3. Install Input Seal on Input Seal Installer (RR1038TR) 5. With seal lip facing the transmission, place Input Seal
with a rotating and pushing motion until seal is 1/2 in. Installer (RR1038TR) with Input Seal on DCM input
from the end. shaft.

4. Inspect Input Seal installation on Input Seal Installer 6. Position Input Seal Driver (RR1032TR) over DCM
(RR1038TR) to ensure seal lip has not flipped. Input Shaft onto Input Seal.

531 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

7. Drive Input Seal into Front Cover until fully seated. 1. Park vehicle in a safe area on level ground.

Note: Front of seal will be flush with Front Cover when • Select Park if equipped with a Shift Lever and
fully seated. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

8. Remove Input Seal Installer (RR1038TR) level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

Install the Transmission

1. Refer to OEM guidelines for transmission installation. 11. Re-install transmission oil level dipstick.
2. Reconnect the negativ Note: Reference the Oil Leak Inspection Process after
3. e battery cable. performing the steps to Fill Oil.

Fill Oil Fill Oil

Note: For a list of Eaton Approved Synthetic Lubricants, see Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). call 1-800-826-HELP (4357).

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Clutch Housing | Disassembly/Assembly TRSM0990

1. Park vehicle in a safe area on level ground. 3. Confirm engine is running at low idle RPM.

• Select Park if equipped with a Shift Lever and 4. Locate the transmission oil level dipstick and tube in
slowly release service brake to engage park pawl. the engine compartment and clean any dirt or debris
• Select Neutral if equipped with a Push Button. from dipstick and tube.

2. Set vehicle parking brake and chock wheels. 5. Remove the transmission oil level dipstick.

3. Locate the transmission oil level dipstick and tube in 6. Wipe transmission oil dipstick clean and reinstall into
the engine compartment and clean any dirt or debris tube.
from dipstick handle and tube.
7. Remove the transmission oil level dipstick and inspect
4. Remove transmission oil level dipstick. oil level.

5. Fill transmission with 12 liters of Eaton Procision DCT 8. Repeat Steps 6 and 7 to confirm oil level.
transmission oil through the dipstick tube.
9. Add or drain transmission oil if oil level is not within
6. Key on, engine running at low idle RPM. the Transmission Oil Level Operating Range based on
transmission oil temperature.
7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
8. Remove transmission oil level dipstick and check oil component damage.
level.
NOTICE: Do not overfill transmission oil.
9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
10. Re-install the transmission oil level dipstick.
component damage.
NOTICE: Do not overfill transmission oil. Calibrate and Clear Faults
Note: If PTO-equipped additional oil will be required. 1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
11. Re-install transmission oil level dipstick. 3. Connect ServiceRanger.
Note: Reference the Oil Leak Inspection Process after 4. Go To “Service Routines”.
performing the steps to Fill Oil.
5. Use engine high-idle switch or cruise control switch in
Inspect Oil Level cab to raise engine idle speed to 950 RPM.
1. Park vehicle in a safe area on level ground. Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 6.
• Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. 6. Select “Start” Rail Calibration and follow on-screen
• Select Neutral if equipped with a Push Button. prompts.

2. Set vehicle parking brake and chock wheels. 7. Select “Start” Line Pressure Calibration and follow
on-screen prompts.

533 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Clutch Housing

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

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TRSM0990 Disassembly/Assembly | Front Cover

Front Cover
Special Instructions Special Tools
None • Front Cover Input Bearing Driver (RR1055TR)
• Universal Driver Handle (OE8044-T0)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1
3
2

1. Front Cover Cap Screws

2. Input Bearing Spiral Retaining Ring
3. Input Bearing
4. Front Cover

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TRSM0990 Disassembly/Assembly | Front Cover

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

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Front Cover | Disassembly/Assembly TRSM0990

Remove the Input Seal 3. Use Slide Hammer Seal Puller to remove Input Seal.

1. Drill 1/8 in. hole in Input Seal at an “indentation”

around outer edge at approximately the 6 o'clock posi-
tion.

NOTICE: Do not penetrate Input Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Input Seal or sealing surface
damage may occur.

4. Discard Input Seal.

Note: New Input Seal is required when reinstalling.

Remove Front Cover/Dual Clutch Module (DCM)

Assembly
1. Remove 16 Front Cover 13 mm cap screws.

2. Thread Slide Hammer Seal Puller screw into drilled

hole 1/4 in. deep.

NOTICE: Do not thread screw more than 6.35 mm (1/4

in.) in depth or sealing surface damage may occur.

537 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

2. Locate 2 jackscrew threaded holes in Front Cover at the 4. Use hand tools to tighten jackscrews equally in an
2 & 8 o'clock positions. alternating pattern until Front Cover separates from
Clutch Housing, then remove jackscrews.

3. Install 2 Front Cover 13 mm cap screws into jackscrew

holes. 5. Carefully pull and remove Front Cover/DCM assembly
from Clutch Housing.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.
Note: Ensure proper support for Front Cover/DCM
assembly when removing to avoid dropping.

Remove the Dual Clutch Module (DCM)

1. If replacing DCM and Clutch Support Manifold, go to
next step.

Note: If not replacing DCM and only removing to gain

access for another procedure, procedure complete. Do
not perform remaining steps.

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Front Cover | Disassembly/Assembly TRSM0990

2. Remove 6 Clutch Support Manifold 13 mm cap screws. 5. Position Front Cover Puller (RR1033TR) assembly on
DCM Input Shaft.

3. Remove Clutch Support Manifold.

6. Hand tighten 2 Front Cover Puller (RR1033TR) 15 mm
cap screws into Front Cover until fully seated.

4. Remove Front Cover Input Bearing Snap Ring from

DCM Input Shaft.

539 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

7. Tighten Front Cover Puller (RR1033TR) forcing screw 10. Position Front Cover Input Bearing Driver (RR1055TR)
to remove Front Cover from DCM Input Shaft. with Universal Driver Handle (OE8044-T0) on Input
Bearing.

8. Remove Input Bearing Spiral Retaining Ring.

11. Drive Input Bearing from Front Cover.

9. Turn Front Cover face down on bench.

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Front Cover | Disassembly/Assembly TRSM0990

Disassemble the Front Cover 4. Drive Input Bearing from Front Cover.

1. Remove Input Bearing Spiral Retaining Ring.

Assemble the Front Cover

2. Turn Front Cover face down on bench. 1. Place Front Cover face up on bench

3. Position Front Cover Input Bearing Driver (RR1055TR)

with Universal Driver Handle (OE8044-T0) to drive
Input Bearing from Front Cover.

2. Position Input Bearing on Front Cover.

541 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

3. Use Front Cover Input Bearing Driver (RR1055TR) 2. Position Input Bearing on Front Cover.
with Universal Driver Handle (OE8044-T0) to drive
Input Bearing into Front Cover.

3. Use Front Cover Input Bearing Driver (RR1055TR) with

Universal Driver Handle (OE8044-T0) to drive Input
4. Install Input Bearing Spiral Retaining Ring. Bearing into Front Cover.

Install the Dual Clutch Module (DCM) 4. Install Input Bearing Spiral Retaining Ring.

1. Place Front Cover face up on bench.

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Front Cover | Disassembly/Assembly TRSM0990

5. Support DCM on bench by setting it on Input Seal 8. Drive Input Bearing and Front Cover onto DCM Input
Driver (RR1032TR). Shaft until fully seated.

9. Install Input Shaft Ring.

6. Place Front Cover on DCM Input Shaft.

10. Clean Clutch Support Manifold (CSM) sealing surfaces

of old oil and debris.

7. Place Input Bearing Driver (RR1049TR) on Input Bear-

ing.

543 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

11. Position CSM to Clutch Housing. 15. Apply Gasket Sealant in an 1/8” bead inward of all cap
screw holes to the Clutch Housing sealing surface fol-
Note: Do not use sealant. lowing the pattern below.

12. Install 6 CSM 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft).

Install Front Cover/Dual Clutch Module (DCM)

Assembly
1. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.
13. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
14. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

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Front Cover | Disassembly/Assembly TRSM0990

3. Apply Gasket Sealant in an 1/8” bead inward of all cap 5. Rotate and push DCM Input Shaft to align DCM onto
screw holes to the Clutch Housing sealing surface fol- both transmission Input Shafts and the Pump Driven
lowing the pattern below. Gear.

6. Rotate Front Cover so “TOP” is at the 12 o'clock posi-

tion.

Note: Ensure Front Cover dowel holes are aligned with

Clutch Housing Dowel pins.
4. Install Front Cover/DCM assembly onto Clutch Support
Manifold.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.

7. Push Front Cover flush to Clutch Housing.

NOTICE: Front Cover should not be forced onto Clutch

Housing. If Cover and Housings do not meet flush,
check internal assembly.
NOTICE: Do not use cap screws to pull Front Cover to
Clutch Housing or damage may occur.

545 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

8. Install 16 Front Cover 13 mm cap screws and torque to 3. Install Input Seal on Input Seal Installer (RR1038TR)
20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern. with a rotating and pushing motion until seal is 1/2 in.
from the end.

Install the Input Seal

4. Inspect Input Seal installation on Input Seal Installer
1. Clean Dual Clutch Module (DCM) Input Shaft and Front (RR1038TR) to ensure seal lip has not flipped.
Cover sealing surfaces of old oil and debris.

2. Lightly lubricate Input Seal lip with Eaton® Procision

DCT transmission oil.

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Front Cover | Disassembly/Assembly TRSM0990

5. With seal lip facing the transmission, place Input Seal 7. Drive Input Seal into Front Cover until fully seated.
Installer (RR1038TR) with Input Seal on DCM input
shaft. Note: Front of seal will be flush with Front Cover when
fully seated.

6. Position Input Seal Driver (RR1032TR) over DCM

Input Shaft onto Input Seal. 8. Remove Input Seal Installer (RR1038TR)

Install the Transmission

1. Refer to OEM guidelines for transmission installation.

2. Reconnect the negativ

3. e battery cable.

Fill Oil
Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).

547 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Front Cover

1. Park vehicle in a safe area on level ground. 1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. • Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels. 2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris the engine compartment and clean any dirt or debris
from dipstick handle and tube. from dipstick handle and tube.

4. Remove transmission oil level dipstick. 4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM. 6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. install in dipstick tube.

8. Remove transmission oil level dipstick and check oil 8. Remove transmission oil level dipstick and check oil
level. level.

9. Repeat steps 7 and 8 to confirm oil level. 9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within 10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on the Transmission Oil Level Operating Range based on
transmission oil temperature. transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in PS-278. Failure to use specified lubricant results in
component damage. component damage.
NOTICE: Do not overfill transmission oil. NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required. Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick. 11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after Note: Reference the Oil Leak Inspection Process after
performing the steps to Fill Oil. performing the steps to Fill Oil.

Fill Oil Inspect Oil Level

Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

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Front Cover | Disassembly/Assembly TRSM0990

3. Confirm engine is running at low idle RPM. 8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.
4. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris Note: If vehicle is not equipped with high-idle switch or
from dipstick and tube. cruise control switch, go to Step 9.

5. Remove the transmission oil level dipstick. 9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.
6. Wipe transmission oil dipstick clean and reinstall into
tube. 10. Select “Start” Clutch Touch Point (PTP) Calibration and
follow on-screen prompts.
7. Remove the transmission oil level dipstick and inspect
oil level. 11. Key off and wait 1 minute.

8. Repeat Steps 6 and 7 to confirm oil level. 12. Key on with engine off.

9. Add or drain transmission oil if oil level is not within 13. Go to “Fault Codes”.
the Transmission Oil Level Operating Range based on
transmission oil temperature. • If active fault code(s) is set, refer to TRTS0990 Pro-
cision Troubleshooting Guide.
! CAUTION: Use only Eaton® approved lubricant • If no active fault codes, select “Clear Eaton Faults”
PS-278. Failure to use specified lubricant results in and follow on-screen prompts.
component damage.
14. Disconnect ServiceRanger.
NOTICE: Do not overfill transmission oil.
15. Key off.

10. Re-install the transmission oil level dipstick.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

549 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Interface Manifold
Special Instructions Special Tools
None • Shift Rail Actuation Tool (RR1039TR)
• Shift Rail Detent Retainer (RR1057TR)
• Universal Driver Handle (OE8044-T0)
• Upper Shaft Mid Bearing Outer Race Driver (Case)
(RR1048TR)
• Lower Shaft Mid Bearing Outer Race Driver (Case)
(RR1050TR)
• IM Housing Rod Seal Installer (RR1051TR)
• Upper Shaft Mid Bearing Outer Race Driver
(RR1042TR)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1045TR)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Interface Manifold

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Interface Manifold | Disassembly/Assembly TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

Activity Report.

4. Select “Close Report”.

5. Disconnect ServiceRanger.

6. Key off.
6. If PTO-equipped, remove PTO and drain oil.
7. Refer to OEM guidelines for transmission removal.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Secure the Transmission (Horizontal)
Note: O-ring is serviced with plug. 1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

551 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Input Seal 3. Use Slide Hammer Seal Puller to remove Input Seal.

1. Drill 1/8 in. hole in Input Seal at an “indentation”

around outer edge at approximately the 6 o'clock posi-
tion.

NOTICE: Do not penetrate Input Seal more than 6.35

mm (1/4 in.) in depth or sealing surface damage may
occur.
NOTICE: Do not use screwdriver or other type of pry-
ing device to remove Input Seal or sealing surface
damage may occur.

4. Discard Input Seal.

Note: New Input Seal is required when reinstalling.

Remove Front Cover/Dual Clutch Module (DCM)

Assembly
1. Remove 16 Front Cover 13 mm cap screws.

2. Thread Slide Hammer Seal Puller screw into drilled

hole 1/4 in. deep.

NOTICE: Do not thread screw more than 6.35 mm (1/4

in.) in depth or sealing surface damage may occur.

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Interface Manifold | Disassembly/Assembly TRSM0990

2. Locate 2 jackscrew threaded holes in Front Cover at the 4. Use hand tools to tighten jackscrews equally in an
2 & 8 o'clock positions. alternating pattern until Front Cover separates from
Clutch Housing, then remove jackscrews.

3. Install 2 Front Cover 13 mm cap screws into jackscrew

holes. 5. Carefully pull and remove Front Cover/DCM assembly
from Clutch Housing.

CAUTION: Front Cover/DCM assembly weighs approxi-

! mately 45 lbs. Keep fingers clear of pinch point
between Front Cover and Clutch Housing. Dropping
Front Cover/DCM assembly could result in component
damage and/or personal injury.
Note: Ensure proper support for Front Cover/DCM
assembly when removing to avoid dropping.

Remove the Dual Clutch Module (DCM)

1. If replacing DCM and Clutch Support Manifold, go to
next step.

Note: If not replacing DCM and only removing to gain

access for another procedure, procedure complete. Do
not perform remaining steps.

553 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Remove 6 Clutch Support Manifold 13 mm cap screws. 5. Position Front Cover Puller (RR1033TR) assembly on
DCM Input Shaft.

3. Remove Clutch Support Manifold.

6. Hand tighten 2 Front Cover Puller (RR1033TR) 15 mm
cap screws into Front Cover until fully seated.

4. Remove Front Cover Input Bearing Snap Ring from

DCM Input Shaft.

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Interface Manifold | Disassembly/Assembly TRSM0990

7. Tighten Front Cover Puller (RR1033TR) forcing screw 10. Position Front Cover Input Bearing Driver (RR1055TR)
to remove Front Cover from DCM Input Shaft. with Universal Driver Handle (OE8044-T0) on Input
Bearing.

8. Remove Input Bearing Spiral Retaining Ring.

11. Drive Input Bearing from Front Cover.

9. Turn Front Cover face down on bench.

555 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Pump Driven Gear 4. Remove Pump Driven Gear.

1. Install drift into Pump Driven Gear.

Remove the OEM Harness Bracket

2. Hold drift securely against Clutch Housing to hold 1. Remove 4 OEM Harness Bracket 10 mm cap screws;
Pump Driven Gear stationary. remove OEM Harness Bracket.

CAUTION: Failure to hold Pump Driven Gear stationary

! during cap screw removal could result in component
damage and/or personal injury.
3. Remove Pump Driven Gear 13 mm cap screw.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

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Interface Manifold | Disassembly/Assembly TRSM0990

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

557 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

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Interface Manifold | Disassembly/Assembly TRSM0990

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

559 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

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 Interface Manifold | Disassembly/Assembly TRSM0990

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

561 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

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 Interface Manifold | Disassembly/Assembly TRSM0990

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

563 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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Interface Manifold | Disassembly/Assembly TRSM0990

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

565 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

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Interface Manifold | Disassembly/Assembly TRSM0990

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

567 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

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Interface Manifold | Disassembly/Assembly TRSM0990

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

569 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

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Interface Manifold | Disassembly/Assembly TRSM0990

Secure Transmission (Vertical) 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
1. Securely place transmission in the vertical position lifting up on the levers.
with front side down.
NOTICE: Do not allow contamination into the TCM or
WARNING: Transmission weighs approximately 375 harness connectors.
! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

571 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Vertically Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

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Interface Manifold | Disassembly/Assembly TRSM0990

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

573 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

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Interface Manifold | Disassembly/Assembly TRSM0990

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

575 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Reverse Idler Gear 3. Remove Reverse Idler Gear, Bearings, and Thrust
Washers.
1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft

and lift to remove Reverse Idler Shaft from Main Hous-
ing.

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Interface Manifold | Disassembly/Assembly TRSM0990

Remove the Main Housing 2. Separate Main Housing from Clutch Housing at 3 pry
points.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws. NOTICE: Do not pry on sealing surfaces. Failure to
avoid prying on sealing surface results in component
NOTICE: To avoid internal transmission contamination, damage.
keep Main Housing cap screws separated.

577 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Lift and remove Main Housing from Clutch Housing. 2. Remove 10 Pump 8 mm cap screws.

CAUTION: Main Housing assembly weighs approxi- Note: Pump cap screws are 3 different lengths. Note
! mately 30 lbs. Dropping Main Housing assembly could their proper position for re-installation.
result in component damage and/or personal injury.

Remove the Pump

1. Lift and remove Main Housing Spray Bar from Pump
Outlet.

3. Remove Pump and Gasket.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 578
Interface Manifold | Disassembly/Assembly TRSM0990

Remove the Clutch Cooling Module Remove the Upper Shaft

1. Remove 5 Clutch Cooling Module Assembly 13 mm 1. Lift and remove Main Housing Spray Bar from Pump
cap screws. Outlet.

2. Remove Clutch Cooling Module with attached gasket. 2. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail B.

579 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Push Shift Rail B downward to engage Rail B Synchro- 5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift mm) roll pin punch.
Rail Actuation Tool (RR1039TR).
Note: Roll Pins will contact Shift Rail A when remov-
Note: Place a rag over the Interface Manifold flange to ing; this is okay.
capture any oil spray.

6. Separate Upper and Lower Shafts to create clearance

4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5 between Reverse Gear and Lower Shaft Mid-Wall Bear-
mm) roll pin punch. ing when removing Upper Shaft.

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Interface Manifold | Disassembly/Assembly TRSM0990

7. Lift and remove Upper Shaft assembly. Remove the Lower Shaft
CAUTION: Upper Shaft assembly weighs approxi- 1. Remove Rail A Shift Yoke from Shift Rail A.
! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

2. Remove Rail B Shift Yoke and Rail B Synchronizer

Sleeve from Shift Rail B.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

581 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Remove Rail B Synchronizer Blocking Ring and Clutch- 5. Remove 3 Primary Input Shaft Retainer 13 mm cap
ing Teeth Gear. screws.

4. Remove Rail D Shift Yoke 13 mm cap screw and 6. To create clearance when removing Lower Shaft pry on
washer. Secondary Driven Gear to release Primary Input Shaft
from Interface Manifold.

Note: Place a rag over the Interface Manifold flange to

capture any oil spray.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 582
Interface Manifold | Disassembly/Assembly TRSM0990

7. Lift and remove Lower Shaft assembly with Rail D Shift 2. Remove Secondary Input Shaft assembly.
Yoke.

CAUTION: Lower Shaft assembly weighs approxi-

! mately 50 lbs. Dropping Lower Shaft assembly could
result in component damage and/or personal injury.

Remove Primary and Secondary Input Shaft

1. Remove Primary Input Shaft, Primary Input Shaft
Retainer, and Primary Input Shaft Lube Elbow assem-
bly.

583 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Remove the Interface Manifold 2. Separate Interface Manifold from Clutch Housing at 3
pry points.
1. Remove 23 Interface Manifold 13 mm cap screws.
NOTICE: Do not pry on sealing surfaces of damage
Note: Interface Manifold cap screws are 4 different may occur.
lengths. Note their proper position for re-installation.

3. Remove Interface Manifold from Clutch Housing.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 584
Interface Manifold | Disassembly/Assembly TRSM0990

Disassemble the Interface Manifold 3. Loosen Shift Rail Detent Retainer (RR1057TR) pin
locking screws and push retainer pins downward into
1. Rotate Shift Rails A, B and C 180-degrees to push shift detent retaining holes.
rail springs and detents into retainer locking position.

4. Hand tighten Shift Rail Detent Retainer (RR1057TR)

2. Install Shift Rail Detent Retainer (RR1057TR) and hand pin locking screws to lock retainer pins into shift rail
tighten Allen head screw. detents, holding them in place.

585 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

5. Push Shift Rails A, B and C through the bottom of the 7. Use a small flat blade screwdriver to remove Shift Rail
Interface Manifold to remove. Seal D from its bore.

NOTICE: Position screwdriver directly on seal when

removing to avoid damage to Shift Rail cylinder bore.

6. Use a small flat blade screwdriver through the shift rail

access openings to remove Shift Rail Seals A, B, and C
from their bores.
8. Remove the Lower Shaft Front Bearing Race from
NOTICE: Position screwdriver directly on seal when Interface Manifold with a medium size crowfoot
removing to avoid damage to Shift Rail cylinder bore.
NOTICE: Use two small reliefs in Interface Manifold to
gain access.

9. Turn over the Interface Manifold.

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Interface Manifold | Disassembly/Assembly TRSM0990

10. Drive Secondary Input Shaft Bearing Race out of Inter- Assemble the Interface Manifold
face Manifold with 7/32" (5.5 mm) Roll Pin punch.
1. Clean Interface Manifold (IM) Upper and Lower Shaft
Note: Use two small reliefs in the Interface Manifold to Bearing Race bores of old oil and debris.
gain access to back of Bearing Race.
2. Place the Upper Shaft Outer Bearing Race on IM bore.

3. Use the Upper Shaft Mid Bearing Outer Race Driver

(RR1042TR) and Universal Driver Handle (OE8044-T0)
to drive the Upper Shaft Outer Bearing Race into bore.

Note: Ensure Bearing Race is fully seated.

587 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

4. Place the Lower Shaft Outer Bearing Race on IM bore. 7. Position Shift Rail A Seal in bottom of Interface Mani-
fold (IM) cylinder bore.

5. Use the Lower Shaft Mid Bearing Outer Race Driver

(RR1045TR) and Universal Driver Handle (OE8044-T0) 8. Use IM Housing Rod Seal Installer (RR1051TR) to seat
to drive the Upper Shaft Outer Bearing Race into bore. Shift Rail A Seal into bore.

Note: Ensure Bearing Race is fully seated.

6. Lightly lubricate Shift Rail Seals with Eaton® Procision

DCT transmission oil to aid in installation.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 588
Interface Manifold | Disassembly/Assembly TRSM0990

9. Position Shift Rail B Seal into bottom of IM cylinder 11. Position Shift Rail C Seal into bottom of Interface Man-
bore. ifold (IM) cylinder bore.

10. Use IM Housing Rod Seal Installer (RR1051TR) to seat 12. Use IM Housing Rod Seal Installer (RR1051TR) to seat
Shift Rail B Seal into bore. Shift Rail C Seal into bore.

589 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

13. Position Shift Rail D Seal into bottom of IM cylinder 15. Push Shift Rails A, B and C into Interface Manifold (IM)
bore. cylinders from back to front until pistons are flush with
IM surface.

14. Use IM Housing Rod Seal Installer (RR1051TR) to seat

Shift Rail D Seal into bore. 16. Loosen Shift Rail Detent Retainer (RR1057TR) pin
locking screws and pull retainer pins upward to disen-
gage shift rail detents.

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Interface Manifold | Disassembly/Assembly TRSM0990

17. Remove Shift Rail Detent Retainer (RR1057TR). Install the Interface Manifold
1. Place Interface Manifold (IM) on Spacer Sealing Plate
Gasket.

Note: Use Clutch Housing Dowel Pins to align.

18. To lock shift rail detents in correct position rotate Shift

Rails A, B, and C until rail letters, etched on shafts, are
visible in the IM rail access openings.

2. Install 23 IM 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

NOTICE: IM Cap screws are 4 different lengths. Refer

to notes taken during Interface Manifold disassembly
for proper position.

19. Ensure Clutch Housing is securely placed in the vertical

position with front side down.

20. Ensure IM to Clutch Housing Spacer Sealing Plate,

Gaskets and Shift Rail D are installed on Clutch Hous-
ing.

Install the Primary and Secondary Input Shaft

1. Ensure Clutch Housing assembly is securely placed in
the vertical position with front side down.

591 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Install Secondary Input Shaft assembly. 3. Install Primary Input Shaft, Primary Input Shaft
Retainer, and Primary Input Shaft Lube Elbow assem-
bly into Secondary Input Shaft. Do not install Primary
Input Shaft Retainer cap screws at this time.

NOTICE: Ensure Lube Elbow aligns with oil passage

holes in the Input Shaft assembly and Interface Mani-
fold. Improper installation will result in gear failure
when run.

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Interface Manifold | Disassembly/Assembly TRSM0990

Assemble the Lower Shaft 5. Install Cluster Gear assembly.

1. Place Lower Shaft Mid-Wall Bearing on Lower Shaft.

6. Install Rail D Synchronizer Blocking Ring.

2. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

7. Place Rail D Synchronizer Hub on Lower Shaft.

Note: Raised side of Synchronizer Hub faces down

3. Press on Lower Shaft Mid-Wall Bearing. toward Cluster Gear.

4. Secure Lower Shaft in the vertical position.

CAUTION: Dropping Lower Shaft assembly could

! result in component damage and/or personal injury.

593 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

8. Align Synchronizer Hub Key Slots with Synchronizer 10. Install Synchronizer Hub Key Retainer Plate.
Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

11. Place Secondary Driven Gear on Lower Shaft.

9. Align Rail D Synchronizer Hub Key Slots with detent

grooves in Rail D Synchronizer Sleeve and install
Sleeve.

NOTICE: Ensure beveled edge of Synchronizer Sleeve

faces front of transmission.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.

12. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

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Interface Manifold | Disassembly/Assembly TRSM0990

13. Press on Secondary Driven Gear. 17. Install Lower Shaft Front Ring.

14. Place Lower Shaft Front Bearing on Lower Shaft.

Assemble the Upper Shaft

15. Position Lower Shaft and Lower Shaft Front Bearing 1. Secure Upper Shaft in the vertical position.
Driver (RR1046TR) in Press.
CAUTION: Dropping Upper Shaft assembly could result
! in component damage and/or personal injury.

16. Press on Lower Shaft Front Bearing.

595 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Install 3rd Gear Bearings. 5. Place Rail B Synchronizer Hub on Upper Shaft.

Note: Raised side of Synchronizer Hub faces down

toward Blocking Ring.

3. Install 3rd Gear.

6. Position Upper Shaft and Upper Shaft Mid Bearing

Driver (RR1049TR) in Press.

4. Install Rail B Synchronizer Blocking Ring.

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Interface Manifold | Disassembly/Assembly TRSM0990

7. Align Rail B Synchronizer Hub Key Slots with Synchro- 11. Install Upper Shaft Front Bearing Snap Ring.
nizer Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

12. Secure Upper Shaft in vertical position.

13. Install 1/2 Gear Bearings.

8. Press on Rail B Synchronizer Hub.

NOTICE: Ensure Synchronizer Hub Key Slots remain

aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.
9. Position Upper Shaft Front Bearing and Upper Shaft
Front Bearing Driver (RR1043TR) on Upper Shaft as
shown.

14. Install 1/2 Gear.

10. Press on Upper Shaft Front Bearing.

597 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

15. Install Rail A Synchronizer Blocking Ring on 1/2 Gear. 18. Press on Rail A Synchronizer Hub.

NOTICE: Ensure Synchronizer Hub Key Slots are

aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.
Note: Pressing Synchronizer Hub onto Upper Shaft
requires pressing down on input end of Upper Shaft
while supporting Synchronizer Hub from below.
19. Install Rail A Synchronizer Hub Snap Ring.

16. Place Rail A Synchronizer Hub on Upper Shaft.

20. Install Synchronizer Springs and Plungers in Rail A

Synchronizer Hub Key Slot pilot holes.

17. Position Upper Shaft in Press as shown.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 598
Interface Manifold | Disassembly/Assembly TRSM0990

21. Position Rail A Synchronizer Sleeve on Rail A Synchro- 23. Push Sleeve over Roller Keys to secure.
nizer Hub.
NOTICE: Ensure all 3 Synchronizer Roller Keys are cor-
rectly positioned in the Sleeve detent groove.

22. Raise Rail A Synchronizer Sleeve slightly to allow Syn-

chronizer Roller Keys to be inserted into Hub Key Slots
from below Sleeve. 24. Install remaining Rail A Synchronizer Blocking Ring.

NOTICE: Ensure Synchronizer Hub Key Slots remain

aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.

599 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

25. Install Reverse Gear Bearings. 28. Place Upper Shaft Mid-Wall Bearing on Upper Shaft.

26. Install Reverse Gear. 29. Position Upper Shaft and Upper Shaft Mid Bearing
Driver (RR1049TR) in Press.

27. Install Upper Shaft Mid-Wall Bearing Spacer.

30. Press on Upper Shaft Mid-Wall Bearing.

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Interface Manifold | Disassembly/Assembly TRSM0990

31. Ensure Rail B Shift Yoke with Rail B Synchronizer Install the Clutch Cooling Module
Sleeve is still positioned on Shift Rail B.
1. Position Clutch Cooling Module with attached gasket
NOTICE: Ensure “REAR” indicated on Shift Yoke faces on Interface Manifold.
rear of transmission.
NOTICE: Inspect Clutch Cooling Module gasket
(in-place) for damage. If damaged, replace Clutch
Cooling Module Assembly.

32. Ensure Rail B Synchronizer Blocking Ring Tabs are

aligned with detent grooves in Rail B Synchronizer
Sleeve.
2. Install 5 Clutch Cooling Module Assembly 13 mm cap
screws and torque 20.5-25.5 Nm (15.1-18.8 lb-ft) in a
crisscross pattern.

601 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Clean Rail D Position Sensor Magnet (in place) of any 2. Align Pump with small Clutch Housing Dowel Pins and
metal shavings or debris. install Pump.

Install the Pump 3. Install 10 Pump 8 mm cap screws and torque to

8.8-10.4 Nm (77.9-92 lb-in) in a crisscross pattern.
1. Position and install Pump Gasket on Clutch Housing.
Note: Pump cap screws are 3 different lengths. Refer
Note: Use small Clutch Housing Dowel Pins to ensure to Pump Removal notes for proper location.
proper alignment.

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Interface Manifold | Disassembly/Assembly TRSM0990

4. Install Main Housing Spray Bar into Pump outlet align- Remove the Upper and Lower Mid-Wall Bearing
ing molded-in cap over Pump cap screw head. Outer Race
NOTICE: The Spray Bar molded-in cap ensures proper
1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm
Spray Bar position for gear lubrication. Improper
cap screws.
installation will result in gear failure when run.

2. Remove Upper Shaft Bearing Retainer Plate and shims.

5. Clean Rail D Position Sensor Magnet (in place) of any
metal shavings or debris. Note: Keep bearing shims. Do not discard.

603 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm 5. Position Upper Shaft Mid Bearing Outer Race Driver
cap screws. (RR1048TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race.

4. Remove Lower Shaft Bearing Retainer Plate and shims.

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from
Note: Keep bearing shims. Do not discard. Main Housing.

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Interface Manifold | Disassembly/Assembly TRSM0990

7. Position Lower Shaft Mid Bearing Outer Race Driver 3. Install Upper Shaft Mid-Wall Bearing Outer Race into
(RR1050TR) and Universal Driver Handle (OE8044-T0) Main Housing bore approximately 1/2 way.
onto Lower Shaft Mid-Wall Bearing Outer Race.

4. Install Lower Shaft Mid-Wall Bearing Outer Race into

8. Drive Lower Shaft Mid-Wall Bearing Outer Race from Main Housing approximately 1/2 way.
Main Housing.

Install the Upper and Lower Mid-Wall Bearing

Outer Race
1. Clean Upper and Lower Shaft Mid-Wall Bearing Race
bores of old oil and debris.

2. Clean mating sealing surfaces on Main Housing and

Clutch Housing with Gasket Remover.

605 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

Install Main Housing without Gasket Sealant 3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
1. Lower Main Housing onto Upper Shaft, Lower Shaft, Main Housing to Clutch Housing.
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Measure and Adjust End-Play

1. Create table as shown.

Original Bearing Shims thickness

2. Push Main Housing flush to Clutch Housing.
Add: + 0.010
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check Baseline Total: =
internal assembly.
End-play measurement:
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing. Upper Shaft: + 0.002

Note: A rubber hammer may be used to gently tap New Shim Thickness: =
Main Housing onto Clutch Housing Dowel Pins.
2. Measure Upper Shaft Original Bearing Shim Thickness
and record in table.

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Interface Manifold | Disassembly/Assembly TRSM0990

3. Add a 0.010 shim to the original Upper Shaft bearing 6. Position a dial indicator plunger against end of Upper
shim set then place shims and Upper Shaft Bearing Shaft.
Retainer Plate on Main Housing.

7. Set dial indicator to zero.

8. Use a pry bar to move the Upper Shaft rearward.

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness.

11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm

cap screws and Upper Shaft Bearing Retainer Plate
from Main Housing.

12. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

5. Rotate Upper Shaft 8 times to center shaft.

607 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

13. Place Upper Shaft Bearing Retainer Plate and shims on 16. Position the dial indicator and pry on Upper Shaft to
Main Housing. verify zero end play. If zero end play exists go to Step
25. If end play exists record measurement in table
NOTICE: Ensure shims are aligned with Main Housing below.
oil passage. Improper installation will result in bearing
failure when run.

End play measurement:

Preload + 0.002
14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a Total: =
crisscross pattern.
17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: =

15. Rotate shaft 8 times to seat bearing to bearing race. 19. Measure Lower Shaft Original Bearing Shim Thickness
and record in table.

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Interface Manifold | Disassembly/Assembly TRSM0990

20. Add a 0.010 shim to the original Lower Shaft bearing 23. Remove 6 PTO cover (right side) 16 mm cap screws.
shim set then place shims and Lower Shaft Bearing
Retainer Plate on Main Housing.

24. Remove PTO cover.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern.

25. Position dial indicator plunger against end of Lower

Shaft.

22. Rotate Lower Shaft 8 times to center shaft.

609 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

26. Set dial indicator to zero. 33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
27. Use a pry bar through PTO opening to move the Lower a crisscross pattern.
Shaft rearward.

34. Rotate shaft 8 times to seat bearing to bearing race.

28. Record end-play reading in a table.
35. Position the dial indicator and pry on Lower Shaft to
29. Use table to calculate New Shim Thickness. verify zero end play. If zero end play go to Step 44. If
30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm end play exists record measurement in table below.
cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End-play measurement:

Preload + 0.002

Total: =

36. Remove the Lower Shaft Bearing Retainer Plate and

the “Total” number amount of shims calculated in the
table above then repeat Steps 32-35.

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Interface Manifold | Disassembly/Assembly TRSM0990

Remove the Main Housing 2. Inspect threaded bolt holes for debris and clean if nec-
essary.
1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing. NOTICE: Ensure there is nothing in the threaded bolt
holes or the Clutch Housing may be damaged when
cap screws are tightened.
3. Apply Gasket Sealant in an 1/8" bead to the Clutch
Housing sealing surface following the pattern below.

2. Lift and remove Main Housing from Clutch Housing.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

4. Lower Main Housing onto Upper Shaft, Lower Shaft,

and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.

611 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

5. Push Main Housing flush to Clutch Housing. Install the PTO Cover
Note: A rubber hammer may be used to gently tap 1. Clean sealing surfaces on the PTO Cover and Main
Main Housing onto Clutch Housing Dowel Pins. Housing with Gasket Remover.
NOTICE: Main Housing should not be forced onto
NOTICE: Do not use abrasive scrapers or power tools
Clutch Housing. If Housings do not meet flush check
to clean sealing surfaces.
internal assembly.
2. Inspect threaded bolt holes for debris and clean if nec-
NOTICE: Do not use cap screws to pull Main Housing
essary.
to Clutch Housing.
NOTICE: Ensure there is nothing in the threaded bolt
holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

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Interface Manifold | Disassembly/Assembly TRSM0990

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

613 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

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Interface Manifold | Disassembly/Assembly TRSM0990

Install the 90-Degree Connector 3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
1. Locate and position 90-Degree Connector in Main
Housing.

Install the Actuation Control Module (ACM)

2. Install 2 90-Degree Connector 10 mm cap screws and 1. Install ACM rear lubrication O-ring.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: Assembly grease can be used to hold O-ring in
place.

615 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 616
Interface Manifold | Disassembly/Assembly TRSM0990

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

617 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

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Interface Manifold | Disassembly/Assembly TRSM0990

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

619 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). 4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
Note: TCM Cover nuts are 10 or 13 mm. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Interface Manifold | Disassembly/Assembly TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

621 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

7. Select “Start” Line Pressure Calibration and follow 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

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Interface Manifold | Disassembly/Assembly TRSM0990

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

623 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 624
Interface Manifold | Disassembly/Assembly TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

625 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Interface Manifold | Disassembly/Assembly TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

627 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

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Interface Manifold | Disassembly/Assembly TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

629 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

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 Interface Manifold | Disassembly/Assembly TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

631 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Slide the Output Yoke over the output shaft.
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern. Note: The Output Yoke may require to be driven on due
to an interference fit.
Note: Three Rear Housing Cover cap screws are a dif-
ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Connect Shift Lever Cable Linkage Nm (70.1-77.4 lb-ft).

1. Install transmission shift selector cable linkage to WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
Transmission Cable Shift Lever.
major vehicle component damage, severe injury or
NOTICE: See OEM Service Manual for shift selector death.
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke
1. Position OEM Harness Bracket to Clutch Housing.
1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

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Interface Manifold | Disassembly/Assembly TRSM0990

2. Install 4 OEM Harness Bracket 10 mm cap screws and 3. Install drift into Pump Driven Gear.
torque to 8.8-10.4 Nm (77.9-92 lb-in).

4. Hold drift securely against Clutch Housing to hold

Install Pump Driven Gear Pump Driven Gear stationary and torque Pump Driven
Gear 13 mm cap screw to 32.5-39.5 Nm (24.0-29.1
1. Align and install Pump Driven Gear onto Pump Drive- lb-ft).
shaft with raised side toward Pump Driveshaft.
CAUTION: Failure to hold Pump Driven Gear stationary
Note: Ensure proper alignment of Gear square opening ! during cap screw installation could result in compo-
onto Driveshaft. nent damage and/or personal injury.

2. Install Pump Driven Gear 13 mm cap screw and hand Install the Dual Clutch Module (DCM)
tighten.
1. Place Front Cover face up on bench.
Note: Do not torque cap screw yet.

633 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

2. Position Input Bearing on Front Cover. 5. Support DCM on bench by setting it on Input Seal
Driver (RR1032TR).

3. Use Front Cover Input Bearing Driver (RR1055TR) with

Universal Driver Handle (OE8044-T0) to drive Input
Bearing into Front Cover.

6. Place Front Cover on DCM Input Shaft.

4. Install Input Bearing Spiral Retaining Ring.

7. Place Input Bearing Driver (RR1049TR) on Input Bear-

ing.

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Interface Manifold | Disassembly/Assembly TRSM0990

8. Drive Input Bearing and Front Cover onto DCM Input 11. Position CSM to Clutch Housing.
Shaft until fully seated.
Note: Do not use sealant.

9. Install Input Shaft Ring.

12. Install 6 CSM 13 mm cap screws and torque to
20.5-25.5 Nm (15.1-18.8 lb-ft).

10. Clean Clutch Support Manifold (CSM) sealing surfaces

of old oil and debris.
13. Clean sealing surfaces on Front Cover and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
14. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

635 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

15. Apply Gasket Sealant in an 1/8” bead inward of all cap 3. Apply Gasket Sealant in an 1/8” bead inward of all cap
screw holes to the Clutch Housing sealing surface fol- screw holes to the Clutch Housing sealing surface fol-
lowing the pattern below. lowing the pattern below.

Install Front Cover/Dual Clutch Module (DCM) 4. Install Front Cover/DCM assembly onto Clutch Support
Assembly Manifold.

CAUTION: Front Cover/DCM assembly weighs approxi-

1. Clean sealing surfaces on Front Cover and Clutch ! mately 45 lbs. Keep fingers clear of pinch point
Housing with Gasket Remover.
between Front Cover and Clutch Housing. Dropping
NOTICE: Do not use abrasive scrapers or power tools Front Cover/DCM assembly could result in component
to clean sealing surfaces. damage and/or personal injury.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Clutch Housing may be damaged when
cap screws are tightened.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 636
Interface Manifold | Disassembly/Assembly TRSM0990

5. Rotate and push DCM Input Shaft to align DCM onto 8. Install 16 Front Cover 13 mm cap screws and torque to
both transmission Input Shafts and the Pump Driven 20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
Gear.

Install the Input Seal

6. Rotate Front Cover so “TOP” is at the 12 o'clock posi-
tion. 1. Clean Dual Clutch Module (DCM) Input Shaft and Front
Cover sealing surfaces of old oil and debris.
Note: Ensure Front Cover dowel holes are aligned with
Clutch Housing Dowel pins. 2. Lightly lubricate Input Seal lip with Eaton® Procision
DCT transmission oil.

7. Push Front Cover flush to Clutch Housing.

NOTICE: Front Cover should not be forced onto Clutch

Housing. If Cover and Housings do not meet flush,
check internal assembly.
NOTICE: Do not use cap screws to pull Front Cover to
Clutch Housing or damage may occur.

637 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

3. Install Input Seal on Input Seal Installer (RR1038TR) 5. With seal lip facing the transmission, place Input Seal
with a rotating and pushing motion until seal is 1/2 in. Installer (RR1038TR) with Input Seal on DCM input
from the end. shaft.

4. Inspect Input Seal installation on Input Seal Installer 6. Position Input Seal Driver (RR1032TR) over DCM
(RR1038TR) to ensure seal lip has not flipped. Input Shaft onto Input Seal.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 638
Interface Manifold | Disassembly/Assembly TRSM0990

7. Drive Input Seal into Front Cover until fully seated. 1. Park vehicle in a safe area on level ground.

Note: Front of seal will be flush with Front Cover when • Select Park if equipped with a Shift Lever and
fully seated. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

8. Remove Input Seal Installer (RR1038TR) level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

Install the Transmission

1. Refer to OEM guidelines for transmission installation. 11. Re-install transmission oil level dipstick.
2. Reconnect the negativ Note: Reference the Oil Leak Inspection Process after
3. e battery cable. performing the steps to Fill Oil.

Fill Oil Fill Oil

Note: For a list of Eaton Approved Synthetic Lubricants, see Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). call 1-800-826-HELP (4357).

639 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Interface Manifold

1. Park vehicle in a safe area on level ground. 3. Confirm engine is running at low idle RPM.

• Select Park if equipped with a Shift Lever and 4. Locate the transmission oil level dipstick and tube in
slowly release service brake to engage park pawl. the engine compartment and clean any dirt or debris
• Select Neutral if equipped with a Push Button. from dipstick and tube.

2. Set vehicle parking brake and chock wheels. 5. Remove the transmission oil level dipstick.

3. Locate the transmission oil level dipstick and tube in 6. Wipe transmission oil dipstick clean and reinstall into
the engine compartment and clean any dirt or debris tube.
from dipstick handle and tube.
7. Remove the transmission oil level dipstick and inspect
4. Remove transmission oil level dipstick. oil level.

5. Fill transmission with 12 liters of Eaton Procision DCT 8. Repeat Steps 6 and 7 to confirm oil level.
transmission oil through the dipstick tube.
9. Add or drain transmission oil if oil level is not within
6. Key on, engine running at low idle RPM. the Transmission Oil Level Operating Range based on
transmission oil temperature.
7. Wipe clean the transmission oil level dipstick and
install in dipstick tube. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
8. Remove transmission oil level dipstick and check oil component damage.
level.
NOTICE: Do not overfill transmission oil.
9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
10. Re-install the transmission oil level dipstick.
component damage.
NOTICE: Do not overfill transmission oil. Calibrate and Clear Faults
Note: If PTO-equipped additional oil will be required. 1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
11. Re-install transmission oil level dipstick. 3. Connect ServiceRanger.
Note: Reference the Oil Leak Inspection Process after 4. Go To “Service Routines”.
performing the steps to Fill Oil.
5. Use engine high-idle switch or cruise control switch in
Inspect Oil Level cab to raise engine idle speed to 950 RPM.
1. Park vehicle in a safe area on level ground. Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 6.
• Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. 6. Select “Start” Rail Calibration and follow on-screen
• Select Neutral if equipped with a Push Button. prompts.

2. Set vehicle parking brake and chock wheels. 7. Select “Start” Line Pressure Calibration and follow
on-screen prompts.

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Interface Manifold | Disassembly/Assembly TRSM0990

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

641 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Lower Shaft
Special Instructions Special Tools
None • Shift Rail Actuation Tool (RR1039TR)
• Lower Shaft Front Press Spacer (RR1047TR)
• Lower Shaft Mid Bearing & Cluster Gear Inner Race
Remover (RR1052TR)
• Lower Shaft Front Bearing Driver (RR1046TR)
• Inner Race Driver (RR1041TR)
• Universal Driver Handle (OE8044-T0)
• Upper Shaft Mid Bearing Outer Race Driver
(RR1048TR)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1050TR)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Lower Shaft Assembly

2. Rail D Shift Yoke Assembly

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Lower Shaft | Disassembly/Assembly TRSM0990

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

6. If PTO-equipped, remove PTO and drain oil. Remove the Output Yoke

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for 1. Remove the driveline. Refer to OEM guidelines for
damage. If damaged, replace the Oil Drain Plug. driveline removal.

Note: O-ring is serviced with plug.

643 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

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Lower Shaft | Disassembly/Assembly TRSM0990

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

645 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

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Lower Shaft | Disassembly/Assembly TRSM0990

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

647 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

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Lower Shaft | Disassembly/Assembly TRSM0990

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

649 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

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Lower Shaft | Disassembly/Assembly TRSM0990

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

651 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

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Lower Shaft | Disassembly/Assembly TRSM0990

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

653 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

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Lower Shaft | Disassembly/Assembly TRSM0990

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

655 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

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Lower Shaft | Disassembly/Assembly TRSM0990

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

657 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Secure Transmission (Vertical) 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
1. Securely place transmission in the vertical position lifting up on the levers.
with front side down.
NOTICE: Do not allow contamination into the TCM or
WARNING: Transmission weighs approximately 375 harness connectors.
! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

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Lower Shaft | Disassembly/Assembly TRSM0990

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Vertically Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

659 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Lower Shaft | Disassembly/Assembly TRSM0990

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

661 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

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Lower Shaft | Disassembly/Assembly TRSM0990

Remove the Reverse Idler Gear 3. Remove Reverse Idler Gear, Bearings, and Thrust
Washers.
1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft

and lift to remove Reverse Idler Shaft from Main Hous-
ing.

663 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Remove the Main Housing 2. Separate Main Housing from Clutch Housing at 3 pry
points.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws. NOTICE: Do not pry on sealing surfaces. Failure to
avoid prying on sealing surface results in component
NOTICE: To avoid internal transmission contamination, damage.
keep Main Housing cap screws separated.

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Lower Shaft | Disassembly/Assembly TRSM0990

3. Lift and remove Main Housing from Clutch Housing. 2. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail B.
CAUTION: Main Housing assembly weighs approxi-
! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

3. Push Shift Rail B downward to engage Rail B Synchro-

nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift
Rail Actuation Tool (RR1039TR).
Remove the Upper Shaft
Note: Place a rag over the Interface Manifold flange to
1. Lift and remove Main Housing Spray Bar from Pump capture any oil spray.
Outlet.

665 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5 6. Separate Upper and Lower Shafts to create clearance
mm) roll pin punch. between Reverse Gear and Lower Shaft Mid-Wall Bear-
ing when removing Upper Shaft.

5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

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Lower Shaft | Disassembly/Assembly TRSM0990

7. Lift and remove Upper Shaft assembly. Remove the Lower Shaft
CAUTION: Upper Shaft assembly weighs approxi- 1. Remove Rail A Shift Yoke from Shift Rail A.
! mately 60 lbs. Dropping Upper Shaft assembly could
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

2. Remove Rail B Shift Yoke and Rail B Synchronizer

Sleeve from Shift Rail B.

Note: Roll Pins will contact Shift Rail A when remov-

ing; this is okay.

667 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

3. Remove Rail B Synchronizer Blocking Ring and Clutch- 5. Remove 3 Primary Input Shaft Retainer 13 mm cap
ing Teeth Gear. screws.

4. Remove Rail D Shift Yoke 13 mm cap screw and 6. To create clearance when removing Lower Shaft pry on
washer. Secondary Driven Gear to release Primary Input Shaft
from Interface Manifold.

Note: Place a rag over the Interface Manifold flange to

capture any oil spray.

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Lower Shaft | Disassembly/Assembly TRSM0990

7. Lift and remove Lower Shaft assembly with Rail D Shift 3. Position Lower Shaft assembly and Lower Shaft Front
Yoke. Press Spacer (RR1047TR) in Press.

CAUTION: Lower Shaft assembly weighs approxi-

! mately 50 lbs. Dropping Lower Shaft assembly could
result in component damage and/or personal injury.

4. Press off: Cluster Gear, Rail D Synchronizer assembly,

Secondary Driven Gear and Lower Shaft Front Bearing.

Disassemble the Lower Shaft

1. Place Lower Shaft securely on work surface.

2. Remove Lower Shaft Front Bearing Ring.

669 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

5. Install Lower Shaft Mid Bearing Remover (RR1052TR) 8. Remove Lower Shaft Mid Bearing Remover
on Lower Shaft as shown. (RR1052TR) from Lower Shaft.

6. Position Lower Shaft assembly in Press. Assemble the Lower Shaft

1. Place Lower Shaft Mid-Wall Bearing on Lower Shaft.

7. Press off Lower Shaft Mid-Wall Bearing.

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Lower Shaft | Disassembly/Assembly TRSM0990

2. Position Lower Shaft and Lower Shaft Mid Bearing 6. Install Rail D Synchronizer Blocking Ring.
Driver (RR1041TR) in Press.

7. Place Rail D Synchronizer Hub on Lower Shaft.

3. Press on Lower Shaft Mid-Wall Bearing.
Note: Raised side of Synchronizer Hub faces down
4. Secure Lower Shaft in the vertical position. toward Cluster Gear.

CAUTION: Dropping Lower Shaft assembly could

! result in component damage and/or personal injury.
5. Install Cluster Gear assembly.

671 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

8. Align Synchronizer Hub Key Slots with Synchronizer 10. Install Synchronizer Hub Key Retainer Plate.
Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

11. Place Secondary Driven Gear on Lower Shaft.

9. Align Rail D Synchronizer Hub Key Slots with detent

grooves in Rail D Synchronizer Sleeve and install
Sleeve.

NOTICE: Ensure beveled edge of Synchronizer Sleeve

faces front of transmission.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.

12. Position Lower Shaft and Lower Shaft Mid Bearing

Driver (RR1041TR) in Press.

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Lower Shaft | Disassembly/Assembly TRSM0990

13. Press on Secondary Driven Gear. 17. Install Lower Shaft Front Ring.

14. Place Lower Shaft Front Bearing on Lower Shaft.

Secure Transmission (Vertical)

15. Position Lower Shaft and Lower Shaft Front Bearing 1. Securely place transmission in the vertical position
Driver (RR1046TR) in Press. with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

16. Press on Lower Shaft Front Bearing.

Install the Primary and Secondary Input Shaft

1. Ensure Clutch Housing assembly is securely placed in
the vertical position with front side down.

673 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

2. Install Secondary Input Shaft assembly. 3. Install Primary Input Shaft, Primary Input Shaft
Retainer, and Primary Input Shaft Lube Elbow assem-
bly into Secondary Input Shaft. Do not install Primary
Input Shaft Retainer cap screws at this time.

NOTICE: Ensure Lube Elbow aligns with oil passage

holes in the Input Shaft assembly and Interface Mani-
fold. Improper installation will result in gear failure
when run.

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Lower Shaft | Disassembly/Assembly TRSM0990

Install the Lower Shaft 3. Lower and install Lower Shaft assembly with Rail D
Shift Yoke onto Front Bearing Outer Race and Shift Rail
1. Position Rail D Shift Yoke onto Rail D Synchronizer D.
Sleeve.
CAUTION: Lower Shaft assembly weighs approxi-
NOTICE: Ensure “REAR” indicated on Shift Yoke faces ! mately 50 lbs. Dropping Lower Shaft assembly could
rear of transmission. result in component damage and/or personal injury.
NOTICE: Ensure Primary and Secondary Driven Gears
are in proper mesh with Primary and Secondary Drive
Gears.

2. Ensure O-ring is in place on top of Shift Rail D.

4. Align bolt hole in Rail D Shift Yoke with threaded hole

in Shift Rail D.

5. Install Rail D Shift Yoke 13 mm cap screw and washer

and torque to 32.5-39.5 Nm (24-29.1 lb-ft).

675 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

6. Install 3 Primary Input Shaft Retainer 13 mm cap 8. Install Rail B Synchronizer Blocking Ring on Clutching
screws and torque to 20.5-25.5 Nm (15.1-18.8 lb-ft). Teeth Gear.

NOTICE: Ensure Primary Input Shaft Lube Elbow aligns

with oil passage holes in the Primary Input Shaft
assembly and Interface Manifold. Improper installation
will result in gear failure when run.

9. Position Rail B Synchronizer Sleeve into Rail B Shift

Yoke.

Note: Ensure beveled edge of Synchronizer Sleeve

faces front of transmission.
7. Install Clutching Teeth Gear on 5/7 Primary Drive Gear.

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Lower Shaft | Disassembly/Assembly TRSM0990

10. Position Rail B Shift Yoke and Rail B Synchronizer 2. Install Rail A Shift Yoke onto Rail A Synchronizer
Sleeve on Shift Rail B and Rail B Synchronizer Blocking Sleeve.
Ring.
NOTICE: Ensure “REAR” indicated on Shift Yoke faces
NOTICE: Ensure “REAR” indicated on Shift Yoke faces rear of transmission.
rear of transmission.

11. Align Rail B Synchronizer Blocking Ring Tabs with

detent grooves in Rail B Synchronizer Sleeve.

Install the Upper Shaft

1. Mark the position of Rail B Synchronizer Sleeve detent
grooves to aid in installing the Upper Shaft assembly.

677 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

3. Separate the Upper and Lower Shafts to create clear- 4. Lower and install Upper Shaft assembly with Rail A
ance between the Reverse Gear and Lower Shaft Shift Yoke onto Rail B Synchronizer Sleeve and Shift
Mid-Wall Bearing when installing Upper Shaft assem- Rail A.
bly.
CAUTION: Upper Shaft assembly weighs approxi-
NOTICE: Ensure all 3 Rail B Synchronizer Keys and ! mately 60 lbs. Dropping Upper Shaft assembly could
Springs are in Synchronizer Hub Key Slots. result in component damage and/or personal injury.
NOTICE: Ensure Synchronizer Hub Key Slots align with
detent grooves and marks on Synchronizer Sleeve.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in installation.

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Lower Shaft | Disassembly/Assembly TRSM0990

5. Install 2 Rail A Shift Yoke Roll Pins. 7. Install Main Housing Spray Bar into Pump outlet align-
ing molded-in cap over Pump cap screw head.

NOTICE: The Spray Bar molded-in cap ensures proper

Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run.

6. Install 2 Rail B Shift Yoke Roll Pins.

8. Clean Rail D Position Sensor Magnet (in place) of any

metal shavings or debris.

679 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Install the Main Housing Spray Bar Remove the Upper and Lower Mid-Wall Bearing
Outer Race
1. Install Main Housing Spray Bar into Pump outlet align-
ing molded-in cap over Pump cap screw head. 1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm
cap screws.
NOTICE: The Spray Bar molded-in cap ensures proper
Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run.

2. Remove Upper Shaft Bearing Retainer Plate and shims.

Note: Keep bearing shims. Do not discard.

2. Clean Rail D Position Sensor Magnet (in place) of any
metal shavings or debris.

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Lower Shaft | Disassembly/Assembly TRSM0990

3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm 5. Position Upper Shaft Mid Bearing Outer Race Driver
cap screws. (RR1048TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race.

4. Remove Lower Shaft Bearing Retainer Plate and shims.

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from
Note: Keep bearing shims. Do not discard. Main Housing.

681 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

7. Position Lower Shaft Mid Bearing Outer Race Driver 3. Install Upper Shaft Mid-Wall Bearing Outer Race into
(RR1050TR) and Universal Driver Handle (OE8044-T0) Main Housing bore approximately 1/2 way.
onto Lower Shaft Mid-Wall Bearing Outer Race.

4. Install Lower Shaft Mid-Wall Bearing Outer Race into

8. Drive Lower Shaft Mid-Wall Bearing Outer Race from Main Housing approximately 1/2 way.
Main Housing.

Measure and Adjust End-Play

Install the Upper and Lower Mid-Wall Bearing
Outer Race 1. Create table as shown.

1. Clean Upper and Lower Shaft Mid-Wall Bearing Race Original Bearing Shims thickness
bores of old oil and debris.
Add: + 0.010
2. Clean mating sealing surfaces on Main Housing and
Baseline Total: =
Clutch Housing with Gasket Remover.
End-play measurement:

Upper Shaft: + 0.002

New Shim Thickness: =

2. Measure Upper Shaft Original Bearing Shim Thickness

and record in table.

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Lower Shaft | Disassembly/Assembly TRSM0990

3. Add a 0.010 shim to the original Upper Shaft bearing 6. Position a dial indicator plunger against end of Upper
shim set then place shims and Upper Shaft Bearing Shaft.
Retainer Plate on Main Housing.

7. Set dial indicator to zero.

8. Use a pry bar to move the Upper Shaft rearward.

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness.

11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm

cap screws and Upper Shaft Bearing Retainer Plate
from Main Housing.

12. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

5. Rotate Upper Shaft 8 times to center shaft.

683 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

13. Place Upper Shaft Bearing Retainer Plate and shims on 16. Position the dial indicator and pry on Upper Shaft to
Main Housing. verify zero end play. If zero end play exists go to Step
25. If end play exists record measurement in table
NOTICE: Ensure shims are aligned with Main Housing below.
oil passage. Improper installation will result in bearing
failure when run.

End play measurement:

Preload + 0.002
14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a Total: =
crisscross pattern.
17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: =

15. Rotate shaft 8 times to seat bearing to bearing race. 19. Measure Lower Shaft Original Bearing Shim Thickness
and record in table.

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Lower Shaft | Disassembly/Assembly TRSM0990

20. Add a 0.010 shim to the original Lower Shaft bearing 23. Remove 6 PTO cover (right side) 16 mm cap screws.
shim set then place shims and Lower Shaft Bearing
Retainer Plate on Main Housing.

24. Remove PTO cover.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern.

25. Position dial indicator plunger against end of Lower

Shaft.

22. Rotate Lower Shaft 8 times to center shaft.

685 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

26. Set dial indicator to zero. 33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
27. Use a pry bar through PTO opening to move the Lower a crisscross pattern.
Shaft rearward.

34. Rotate shaft 8 times to seat bearing to bearing race.

28. Record end-play reading in a table.
35. Position the dial indicator and pry on Lower Shaft to
29. Use table to calculate New Shim Thickness. verify zero end play. If zero end play go to Step 44. If
30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm end play exists record measurement in table below.
cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End-play measurement:

Preload + 0.002

Total: =

36. Remove the Lower Shaft Bearing Retainer Plate and

the “Total” number amount of shims calculated in the
table above then repeat Steps 32-35.

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Lower Shaft | Disassembly/Assembly TRSM0990

Install Main Housing without Gasket Sealant 3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
1. Lower Main Housing onto Upper Shaft, Lower Shaft, Main Housing to Clutch Housing.
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Remove the Main Housing

1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing.
2. Push Main Housing flush to Clutch Housing.

NOTICE: Main Housing should not be forced onto

Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.

687 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

2. Lift and remove Main Housing from Clutch Housing. 3. Apply Gasket Sealant in an 1/8" bead to the Clutch
Housing sealing surface following the pattern below.
CAUTION: Main Housing assembly weighs approxi-
! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools 4. Lower Main Housing onto Upper Shaft, Lower Shaft,
to clean sealing surfaces. and Clutch Housing Dowel Pins.
2. Inspect threaded bolt holes for debris and clean if nec-
CAUTION: Main Housing assembly weighs approxi-
essary. ! mately 30 lbs. Dropping Main Housing assembly could
NOTICE: Ensure there is nothing in the threaded bolt result in component damage and/or personal injury.
holes or the Clutch Housing may be damaged when
cap screws are tightened.

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Lower Shaft | Disassembly/Assembly TRSM0990

5. Push Main Housing flush to Clutch Housing. Install the PTO Cover
Note: A rubber hammer may be used to gently tap 1. Clean sealing surfaces on the PTO Cover and Main
Main Housing onto Clutch Housing Dowel Pins. Housing with Gasket Remover.
NOTICE: Main Housing should not be forced onto
NOTICE: Do not use abrasive scrapers or power tools
Clutch Housing. If Housings do not meet flush check
to clean sealing surfaces.
internal assembly.
2. Inspect threaded bolt holes for debris and clean if nec-
NOTICE: Do not use cap screws to pull Main Housing
essary.
to Clutch Housing.
NOTICE: Ensure there is nothing in the threaded bolt
holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

689 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

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Lower Shaft | Disassembly/Assembly TRSM0990

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

691 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

Install the 90-Degree Connector 3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
1. Locate and position 90-Degree Connector in Main
Housing.

Install the Actuation Control Module (ACM)

2. Install 2 90-Degree Connector 10 mm cap screws and 1. Install ACM rear lubrication O-ring.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: Assembly grease can be used to hold O-ring in
place.

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Lower Shaft | Disassembly/Assembly TRSM0990

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

693 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

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Lower Shaft | Disassembly/Assembly TRSM0990

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

695 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

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Lower Shaft | Disassembly/Assembly TRSM0990

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). 4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
Note: TCM Cover nuts are 10 or 13 mm. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

697 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

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Lower Shaft | Disassembly/Assembly TRSM0990

7. Select “Start” Line Pressure Calibration and follow 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

699 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

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Lower Shaft | Disassembly/Assembly TRSM0990

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

701 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

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Lower Shaft | Disassembly/Assembly TRSM0990

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

703 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

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Lower Shaft | Disassembly/Assembly TRSM0990

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

705 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

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Lower Shaft | Disassembly/Assembly TRSM0990

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

707 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

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Lower Shaft | Disassembly/Assembly TRSM0990

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Slide the Output Yoke over the output shaft.
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern. Note: The Output Yoke may require to be driven on due
to an interference fit.
Note: Three Rear Housing Cover cap screws are a dif-
ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Connect Shift Lever Cable Linkage Nm (70.1-77.4 lb-ft).

1. Install transmission shift selector cable linkage to WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
Transmission Cable Shift Lever.
major vehicle component damage, severe injury or
NOTICE: See OEM Service Manual for shift selector death.
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke
1. Position OEM Harness Bracket to Clutch Housing.
1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

709 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Lower Shaft

2. Install 4 OEM Harness Bracket 10 mm cap screws and 9. Repeat steps 7 and 8 to confirm oil level.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

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Lower Shaft | Disassembly/Assembly TRSM0990

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

711 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

Main Housing
Special Instructions 7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
None damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

Special Tools
• Upper Shaft Mid Bearing Outer Race Driver (Case)
(RR1048TR)
• Lower Shaft Mid Bearing Outer Race Driver
(Case)(RR1050TR)
• Universal Driver Handle (OE8044-T0)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Drain Oil
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
2. Set vehicle parking brake and chock wheels.
NOTICE: Do not over-torque Oil Drain Plug or damage
3. Locate the Oil Drain Plug on the Sump Pan.
to threads may occur.
4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Transmission

1. Key on with engine off.

2. Connect ServiceRanger.

3. Select “Service Activity Report” and create a Service

6. If PTO-equipped, remove PTO and drain oil. Activity Report.

4. Select “Close Report”.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 712
Main Housing | Disassembly/Assembly TRSM0990

5. Disconnect ServiceRanger. 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
6. Key off. lifting up on the levers.
7. Refer to OEM guidelines for transmission removal. NOTICE: Do not allow contamination into the TCM or
harness connectors.
Secure the Transmission (Horizontal)
1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Remove the OEM Harness Bracket

1. Remove 4 OEM Harness Bracket 10 mm cap screws;
remove OEM Harness Bracket.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

713 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Horizontally Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the 74-Way Connector Retainer

1. Remove the 8 mm cap screw at the top of the 74-Way
Connector Retainer.
2. Unscrew the 7 mm jackscrew and remove TCM from
transmission.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 714
Main Housing | Disassembly/Assembly TRSM0990

2. Unlatch 74-Way Connector Retainer from 74-Way Remove the Output Yoke
Transmission Harness Connector.
1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

2. Remove the two 15 mm yoke Retainer Bolts, Retainer

Plate, and Retainer O-ring.

Note: New Retainer Bolts, Retainer Plate and Retainer

O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

3. Remove the 5 remaining 74-Way Connector Retainer 8

mm cap screws.

4. Remove 74-Way Connector Retainer.

715 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

3. Remove the Output Yoke Remove the Transmission Range Sensor (TRS)
Note: There is an interference fit between the Output 1. Place the Transmission Cable Shift Lever in the Neutral
Yoke and output shaft splines that may require an out- (N) position.
put yoke puller.

2. Use hand tools to remove 15 mm Transmission Cable

Disconnect Shift Lever Cable Linkage Shift Lever Retaining Nut.
1. Unlock and disconnect Vehicle 4-Way Harness Con- NOTICE: Retain TRS Internal Shift Shaft position by
nector from 4-Way TRS Harness Connector. holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

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Main Housing | Disassembly/Assembly TRSM0990

3. Remove Transmission Cable Shift Lever. Remove the Rear Housing Cover
1. Remove Output Seal Slinger Shield.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

717 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

3. Separate Rear Housing Cover from Main Housing at 2 Disassemble Rear Housing with Park Pawl
pry points.
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
CAUTION: Do not pry on sealing surfaces. Failure to Rail C and place Shift Rail C in the Neutral position;
! avoid prying on sealing surface results in component remove Shift Rail Actuation Tool (RR1039TR).
damage.
Note: Confirm Rail C Synchronizer is in Neutral posi-
NOTICE: If transmission is equipped with a Park Pawl,
tion.
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Install puller Medium Jaws (CJ105-6) or equivalent

into puller crossarm as shown.

4. Remove Rear Housing Cover.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 718
 Main Housing | Disassembly/Assembly TRSM0990

3. For gear pulling clearance, rotate and align Park Pawl 5. Pull off 4th Driven Gear, Park Pawl Gear and Upper
Gear tooth gap with Lower Shaft Bearing Inner Race as Shaft Rear Bearing Inner Race.
shown.
CAUTION: Ensure a Park Pawl Gear tooth gap is
CAUTION: Ensure a Park Pawl Gear tooth gap is ! aligned with the Lower Shaft Bearing Inner Race. Fail-
! aligned with the Lower Shaft Bearing Inner Race. Fail- ure to align a gear tooth with the race results in com-
ure to align a gear tooth with the race results in com- ponent damage.
ponent damage.

4. Install puller assembly onto Upper Shaft and under

Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

719 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

7. Remove Rear Housing Spray Bar from Main Housing 9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
and end of Reverse Idler Shaft. onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C. 10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 720
Main Housing | Disassembly/Assembly TRSM0990

11. Remove Lower Shaft Rear Bearing Inner Race Snap 13. Install puller assembly onto Lower Shaft and under 6th
Ring from Lower Shaft and discard. Gear with puller jaws in the 10 and 4 o'clock positions
as shown.
Note: New Snap Ring is required when reinstalling.
CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
component damage.

12. Install puller Large Jaws (CJ105-7) or equivalent into

puller crossarm as shown.

721 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 15. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
Bearing Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 722
Main Housing | Disassembly/Assembly TRSM0990

17. Remove 6th Gear Mid-Wall Bearing Spacer. 19. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disassemble Rear Housing without Park Pawl

1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR).
18. Use a magnet to remove 6th Gear Mid-Wall Spacer
Note: Confirm Rail C Synchronizer is in Neutral posi-
Alignment Ball.
tion.

723 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing
into puller crossarm as shown. Inner Race.

3. Install puller assembly onto Upper Shaft and under 4th 5. Remove 2 Rear Lube Bar 10 mm cap screws.
Driven Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 724
Main Housing | Disassembly/Assembly TRSM0990

7. Install Shift Rail Actuation Tool (RR1039TR) into Shift 9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
Rail C. mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve

onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).
10. Remove Lower Shaft Rear Bearing Inner Race Snap
Ring from Lower Shaft and discard.

Note: New Snap Ring is required when reinstalling.

725 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

11. Install puller Large Jaws (CJ105-7) or equivalent into 13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
puller crossarm as shown. Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 726
Main Housing | Disassembly/Assembly TRSM0990

14. Remove 6th Gear Bearing from Lower Shaft. 16. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

17. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

727 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

18. Remove 6th Driven Gear from Upper Shaft. Remove the 3-Rail Position Sensor and Mag-
nets
1. Remove 4, 3-Rail Position Sensor T30 torx head
screws.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector. 2. Remove 3-Rail Position Sensor.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 728
Main Housing | Disassembly/Assembly TRSM0990

3. Remove the 3 Shift Rail Magnet T20 torx head screws Secure Transmission (Vertical)
from Shift Rails A, B and C.
1. Securely place transmission in the vertical position
with front side down.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

4. Remove Shift Rail Magnets A, B and C.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

729 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

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Main Housing | Disassembly/Assembly TRSM0990

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

731 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 732
Main Housing | Disassembly/Assembly TRSM0990

Remove the 90-Degree Connector 3. Remove 90-Degree Connector.

1. Locate and disconnect 8-Way Transmission Harness

Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

Remove the Reverse Idler Gear

1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Remove 2 90-Degree Connector 10 mm cap screws.

733 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft Remove the Main Housing
and lift to remove Reverse Idler Shaft from Main Hous-
ing. 1. Remove 16 external and 5 internal Main Housing 16
mm cap screws.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

3. Remove Reverse Idler Gear, Bearings, and Thrust

Washers.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 734
Main Housing | Disassembly/Assembly TRSM0990

2. Separate Main Housing from Clutch Housing at 3 pry 3. Lift and remove Main Housing from Clutch Housing.
points.
CAUTION: Main Housing assembly weighs approxi-
NOTICE: Do not pry on sealing surfaces. Failure to ! mately 30 lbs. Dropping Main Housing assembly could
avoid prying on sealing surface results in component result in component damage and/or personal injury.
damage.

Remove the Upper and Lower Mid-Wall Bearing

Outer Race
1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm
cap screws.

735 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Remove Upper Shaft Bearing Retainer Plate and shims. 4. Remove Lower Shaft Bearing Retainer Plate and shims.

Note: Keep bearing shims. Do not discard. Note: Keep bearing shims. Do not discard.

3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm 5. Position Upper Shaft Mid Bearing Outer Race Driver
cap screws. (RR1048TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 736
Main Housing | Disassembly/Assembly TRSM0990

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from 8. Drive Lower Shaft Mid-Wall Bearing Outer Race from
Main Housing. Main Housing.

7. Position Lower Shaft Mid Bearing Outer Race Driver Install the Upper and Lower Mid-Wall Bearing
(RR1050TR) and Universal Driver Handle (OE8044-T0) Outer Race
onto Lower Shaft Mid-Wall Bearing Outer Race.
1. Clean Upper and Lower Shaft Mid-Wall Bearing Race
bores of old oil and debris.

2. Clean mating sealing surfaces on Main Housing and

Clutch Housing with Gasket Remover.

3. Install Upper Shaft Mid-Wall Bearing Outer Race into

Main Housing bore approximately 1/2 way.

737 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

4. Install Lower Shaft Mid-Wall Bearing Outer Race into 2. Push Main Housing flush to Clutch Housing.
Main Housing approximately 1/2 way.
NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.

Install Main Housing without Gasket Sealant

1. Lower Main Housing onto Upper Shaft, Lower Shaft,
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.
3. Install 4 external Main Housing 16 mm cap screws at
each corner of the Main Housing to temporarily secure
Main Housing to Clutch Housing.

Measure and Adjust End-Play

1. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 738
Main Housing | Disassembly/Assembly TRSM0990

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

Baseline Total: =
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
End-play measurement: crisscross pattern.

Upper Shaft: + 0.002

New Shim Thickness: =

2. Measure Upper Shaft Original Bearing Shim Thickness

and record in table.

3. Add a 0.010 shim to the original Upper Shaft bearing

shim set then place shims and Upper Shaft Bearing
Retainer Plate on Main Housing.

5. Rotate Upper Shaft 8 times to center shaft.

6. Position a dial indicator plunger against end of Upper

Shaft.

7. Set dial indicator to zero.

739 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

8. Use a pry bar to move the Upper Shaft rearward. 14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness. 15. Rotate shaft 8 times to seat bearing to bearing race.
11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm 16. Position the dial indicator and pry on Upper Shaft to
cap screws and Upper Shaft Bearing Retainer Plate verify zero end play. If zero end play exists go to Step
from Main Housing. 25. If end play exists record measurement in table
12. Select shims to meet New Shim Thickness. below.

Note: Allowable preload is 0.000"-0.002".

13. Place Upper Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End play measurement:

Preload + 0.002

Total: =

17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 740
Main Housing | Disassembly/Assembly TRSM0990

23. Remove 6 PTO cover (right side) 16 mm cap screws.

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: =

19. Measure Lower Shaft Original Bearing Shim Thickness

and record in table.

20. Add a 0.010 shim to the original Lower Shaft bearing

shim set then place shims and Lower Shaft Bearing
Retainer Plate on Main Housing.

24. Remove PTO cover.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern.

25. Position dial indicator plunger against end of Lower

Shaft.

22. Rotate Lower Shaft 8 times to center shaft.

741 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

26. Set dial indicator to zero. 33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
27. Use a pry bar through PTO opening to move the Lower a crisscross pattern.
Shaft rearward.

34. Rotate shaft 8 times to seat bearing to bearing race.

28. Record end-play reading in a table.
35. Position the dial indicator and pry on Lower Shaft to
29. Use table to calculate New Shim Thickness. verify zero end play. If zero end play go to Step 44. If
30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm end play exists record measurement in table below.
cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

End-play measurement:

Preload + 0.002

Total: =

36. Remove the Lower Shaft Bearing Retainer Plate and

the “Total” number amount of shims calculated in the
table above then repeat Steps 32-35.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 742
Main Housing | Disassembly/Assembly TRSM0990

Remove the Main Housing 2. Inspect threaded bolt holes for debris and clean if nec-
essary.
1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing. NOTICE: Ensure there is nothing in the threaded bolt
holes or the Clutch Housing may be damaged when
cap screws are tightened.
3. Apply Gasket Sealant in an 1/8" bead to the Clutch
Housing sealing surface following the pattern below.

2. Lift and remove Main Housing from Clutch Housing.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

4. Lower Main Housing onto Upper Shaft, Lower Shaft,

and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

Install the Main Housing

1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.

743 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

5. Push Main Housing flush to Clutch Housing. Install the PTO Cover
Note: A rubber hammer may be used to gently tap 1. Clean sealing surfaces on the PTO Cover and Main
Main Housing onto Clutch Housing Dowel Pins. Housing with Gasket Remover.
NOTICE: Main Housing should not be forced onto
NOTICE: Do not use abrasive scrapers or power tools
Clutch Housing. If Housings do not meet flush check
to clean sealing surfaces.
internal assembly.
2. Inspect threaded bolt holes for debris and clean if nec-
NOTICE: Do not use cap screws to pull Main Housing
essary.
to Clutch Housing.
NOTICE: Ensure there is nothing in the threaded bolt
holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 744
Main Housing | Disassembly/Assembly TRSM0990

Install Reverse Idler Gear 3. Install Reverse Idler Gear assembly into Main Housing.

1. Install Reverse Idler Gear Thrust Washers into Main NOTICE: Ensure “REAR” indicated on Gear faces rear
Housing. of transmission.

Note: Assembly Grease may be used to hold thrust

washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

745 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

4. Install Reverse Idler Shaft into Main Housing and onto 6. Install Reverse Idler Shaft 13 mm cap screw and
Main Housing Spray Bar. torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).

NOTICE: Ensure Spray Bar is centered in Main Housing

shaft opening prior to installing shaft or damage may
occur.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 746
Main Housing | Disassembly/Assembly TRSM0990

Install the 90-Degree Connector 3. Connect 8-Way Transmission Harness Connector to

90-Degree Connector and latch red lock tab.
1. Locate and position 90-Degree Connector in Main
Housing.

Install the Actuation Control Module (ACM)

2. Install 2 90-Degree Connector 10 mm cap screws and 1. Install ACM rear lubrication O-ring.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: Assembly grease can be used to hold O-ring in
place.

747 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Install 2 ACM Alignment Pins (RR1036TR) into Inter- 5. Route 74-Way Transmission Harness Connector into
face Manifold outermost threaded mounting holes. 74-Way Connector Retainer.

3. Orient and install ACM to Interface Manifold Gasket on 6. Latch 74-Way Connector Retainer to 74-Way Trans-
ACM Dowel Pins. mission Harness Connector.

4. Position ACM to Main Housing.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 748
Main Housing | Disassembly/Assembly TRSM0990

7. Position ACM onto ACM Alignment Pins (RR1036TR). 10. Install ACM Retainer Tab, O-ring isolator, and 13 mm
cap screw and hand tighten.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation. Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

8. Push ACM flush to Interface Manifold and Main Hous-

ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa- 11. Remove the 2 ACM Alignment Pins (RR1036TR) from
tion will result in failure when run. Interface Manifold outermost threaded mounting
holes.
9. Install 4 ACM 10 mm cap screws and hand tighten.

749 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

12. Install the 2 remaining ACM to Interface Manifold 10 14. Torque ACM Retainer Tab 13 mm cap screw to
mm cap screws into Interface Manifold outermost 20.5-25.5 Nm (15.14-18 lb-ft).
threaded mounting holes and hand tighten.
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 750
Main Housing | Disassembly/Assembly TRSM0990

16. Install 2 Transmission Harness to Main Housing 10 18. Connect 8-Way Transmission Harness Connector to
mm cap screws and torque to 8.8-10.4 Nm (77.9-92 90-degree pass-through connector and latch red lock
lb-in). tab.

17. Connect 2-Way Transmission Harness Connector to Install the Transmission Control Module (TCM)
Engine Speed Sensor Connector. Vertically
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

751 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in). 4. Install Sump Pan Filter.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
Note: TCM Cover nuts are 10 or 13 mm. viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

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Main Housing | Disassembly/Assembly TRSM0990

6. Position Sump Pan on Main Housing. 8. Ensure Oil Drain Plug is installed. If not, Install the Oil
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

753 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

7. Select “Start” Line Pressure Calibration and follow 2. Install Shift Rail Magnets A, B and C on Shift Rails A, B,
on-screen prompts. and C with T20 torx head screws and torque to
1.55-1.85 Nm (13.7-16.3 lb-in).
8. Use engine high-idle switch or cruise control switch in
cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

Install the 3-Rail Position Sensor and Magnets

1. Clean Shift Rail Magnets A, B and C of any metal shav-
ings or debris.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

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Main Housing | Disassembly/Assembly TRSM0990

4. Install 4, 3-Rail Position Sensor T30 torx head screws Assemble Rear Housing with/without Park Pawl
and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.
2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing
Spacer Alignment Ball locating hole is in 12 o'clock
position.

755 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

3. Install Mid-Wall Bearing Spacer Alignment Ball on 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Lower Shaft. Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.
Note: Assembly Grease should be used to hold Ball in
place. ! CAUTION: Ensure the raised side of spacer faces front
of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

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Main Housing | Disassembly/Assembly TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

757 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Main Housing | Disassembly/Assembly TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

759 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

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Main Housing | Disassembly/Assembly TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

761 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 762
 Main Housing | Disassembly/Assembly TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

763 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Slide the Output Yoke over the output shaft.
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern. Note: The Output Yoke may require to be driven on due
to an interference fit.
Note: Three Rear Housing Cover cap screws are a dif-
ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Connect Shift Lever Cable Linkage Nm (70.1-77.4 lb-ft).

1. Install transmission shift selector cable linkage to WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
Transmission Cable Shift Lever.
major vehicle component damage, severe injury or
NOTICE: See OEM Service Manual for shift selector death.
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Install OEM Harness Bracket

Install the Output Yoke
1. Position OEM Harness Bracket to Clutch Housing.
1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

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Main Housing | Disassembly/Assembly TRSM0990

2. Install 4 OEM Harness Bracket 10 mm cap screws and 9. Repeat steps 7 and 8 to confirm oil level.
torque to 8.8-10.4 Nm (77.9-92 lb-in).
10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Install the Transmission
Note: Reference the Oil Leak Inspection Process after
1. Refer to OEM guidelines for transmission installation. performing the steps to Fill Oil.
2. Reconnect the negativ Fill Oil
3. e battery cable.
Note: For a list of Eaton Approved Synthetic Lubricants, see
Fill Oil Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
Note: For a list of Eaton Approved Synthetic Lubricants, see 1. Park vehicle in a safe area on level ground.
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357). • Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl.
1. Park vehicle in a safe area on level ground.
• Select Neutral if equipped with a Push Button.
• Select Park if equipped with a Shift Lever and 2. Set vehicle parking brake and chock wheels.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button. 3. Locate the transmission oil level dipstick and tube in
the engine compartment and clean any dirt or debris
2. Set vehicle parking brake and chock wheels. from dipstick handle and tube.
3. Locate the transmission oil level dipstick and tube in
4. Remove transmission oil level dipstick.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. 5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube.
4. Remove transmission oil level dipstick.
6. Key on, engine running at low idle RPM.
5. Fill transmission with 12 liters of Eaton Procision DCT
transmission oil through the dipstick tube. 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
6. Key on, engine running at low idle RPM.
8. Remove transmission oil level dipstick and check oil
7. Wipe clean the transmission oil level dipstick and level.
install in dipstick tube.
9. Repeat steps 7 and 8 to confirm oil level.
8. Remove transmission oil level dipstick and check oil
level.

765 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Main Housing

10. Add or drain transmission oil if oil level is not within 10. Select “Start” Clutch Touch Point (PTP) Calibration and
the Transmission Oil Level Operating Range based on follow on-screen prompts.
transmission oil temperature.
11. Key off and wait 1 minute.
! CAUTION: Use only Eaton® approved lubricant
12. Key on with engine off.
PS-278. Failure to use specified lubricant results in
component damage. 13. Go to “Fault Codes”.
NOTICE: Do not overfill transmission oil.
• If active fault code(s) is set, refer to TRTS0990 Pro-
Note: If PTO-equipped additional oil will be required. cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

7. Select “Start” Line Pressure Calibration and follow

on-screen prompts.

8. Use engine high-idle switch or cruise control switch in

cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

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TRSM0990 Disassembly/Assembly | Rear Housing

Rear Housing
Special Instructions Special Tools
• This procedure is for transmissions equipped with • Shift Rail Actuation Tool (RR1039TR)
or without a Park Pawl. • Snap-on CJ85-1 Puller or equivalent
• Snap-on CJ105-6 Medium Jaw (Qty 2) or equiva-
lent
• Snap-on CJ105-7 Large Jaw (Qty 2) or equivalent
• Lower Shaft Rear Bearing Inner Race & 4th Gear
Inner Sleeve Driver (RR1040TR)
• Inner Race Driver (RR1041TR)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

6
7
2
1 8
9
10

1. Transmission Cable Shift Lever 6. Output Seal Slinger Shield

2. TRS Assembly 7. Output Yoke
3. Park Pawl Gear 8. Output Yoke O-ring
4. Rear Housing Cover 9. Output Yoke Retainer Plate
5. Rear Housing Cover Cap Screws 10. Output Yoke Retainer Bolts

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TRSM0990 Disassembly/Assembly | Rear Housing

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

6. If PTO-equipped, remove PTO and drain oil.

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug.

Note: O-ring is serviced with plug.

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Rear Housing | Disassembly/Assembly TRSM0990

2. Remove the two 15 mm yoke Retainer Bolts, Retainer 3. Remove the Output Yoke
Plate, and Retainer O-ring.
Note: There is an interference fit between the Output
Note: New Retainer Bolts, Retainer Plate and Retainer Yoke and output shaft splines that may require an out-
O-ring are required when reinstalling. put yoke puller.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

769 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

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Rear Housing | Disassembly/Assembly TRSM0990

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

771 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

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 Rear Housing | Disassembly/Assembly TRSM0990

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

773 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 774
 Rear Housing | Disassembly/Assembly TRSM0990

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

775 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

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Rear Housing | Disassembly/Assembly TRSM0990

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

777 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

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Rear Housing | Disassembly/Assembly TRSM0990

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

779 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

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Rear Housing | Disassembly/Assembly TRSM0990

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Assemble Rear Housing with/without Park Pawl

1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission.

! CAUTION: Ensure the raised side of gear faces rear of

17. Use a magnet to remove 6th Gear Mid-Wall Spacer
transmission. Incorrect installation results in compo-
Alignment Ball.
nent damage and Active fault codes after installation.

781 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing 4. Install 6th Gear Mid-Wall Bearing Spacer on Lower
Spacer Alignment Ball locating hole is in 12 o'clock Shaft with raised side facing the front of transmission
position. and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

3. Install Mid-Wall Bearing Spacer Alignment Ball on

Lower Shaft.

Note: Assembly Grease should be used to hold Ball in

place.

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Rear Housing | Disassembly/Assembly TRSM0990

5. Install 6th Gear Bearing on Lower Shaft. 7. Install 2 Rear Lube Bar 10 mm cap screws and torque
to 8.8-10.4 Nm (77.9-92 lb-in).

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft. 8. Install 6th Gear on Lower Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main Note: Raised side of gear faces rear of transmission.
Housing and Reverse Idler Shaft. Proper orientation is critical to final assembly.

783 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

9. Install Rail C Synchronizer Blocking Ring onto 6th 11. Position Rail C Shift Yoke onto Rail C Synchronizer
Gear. assembly.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

10. Assemble Rail C Synchronizer assembly.

NOTICE: Ensure all 3 Rail C Synchronizer Keys and

Springs are in Synchronizer Hub Key Slots. 12. Install Rail C Synchronizer assembly with Rail C Shift
Yoke on Lower Shaft and Shift Rail C.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

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Rear Housing | Disassembly/Assembly TRSM0990

14. Install remaining Rail C Synchronizer Blocking Ring 16. Place 4th Gear assembly onto Lower Shaft.
onto Rail C Synchronizer Hub.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
15. Install 4th Gear Bearing and Captured Inner Race into
4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

785 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

18. Drive 4th Gear assembly onto Lower Shaft. 20. Place Lower Shaft Rear Bearing Inner Race onto end of
Lower Shaft.
NOTICE: Ensure Rail C Synchronizer Blocking Ring
tabs stay aligned with Hub Key Slots during 4th Gear
installation.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.
19. Install Spacer onto Lower Shaft.
Note: Ensure Rear Bearing Inner Race is fully seated.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 786
Rear Housing | Disassembly/Assembly TRSM0990

22. Install new Snap Ring on Lower Shaft. 24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and
Shift Rail C into the 4th Gear position then remove
NOTICE: If Snap Ring cannot be properly installed into Shift Rail Actuation Tool (RR1039TR).
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer Note: Ensure Rail C is fully extended rearward. Roll Pin
installation orientation (Step 4). Raised side of Spacer hole in Rail must be aligned with Roll Pin hole in Shift
must face front of transmission. Proper orientation is Yoke.
critical to final assembly.

25. Install Rail C Shift Yoke Roll Pin.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C. Note: Roll Pin must be driven from the inside of hous-
ing outward.

787 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

26. Install 4th Driven Gear and Park Pawl Gear assembly 28. Use Upper Shaft Rear Bearing Inner Race Driver
on Upper Shaft. (RR1041TR) to drive Upper Shaft Rear Bearing Inner
Race onto Upper Shaft.
NOTICE: Align Park Pawl Gear tooth gap with Lower
Shaft Bearing Race or damage may occur. NOTICE: Ensure Park Pawl Gear tooth gap stays
aligned with Lower Shaft Bearing Race or damage may
Note: For transmissions without a Park Pawl, install occur.
4th Driven Gear on Upper Shaft.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Install the Rear Housing Cover
Upper Shaft.
1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

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 Rear Housing | Disassembly/Assembly TRSM0990

3. Apply Gasket Sealant in an 1/8" bead inward of all cap 4. Install Rear Housing Cover onto Upper Shaft, Lower
screw holes to the Main Housing sealing surface fol- Shaft and Main Housing Dowel Pins.
lowing the pattern below.
NOTICE: If transmission is equipped with a park pawl
CAUTION: Ensure there is no Gasket Sealant in Main confirm the Internal Shift Shaft has remained in the
! Housing Rear Bearing Oil Passage. Failure to keep oil Neutral position as shown prior to installing the Rear
passage clear of sealant results in component damage. Housing Cover or damage to the internal Park Pawl
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

789 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

6. Install 18 Rear Housing Cover 16 mm cap screws 2. Install 5 TRS Harness Bracket to T30 torx head screws
torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss- and torque to 8.8-10.4 Nm (77.9-92 lb-in).
cross pattern.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Refer to Rear Housing
Cover removal notes for proper location.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
Install the Transmission Range Sensor (TRS) cause gear selection problems.

1. Install TRS assembly on Internal Shift Shaft and push

flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 790
Rear Housing | Disassembly/Assembly TRSM0990

4. Use hand tools to install the Transmission Cable Shift 2. Slide the Output Yoke over the output shaft.
Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft). Note: The Output Yoke may require to be driven on due
to an interference fit.
NOTICE: Retain TRS Internal Shift Shaft position by
holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install new Retainer Plate, Retainer Plate O-ring, and

two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105
Nm (70.1-77.4 lb-ft).
Connect Shift Lever Cable Linkage
WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever. major vehicle component damage, severe injury or
death.
NOTICE: See OEM Service Manual for shift selector
cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

4. Install the driveline. Refer to OEM guidelines for drive-

line Installation.

Fill Oil

Install the Output Yoke Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
1. Clean the mating surfaces and splines on the output call 1-800-826-HELP (4357).
shaft and Output Yoke.

791 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Rear Housing

1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

level.

9. Repeat steps 7 and 8 to confirm oil level.

10. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

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Synchronizer | Disassembly/Assembly TRSM0990

Synchronizer
Special Instructions Special Tools
When a replacing synchronizer do not replace a single part None
only. Always replace the whole assembly.

Before removing synchronizer assemblies from shafts it is

important to be able to identify their design features.

Component Identification

1
2
3
4

1. Key
2. Spring
3. Synchronizer Hub
4. Synchronizer Sleeve

793 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Synchronizer

Rails B, C and D Synchronizers 4. Slide Keys and Springs out from Synchronizer Hub Key
Slot.
1. These synchronizers consist of the following parts:

• Synchronizer Hub
• Synchronizer Sleeve
• Spring (3x)
• Key (3x)

2. Perform“Upper Shaft” on page 801 or “Lower Shaft”

on page 642.

3. Remove the Synchronizer Sleeve from Hub.

NOTICE: Note orientation of Synchronizer Sleeve to

Hub. When installed in transmission beveled edge of
Synchronizer Sleeve faces front of transmission.
NOTICE: Retain Keys and Springs in Hub Key Slots
while removing Sleeve or they may pop out and be lost.

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Synchronizer | Disassembly/Assembly TRSM0990

Rail A Synchronizer 4. Remove Roller Keys, Plungers and Springs from Syn-
chronizer Hub Key Slots.
1. This synchronizer consist of the following parts:

• Synchronizer Hub
• Synchronizer Sleeve
• Spring (3x)
• Plunger (3x)
• Roller Key (3x)

2. Perform “Upper Shaft” on page 801.

3. Remove Synchronizer Sleeve from Hub.

NOTICE: Retain Roller Keys, Springs and Plungers

while removing Sleeve or they may pop out and be lost.

795 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Synchronizer

Rails B, C and D Synchronizers 3. Install a Synchronizer Spring in the Hub Key Slot pilot
hole.
1. These synchronizers consist of the following parts:

• Synchronizer Hub
• Synchronizer Sleeve
• Spring (3x)
• Key (3x)

4. Install the Synchronizer Key on the Spring as shown.

Note: The raised center of Key should be transverse to

Hub Key slot.

2. Place the Synchronizer Hub on a flat surface in the ver-

tical position.

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Synchronizer | Disassembly/Assembly TRSM0990

5. Move Key with Spring to the edge of the Hub Key Slot. 7. Slide the Key and Spring to the center of the Hub Key
Slot.

6. Push down on the Key and Spring to move Key under

the outer lip of Synchronizer Hub. 8. Repeat this procedure for the 2 remaining Keys and
Springs.
Note: A small screwdriver may be used to keep the
Spring in the Hub pilot hole while moving the Key into NOTICE: Ensure the Springs are positioned correctly
the Hub Key Slot. in the Hub pilot holes or the Keys and Springs may pop
out and be lost when installing the Synchronizer
Sleeve.

797 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Synchronizer

9. Place the Synchronizer Hub on a Synchronizer Block- 11. Align the center of Synchronizer Sleeve detent grooves
ing Ring to hold the Keys and Springs in position. with the Keys in the Hub Key Slots.

Note: Marking the center of the detent grooves on the

edges of the Sleeve will aid in final assembly.

10. Place the Synchronizer Sleeve on the edge of the hub.

NOTICE: Ensure correct orientation of Sleeve beveled

edge to the Synchronizer Hub as this is critical to final 12. Push Synchronizer Sleeve down onto Synchronizer
assembly and transmission functioning properly. Hub.

NOTICE: Ensure all 3 Synchronizer Keys are correctly

positioned in the Sleeve detent grooves.

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Synchronizer | Disassembly/Assembly TRSM0990

Rail A Synchronizer 3. Install Springs and Plungers in pilot holes in Synchro-

nizer Hub Key Slots.
1. This synchronizer consist of the following parts:

• Synchronizer Hub
• Synchronizer Sleeve
• Spring (3x)
• Plunger (3x)
• Roller Key (3x)

4. Install the Synchronizer Sleeve on the Hub.

NOTICE: Ensure correct orientation of Sleeve beveled

edge to the Synchronizer Hub as this is critical to final
assembly and transmission functioning properly.
Note: Ensure Springs and Plungers are still in Hub pilot
holes
2. Place Synchronizer Hub on a Synchronizer Blocking
Ring.

NOTICE: Ensure Blocking Ring tabs align with Hub Key

Slots.
Note: Placing the raised side of the Synchronizer Hub
facing up will aid assembly.

799 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Synchronizer

5. Raise Synchronizer Sleeve enough to allow Roller Keys

to be installed into Hub Key Slots from below Sleeve.

NOTICE: Ensure all 3 Synchronizer Roller Keys are cor-

rectly positioned in the Sleeve detent groove.

6. Push Sleeve over Roller keys to secure.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 800
Upper Shaft | Disassembly/Assembly TRSM0990

Upper Shaft
Special Instructions Special Tools
None • Bearing Splitter
• Shift Rail Actuation Tool (RR1039TR)
• Upper Shaft Front Press Spacer (RR1044TR)
• Upper Shaft Front Bearing Driver (RR1043TR)
• Upper Shaft Mid Bearing Driver (RR1049TR)
• Universal Driver Handle (OE8044-T0)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1050TR)
• Upper Shaft Mid Bearing Outer Race Driver
(RR1048TR)
• Gasket Remover (Loctite SF 7631)
• Gasket Sealant (Loctite 5188)

Component Identification

1. Upper Shaft Assembly

801 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Drain Oil 8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm
(20.3-24 lb-ft)
1. Park vehicle in a safe area on level ground.
NOTICE: Do not over-torque Oil Drain Plug or damage
• Select Park if equipped with a Shift Lever and to threads may occur.
slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.
5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.

Secure the Transmission (Horizontal)

1. Securely place transmission in the horizontal position.

WARNING: Transmission weighs approximately 375

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

6. If PTO-equipped, remove PTO and drain oil. Remove the OEM Harness Bracket

7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for 1. Remove 4 OEM Harness Bracket 10 mm cap screws;
damage. If damaged, replace the Oil Drain Plug. remove OEM Harness Bracket.

Note: O-ring is serviced with plug.

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Upper Shaft | Disassembly/Assembly TRSM0990

Remove the Output Yoke 3. Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for Note: There is an interference fit between the Output
driveline removal. Yoke and output shaft splines that may require an out-
put yoke puller.
2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.

Note: New Retainer Bolts, Retainer Plate and Retainer

O-ring are required when reinstalling.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

Disconnect Shift Lever Cable Linkage

1. Unlock and disconnect Vehicle 4-Way Harness Con-
nector from 4-Way TRS Harness Connector.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

803 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Remove the Transmission Range Sensor (TRS) 3. Remove Transmission Cable Shift Lever.

1. Place the Transmission Cable Shift Lever in the Neutral

(N) position.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Use hand tools to remove 15 mm Transmission Cable

Shift Lever Retaining Nut.

NOTICE: Retain TRS Internal Shift Shaft position by

holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 804
Upper Shaft | Disassembly/Assembly TRSM0990

Remove the Rear Housing Cover 3. Separate Rear Housing Cover from Main Housing at 2
pry points.
1. Remove Output Seal Slinger Shield.
CAUTION: Do not pry on sealing surfaces. Failure to
! avoid prying on sealing surface results in component
damage.
NOTICE: If transmission is equipped with a Park Pawl,
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

4. Remove Rear Housing Cover.

805 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Disassemble Rear Housing with Park Pawl 3. For gear pulling clearance, rotate and align Park Pawl
Gear tooth gap with Lower Shaft Bearing Inner Race as
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure a Park Pawl Gear tooth gap is
! aligned with the Lower Shaft Bearing Inner Race. Fail-
Note: Confirm Rail C Synchronizer is in Neutral posi- ure to align a gear tooth with the race results in com-
tion. ponent damage.

2. Install puller Medium Jaws (CJ105-6) or equivalent 4. Install puller assembly onto Upper Shaft and under
into puller crossarm as shown. Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 806
 Upper Shaft | Disassembly/Assembly TRSM0990

5. Pull off 4th Driven Gear, Park Pawl Gear and Upper 7. Remove Rear Housing Spray Bar from Main Housing
Shaft Rear Bearing Inner Race. and end of Reverse Idler Shaft.

CAUTION: Ensure a Park Pawl Gear tooth gap is

! aligned with the Lower Shaft Bearing Inner Race. Fail-
ure to align a gear tooth with the race results in com-
ponent damage.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

807 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

9. Pull Shift Rail C to engage Rail C Synchronizer Sleeve 11. Remove Lower Shaft Rear Bearing Inner Race Snap
onto 4th Gear, remove Shift Rail Actuation Tool Ring from Lower Shaft and discard.
(RR1039TR).
Note: New Snap Ring is required when reinstalling.

10. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch. 12. Install puller Large Jaws (CJ105-7) or equivalent into
puller crossarm as shown.
Note: Roll Pin must be driven from the outside of
housing inward or damage may occur.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 808
 Upper Shaft | Disassembly/Assembly TRSM0990

13. Install puller assembly onto Lower Shaft and under 6th 14. Pull off 6th Gear, Rail C Synchronizer assembly, 4th
Gear with puller jaws in the 10 and 4 o'clock positions Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
as shown. Bearing Inner Race.

CAUTION: Ensure puller jaws are fully seated under NOTICE: Ensure Rail C Shift Yoke does not bind on
! gear. Failure to fully seat jaws under gear results in Shift Rail C when pulling or damage may occur.
component damage.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

809 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

15. Remove 6th Gear Bearing from Lower Shaft. 17. Remove 6th Gear Mid-Wall Bearing Spacer.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

16. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

18. Use a magnet to remove 6th Gear Mid-Wall Spacer

Alignment Ball.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 810
Upper Shaft | Disassembly/Assembly TRSM0990

19. Remove 6th Driven Gear from Upper Shaft. 2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

Disassemble Rear Housing without Park Pawl

3. Install puller assembly onto Upper Shaft and under 4th
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift Driven Gear as shown.
Rail C and place Shift Rail C in the Neutral position;
remove Shift Rail Actuation Tool (RR1039TR). CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: Confirm Rail C Synchronizer is in Neutral posi- component damage.
tion.

811 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing 7. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Inner Race. Rail C.

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 812
Upper Shaft | Disassembly/Assembly TRSM0990

9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 11. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

12. Install puller assembly onto Lower Shaft and under 6th
Gear as shown.
10. Remove Lower Shaft Rear Bearing Inner Race Snap CAUTION: Ensure puller jaws are fully seated under
Ring from Lower Shaft and discard. ! gear. Failure to fully seat jaws under gear results in
component damage.
Note: New Snap Ring is required when reinstalling.

813 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

15. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 814
Upper Shaft | Disassembly/Assembly TRSM0990

16. Remove 6th Gear Mid-Wall Bearing Spacer. 18. Remove 6th Driven Gear from Upper Shaft.

Note: A magnet or small flat blade screwdriver may be

used to aid in Spacer removal.
NOTICE: Note spacer orientation for re-installation.
Raised side of Spacer faces front of transmission.

Disconnect the 3-Rail Position Sensor and Mag-

nets
1. Disconnect 8-Way 3-Rail Position Sensor Harness
Connector from 90-Degree Connector.
17. Use a magnet to remove 6th Gear Mid-Wall Spacer
Alignment Ball. Note: Connector red lock tab must be unlatched and
the top of the connector depressed to remove.

815 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Remove the 3-Rail Position Sensor and Mag- 3. Remove the 3 Shift Rail Magnet T20 torx head screws
nets from Shift Rails A, B and C.

1. Remove 4, 3-Rail Position Sensor T30 torx head

screws.

4. Remove Shift Rail Magnets A, B and C.

2. Remove 3-Rail Position Sensor.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 816
Upper Shaft | Disassembly/Assembly TRSM0990

Secure Transmission (Vertical) 2. Disconnect the 20-Way Vehicle and Body Harness Con-
nectors from the TCM by depressing the lock tab and
1. Securely place transmission in the vertical position lifting up on the levers.
with front side down.
NOTICE: Do not allow contamination into the TCM or
WARNING: Transmission weighs approximately 375 harness connectors.
! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
may result in major component damage, severe injury
or death.
NOTICE: Use an appropriate lifting device to safely lift
component.

Disconnect the Transmission Control Module

(TCM)
1. Disconnect the negative battery cable.

NOTICE: Leaving battery cable connected may damage

the TCM.

817 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Remove the Transmission Control Module 3. Unlatch 74-Way Connector Retainer from 74-Way
(TCM) Vertically Transmission Harness Connector.

1. Unscrew 4 TCM Cover nuts and remove TCM Cover.

Note: TCM Cover nuts are 10 or 13 mm.

Remove the Sump Pan and Filter

1. Remove 20 Sump Pan 13 mm cap screws.

2. Unscrew the 7 mm jackscrew and remove TCM from

transmission.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 818
Upper Shaft | Disassembly/Assembly TRSM0990

2. Remove Sump Pan. Remove the Actuation Control Manifold (ACM)

1. Locate and disconnect 8-Way Transmission Harness
Connector from 90-Degree Connector.

Note: Connector red lock tab must be unlatched and

the top of the connector depressed to remove.

3. Remove Sump Pan Filter

Note: Ensure Sump Pan Filter neck O-ring is attached.

If not attached, inspect Pump inlet and remove.
NOTICE: If O-ring must be removed from Pump inlet,
do not damage Pump inlet sealing surface. 2. Disconnect 2-Way Engine Speed Sensor Connector
from Transmission Harness Connector.

4. Inspect Sump Pan Seal (in place) for damage. If dam-

aged, replace seal.

Note: If replacing Sump Pan Filter, the Sump Pan Seal

must be replaced.
Note: Sump Pan Seal can only go in the Main Housing
recess in one direction; use seal alignment tabs to
ensure proper alignment during re-installation.

819 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Remove the 2 Transmission Harness to Main Housing 5. Remove the ACM Retainer Tab 13 mm cap screw.
10 mm cap screws.

6. Remove ACM Retainer Tab and O-ring isolator.

4. Remove Output Speed Sensor 10 mm cap screw and
pull Output Speed Sensor free from Main Housing. Note: Ensure the O-ring isolator came off the ACM with
the ACM Retainer Tab, if not remove O-ring isolator
from ACM.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 820
Upper Shaft | Disassembly/Assembly TRSM0990

7. Remove 6 ACM to Interface Manifold 10 mm cap 9. Remove ACM rear lubrication O-ring.
screws.
Note: If O-ring is missing it may be located on ACM.
CAUTION: Support ACM when removing cap screws.
! Dropping ACM could result in component damage
and/or personal injury.

10. Remove ACM to Interface Manifold Gasket.

8. Remove ACM/Transmission Harness assembly from

Main Housing.

Note: When removing ACM ensure 74-Way Transmis-

sion Harness Connector is free of 74-Way Connector
Retainer.

11. Inspect ACM to Interface Manifold Gasket for damage.

If damaged, replace Gasket.

Note: If replacing the ACM the Gasket must also be

replaced.

821 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Remove the Reverse Idler Gear 3. Remove Reverse Idler Gear, Bearings, and Thrust
Washers.
1. Remove Reverse Idler Shaft 13 mm cap screw.

2. Install an M12x1.75x60 bolt into Reverse Idler Shaft

and lift to remove Reverse Idler Shaft from Main Hous-
ing.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 822
Upper Shaft | Disassembly/Assembly TRSM0990

Remove the Main Housing 2. Separate Main Housing from Clutch Housing at 3 pry
points.
1. Remove 16 external and 5 internal Main Housing 16
mm cap screws. NOTICE: Do not pry on sealing surfaces. Failure to
avoid prying on sealing surface results in component
NOTICE: To avoid internal transmission contamination, damage.
keep Main Housing cap screws separated.

823 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Lift and remove Main Housing from Clutch Housing. Remove the Upper Shaft
CAUTION: Main Housing assembly weighs approxi- 1. Lift and remove Main Housing Spray Bar from Pump
! mately 30 lbs. Dropping Main Housing assembly could Outlet.
result in component damage and/or personal injury.

2. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail B.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 824
Upper Shaft | Disassembly/Assembly TRSM0990

3. Push Shift Rail B downward to engage Rail B Synchro- 5. Drive out 2 Rail B Shift Yoke Roll Pins with 7/32 in. (5.5
nizer Sleeve onto 5/7 Primary Drive Gear, remove Shift mm) roll pin punch.
Rail Actuation Tool (RR1039TR).
Note: Roll Pins will contact Shift Rail A when remov-
Note: Place a rag over the Interface Manifold flange to ing; this is okay.
capture any oil spray.

6. Separate Upper and Lower Shafts to create clearance

4. Drive out 2 Rail A Shift Yoke Roll Pins with 7/32 in. (5.5 between Reverse Gear and Lower Shaft Mid-Wall Bear-
mm) roll pin punch. ing when removing Upper Shaft.

825 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

7. Lift and remove Upper Shaft assembly. Disassemble the Upper Shaft
CAUTION: Upper Shaft assembly weighs approxi- 1. Place Upper Shaft securely in the vertical position with
! mately 60 lbs. Dropping Upper Shaft assembly could front side down.
result in component damage and/or personal injury.
NOTICE: Ensure Rail A Shift Yoke does not bind on
Shift Rail A when removing Upper Shaft assembly or
damage may occur.
Note: Retain Rail B Synchronizer Springs and Keys in
Hub Key Slots while removing shaft or they may pop
out and be lost.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in removal.

2. Slide Rail A Synchronizer Sleeve downward onto 1/2

Gear.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 826
Upper Shaft | Disassembly/Assembly TRSM0990

3. Install bearing splitter under Reverse Gear as shown. 6. Remove Reverse Gear Bearings.

4. Position Upper Shaft in press. 7. Remove Rail A Synchronizer Blocking Ring.

5. Press off: Reverse Gear, Upper Shaft Mid-Wall Bearing 8. Remove Rail A Synchronizer Sleeve.
Spacer and Mid-Wall Bearing.
Note: Retain the Roller Keys, Springs and Plungers
while removing Sleeve or they may pop out and be lost.

827 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

9. Remove the Roller Keys, Plungers and Springs from 12. Press off: 1/2 Gear, Rail A Synchronizer Blocking Ring
the Rail A Synchronizer Hub Key Slots. and Rail A Synchronizer Hub.

10. Remove Rail A Synchronizer Hub Snap Ring. 13. Remove 1/2 Gear Bearings.

11. Position Upper Shaft in press. 14. Remove Upper Shaft Front Bearing Snap Ring.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 828
Upper Shaft | Disassembly/Assembly TRSM0990

15. Position Upper Shaft and Upper Shaft Front Press 17. Remove 3rd Gear Bearings.
Spacer (RR1044TR) in Press.

16. Press off: 3rd Gear, Rail B Synchronizer Blocking Ring,

Rail B Synchronizer Hub and Upper Shaft Front Bear-
ing.

Note: Retain Synchronizer Springs and Keys so they

remain in Synchronizer Hub Key Slots.

829 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Assemble the Upper Shaft 3. Install 3rd Gear.

1. Secure Upper Shaft in the vertical position.

CAUTION: Dropping Upper Shaft assembly could result

! in component damage and/or personal injury.

4. Install Rail B Synchronizer Blocking Ring.

2. Install 3rd Gear Bearings.

5. Place Rail B Synchronizer Hub on Upper Shaft.

Note: Raised side of Synchronizer Hub faces down

toward Blocking Ring.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 830
Upper Shaft | Disassembly/Assembly TRSM0990

6. Position Upper Shaft and Upper Shaft Mid Bearing 8. Press on Rail B Synchronizer Hub.
Driver (RR1049TR) in Press.
NOTICE: Ensure Synchronizer Hub Key Slots remain
aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.
9. Position Upper Shaft Front Bearing and Upper Shaft
Front Bearing Driver (RR1043TR) on Upper Shaft as
shown.

10. Press on Upper Shaft Front Bearing.

11. Install Upper Shaft Front Bearing Snap Ring.

7. Align Rail B Synchronizer Hub Key Slots with Synchro-

nizer Blocking Ring Tabs.

NOTICE: Ensure all 3 Synchronizer Keys and Springs

are in Synchronizer Hub Key Slots.

12. Secure Upper Shaft in vertical position.

831 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

13. Install 1/2 Gear Bearings. 16. Place Rail A Synchronizer Hub on Upper Shaft.

14. Install 1/2 Gear. 17. Position Upper Shaft in Press as shown.

15. Install Rail A Synchronizer Blocking Ring on 1/2 Gear. 18. Press on Rail A Synchronizer Hub.

NOTICE: Ensure Synchronizer Hub Key Slots are

aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.
Note: Pressing Synchronizer Hub onto Upper Shaft
requires pressing down on input end of Upper Shaft
while supporting Synchronizer Hub from below.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 832
Upper Shaft | Disassembly/Assembly TRSM0990

19. Install Rail A Synchronizer Hub Snap Ring. 22. Raise Rail A Synchronizer Sleeve slightly to allow Syn-
chronizer Roller Keys to be inserted into Hub Key Slots
from below Sleeve.

20. Install Synchronizer Springs and Plungers in Rail A

Synchronizer Hub Key Slot pilot holes.
23. Push Sleeve over Roller Keys to secure.

NOTICE: Ensure all 3 Synchronizer Roller Keys are cor-

rectly positioned in the Sleeve detent groove.

21. Position Rail A Synchronizer Sleeve on Rail A Synchro-

nizer Hub.

833 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

24. Install remaining Rail A Synchronizer Blocking Ring. 26. Install Reverse Gear.

NOTICE: Ensure Synchronizer Hub Key Slots remain

aligned with Synchronizer Blocking Ring Tabs or dam-
age may occur.

27. Install Upper Shaft Mid-Wall Bearing Spacer.

25. Install Reverse Gear Bearings.

28. Place Upper Shaft Mid-Wall Bearing on Upper Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 834
Upper Shaft | Disassembly/Assembly TRSM0990

29. Position Upper Shaft and Upper Shaft Mid Bearing 32. Ensure Rail B Synchronizer Blocking Ring Tabs are
Driver (RR1049TR) in Press. aligned with detent grooves in Rail B Synchronizer
Sleeve.

30. Press on Upper Shaft Mid-Wall Bearing.

Install the Upper Shaft
31. Ensure Rail B Shift Yoke with Rail B Synchronizer
Sleeve is still positioned on Shift Rail B. 1. Mark the position of Rail B Synchronizer Sleeve detent
NOTICE: Ensure “REAR” indicated on Shift Yoke faces grooves to aid in installing the Upper Shaft assembly.
rear of transmission. 2. Install Rail A Shift Yoke onto Rail A Synchronizer
Sleeve.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces

rear of transmission.

835 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Separate the Upper and Lower Shafts to create clear- 4. Lower and install Upper Shaft assembly with Rail A
ance between the Reverse Gear and Lower Shaft Shift Yoke onto Rail B Synchronizer Sleeve and Shift
Mid-Wall Bearing when installing Upper Shaft assem- Rail A.
bly.
CAUTION: Upper Shaft assembly weighs approxi-
NOTICE: Ensure all 3 Rail B Synchronizer Keys and ! mately 60 lbs. Dropping Upper Shaft assembly could
Springs are in Synchronizer Hub Key Slots. result in component damage and/or personal injury.
NOTICE: Ensure Synchronizer Hub Key Slots align with
detent grooves and marks on Synchronizer Sleeve.
NOTICE: Proper alignment of Synchronizer Hub Key
Slots and Blocking Ring Tabs is critical to final assem-
bly and transmission functioning properly.
Note: Output Yoke, old Retainer Plate, and old Retainer
Bolts can be temporarily installed on Upper Shaft to aid
in installation.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 836
Upper Shaft | Disassembly/Assembly TRSM0990

5. Install 2 Rail A Shift Yoke Roll Pins. 7. Install Main Housing Spray Bar into Pump outlet align-
ing molded-in cap over Pump cap screw head.

NOTICE: The Spray Bar molded-in cap ensures proper

Spray Bar position for gear lubrication. Improper
installation will result in gear failure when run.

6. Install 2 Rail B Shift Yoke Roll Pins.

8. Clean Rail D Position Sensor Magnet (in place) of any

metal shavings or debris.

837 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Remove the Upper and Lower Mid-Wall Bearing 3. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm
Outer Race cap screws.

1. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm

cap screws.

4. Remove Lower Shaft Bearing Retainer Plate and shims.

Note: Keep bearing shims. Do not discard.

2. Remove Upper Shaft Bearing Retainer Plate and shims.

Note: Keep bearing shims. Do not discard.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 838
Upper Shaft | Disassembly/Assembly TRSM0990

5. Position Upper Shaft Mid Bearing Outer Race Driver 7. Position Lower Shaft Mid Bearing Outer Race Driver
(RR1048TR) and Universal Driver Handle (OE8044-T0) (RR1050TR) and Universal Driver Handle (OE8044-T0)
onto Upper Shaft Mid-Wall Bearing Outer Race. onto Lower Shaft Mid-Wall Bearing Outer Race.

6. Drive Upper Shaft Mid-Wall Bearing Outer Race from 8. Drive Lower Shaft Mid-Wall Bearing Outer Race from
Main Housing. Main Housing.

Install the Upper and Lower Mid-Wall Bearing

Outer Race
1. Clean Upper and Lower Shaft Mid-Wall Bearing Race
bores of old oil and debris.

2. Clean mating sealing surfaces on Main Housing and

Clutch Housing with Gasket Remover.

839 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Install Upper Shaft Mid-Wall Bearing Outer Race into Install Main Housing without Gasket Sealant
Main Housing bore approximately 1/2 way.
1. Lower Main Housing onto Upper Shaft, Lower Shaft,
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

4. Install Lower Shaft Mid-Wall Bearing Outer Race into

Main Housing approximately 1/2 way.

2. Push Main Housing flush to Clutch Housing.

NOTICE: Main Housing should not be forced onto

Clutch Housing. If Housings do not meet flush check
internal assembly.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.
Note: A rubber hammer may be used to gently tap
Main Housing onto Clutch Housing Dowel Pins.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 840
Upper Shaft | Disassembly/Assembly TRSM0990

3. Install 4 external Main Housing 16 mm cap screws at 3. Add a 0.010 shim to the original Upper Shaft bearing
each corner of the Main Housing to temporarily secure shim set then place shims and Upper Shaft Bearing
Main Housing to Clutch Housing. Retainer Plate on Main Housing.

Measure and Adjust End-Play

1. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

Baseline Total: =

End-play measurement:

Upper Shaft: + 0.002

New Shim Thickness: =

4. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap
2. Measure Upper Shaft Original Bearing Shim Thickness screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
and record in table. crisscross pattern.

5. Rotate Upper Shaft 8 times to center shaft.

841 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

6. Position a dial indicator plunger against end of Upper 13. Place Upper Shaft Bearing Retainer Plate and shims on
Shaft. Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
failure when run.

7. Set dial indicator to zero.

8. Use a pry bar to move the Upper Shaft rearward.

14. Install 4 Upper Shaft Bearing Retainer Plate 16 mm cap

screws and torque to 44.5-51.5 Nm (32.5-38 lb-ft) in a
crisscross pattern.

9. Record end play measurement in a table.

10. Use table to calculate New Shim Thickness.

11. Remove 4 Upper Shaft Bearing Retainer Plate 16 mm

cap screws and Upper Shaft Bearing Retainer Plate 15. Rotate shaft 8 times to seat bearing to bearing race.
from Main Housing.

12. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 842
Upper Shaft | Disassembly/Assembly TRSM0990

16. Position the dial indicator and pry on Upper Shaft to 20. Add a 0.010 shim to the original Lower Shaft bearing
verify zero end play. If zero end play exists go to Step shim set then place shims and Lower Shaft Bearing
25. If end play exists record measurement in table Retainer Plate on Main Housing.
below.

21. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap

End play measurement:
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
Preload + 0.002 a crisscross pattern.

Total: =

17. Remove the Upper Shaft Bearing Retainer Plate and the
“Total” number amount of shims calculated in table
above then repeat Steps 13-16.

18. Create table as shown.

Original Bearing Shims thickness

Add: + 0.010

Baseline Total: =

End-play measurement:

Lower Shaft: + 0.002

New Shim Thickness: = 22. Rotate Lower Shaft 8 times to center shaft.

19. Measure Lower Shaft Original Bearing Shim Thickness

and record in table.

843 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

23. Remove 6 PTO cover (right side) 16 mm cap screws. 26. Set dial indicator to zero.

27. Use a pry bar through PTO opening to move the Lower
Shaft rearward.

24. Remove PTO cover.

28. Record end-play reading in a table.

29. Use table to calculate New Shim Thickness.

30. Remove 5 Lower Shaft Bearing Retainer Plate 13 mm

cap screws and Lower Shaft Bearing Retainer Plate
from Main Housing.

31. Select shims to meet New Shim Thickness.

Note: Allowable preload is 0.000"-0.002".

32. Place Lower Shaft Bearing Retainer Plate and shims on
Main Housing.

NOTICE: Ensure shims are aligned with Main Housing

oil passage. Improper installation will result in bearing
25. Position dial indicator plunger against end of Lower failure when run.
Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 844
Upper Shaft | Disassembly/Assembly TRSM0990

33. Install 5 Lower Shaft Bearing Retainer Plate 13 mm cap Remove the Main Housing
screws and torque to 24.5-29.5 Nm (18.1-21.8 lb-ft) in
a crisscross pattern. 1. Remove the 4 external Main Housing 16 mm cap
screws at each corner of the Main Housing.

34. Rotate shaft 8 times to seat bearing to bearing race.

2. Lift and remove Main Housing from Clutch Housing.
35. Position the dial indicator and pry on Lower Shaft to
verify zero end play. If zero end play go to Step 44. If CAUTION: Main Housing assembly weighs approxi-
end play exists record measurement in table below. ! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

End-play measurement:

Preload + 0.002 Install the Main Housing

Total: = 1. Clean sealing surfaces on Main Housing and Clutch
Housing with Gasket Remover.
36. Remove the Lower Shaft Bearing Retainer Plate and
the “Total” number amount of shims calculated in the NOTICE: Do not use abrasive scrapers or power tools
table above then repeat Steps 32-35. to clean sealing surfaces.

845 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

2. Inspect threaded bolt holes for debris and clean if nec- 5. Push Main Housing flush to Clutch Housing.
essary.
Note: A rubber hammer may be used to gently tap
NOTICE: Ensure there is nothing in the threaded bolt Main Housing onto Clutch Housing Dowel Pins.
holes or the Clutch Housing may be damaged when
cap screws are tightened. NOTICE: Main Housing should not be forced onto
Clutch Housing. If Housings do not meet flush check
3. Apply Gasket Sealant in an 1/8" bead to the Clutch internal assembly.
Housing sealing surface following the pattern below.
NOTICE: Do not use cap screws to pull Main Housing
to Clutch Housing.

6. Install 16 external and 5 internal Main Housing 16 mm

cap screws and torque to 44.5-51.5 Nm (32.8-38 lb-ft)
in a crisscross pattern.

NOTICE: To avoid internal transmission contamination,

keep Main Housing cap screws separated.
4. Lower Main Housing onto Upper Shaft, Lower Shaft,
and Clutch Housing Dowel Pins.

CAUTION: Main Housing assembly weighs approxi-

! mately 30 lbs. Dropping Main Housing assembly could
result in component damage and/or personal injury.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 846
Upper Shaft | Disassembly/Assembly TRSM0990

Install the PTO Cover Install Reverse Idler Gear

1. Clean sealing surfaces on the PTO Cover and Main 1. Install Reverse Idler Gear Thrust Washers into Main
Housing with Gasket Remover. Housing.

NOTICE: Do not use abrasive scrapers or power tools Note: Assembly Grease may be used to hold thrust
to clean sealing surfaces. washers in place to aid in Reverse Idler Gear, Bearings
and Shaft installation.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Apply Gasket Sealant in an 1/8” bead to the Main Hous-
ing sealing surface following the pattern below.

2. Install Reverse Idler Gear Bearings into Reverse Idler

Gear.

4. Install the PTO Cover and 6 PTO Cover 16 mm cap

screws and torque to 42.5-51.5 Nm (31.5-38.0 lb-ft) in
a crisscross pattern.

847 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Install Reverse Idler Gear assembly into Main Housing. 4. Install Reverse Idler Shaft into Main Housing and onto
Main Housing Spray Bar.
NOTICE: Ensure “REAR” indicated on Gear faces rear
of transmission. NOTICE: Ensure Spray Bar is centered in Main Housing
shaft opening prior to installing shaft or damage may
occur.

5. Align Reverse Idler Shaft to Main Housing to allow

installation of the Main Housing to Reverse Idler Shaft
cap screw.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 848
Upper Shaft | Disassembly/Assembly TRSM0990

6. Install Reverse Idler Shaft 13 mm cap screw and Install the 90-Degree Connector
torque to 27.5-31.5 Nm (20.2-23.2 lb-ft).
1. Locate and position 90-Degree Connector in Main
Housing.

7. Remove the M12x1.75x60 bolt used during disassem-

bly/assembly from Reverse Idler Shaft.
2. Install 2 90-Degree Connector 10 mm cap screws and
torque to 8.8-10.4 Nm (77.9-92 lb-in).

849 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

3. Connect 8-Way Transmission Harness Connector to 2. Install 2 ACM Alignment Pins (RR1036TR) into Inter-
90-Degree Connector and latch red lock tab. face Manifold outermost threaded mounting holes.

Install the Actuation Control Module (ACM) 3. Orient and install ACM to Interface Manifold Gasket on
ACM Dowel Pins.
1. Install ACM rear lubrication O-ring.

Note: Assembly grease can be used to hold O-ring in

place.

4. Position ACM to Main Housing.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 850
Upper Shaft | Disassembly/Assembly TRSM0990

5. Route 74-Way Transmission Harness Connector into 7. Position ACM onto ACM Alignment Pins (RR1036TR).
74-Way Connector Retainer.
Note: Ensure Engine Speed Sensor Connector remains
accessible after ACM installation.

6. Latch 74-Way Connector Retainer to 74-Way Trans-

mission Harness Connector.
8. Push ACM flush to Interface Manifold and Main Hous-
ing rear lubrication O-ring.

NOTICE: Ensure ACM to Interface Manifold Gasket is

still positioned on ACM Dowel Pins. Improper installa-
tion will result in failure when run.
9. Install 4 ACM 10 mm cap screws and hand tighten.

851 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

10. Install ACM Retainer Tab, O-ring isolator, and 13 mm 12. Install the 2 remaining ACM to Interface Manifold 10
cap screw and hand tighten. mm cap screws into Interface Manifold outermost
threaded mounting holes and hand tighten.
Note: Assembly grease may be used to hold O-ring in
place.
Note: Ensure ACM Retainer Tab is square with Main
Housing and completely covers O-ring isolator.

13. Torque all 6 ACM to Interface Manifold 10 mm cap

screws to 8.8-10.4 Nm (77.9-92 lb-in).

11. Remove the 2 ACM Alignment Pins (RR1036TR) from

Interface Manifold outermost threaded mounting
holes.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 852
Upper Shaft | Disassembly/Assembly TRSM0990

14. Torque ACM Retainer Tab 13 mm cap screw to 16. Install 2 Transmission Harness to Main Housing 10
20.5-25.5 Nm (15.14-18 lb-ft). mm cap screws and torque to 8.8-10.4 Nm (77.9-92
lb-in).
Note: Ensure that ACM Retainer Tab is square with
Main Housing and completely covers O-ring isolator.

17. Connect 2-Way Transmission Harness Connector to

Engine Speed Sensor Connector.
15. Install Output Speed Sensor and 10 mm cap screw into
Main Housing and torque screw to 8.8-10.4 Nm
(77.9-92 lb-in).

853 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

18. Connect 8-Way Transmission Harness Connector to 2. Torque TCM jackscrew to 3.0-4.0 Nm (26.6-35.4 lb-in).
90-degree pass-through connector and latch red lock
tab.

3. Install TCM Cover with 4 nuts over TCM studs and

torque to 8.8-10.4 Nm (77.9-92 lb-in) in a crisscross
Install the Transmission Control Module (TCM) pattern.
Vertically Note: TCM Cover nuts are 10 or 13 mm.
1. Align the TCM to the 74-Way Transmission Harness
Connector and TCM studs.

Install the Sump Pan and Filter

1. Clean Sump Pan and Main Housing sealing surfaces of
old oil and debris.

2. Inspect threaded bolt holes for debris and clean if nec-

essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.
3. Lubricate Sump Pan Filter O-ring with Eaton® Proci-
sion DCT transmission oil.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 854
Upper Shaft | Disassembly/Assembly TRSM0990

4. Install Sump Pan Filter. 6. Position Sump Pan on Main Housing.

Note: If the Sump Pan Filter was replaced with new the
Sump Pan Seal must be replaced.

7. Install 20 Sump Pan 13 mm cap screws and torque to

20.5-25.5 Nm (15.1-18.8 lb-ft) in a crisscross pattern.
5. Install Sump Pan Seal into Main Housing recess if pre-
viously removed.

Note: The Sump Pan Seal can only go in the Main

Housing recess in one direction; use seal alignment
tabs to ensure proper alignment during installation.

855 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

8. Ensure Oil Drain Plug is installed. If not, Install the Oil 7. Select “Start” Line Pressure Calibration and follow
Drain Plug and torque to 27.5-32.5 Nm (20.3-24 lb-ft) on-screen prompts.

NOTICE: Do not over-torque Oil Drain Plug or damage 8. Use engine high-idle switch or cruise control switch in
to threads may occur. cab to lower engine idle to normal idle speed.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 9.
9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
Secure the Transmission (Horizontal) and follow on-screen prompts.
1. Securely place transmission in the horizontal position. 14. Disconnect ServiceRanger.

WARNING: Transmission weighs approximately 375 15. Key off.

! lbs. Keep fingers clear of pinch point between Clutch
Housing and other surfaces. Dropping transmission
Install the 3-Rail Position Sensor and Magnets
may result in major component damage, severe injury
1. Clean Shift Rail Magnets A, B and C of any metal shav-
or death.
ings or debris.
NOTICE: Use an appropriate lifting device to safely lift
component.

Calibrate and Clear Faults

1. Key on with engine running.

2. Complete engine warm-up by running engine at idle

speed for 15 minutes.

Note: If Engine Idle Shutdown engine setting is pre-

venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
3. Connect ServiceRanger.

4. Go To “Service Routines”.

5. Use engine high-idle switch or cruise control switch in

cab to raise engine idle speed to 950 RPM.

Note: If vehicle is not equipped with high-idle switch or

cruise control switch, go to Step 6.
6. Select “Start” Rail Calibration and follow on-screen
prompts.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 856
Upper Shaft | Disassembly/Assembly TRSM0990

2. Install Shift Rail Magnets A, B and C on Shift Rails A, B, 4. Install 4, 3-Rail Position Sensor T30 torx head screws
and C with T20 torx head screws and torque to and torque to 8.8-10.4 Nm (77.9-92 lb-in).
1.55-1.85 Nm (13.7-16.3 lb-in).

Connect the 3-Rail Position Sensor and Mag-

nets
1. Connect 8-Way 3-Rail Position Sensor Harness Con-
nector to 90-Degree Connector and latch red lock tab.

3. Position 3-Rail Position Sensor on Main Housing

Mid-Wall.

857 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

Assemble Rear Housing with/without Park Pawl 3. Install Mid-Wall Bearing Spacer Alignment Ball on
Lower Shaft.
1. Install 6th Driven Gear on Upper Shaft with raised side
facing the rear of transmission. Note: Assembly Grease should be used to hold Ball in
place.
! CAUTION: Ensure the raised side of gear faces rear of
transmission. Incorrect installation results in compo-
nent damage and Active fault codes after installation.

2. Rotate Lower Shaft until 6th Gear Mid-Wall Bearing

Spacer Alignment Ball locating hole is in 12 o'clock
position.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 858
Upper Shaft | Disassembly/Assembly TRSM0990

4. Install 6th Gear Mid-Wall Bearing Spacer on Lower 5. Install 6th Gear Bearing on Lower Shaft.
Shaft with raised side facing the front of transmission
and align notch with Mid-Wall Bearing Spacer Ball.

! CAUTION: Ensure the raised side of spacer faces front

of transmission. Incorrect installation results in com-
ponent damage and Active fault codes after installation.

6. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main

Housing and Reverse Idler Shaft.

859 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

7. Install 2 Rear Lube Bar 10 mm cap screws and torque 9. Install Rail C Synchronizer Blocking Ring onto 6th
to 8.8-10.4 Nm (77.9-92 lb-in). Gear.

8. Install 6th Gear on Lower Shaft. 10. Assemble Rail C Synchronizer assembly.

Note: Raised side of gear faces rear of transmission. NOTICE: Ensure all 3 Rail C Synchronizer Keys and
Proper orientation is critical to final assembly. Springs are in Synchronizer Hub Key Slots.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 860
Upper Shaft | Disassembly/Assembly TRSM0990

11. Position Rail C Shift Yoke onto Rail C Synchronizer 14. Install remaining Rail C Synchronizer Blocking Ring
assembly. onto Rail C Synchronizer Hub.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces NOTICE: Ensure Blocking Ring tabs align with Hub Key
rear of transmission. Slots.

12. Install Rail C Synchronizer assembly with Rail C Shift 15. Install 4th Gear Bearing and Captured Inner Race into
Yoke on Lower Shaft and Shift Rail C. 4th Gear.

Note: Bearing and Captured Inner Race may already be

installed in 4th Gear.

13. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

861 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

16. Place 4th Gear assembly onto Lower Shaft. 18. Drive 4th Gear assembly onto Lower Shaft.

NOTICE: Ensure Rail C Synchronizer Blocking Ring

tabs stay aligned with Hub Key Slots during 4th Gear
installation.

17. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
19. Install Spacer onto Lower Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 862
Upper Shaft | Disassembly/Assembly TRSM0990

20. Place Lower Shaft Rear Bearing Inner Race onto end of 22. Install new Snap Ring on Lower Shaft.
Lower Shaft.
NOTICE: If Snap Ring cannot be properly installed into
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer
installation orientation (Step 4). Raised side of Spacer
must face front of transmission. Proper orientation is
critical to final assembly.

21. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.

Note: Ensure Rear Bearing Inner Race is fully seated.

23. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

863 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

24. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and 26. Install 4th Driven Gear and Park Pawl Gear assembly
Shift Rail C into the 4th Gear position then remove on Upper Shaft.
Shift Rail Actuation Tool (RR1039TR).
NOTICE: Align Park Pawl Gear tooth gap with Lower
Note: Ensure Rail C is fully extended rearward. Roll Pin Shaft Bearing Race or damage may occur.
hole in Rail must be aligned with Roll Pin hole in Shift
Yoke. Note: For transmissions without a Park Pawl, install
4th Driven Gear on Upper Shaft.

25. Install Rail C Shift Yoke Roll Pin.

27. Place Upper Shaft Rear Bearing Inner Race onto end of
Note: Roll Pin must be driven from the inside of hous- Upper Shaft.
ing outward.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 864
Upper Shaft | Disassembly/Assembly TRSM0990

28. Use Upper Shaft Rear Bearing Inner Race Driver 3. Apply Gasket Sealant in an 1/8" bead inward of all cap
(RR1041TR) to drive Upper Shaft Rear Bearing Inner screw holes to the Main Housing sealing surface fol-
Race onto Upper Shaft. lowing the pattern below.

NOTICE: Ensure Park Pawl Gear tooth gap stays CAUTION: Ensure there is no Gasket Sealant in Main
aligned with Lower Shaft Bearing Race or damage may ! Housing Rear Bearing Oil Passage. Failure to keep oil
occur. passage clear of sealant results in component damage.

Install the Rear Housing Cover

1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt

holes or the Main Housing may be damaged when cap
screws are tightened.

865 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

4. Install Rear Housing Cover onto Upper Shaft, Lower 6. Install 18 Rear Housing Cover 16 mm cap screws
Shaft and Main Housing Dowel Pins. torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern.
NOTICE: If transmission is equipped with a park pawl
confirm the Internal Shift Shaft has remained in the Note: Three Rear Housing Cover cap screws are a dif-
Neutral position as shown prior to installing the Rear ferent length than the rest. Refer to Rear Housing
Housing Cover or damage to the internal Park Pawl Cover removal notes for proper location.
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

Connect Shift Lever Cable Linkage

1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever.

NOTICE: See OEM Service Manual for shift selector

cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

5. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 866
Upper Shaft | Disassembly/Assembly TRSM0990

2. Slide the Output Yoke over the output shaft. 2. Install 4 OEM Harness Bracket 10 mm cap screws and
torque to 8.8-10.4 Nm (77.9-92 lb-in).
Note: The Output Yoke may require to be driven on due
to an interference fit.

Install the Transmission

3. Install new Retainer Plate, Retainer Plate O-ring, and
1. Refer to OEM guidelines for transmission installation.
two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105 2. Reconnect the negativ
Nm (70.1-77.4 lb-ft).
3. e battery cable.
WARNING: Reusing previously removed Retainer
! Bolts, Retainer Plate and Retainer O-ring could result in Fill Oil
major vehicle component damage, severe injury or
death. Note: For a list of Eaton Approved Synthetic Lubricants, see
Eaton TCMT0021 Lubrication guide on Roadranger.com or
call 1-800-826-HELP (4357).
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.
4. Install the driveline. Refer to OEM guidelines for drive-
line Installation. 6. Key on, engine running at low idle RPM.

Install OEM Harness Bracket 7. Wipe clean the transmission oil level dipstick and
install in dipstick tube.
1. Position OEM Harness Bracket to Clutch Housing.
8. Remove transmission oil level dipstick and check oil
level.

867 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Disassembly/Assembly | Upper Shaft

9. Repeat steps 7 and 8 to confirm oil level. 10. Add or drain transmission oil if oil level is not within
the Transmission Oil Level Operating Range based on
10. Add or drain transmission oil if oil level is not within transmission oil temperature.
the Transmission Oil Level Operating Range based on
transmission oil temperature. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
! CAUTION: Use only Eaton® approved lubricant component damage.
PS-278. Failure to use specified lubricant results in
component damage. NOTICE: Do not overfill transmission oil.

NOTICE: Do not overfill transmission oil. Note: If PTO-equipped additional oil will be required.

Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

11. Re-install transmission oil level dipstick. Note: Reference the Oil Leak Inspection Process after
performing the steps to Fill Oil.
Note: Reference the Oil Leak Inspection Process after
performing the steps to Fill Oil. Calibrate and Clear Faults
Fill Oil 1. Key on with engine running.

Note: For a list of Eaton Approved Synthetic Lubricants, see 2. Complete engine warm-up by running engine at idle
Eaton TCMT0021 Lubrication guide on Roadranger.com or speed for 15 minutes.
call 1-800-826-HELP (4357).
Note: If Engine Idle Shutdown engine setting is pre-
1. Park vehicle in a safe area on level ground. venting 15-minute idle time requirement, restart engine
immediately after shutdown as needed to complete.
• Select Park if equipped with a Shift Lever and
slowly release service brake to engage park pawl. 3. Connect ServiceRanger.
• Select Neutral if equipped with a Push Button. 4. Go To “Service Routines”.
2. Set vehicle parking brake and chock wheels.
5. Use engine high-idle switch or cruise control switch in
3. Locate the transmission oil level dipstick and tube in cab to raise engine idle speed to 950 RPM.
the engine compartment and clean any dirt or debris
from dipstick handle and tube. Note: If vehicle is not equipped with high-idle switch or
cruise control switch, go to Step 6.
4. Remove transmission oil level dipstick.
6. Select “Start” Rail Calibration and follow on-screen
5. Fill transmission with 12 liters of Eaton Procision DCT prompts.
transmission oil through the dipstick tube.
7. Select “Start” Line Pressure Calibration and follow
6. Key on, engine running at low idle RPM. on-screen prompts.

7. Wipe clean the transmission oil level dipstick and 8. Use engine high-idle switch or cruise control switch in
install in dipstick tube. cab to lower engine idle to normal idle speed.

8. Remove transmission oil level dipstick and check oil Note: If vehicle is not equipped with high-idle switch or
level. cruise control switch, go to Step 9.

9. Repeat steps 7 and 8 to confirm oil level. 9. Select “Start” Clutch Pressure (PI) Calibration and fol-
low on-screen prompts.

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Upper Shaft | Disassembly/Assembly TRSM0990

10. Select “Start” Clutch Touch Point (PTP) Calibration and

follow on-screen prompts.

11. Key off and wait 1 minute.

12. Key on with engine off.

13. Go to “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
14. Disconnect ServiceRanger.

15. Key off.

869 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | OEM and Engine Specific Transmission Kits

OEM and Engine Specific Transmission Kits

Damper
Description P/N QTY

6 Cylinder - Navistar 811200 1

and Bluebird

6 Cylinder - Freightliner 811201 1

4-Cylinder - Freightliner 811204 1

Transmission Driver Interface Device

Description P/N QTY

Pushbutton Shift 4308831 1

Selector

Transmission Service Units

Description P/N QTY

EDCO-6F107A Reman TN-K00-12R 1

Transmission (Non-Park
Pawl)

EDCO-6F107B Reman TN-K00-12R 1

Transmission (Non-Park
Pawl ext. Parking Brake)

EDCO-6F107A-P Reman TN-K01-12R 1

Transmission (With
Park Pawl)

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 8
OEM and Engine Specific Transmission Kits | Service Parts and Kits TRPB0990

Clutch Housing Service Kits Cartridge Filter Service Kit

Dual Clutch Module Assembly Kit

1 2

K-4531 K-4273
Description P/N QTY Description P/N QTY
1 (DCM) w/Front Cover S-8526 1 1 Cartridge Filter 4307752 1
Assembly
2 Cartridge Filter Cover 4307971 1
2 Clutch Support Manifold X-8C-0839 6 O-ring
Cap Screws M
Description P/N QTY
3 Clutch Support Manifold A-8540 1
Assembly Cartridge Filter Cover 4307834 1
4 Cartridge Filter 4307752 1

5 Sump Pan Filter 4308798 1

9 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | OEM and Engine Specific Transmission Kits

Front Cover Seal & Bearing Kit Heat Exchanger Relief Valve Kit
1

3
4

K-4410 2

Description P/N QT 3
Y

1 Input Bearing 4307847 1

K-4414
2 Input Bearing Spiral 4307848 1
Retainer Ring Description P/N QT
Y
3 Front Cover Input Bearing 4307849 1
Snap Ring 1 HECV Poppet 4308803 1

4 Input Seal 4307850 1 2 HECV Spring 4307921 1

3 HECV Hole Plug 4308802 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 10
OEM and Engine Specific Transmission Kits | Service Parts and Kits TRPB0990

Complete Clutch Housing Kit Clutch Cooling Module Assembly Kit

K-4411 K-4435
Description P/N QTY Description P/N QTY

1 Clutch Housing Assem- S-8519 1 1 CCM Cap Screws X-8-0835M 5

bly
2 Clutch Cooling Module A-8412 1
(CCM) Assembly
Description P/N QTY
3 CCM Gasket 4307704 1
Seal Plate 4307737 1

Seal Plate Gasket 4307736 1

11 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | OEM and Engine Specific Transmission Kits

Pump Assembly Kit Interface Manifold to Clutch Housing

Gasket Kit
1

2
1

K-4472
Description P/N QT
Y K-4412
1 Pump Gasket 4307693 1
Description P/N QT
2 Pump Assembly A-1000400 1 Y
6
1 Clutch Housing to Seal 4307760 1
3 Calibration Instructions L-2018-04 1 Plate Gasket

2 Interface Manifold to Seal 4307761 1

Description P/N QT
Plate Gasket
Y
3 Pump Gasket 4307693 1
Pump Driven Gear 4307694 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 12
OEM and Engine Specific Transmission Kits | Service Parts and Kits TRPB0990

Rail D Shift Yoke Kit Rail D Magnet Kit

2
3

K-4400
Description P/N QTY

1 Rail D Shift Yoke Cap X-8C-0839M 1

Screw w/ Washer
3
2 Rail D Shift Yoke 4307978 1

3 Shift Yoke Wear Pads 4307673 2 2

K-4408
Description P/N QT
Y

1 Rail D Magnet Retainer 4308306 1

Ring

2 Rail D Magnet 4308392 1

3 Rail D Magnet O-ring 4308307 1

4 Calibration Instructions L-2018-04 1

13 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | OEM and Engine Specific Transmission Kits

Rail D Detent Kit Complete Interface Manifold Assembly

2 Kit
1

K-4413 1

Description P/N QT
Y 2

1 Shift Rail D Detent 4307820 1

2 Shift Rail D Detent Spring 4307955 1

3 Shift Rail D Hole Plug 4308231 1

K-4420
Description P/N QTY

1 Interface Manifold w/ S-8525 1

Shift Rails A, B, C
Assembly

2 Shift Rails A, B, D Rod 4307841 3

Seals (Clutch Housing
Side)

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 14
OEM and Engine Specific Transmission Kits | Service Parts and Kits TRPB0990

Shift Rail Detent Kit Lower Shaft Front Bearing Kit

1

2
2

K-4425 K-4429
Description P/N QTY Description P/N QT
Y
1 Shift Rail A, B, C Detent 4307955 3
Spring 1 Lower Shaft Front Bearing 4307919 1
2 Shift Rail A, B, C Detent 4307820 3 2 Lower Shaft Front Bearing 4307918 1
Outer Race

Shift Rail Piston Kit 3 Lower Shaft Snap Ring Kit K-4283 1

1 2 3 4 5
Miscellaneous Parts
Description P/N QTY

Lifting Eye 20815

Harness Bracket 4307676

Plug, HPTO/LPTO (2) 4308231

HPTO Orifice 4307840

K-4426
Plug, Clutch Housing 4308229
Description P/N QTY Lower (2)
1 Shift Rail A, B, D Rod 4307841 3 Breather X2014210
Seals (Clutch Housing
Side) Cap Screw, Harness X-8-0625M
Bracket and Seal Plate -
2 Shift Rails Piston Snap 4307813 4 M6x1.0x16 (22)
Ring
Cap Screw, Front Cover X-8-0833M
3 Shift Rail B, C, D Piston 4307811 3 to Clutch Hsg -
M8X1.25x35 (16)
4 Shift Rail A Piston 4307812 1
Cap Screw, Clutch Sup- X-8C-839M
5 Shift Rail A, B, C, D Rod 4307842 4
port Manifold and Pump
Seals (Interface Mani-
Drive Gear - M8x1.25X20
fold Side)
(7)

15 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Main Housing Service Kits

Main Housing Service Kits

Transmission Control Module (TCM) Kits

K-4266
• EDCO-xx107A

Description P/N QTY

TCM - Non Park Pawl 10001705 1

Calibration Instructions L-2017-04 1

K-4269
• EDCO-xx107A-P

Description P/N QTY

TCM - Park Pawl 10001705 1

Calibration Instructions L-2017-04 1

K-4274
• EDCO-xx107A-B

Description P/N QTY

TCM - B-Ratio 10001705 1

Calibration Instructions L-2017-04 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 16
Main Housing Service Kits | Service Parts and Kits TRPB0990

TCM Cover and Mounting Studs Sump Pan Replacement Kit

1 1

Description P/N QTY

1 TCM Cover 4307675 1

2 TCM Mounting Stud 5577511-MP4 4

(M6x50.0)

2
Drain Plug Kit

K-4270
K-4271
Description P/N QTY

1 Sump Pan Seal 4307881 1

2 Sump Pan Assembly S-3146 1

1 2

Description P/N QTY

1 Oil Drain Plug O-ring 4307986 1

2 Oil Drain Plug 4307987 1

17 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Main Housing Service Kits

Complete Filter Kit Transmission Harness Kit

3
1 2

4
2

K-4275
Description P/N QTY
K-4272
1 Actuation Control Manifold 4307738 1
Description P/N QTY (ACM) to Interface Mani-
fold Gasket
1 Cartridge Filter 4307752 1
2 ACM Lube Passage/Isola- 4307944 2
2 Cartridge Filter Cover 4307971 1
tor O-ring
O-ring
3 Transmission Harness A-8500 1
3 Sump Pan Filter 4308798 1
Assembly
4 Sump Pan Seal 4307881 1
4 Sump Pan Seal 4307881 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 18
Main Housing Service Kits | Service Parts and Kits TRPB0990

74-Way Connector Retainer Kit Actuation Control Manifold Gasket Kit

K-4439
1 Description P/N QTY
2 1 Actuation Control Manifold 4307738 1
(ACM) to Interface Mani-
fold Gasket

2 ACM Lube Passage/Isola- 4307944 2

K-4276 tor O-ring

Description P/N QTY 3 Oil Drain Plug O-ring 4307986 1

1 74-Way Connector X-8-0510M 6 4 Sump Pan Seal 4307881 1

Retainer Cap Screw

2 74-Way Connector 4307602 1

Retainer

19 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Main Housing Service Kits

Actuation Control Manifold Complete Kit Triple Pressure / Temp Sensor Kit
1

3 2

2
1

K-4279
Description P/N QTY

1 Triple Pressure Sensor 4307773 1

(TPS)

2 TPS Cap Screws 4307774 2

K-4277 3 Calibration Instructions L-2018-04 1

Description P/N QTY

1 Actuation Control Manifold A-8568 1

(ACM) w/ Transmission
Harness Assembly

2 ACM Lube Passage/Isola- 4307944 2

tor O-ring

3 ACM to Interface Manifold 4307738 1

Gasket

4 Calibration Instructions L-2018-04 1

Description P/N QTY

Actuation Control Manifold 4307877 1

Retainer Tab

Cooler Oil Temp Sensor 4307775 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 20
Main Housing Service Kits | Service Parts and Kits TRPB0990

Rail D Position Sensor Kit Engine Speed Sensor Kit

1

1 2

2
K-4281
Description P/N QTY
3
1 Engine Speed Sensor Har- 4307790 2
ness Torx Head Screw
1
2 Engine Speed Sensor Cap 4307917 1
Screw
K-4280 3 Engine Speed Sensor 4307607 1

Description P/N QTY

1 Rail D Position Sensor 4307795 2

Wire Harness Cap Screw

2 Rail D Position Sensor 4308305 2

Wire Retainer Clip

3 Rail D Position Sensor 4308393 1

4 Calibration Instructions L-2018-04 1

21 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Main Housing Service Kits

Primary and Secondary Input Shaft Kit Cluster Gear Kit

1

2
1 2 3 4

K-4415
Description P/N QTY

1 Primary Input Bearing Lube 4307951 1 K-4436

Tube
Description P/N QTY
2 Primary Input Shaft & S-8510 1
5th/7th Gear Assembly 1 Cluster Gear Assembly S-8562
3 Secondary Input Shaft & S-8511 1 2 Cluster Gear Inner Bear- 4307712
Drive Gear Assembly ing Race
4 Secondary Input Shaft 4307724 1
Bearing Outer Race
Upper Shaft Front Bearing Kit
1
Rail D Synchronizer and Cluster Gear Kit
1

2
2

K-4417
Description P/N QTY
K-4404
1 Upper Shaft Front Bear- 4307739 1
Description P/N QTY ing
1 Rail D Synchronizer S-8509 1 2 Upper Shaft Front Bear- 4307746 1
Assembly ing Snap Ring
2 Cluster Gear Assembly S-8562 1

3 Cluster Gear Inner Bearing 4307712 1

Race

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 22
Main Housing Service Kits | Service Parts and Kits TRPB0990

Upper Shaft Mid-Wall Bearing Kit Lower Shaft Mid-Wall Bearing Kit
1
1

2
2

K-4405
K-4419 Description P/N QTY

Description P/N QTY 1 Lower Shaft Mid-Wall 4307720 1

Bearing Outer Race
1 Upper Shaft Mid-Wall Bear- 4307856 1
ing Outer Race 2 Lower Shaft Mid-Wall 4307719 1
Bearing
2 Upper Shaft Mid-Wall Bear- 4307988 1
ing 3 Lower Shaft Shim Kit K-4431 1

3 Upper Shaft Shim Kit K-4430 1

Upper Shaft Mid-Wall Bearing Shim Kit

K-4430
Description P/N QTY

1 Shim (0.05mm) 4307896 3

2 Shim (0.076mm) 4307897 3

3 Shim (0.10mm) 4307898 2

4 Shim (0.25mm) 4307899 2

5 Shim (0.50mm) 4307900 2

6 Shim (1.00mm) 4307901 1

23 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Main Housing Service Kits

Lower Shaft Snap Ring Kit Miscellaneous Part

Description P/N QTY
K-4283
Reverse Idler Shaft Cap X-8-0833M
Description P/N QTY Screw
1 Snap Ring (2.12mm) X8870370 1 Reverse Idler Shaft 4307708
2 Snap Ring (2.07mm) X8870371 1 Reverse Idler Thrust 4308951
Washer
3 Snap Ring (2.02mm) X8870372 1
Reverse Idler Bearing 4307822
4 Snap Ring (1.97mm) X8871536 1
Reverse Idler Gear 4307666
5 Snap Ring (1.92mm) X8871537 1
Secondary Driven Gear 4307647
6 Snap Ring (1.87mm) X8871538 1
Rail A Synchro Assembly S-8563
7 Snap Ring (1.82mm) X8871539 1
Rail A Synchro Hub Snap 4307980
8 Snap Ring (1.77mm) X8871540 1
Ring

1st/2nd Gear Needle 3315703

Lower Shaft Mid-Wall Bearing Shim Kit Bearing (2)

1st/2nd Gear A-8553

K-4431
Reverse Gear A-8554
Description P/N QTY
Rail B Synchro Assembly A-8555
1 Shim (0.05mm) 4307903 3
3rd Gear Needle Bearing 4124075
2 Shim (0.076mm) 4307904 3 (2)
3 Shim (0.10mm) 4307905 2 3rd Gear A-8515
4 Shim (0.25mm) 4307906 2 5th/7th Clutch Teeth Gear 4307762
5 Shim (0.50mm) 4307907 2 Upper Shaft Assembly A-8556
Complete
6 Shim (1.00mm) 4307908 1
Upper Shaft Mid-Wall 4307979
Baring Spacer

Upper Shaft 4308250

Lower Shaft Assembly A-8507

Cap Screw, Transmis- X-8-0625M

sion Harness

Cap Screw, Actuation X-8-0633M

Control Manifold

90-Degree Connector 4307615

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 24
TRPB0990 Service Parts and Kits | Rear Housing Service Kits

Rear Housing Service Kits

Output Yoke/Flange Retainer Kit Rail A Magnet Kit

1

1
2

K-4291 K-4547
Description P/N QT Description P/N QTY
Y
1 Rail A Magnet 4307609 1
1 Output Yoke Retainer 4307982 1
O-ring 2 Rail Magnet Torx Head X-8-0408M 1
Screw
2 Output Yoke Retainer Plate 4307880 1
Calibration Instructions L-2018-04 1
3 Output Yoke/Retainer Plate X-7-1206M 2
Cap Screws

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 25
TRPB0990 Service Parts and Kits | Rear Housing Service Kits

Rail B Magnet Kit 3 Rail Position Sensor Assembly Kit

4
2
2

K-4546 5

Description P/N QTY

1 Rail B Magnet 10004051 1

2 Rail Magnet Torx Head X-8-0408M 1

Screw 1
Calibration Instructions L-2018-04 1

Rail C Magnet Kit

2

Description P/N QTY

1 3-Rail Position Sensor 4307606 1

1
2 Rail Magnet Torx Head X-8-0408M 3
Screw

3 Rail A Magnet 4307609 1

K-4548
4 Rail B Magnet 10004051 1
Description P/N QTY
5 Rail C Magnet 4307611 1
1 Rail C Magnet 4307611 1
6 Calibration Instructions L-2018-04 1
2 Rail Magnet Torx Head X-8-0408M 1
Screw

Calibration Instructions L-2018-04 1

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 26
Rear Housing Service Kits | Service Parts and Kits TRPB0990

Rear Housing Cover Kit - Non Park Pawl Rear Housing Cover Kit - Park Pawl

3 4

1 2

2
K-4422
1 Description P/N QTY

1 Rear Housing Cover S-8866 1

K-4268 Assembly - Park Pawl

Description P/N QTY 2 Lower Shaft Rear Bear- 4307826 1

ing Inner Race
1 Rear Housing Cover S-8545 1
Assembly - Non Park 3 Upper Shaft Rear Bearing 4307824 1
Pawl Inner Race

2 Lower Shaft Rear Bear- 4307826 1 4 4th Driven Gear & Park S-8668 1
ing Inner Race Pawl Rotor Assembly

3 Upper Shaft Rear Bear- 4307824 1 Lower Shaft Snap Ring K-4283 1
ing Inner Race Kit

4 Lower Shaft Snap Ring K-4283 1

Kit

27 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRPB0990 Service Parts and Kits | Rear Housing Service Kits

Speed Sensor Plug Kit K-4423

Description P/N QTY

1 Upper Shaft Rear Bearing 4307824 1

1 Inner Race

2 Upper Shaft Rear Bearing 4307825 1

2
3 Upper Shaft Rear Bearing 4307829 1
3 Snap Ring

Lower Shaft Rear Bearing Kit

2
1
K-4267
Description P/N QTY

1 External Output Speed X-8-0840M 1 K-4424

Sensor Plug Cap Screw
Description P/N QTY
2 External Output Speed 4306402 1
Sensor Plug 1 Lower Shaft Rear Bearing 4307826 1
Inner Race
3 External Output Speed 14142 1
Sensor Plug O-ring 2 Lower Shaft Rear Bearing 4307827 1

3 Lower Shaft Snap Ring Kit K-4283 1

Upper Shaft Rear Bearing Kit
1 4th Drive Gear Kit
2 1

3 2

2024.08.14 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 28
Rear Housing Service Kits | Service Parts and Kits TRPB0990

K-4478 Miscellaneous Parts

Description P/N QTY Description P/N QTY
1 4th and 6th Drive Gear 4307821 1 Rear Bearing Spacer 4307972
Needle Bearing
6th Drive Gear Mid-Wall 4307755
2 4th Drive Gear Assembly A-8551 1 Bearing Spacer
3 4th Drive Gear Bearing 4307973 1 6th Drive Gr Mid-Wall X-14-0500
Inner Race Brg Spcer Alignment Ball M
(5mm)
4 4th Drive Gear Oil Retainer 4307858 1
Ring 6th Driven Gear 4307659

4th Driven Gear 4307891

6/4 Drive Gear Set with Rail C Output Shaft Slinger 4307669
Synchronizer Kit Shield
1
Output Seal 4307882

Rear Housing Spray Bar A-8536

2
Transmission Range 4307605
Sensor Assembly
3 Cap Screw, Rear Housing X-8-0625M
Spray Bar and Oil Trough
- M6x1.0x16 (4)
4

Cap Screw, Short Rear X-8-1046M

Housing to Main Housing
- M10x1.5x35 (15)

Cap Screw, Long Rear X-8-1047M

Housing to Mian Housing
K-4407 - M10x1.5x90 (3)

Description P/N QTY Cap Scew, Lower Shaft X-8-1212M

Rear Cover M12x1.75x25
1 6th Drive Gear Assembly A-8518 1 (4)
2 Rail C Synchronizer S-8564 1
Assembly
Lubricant, PS-278 Synthetic
3 4th Drive Gear Assembly A-8551 1 Transmission
4 4th Drive Gear Oil 4307858 1
Retainer Ring Description P/N QTY

Lower Shaft Snap Ring K-4283 1 5 Gallon Pail 5564547 1

Kit

29 © 2023 Eaton Cummins Automated Transmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | Lubrication Specifications

Lubrication Specifications
Use only Eaton approved lubricant. For information, see
TCMT0021 Eaton Lubrication Manual.

NOTICE: Failure to use approved lubricant will affect trans-

mission performance and warranty coverage.
NOTICE: Do not introduce additives and friction modifiers.
NOTICE: Never mix standard oils and synthetic transmis-
sion oils in the same transmission. Drain components thor-
oughly before switching lubricant types. Do not mix
lubricants of different grades.
For a list of Eaton approved lubricant suppliers, see
TCMT0020 Eaton Lubricant Suppliers Guide.

Maintenance and Lubricant Change Intervals

Transmission oil level inspection and change intervals are
necessary to maintain optimal transmission performance.

Transmission inspections and lubricant changes are out-

lined below.

NOTICE: Extended Drain Intervals are not recommended.

Interval Description

Daily Pre-Trip Inspect transmission oil level by

Inspection following the Transmission Oil Level
Procedure.

30,000 miles Perform oil level inspection and

check for leaks.

150,000 miles Perform transmission Oil Drain and

Fill Procedures. Change lubrication
filter.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 892
TRSM0990 Appendix | Oil Leak Inspection Process

Oil Leak Inspection Process

Inspect for Oil Leak

Determine if it is a Weep or a Leak.

Weep: Stained, damp, no drips, light oil film Leak: Extremely wet or dripping of oil
or dirt adhered to the contaminated area. in the contaminated area.

Gasket/Rear Seal Leak

Step 1

1. Clean suspected oil weep 1. Determine the origin of the leak path.
area with a clean, dry cloth 2. If the origin of leak is obvious, skip to Step 3.
or mild soluble degreaser. 3. If the origin of the oil leak is not obvious, then
use either of the two following steps to determine
2. Ensure lube is filled to the the oil leak:
proper lube level. Note: Do not use a high-pressure spray washer to
clean the area. Use of a high-pressure spray may
3. Notify the customer that it force contamination into the area of concern and
is only a weep and it is not temporarily disrupt the leak path.
considered to be detrimental
i. Clean area with a clean, dry cloth or mild
to the life of the transmission.
soluble degreaser and fill the transmission to
the proper lube level.
4. Repair is complete.
OR
ii. Clean the area as noted above and insert tracer
dye into the transmission lube and fill
transmission to proper lube level.

Step 2

Operate vehicle to normal transmission operating

temperature and inspect the area for oil leak(s)
visually or if tracer dye was introduced use an UVL
(Ultraviolet Light) to detect the tracer dye’s point
of origin.
Note: When inspecting for the origin of the leak(s)
make sure the assumed leak area is not being
contaminated by a source either forward or above
the identified area such as the engine oil lines.

Step 3

Once the origin of the leak is identified, repair the

oil leak using proper repair procedures from the
designated model service manual.

Step 4

After the repair is completed, verify the leak is

repaired and operate the vehicle to normal
transmission operating temperature. Inspect
repaired area to ensure oil leak has been eliminated.
If the leak(s) still occurs, repeat steps or contact
the Roadranger Call Center at 1-800-826-4357.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 893
TRSM0990 Appendix | Oil Level Inspection Procedure

Oil Level Inspection Procedure

Special Instructions Inspect Oil Level
None
1. Park vehicle in a safe area on level ground.
Special Tools • Select Park if equipped with a Shift Lever and
None slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Confirm engine is running at low idle RPM.

4. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick and tube.

5. Remove the transmission oil level dipstick.

6. Wipe transmission oil dipstick clean and reinstall into

tube.

7. Remove the transmission oil level dipstick and inspect

oil level.

8. Repeat Steps 6 and 7 to confirm oil level.

9. Add or drain transmission oil if oil level is not within

the Transmission Oil Level Operating Range based on
transmission oil temperature.

! CAUTION: Use only Eaton® approved lubricant

PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.

10. Re-install the transmission oil level dipstick.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 894
TRSM0990 Appendix | Inspection Precautions

Inspection Precautions
Before reassembling the transmission, check each part • Check for gears with clutching teeth abnormally
carefully for abnormal wear, excessive wear or damage to worn, tapered, or reduced in length from clashing
determine if the part is suitable for reuse. When replace- during shifting. Replace gears found in any of these
ment is necessary, use only genuine Eaton Transmission conditions.
parts to assure continued performance and extended life
• Check axial clearance of gears.
from your unit.

Since the cost of a new part is generally a small fraction of All Parts
the total cost of downtime and labor, avoid reusing a ques-
tionable part. This could lead to additional repairs and • Check all parts for cracks and breaks.
expense soon after assembly. Consideration should also be • Replace damaged parts.
given to the unit's history, mileage, application, etc. when
determining the reuse or replacement of any transmission
Oil Seals
part.
• Check oil seal. If sealing action of a lip has been
Bearings destroyed, replace seal.

• Wash all bearings in clean solvent. Check balls,

O-Rings
rollers and raceways for pitting, discoloration and
spalled areas. • Check all O-rings for cracks or distortion. Replace if
worn.
• Replace bearings that are pitted, discolored,
spalled or damaged during disassembly.
Reverse Idler Gear Assembly
• Lubricate bearings that are not pitted, discolored or
spalled and check for axial and radial clearances. • Check for excessive wear from action of roller bear-
ings.
• Replace bearings with excessive clearances.
• Check bearing fit. Bearing inner races should be Splines
tight to shaft; outer races slightly tight to slightly
loose in case bore. If the bearing spins freely in the • Check splines on all shafts for abnormal wear. If
bore the case should be replaced. synchronizer hubs have wear marks in the spline
sides, replace the specific shaft affected.
Bearing Cover
Shift Yokes and Rails
• Check covers for wear from thrust of adjacent bear-
ing. Replace covers if damaged from thrust of bear- • Check for bent shift rails.
ing outer race. • Check shift yokes for cracked or bent arms.
• Check cover bores for wear. Replace those worn or • Inspect shift yoke pads for wear.
oversized.
• Check mating surface on synchronizer locking
sleeve for wear.
Gears
• Replace bent or worn parts.
• Check gear teeth for frosting and pitting. Frosting
of gear teeth faces presents no threat of transmis-
sion failure. Often in continued operation of the Synchronizer Assembly
unit, frosted gears “heal” and do not progress to • Check synchronizer hub for burrs.
the pitting stage. In most cases, gears with light to
moderate pitted teeth have considerable gear life • Check blocking ring for uneven and excessive wear
remaining and can be reused, but gears in the at contact surface.
advanced stage of pitting should be replaced.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 895
TRSM0990 Appendix | Inspection Precautions

• Check blocking ring and locking sleeve clutching

Description Torque
teeth for abnormal wear, tapering or reduction in
length as a result of clashing during shifting. ACM Flange to Interface Manifold 8.8–10.4 Nm
Replace the synchronizer assembly if affected. Flange (77.9–92 lb–in)

ACM Rear Retainer Tab to Main 20.5–25.5 Nm

Washers
Housing (15.1–18.8 lb–ft)
• Check surfaces of all washers. Washers scored or
reduced in thickness should be replaced. ACM Harness to Main Housing 8.8–10.4 Nm
(77.9–92 lb–in)

Torque Specifications Primary Input Shaft Speed Sensor to 8.8–10.4 Nm

ACM (77.9–92 lb–in)
Description Torque Secondary Input Shaft Speed Sen- 8.8–10.4 Nm
Damper to Flywheel 40.7–54.2 Nm sor to ACM (77.9–92 lb–in)
(30–40 lb–ft) Shift Rail D Position Sensor to ACM 8.8–10.4 Nm
Front Cover to Clutch Housing 20.5–25.5 Nm (77.9–92 lb–in)
(15.1–18.8 lb–ft) CCPS & CCSS Retainer to ACM 2.25–2.8 Nm
Support Manifold to Clutch Housing 20.5–25.5 Nm (20.0–24.8
(15.1–18.8 lb–ft) lb–in)

Pump Driven Gear to Pump Drive 32.5–39.5 Nm ACM Harness to ACM 8.8–10.4 Nm
Shaft (24.0–29.1 lb–ft) (77.9–92 lb–in)

Seal Plate to Clutch Housing 8.8–10.4 Nm 3-Rail Position Sensor to Main 8.8–10.4 Nm
(77.9–92 lb–in) Housing (77.9–92 lb–in)

Main Housing to Clutch Housing 44.5–51.5 Nm Magnets to Rail A, B and C 1.55–1.85 Nm

(32.8–38 lb–ft) (13.7–16.3
lb–in)
Front Lifting Eye Bracket to Clutch 43.5–50.5 Nm
Housing (32.1–37.3 lb–ft) Shift Yoke D to Rail D 32.5–39.5 Nm
(24.0–29.1 lb–ft)
Rear Lifting Eye Bracket to Main 44.5–51.5 Nm
Housing (32.8–38 lb–ft) Primary Input Shaft Retainer to 20.5–25.5 Nm
Interface Manifold (15.1–18.8 lb–ft)
TCM Cover to Main Housing Studs 8.8–10.4 Nm
(77.9–92 lb–in) Primary Input Shaft Bearing 20.5–25.5 Nm
Retainer to Primary Input Shaft (15.1–18.8 lb–ft)
Sump Pan to Main Housing 20.5–25.5 Nm Retainer
(15.1–18.8 lb–ft)
Pump to Clutch Housing 8.8–10.4 Nm
TCM to Internal Harness 3.0–4.0 Nm (78–92.4 lb–in)
(26.6–35.4
lb–in) Interface Manifold to Clutch Housing 20.5–25.5 Nm
(15.1–18.8 lb–ft)
74-Way TCM Connector Bulkhead 5.3–6.3 Nm
Retainer to Main Housing (46.8–55.2 Output Yoke to Upper Shaft 75–85 Nm
lb–in) (55.3–62.7
lb–ft). Then,
Rear Cover to Main Housing 44.5–51.5 Nm 95–105 Nm
(32.8–38 lb–ft) (70.1–77.4 lb–ft)

Lower Shaft Rear Bearing Oil 8.8–10.4 Nm Rear Spray Bar to Main Housing 8.8–10.4 Nm
Retainer to Rear Cover (77.9–92 lb–in) (77.9–92 lb–in)

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Inspection Precautions | Appendix TRSM0990

Description Torque

Upper Shaft Mid Bearing Race 44.5–51.5 Nm

Retainer to Main Housing (32.5–38 lb–ft)

Lower Shaft Mid Bearing Race 24.5–29.5 Nm

Retainer to Main Housing (18.1–21.8 lb–ft)

Reverse Idler to Main Housing 27.5–31.5 Nm

(20.3–23.2 lb–ft)

Lower Shaft Rear Bearing Cover 69–81 Nm

Plate to Rear Cover (50.9–59.7 lb–ft)

Output Speed Sensor to Main Hous- 8.8–10.4 Nm

ing (77.9–92 lb–in)

Clutch Cooling Module Assembly to 20.5–25.5 Nm

Clutch Cover (15.1–18.8 lb–ft)

Shift Rail D Detent 24.5–29.5 Nm

(18.1–21.8 lb–ft)

PTO Cover to Main Housing 42.5–51.5 Nm

(31.5–38.0 lb–ft)

90-Degree Connector to Main Hous- 8.8–10.4 Nm

ing (77.9–92 lb–in)

Cartridge Filter Cover to Clutch Hand tighten to

Housing seat O-Ring.
Then, torque to
27.5–32.5 Nm
(20.3–24 lb–ft)

Low Pressure (LP) PTO to Clutch 19–23 Nm

Housing (14–17 lb–ft)

High Pressure (HP) PTO to Clutch 19–23 Nm

Housing (14–17 lb–ft)

897 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | Handling, Inspection and Cleaning of Parts

Handling, Inspection and Cleaning of Parts

Handling
All hydraulic components of the transmission require a
clean environment. If parts are not immediately reinstalled
into the transmission, they should be stored in a clean con-
tainer and covered with a lint-free cloth.

The components associated with the Actuation Control

Manifold (ACM) and Interface Manifold (IM) must be han-
dled with care. These components are crucial to the func-
tionality of the transmission and should be handled in a
clean environment.

Inspection and Cleaning

Inspect all transmission components with care. If any dam-
age is found during a component inspection, replace the
component and do not reuse.

NOTICE: Debris or foreign material can cause valves or

hydraulics to malfunction.
If any hydraulic component is exposed to dirt, or foreign
material, clean properly with a solvent-based cleaner and
dry with lint-free cloth before installing in the transmission.

Replacing Parts
Any replacement part to be used to fix the transmission
must, first, be cleaned with a solvent-based cleaner to
remove debris and dried with a lint-free cloth before instal-
lation.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 898
TRSM0990 Appendix | Recycling Parts and Oil

Recycling Parts and Oil

Recycling Parts
Properly dispose of transmission components (copper, alu-
minum, steel or iron components) that are not reused or
returned for warranty. Used transmission components
should be collected and recycled at an authorized facility.

Recycling Oil
Properly dispose of transmission oil. Used transmission oil
should be collected and recycled at an authorized facility.

Note: Never dispose of oil by putting it in the trash or pour-

ing it on the ground, into sewers, or into streams or bodies
of water.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 899
TRSM0990 Appendix | Roadranger Specialty Tools

Roadranger Specialty Tools

Level 1 Service Tool Kit (RR2000TR) Hydraulic Diagnostic Kit (RR2000HY)
• Universal Driver Handle (OE8044-T0) • Pressure Gauge Kit (RR1028TR)
• Input Seal Driver (RR1032TR) • Diagnostic Manifold Kit (RR1031TR)
• Front Cover Puller Kit (RR1033TR) • ACM Alignment Pins (RR1036TR)
• Output Seal Installer (RR1034TR) • Shift Rail Actuation Tool (RR1039TR)
• Damper Alignment Tool (RR1037TR) • Shift Rail Detent Retainer (RR1057TR)
• Input Seal Installer (RR1038TR)
Interchangeable 3” Jaw Puller (x2) (CJ85-1)
• Lower Shaft Rear Bearing Inner Race & 4th Gear
Inner Sleeve Driver (RR1040TR) Note: -on CJ85-1 Puller or equivalent.
• Lower Shaft Mid Bearing, Cluster Gear Bearing
Inner Race & Upper Shaft Rear Bearing Inner Race Interchangeable Jaw, Medium, Puller (x2)
Drivers (RR1041TR) (CJ105-6)
• Input Bearing Driver & Upper Shaft Mid Bearing Note: -on CJ105-6 Puller or equivalent.
Driver (RR1049TR)
• Upper Shaft Rear Bearing Driver (RR1053TR) Interchangeable Jaw, Large, Puller (x2)
(CJ105-7)
• Lower Shaft Rear Bearing Driver (RR1054TR)
Note: -on CJ105-7 Puller or equivalent.
• Front Cover Input Bearing Driver (RR1055TR)

Level 2 Service Tool Kit (RR2001TR)

• Universal Driver Handle (OE8044-T0)
• Secondary Input Front Bearing Outer Race Driver
(RR1042TR)
• Upper Shaft Front Bearing Driver (RR1043TR)
• Upper Shaft Front Press Spacer (RR1044TR)
• Lower Shaft Front Bearing Outer Race Driver
(RR1045TR)
• Lower Shaft Front Bearing Driver (RR1046TR)
• Lower Shaft Front Press Spacer (RR1047TR)
• Upper Shaft Mid Bearing Outer Race Driver
(RR1048TR)
• Lower Shaft Mid Bearing Outer Race Driver
(RR1050TR)
• IM Housing Rod Seal Installer (RR1051TR)
• Lower Shaft Mid Bearing & Cluster Gear Inner Race
Remover (RR1052TR)
• Clutch Housing Rod Seal Installer (RR1056TR)

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 900
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

4th and 6th Gear Needle Bearing Service Procedure

Special Instructions
4th and 6th Gear Needle Bearing procedure can be per-
formed with transmission in chassis using.

Note: Use K-4507 parts when performing 4th and 6th Gear
Needle Bearing Service Procedure.

Special Tools
• Shift Rail Actuation tool RR1039TR or M6X1.0X70
bolt
• Snap-on CJ85-1 Puller or equivalent
• Snap-on CJ105-6 Medium Jaw (Qty 2) or equiva-
lent
• Upper Shaft Rear Bearing Race Driver RR1041TR
• Lower Shaft Rear Bearing Race Driver RR1040TR
• Gasket Remover Loctite SF 7631
• Gasket Sealant Loctite 5188
• Transmission Assembly Lube (Lubegard® Assem-
blee Goo Firm Tack - Green #19250 or equivalent)

901 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

Component Identification

Drain Oil 5. Remove Oil Drain Plug with a 3/8” square drive ratchet
and drain oil.
1. Park vehicle in a safe area on level ground.

• Select Park if equipped with a Shift Lever and

slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the Oil Drain Plug on the Sump Pan.

4. Place a suitable container under the Oil Drain Plug.

Note: If reusing oil, use a clean container free of con-

tamination and debris.

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4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

6. If PTO-equipped, remove PTO and drain oil. 2. Remove the two 15 mm yoke Retainer Bolts, Retainer
Plate, and Retainer O-ring.
7. Inspect the Oil Drain Plug and Oil Drain Plug O-ring for
damage. If damaged, replace the Oil Drain Plug. Note: New Retainer Bolts, Retainer Plate and Retainer
O-ring are required when reinstalling.
Note: O-ring is serviced with plug.
WARNING: Reusing Retainer Bolts, Retainer Plate and
! Retainer O-ring could result in major vehicle compo-
nent damage, severe injury or death.

8. Install the Oil Drain Plug and torque to 27.5-32.5 Nm

(20.3-24 lb-ft)

NOTICE: Do not over-torque Oil Drain Plug or damage

to threads may occur.

Remove the Output Yoke

1. Remove the driveline. Refer to OEM guidelines for
driveline removal.

903 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

3. Remove the Output Yoke Remove the Transmission Range Sensor (TRS)
Note: There is an interference fit between the Output 1. Place the Transmission Cable Shift Lever in the Neutral
Yoke and output shaft splines that may require an out- (N) position.
put yoke puller.

2. Use hand tools to remove 15 mm Transmission Cable

Disconnect Shift Lever Cable Linkage Shift Lever Retaining Nut.
1. Unlock and disconnect Vehicle 4-Way Harness Con- NOTICE: Retain TRS Internal Shift Shaft position by
nector from 4-Way TRS Harness Connector. holding Transmission Shift Lever in the Neutral (N)
position while loosening the retaining nut to prevent
internal TRS damage. Do not use power tools.

2. Remove vehicle shift lever cable linkage from Trans-

mission Cable Shift Lever.

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4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

3. Remove Transmission Cable Shift Lever. Remove the Rear Housing Cover
1. Remove Output Seal Slinger Shield.

4. Remove 5 TRS Harness Bracket T30 torx head screws.

2. Remove 18 Rear Housing Cover cap screws.

Note: Three Rear Housing Cover cap screws are a dif-

ferent length than the rest. Note their proper position
for re-installation.

5. Remove TRS assembly from Main Housing and Rear

Housing Cover Internal Shift Shaft.

905 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

3. Separate Rear Housing Cover from Main Housing at 2 Disassemble Rear Housing with Park Pawl
pry points.
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
CAUTION: Do not pry on sealing surfaces. Failure to Rail C and place Shift Rail C in the Neutral position;
! avoid prying on sealing surface results in component remove Shift Rail Actuation Tool (RR1039TR).
damage.
Note: Confirm Rail C Synchronizer is in Neutral posi-
NOTICE: If transmission is equipped with a Park Pawl,
tion.
confirm the Internal Shift Shaft has remained in the
Neutral position prior to removing the Rear Housing
Cover or damage to the internal Park Pawl mechanism
and Lower Shaft Rear Inner Bearing Race will occur.

2. Install puller Medium Jaws (CJ105-6) or equivalent

into puller crossarm as shown.

4. Remove Rear Housing Cover.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 906
 4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

3. For gear pulling clearance, rotate and align Park Pawl 5. Pull off 4th Driven Gear, Park Pawl Gear and Upper
Gear tooth gap with Lower Shaft Bearing Inner Race as Shaft Rear Bearing Inner Race.
shown.
CAUTION: Ensure a Park Pawl Gear tooth gap is
CAUTION: Ensure a Park Pawl Gear tooth gap is ! aligned with the Lower Shaft Bearing Inner Race. Fail-
! aligned with the Lower Shaft Bearing Inner Race. Fail- ure to align a gear tooth with the race results in com-
ure to align a gear tooth with the race results in com- ponent damage.
ponent damage.

4. Install puller assembly onto Upper Shaft and under

Park Pawl Gear as shown.

CAUTION: Ensure puller jaws are fully seated under

! gear. Failure to fully seat jaws under gear results in
component damage.

6. Remove 2 Rear Housing Spray Bar 10 mm cap screws.

907 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

7. Remove Rear Housing Spray Bar from Main Housing 9. Push or pull to neutralize Rail C. 4th gear should rotate
and end of Reverse Idler Shaft. freely without binding or seizure. If binding or seizure
is observed after verifying that Rail C is neutralized the
transmission must be replaced. If 4th gear rotates
freely continue with repair procedure.

8. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

10. Pull Shift Rail C to engage Rail C Synchronizer Sleeve

onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 908
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

11. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5 13. Install puller Large Jaws (CJ105-7) or equivalent into
mm) roll pin punch. puller crossarm as shown.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

14. Install puller assembly onto Lower Shaft and under 6th
Gear with puller jaws in the 10 and 4 o'clock positions
as shown.
12. Remove Lower Shaft Rear Bearing Inner Race Snap
Ring from Lower Shaft and discard. CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
Note: New Snap Ring is required when reinstalling.
component damage.

909 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

15. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 16. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke, Spacer, and Lower Shaft Rear
Bearing Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

17. Rotate Lower Shaft to position 6th Gear Mid-Wall Bear-

ing Spacer and Alignment Ball in 12 o'clock position.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 910
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

Disassemble Rear Housing without Park Pawl 3. Install puller assembly onto Upper Shaft and under 4th
Driven Gear as shown.
1. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C and place Shift Rail C in the Neutral position; CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
remove Shift Rail Actuation Tool (RR1039TR).
component damage.
Note: Confirm Rail C Synchronizer is in Neutral posi-
tion.

4. Pull off 4th Driven Gear and Upper Shaft Rear Bearing
Inner Race.
2. Install puller Medium Jaws (CJ105-6) or equivalent
into puller crossarm as shown.

911 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

5. Remove 2 Rear Lube Bar 10 mm cap screws. 8. Pull Shift Rail C to engage Rail C Synchronizer Sleeve
onto 4th Gear, remove Shift Rail Actuation Tool
(RR1039TR).

6. Remove Rear Lube Bar from Main Housing and

Reverse Idler Shaft.
9. Drive out Rail C Shift Yoke Roll Pin with 7/32 in. (5.5
mm) roll pin punch.

Note: Roll Pin must be driven from the outside of

housing inward or damage may occur.

7. Install Shift Rail Actuation Tool (RR1039TR) into Shift

Rail C.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 912
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

10. Remove Lower Shaft Rear Bearing Inner Race Snap 12. Install puller assembly onto Lower Shaft and under 6th
Ring from Lower Shaft and discard. Gear as shown.

Note: New Snap Ring is required when reinstalling. CAUTION: Ensure puller jaws are fully seated under
! gear. Failure to fully seat jaws under gear results in
component damage.

11. Install puller Large Jaws (CJ105-7) or equivalent into

puller crossarm as shown.

913 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

13. Pull off 6th Gear, Rail C Synchronizer assembly, 4th 14. Remove 6th Gear Bearing from Lower Shaft.
Gear, Rail C Shift Yoke and Lower Shaft Rear Bearing
Inner Race.

NOTICE: Ensure Rail C Shift Yoke does not bind on

Shift Rail C when pulling or damage may occur.
NOTICE: Ensure Synchronizer assembly remains
together or Keys and Springs in Hub Key Slots may
pop out and be lost.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 914
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

Assemble Rear Housing with/without Park Pawl 3. Install new 6th Gear Bearing on Lower Shaft.

1. Verify that the 6th Gear Mid Wall Bearing Spacer on

Lower Shaft has the raised side facing the front of
transmission. Notch of the Mid Wall bearing spacer
and ball must be aligned.

4. Install Rear Lube Bar into Main Housing and Reverse

Idler Shaft.

Note: Ensure Rear Lube Bar is fully seated into Main

Housing and Reverse Idler Shaft.

2. Replace 5 mm Steel Ball.

Note: Apply a dab of transmission assembly lube to the

5 mm Steel Ball to hold it in place prior to the Mid Wall
Bearing Spacer installation.

915 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

5. Install 2 Rear Lube Bar 10 mm cap screws and torque 7. Install Rail C Synchronizer Blocking Ring onto 6th
to 8.8-10.4 Nm (77.9-92 lb-in). Gear.

6. Install 6th Gear on Lower Shaft. 8. Assemble Rail C Synchronizer assembly.

Note: Raised side of gear faces rear of transmission. NOTICE: Ensure all 3 Rail C Synchronizer Keys and
Proper orientation is critical to final assembly. Springs are in Synchronizer Hub Key Slots.
NOTICE: When installed in transmission beveled edge
of Synchronizer Sleeve faces front of transmission
while raised side of Synchronizer hub faces rear of
transmission.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 916
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

9. Position Rail C Shift Yoke onto Rail C Synchronizer 12. Install remaining Rail C Synchronizer Blocking Ring
assembly. onto Rail C Synchronizer Hub.

NOTICE: Ensure “REAR” indicated on Shift Yoke faces Note: Apply three evenly spaced dabs of transmission
rear of transmission. assembly lube to the Rail C Synchronizer Blocking
Ring prior to installing to hold the Blocking Ring in
place.
Note: Ensure Blocking Ring tabs align with Hub Key
Slots.

10. Install Rail C Synchronizer assembly with Rail C Shift

Yoke on Lower Shaft and Shift Rail C.

13. Install new 4th Gear Bearing into 4th Gear.

Note: Original Bearing and Captured Inner Race may

already be installed in 4th Gear. Replace Bearing.

11. Check proper assembly to this point before proceeding

to next step. Confirm the following:

• Synchronizer Blocking Ring tabs are aligned with

Hub Key Slots.
• Raised side of Synchronizer Hub faces rear of
transmission.
• Beveled edge of Synchronizer Sleeve faces front of
transmission.
• “REAR” indicated on Rail C Shift Yoke faces rear of
transmission.

917 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

14. Place 4th Gear assembly onto Lower Shaft. 16. Drive 4th Gear assembly onto Lower Shaft.

NOTICE: Ensure Rail C Synchronizer Blocking Ring

tabs stay aligned with Hub Key Slots during 4th Gear
installation.

15. Place Lower Shaft 4th Gear Inner Sleeve Driver

(RR1040TR) on Lower Shaft and against 4th Gear Cap-
tured Inner Race.
17. Install Spacer onto Lower Shaft.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 918
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

18. Place Lower Shaft Rear Bearing Inner Race onto end of 20. Install new Snap Ring on Lower Shaft.
Lower Shaft.
NOTICE: If Snap Ring cannot be properly installed into
Snap Ring groove due to Rear Bearing Inner Race
interference, check 6th Gear Mid-Wall Bearing Spacer
installation orientation (Step 4). Raised side of Spacer
must face front of transmission. Proper orientation is
critical to final assembly.

19. Use Lower Shaft Rear Bearing Inner Race Driver

(RR1040TR) to drive Lower Shaft Rear Bearing Inner
Race onto Lower Shaft.

Note: Ensure Rear Bearing Inner Race is fully seated. If

the white plastic slinger pops off during the race instal-
lation procedure, install using replacement slinger 21. Install Shift Rail Actuation Tool (RR1039TR) into Shift
Rail C.

919 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

22. Place Rail C Synchronizer Sleeve, Rail C Shift Yoke and 24. Install 4th Driven Gear and Park Pawl Gear assembly
Shift Rail C into the 4th Gear position then remove on Upper Shaft.
Shift Rail Actuation Tool (RR1039TR).
NOTICE: Align Park Pawl Gear tooth gap with Lower
Note: Ensure Rail C is fully extended rearward. Roll Pin Shaft Bearing Race or damage may occur.
hole in Rail must be aligned with Roll Pin hole in Shift
Yoke. Note: For transmissions without a Park Pawl, install
4th Driven Gear on Upper Shaft.

23. Install new Rail C Shift Yoke Roll Pin.

25. Place Upper Shaft Rear Bearing Inner Race onto end of
Note: Roll Pin must be driven from the inside of hous- Upper Shaft.
ing outward.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 920
4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

26. Use Upper Shaft Rear Bearing Inner Race Driver 3. Apply Gasket Sealant in an 1/8" bead inward of all cap
(RR1041TR) to drive Upper Shaft Rear Bearing Inner screw holes to the Main Housing sealing surface fol-
Race onto Upper Shaft. lowing the pattern below.

NOTICE: Ensure Park Pawl Gear tooth gap stays CAUTION: Ensure there is no Gasket Sealant in Main
aligned with Lower Shaft Bearing Race or damage may ! Housing Rear Bearing Oil Passage. Failure to keep oil
occur. passage clear of sealant results in component damage.

Install the Rear Housing Cover

1. Clean sealing surfaces on Rear Housing Cover and
Main Housing with Gasket Remover.

NOTICE: Do not use abrasive scrapers or power tools

to clean sealing surfaces.
2. Inspect threaded bolt holes for debris and clean if nec-
essary.

NOTICE: Ensure there is nothing in the threaded bolt 4. Install new Output Seal.
holes or the Main Housing may be damaged when cap
Note: Reference Procision Service Manual TRSM0990.
screws are tightened.

921 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

5. Install Rear Housing Cover onto Upper Shaft, Lower 7. Install 18 Rear Housing Cover 16 mm cap screws
Shaft and Main Housing Dowel Pins. torque to 44.5-51.5 Nm (32.8-38.0 lb-ft) in a criss-
cross pattern.
NOTICE: If transmission is equipped with a park pawl
confirm the Internal Shift Shaft has remained in the Note: Three Rear Housing Cover cap screws are a dif-
Neutral position as shown prior to installing the Rear ferent length than the rest. Refer to Rear Housing
Housing Cover or damage to the internal Park Pawl Cover removal notes for proper location.
mechanism and Lower Shaft Rear Inner Bearing Race
will occur.

Install the Transmission Range Sensor (TRS)

1. Install TRS assembly on Internal Shift Shaft and push
flush to Rear Housing Cover and Main Housing.

Note: Flat side of TRS must align with flat side of Inter-
nal Shift Shaft.

6. Push Rear Housing Cover flush to Main Housing.

NOTICE: Rear Housing Cover should not be forced

onto Main Housing. If Housings do not meet flush
check internal assembly.
NOTICE: Do not use cap screws to pull Rear Housing
Cover to Main Housing.
Note: A rubber hammer may be used to gently tap Rear
Housing Cover onto Main Housing Dowel Pins.

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4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

2. Install 5 TRS Harness Bracket to T30 torx head screws 4. Use hand tools to install the Transmission Cable Shift
and torque to 8.8-10.4 Nm (77.9-92 lb-in). Lever retaining nut on Internal Shift Shaft and torque
nut to 20.5-25.5 Nm (15.1-18.8 lb-ft).

NOTICE: Retain TRS Internal Shift Shaft position by

holding Cable Shift Lever in the Neutral (N) position
while tightening the retaining nut to prevent internal
TRS damage. Do not use power tools.

3. Install Transmission Cable Shift Lever on Internal Shift

Shaft.

NOTICE: Cable Shift Lever must point upward and

curve toward transmission. Improper installation will
cause gear selection problems.
Connect Shift Lever Cable Linkage
1. Install transmission shift selector cable linkage to
Transmission Cable Shift Lever.

NOTICE: See OEM Service Manual for shift selector

cable linkage adjustment procedure.
2. Connect and lock OEM 4-Way Connector to 4-Way TRS
Harness Connector.

Install the Output Yoke

1. Clean the mating surfaces and splines on the output
shaft and Output Yoke.

923 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | 4th and 6th Gear Needle Bearing Service Procedure

2. Slide the Output Yoke over the output shaft. 1. Park vehicle in a safe area on level ground.

Note: The Output Yoke may require to be driven on due • Select Park if equipped with a Shift Lever and
to an interference fit. slowly release service brake to engage park pawl.
• Select Neutral if equipped with a Push Button.
2. Set vehicle parking brake and chock wheels.

3. Locate the transmission oil level dipstick and tube in

the engine compartment and clean any dirt or debris
from dipstick handle and tube.

4. Remove transmission oil level dipstick.

5. Fill transmission with 12 liters of Eaton Procision DCT

transmission oil through the dipstick tube.

6. Key on, engine running at low idle RPM.

7. Wipe clean the transmission oil level dipstick and

install in dipstick tube.

8. Remove transmission oil level dipstick and check oil

3. Install new Retainer Plate, Retainer Plate O-ring, and level.
two 15 mm Retainer Bolts and torque to 75-85 Nm
(55.3-62.7 lb-ft), then perform final torque to 95-105 9. Repeat steps 7 and 8 to confirm oil level.
Nm (70.1-77.4 lb-ft).
10. Add or drain transmission oil if oil level is not within
WARNING: Reusing previously removed Retainer the Transmission Oil Level Operating Range based on
! Bolts, Retainer Plate and Retainer O-ring could result in transmission oil temperature.
major vehicle component damage, severe injury or
death. ! CAUTION: Use only Eaton® approved lubricant
PS-278. Failure to use specified lubricant results in
component damage.
NOTICE: Do not overfill transmission oil.
Note: If PTO-equipped additional oil will be required.

11. Re-install transmission oil level dipstick.

Note: Reference the Oil Leak Inspection Process after

performing the steps to Fill Oil.

Calibrate Rail and TRS Shift Device

4. Install the driveline. Refer to OEM guidelines for drive-
line Installation. 1. Key on with engine running.

Fill Oil 2. Connect ServiceRanger.

Note: For a list of Eaton Approved Synthetic Lubricants, see 3. Go To “Service Routines”.
Eaton TCMT0021 Lubrication guide on Roadranger.com or 4. Select “Start” Rail Calibration and follow on-screen
call 1-800-826-HELP (4357). prompts.

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4th and 6th Gear Needle Bearing Service Procedure | Appendix TRSM0990

5. Key off and wait 1 minute.

6. Key on with engine off.

7. Select “Start” TRS Shift Device Calibration and follow

on-screen prompts.

Note: If transmission is not equipped with a Transmis-

sion Range Sensor (TRS) go to Step 9.
8. Go To “Fault Codes”.

• If active fault code(s) is set, refer to TRTS0990 Pro-

cision Troubleshooting Guide.
• If no active fault codes, select “Clear Eaton Faults”
and follow on-screen prompts.
9. Disconnect ServiceRanger.

10. Key off.

925 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 2024.08.14
TRSM0990 Appendix | Change Log

Change Log

Date Description

June 2023 Added: Clutch Cooling Module Assembly Kit

April 2023 Updated: Calibrate and Clear Faults Procedure

February 2023 Updated: Main Housing Service Kits, Service Kits & Parts Index

January 2023 Updated: Main Housing Service Kits

May 2022 Updated: Clutch Housing Service Kits

January 2022 Updated: TCM part number for EDCO-xx107A-P

February 2021 Updated: Transmission Service Procedure

October 2020 Added: 4th & 6th Gear Needle Bearing Service Procedure to Appendix
Updated: Input Seal Service Procedure

July 2020 Updated:

Service Kit Parts Index
Clutch Housing Service Kits
Roadranger Specialty Tools
Rear Housing Disassembly/Assembly
Primary and Secondary Input Shaft Procedure

January 2020 Updated: manual to new format

July 2019 Updated: page numbers

January 2019 Total rewrite of this Service Manual.

2024.08.14 © 2023 Eaton Cummins Automated Tranmission Technologies. All rights reserved. 926
Copyright Eaton, 2023.
Eaton hereby grant their customers,
vendors, or distributors permission to
freely copy, reproduce and/or distribute
this document in printed format. It may
be copied only in its entirety without any
changes or modifications. THIS INFOR-
MATION IS NOT INTENDED FOR SALE
OR RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.

Note: Features and specifications listed

in this document are subject to change
without notice and represent the maxi-
mum capabilities of the software and
products with all options installed.
Although every attempt has been made
to ensure the accuracy of information
contained within, Eaton makes no repre-
sentation about the completeness, cor-
rectness or accuracy and assumes no
responsibility for any errors or omis-
sions. Features and functionality may
vary depending on selected options.

For spec’ing or service assistance,

call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.

Roadranger: Eaton and trusted partners

providing the best products and ser-
vices in the industry, ensuring more
time on the road.

Eaton
Vehicle Group
13100 E. Michigan Ave.
Galesburg, MI 49053 USA
800-826-HELP (4357)
www.eaton.com/roadranger

Printed in USA

Eaton
1111 Superior Ave.
Cleveland, OH 44114