NHTSA ID Number: 10162291
Manufacturer Communication Number: 0306-19
TSB/Document Date: 2019-07-08
Summary
Service information Bulletin
03 06-19
1
03 06-19
SUBJECT
DATE
Removal and Installation of the Service Range Group
March 2019
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0140
Platform
Section Title
Change
DT12
External Component
Repair - Service Range
Group
New procedures.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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2 Removal of the Service Range Group
2
Removal of the Service Range Group
Remove as follows:
Table 1.
Service Tools Used in the Procedure
Tool Number
Tool Name
DDE W 715 589 00 40 00
Lifting Eye
DDE W 715 589 14 33 00
Pushing Screw
Tool Graphic
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
1. Disconnect the batteries at the negative post, including the batteries for the auxiliary HVAC, if equipped.
2. Remove the transmission. Refer to section "Removal of the Transmission".
3. Remove the air fittings (3) connected to the range cylinder (4). See below.
4
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Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 1. Range Cylinder Air Lines
4. Disconnect the range position sensor (1) and output shaft speed sensor (2) from the transmission wiring harness.
5. Remove the air line and wire harness raceway.
WARNING: EYE INJURY
To avoid injury from flying parts when working with components under spring tension, wear
adequate eye protection (face shield or safety goggles).
NOTICE: The range detent spring is under pressure, and must be held back to prevent the spring from
catapulting the shift fork detent spring nut, possibly causing thread damage to the case and potential injury from
flying parts.
6. Remove the range shift fork detent spring nut cap (1). As the nut is removed, push in with enough force to prevent the
spring from catapulting the nut. After the spring is removed, remove the range detent shaft. See figure below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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2 Removal of the Service Range Group
Figure 2. Range Shift Fork Detent Spring Nut Cap
7. For A-box transmissions only, remove the top two bolts on the range housing bolting flange, and install the lifting eye
(special tool DDE W 715 589 00 40 00). B-box transmissions have an integrated lift eye in the range housing casting.
See figure below.
6
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 3. Lifting Eye (special tool DDE W 715 589 00 40 00) Installed
8. Remove the oil pump cover (see figure below), or PTO, if installed. See the workshop instructions for detailed PTO
removal steps. Refer to section "Removal of the Power Take-Off".
Figure 4. Oil Pump Cover
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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2 Removal of the Service Range Group
9. Remove the oil pump relief valve (1), oil pump drive shaft (3), and pump rotors. See figure below.
Figure 5. Oil Pump Relief Valve and Drive Shaft
10. Attach the lifting device and then remove the remaining fasteners.
Table 2.
NOTE: Manufacture two guide pins from M12 bolts according to the dimensions shown:
A. Approx. 160 mm (6-1/4 in.)
B. Approx. 30 mm (1-3/16 in.)
C. M12 x 1.75
11. Install guide pins. See figure below.
8
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 6. Guide Pins
12. Install the kit of three set screws and pushing screws (special tool DDE W 715 589 14 33 00). See figure below for
pushing screw locations. Turn all three screws in even, incremental steps, to push the housing off the dowel pins.
While the housing is being pushed back, the planetary housing flange may tend to bind on the alignment dowels. Take
steps to keep the flange parallel to the housing face to ease the removal of the housing. See figure below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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2 Removal of the Service Range Group
Figure 7. Pushing Screw Locations
13. The housing alignment dowels (1), and planetary plate dowels (2) may pull out from the center housing during the
Range housing removal; if necessary, use table 2 to set the height of the of the housing dowels, and seat the plate
dowels into the bottom of the pocket, in the center housing, using a non-mar mallet. See figure below.
Table 3.
Housing Alignment Dowel Pin Protrusion
10
A - Box Housing Pin Protrusion
32.5 mm (1.3 in.) visible
B - Box Housing Pin Protrusion
22.0 mm (0.87 in.) visible
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 8. Dowel Locations
14. Remove the pushing screws, set screws, and guide pins.
15. Inspect the main shaft for an oil restrictor. If the transmission does not have a restrictor installed, a service range group
is not compatible with the main shaft of the transmission. Installing a range group on an incompatible transmission
will cause a low-lube failure of the main shaft bearings. See figure below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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2 Removal of the Service Range Group
Figure 9. Oil Restrictor Inspection
16. Clean the housing flanges and threaded holes.
17. Remove the sun gear snap ring and gear.
12
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
3
Installation of the Service Range Group
Install as follows:
1. I f not already done, clean the sealing faces of the center and range housings, and the threads of the fastener holes in
the center housing.
NOTICE: The location of the oil groove and holes in the sun gear, and the oil holes in the main shaft must be
aligned to supply oil between the sun and planet gears of the range group.
2. Install the new sun gear and snap ring, ensuring the gear is in the correct orientation. The end of the sun gear with the
flat side faces out, towards the snap ring groove (See callout A). The side of the sun gear, with the beveled spline,
faces inwards, towards the center housing (See callout B, Figure 2). See Figures 1 and 2 below.
Figure 10. Sun Gear with the Flat Side Facing Out Towards the Snap Ring Groove
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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3 Installation of the Service Range Group
Figure 11. Sun Gear with the Beveled Spline Side Facing In Towards the Center Housing
3. Apply Loctite® 518 sealant to the flange on the range group.
Table 4.
NOTE: Manufacture two guide pins from M12 bolts according to the dimensions shown:
A. Approx. 160 mm (6-1/4 in.)
B. Approx. 30 mm (1-3/16 in.)
C. M12 x 1.75
4. Install the guide pins.
5. Align the range housing on the guide bolts and slide the range housing into position, while engaging the eyes in the
plate of the planetary carrier
, on the guide pins. Use the flange bolts to evenly pull the range box onto the dowel pins.
6. Torque the range housing flange bolts to 80 N·m (59 lb·ft).
7. Apply medium-strength thread locker to the range shift fork detent spring nut cap, and reinstall the detent, spring, and
cap into the transmission. You will need to push on the nut cap towards the transmission to compress the spring (50
lbs.) when installing it. Tighten the nut cap to 60 N·m (44 lb·ft). See figure below.
14
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 12. Installation of Range Shift Fork Detent Spring Nut Cap
8. Install the harness raceway, and tighten to 10 N·m (90 lb·in.).
9. Install the range shift air lines, and torque it to 12 N·m (105 lb·in.).
10. Install the wire harness connections for the output shaft speed sensor, and range position sensor. If any zip ties were
removed during the procedure, apply new ones, of the same type, in the same locations.
11. Install the oil pump drive shaft. Make sure the rotors have the sides with the dot (A) facing the oil pump cover. See
figure below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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3 Installation of the Service Range Group
Figure 13. Installation of Oil Pump Rotors
12. Clean the bore for the oil control valve. This helps the O-ring retain the relief spring force while the pump cover is
being installed.
13. Apply Loctite® 518 sealant to the oil pump cover mating surface.
16
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Table 5.
NOTICE: On oil-cooler-equipped transmissions, align the pressure relief valve locating dowel pin, with the hole on the cover. The
correct pin position is approximately the 9 o'clock. See figure below.
Figure 14. Locating Dowel Clocking
14. Install the oil pump relief valve. See figure and table below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
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3 Installation of the Service Range Group
Figure 15. Oil Pump Relief Valve
Table 6.
Oil Pump Relief Valve
A
Transmission without an oil cooler (previous design)
B
Transmission without an oil cooler (current design)
C
Transmission with an oil cooler
15. Install the oil pump cover, and apply medium strength thread locker to the bolts. Tighten the bolts evenly to 50 N·m
(37 lb·ft). If equipped with a PTO, Refer to section "Installation of the Power Take-Off".
NOTICE: The drilling process is only required to allow the head of the rivet to break off easily. Do not drill into the
rivet more than 2.5mm (0.1 in.).
16. Using a 2.38 mm (3/32 in.) bit, drill the rivets on the identification tag on the old range housing. See figure above.
17. Gently pry off the identification tag for transfer to the new range housing. See figure below.
18
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
03 06-19
Figure 16. Identification Tag Removal
18. Thoroughly clean and dry the identification tag and the area on the new range housing.
19. Install the identification tag on the new range housing by applying some RTV sealant to the back, and hammering the
U-Drive rivets, included with the remanufactured range housing, into position. See figure below.
All information subject to change without notice.
03 06-19
Copyright © 2019 DETROIT DIESEL CORPORATION
19
3 Installation of the Service Range Group
Figure 17. Identification Tag Installation
20. Install the transmission. Refer to section "Installation of the Transmission".
21. Fill the transmission with oil.
22. Connect to DiagnosticLink® 8.07 or higher, and under Actions menu Transmission, perform the Transmission Learn
Routine.
20
All information subject to change without notice.
Copyright © 2019 DETROIT DIESEL CORPORATION
03 06-19
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TSB/Document ID: 0306-19
Replacement Service Bulletin Number:
MFR Communication Date: 2019-05-31
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
MFR Component System:
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