Alliance Prime Trans Plus 40

Socket, 1 1/16”, 1/2” Drive

1

Socket, 10, 13, 15, 19mm

1 each

Multiple

Hex Bit, 3, 6, 8mm

1 each

Multiple

Oil Fill Pump

1

Pry Bar Variety:
Small, Medium, Large

1 each

Pick Variety

1 each

9-172

Gearbox Oil Refill
Multiple
Multiple

Proterra Operating Company, Inc.

Manufacturer

Table 9-5: Additional Fix-if-Fail Supporting Documentation

Product

Navistar

Fleetrite PS-386 Synthetic Manual Transmission
Lubricant

Northland Products Co.

Northland Synergy Synthetic® ExP Transmission
50

Petro-Canada Lubricants Inc.

TRAXON E Synthetic MTF (Synthetic Transmission
Fluid)

Phillips 66 Company

Triton® Synthetic MTF
Kendall SHP® Synthetic MTF

Quick Smart Products P/L

Road Trans MTF PS-386

Raloy Lubricantes, S.A. C.V.

Document

Description

Maintenance Manual

Gearbox Removal and Replacement Procedure

Maintenance Manual

Traction Motor Removal and Replacement
Procedure
Table 9-6: Additional Fix-if-Fail Parts

Proterra PN

Description

040924

Motor, GVM, 310-125

Raloy Transintex Plus SAE 40

140-3817

Lubricant, Spline, Chelsea

Repsol Lubricantes Y
Especialidades S.A.

Repsol Cartago LD 40

063900

Gearbox, DuoPower

Royal Manufacturing Co

Monarch Syntran Plus SAE 40

125-6417

Washer, Lock

Safety-Kleen Oil

Performance Plus Synthetic HD PS-386
Transmission Fluid

052501

Oil Filter, Replacement Kit, Oil Cooler, Gearbox, EMP

048430

Skid-Plate, Retainer, Ring, Locking

Shell

Spirax S6 GME 40

048427

Skid-Plate, Retainer, Plate, SS, Locking

Texas Refinery

Syntex 2000 SAE40 Synthetic Manual
Transmission Lubricant

048429

Skid-Plate, Bolt, M10-1.5, 20mm, 10.9, 100HSS, Locking

The Valvoline Company

Syn Gard™ Transmission Fluid E386

050190

Motor Stud, Gear Box, Axle

Total Mexico S.A. DE C.V.

Transmission SYN 7000

050259

12 Point Nut-Motor, Gear Box, Axle

TOTAL Specialties USA, Inc

TOTAL Transmission Gear 8 FE SAE 40

Warren Oil

America Max Full Synthetic SAE 40 Manual
Transmission Fluid

Warren Oil

Lubriguard SAE 40 Synthetic Heavy Duty
Transmission Fluid

Warren Oil

PURUS Synthetic SAE 40 Heavy Duty
Transmission Fluid

Proterra Operating Company, Inc.

Table 9-7: Additional Fix-if-Fail Tools

Description

QTY

Use

Laptop computer and Proterra Diagnostic Tool
(current version)
https://diag.proterra.com/

1

Pairing the Traction Motor
and Power Inverter

Nexiq USB-Link 2

1

Pairing the Traction Motor
and Power Inverter

Tool, Wheelend, Axial Nut, TMFS 5, 38mm
Vendor: Reliability Direct
VPN: SKF-TMFS 5

1

Gearbox Replacement

Kit, Broken Bolt Extraction

1

Broken Bolt

9-173

Procedure
Vehicle Preparation
1. Record the odometer reading on the vehicle’s maintenance log.
2. Position the vehicle on an approved lifting device.
3. Perform the Proterra High-Voltage Lockout/Tagout procedure as specified in
the vehicle’s maintenance manual.
4. Lift the bus using the approved lifting device.
5. Remove and retain the large front cage dust cover (1) using a 10 mm socket/
wrench.
6. Remove and retain the high voltage cable guard (2) using a 10 mm socket/
wrench.
1

7. Place a coolant drain pan underneath the bulkhead coolant fitting (3).
8. Drain the coolant by slowly disconnecting the coolant hose from the bulkhead
coolant fitting (3) using an adjustable wrench.
9. Reconnect the bulkhead coolant fitting (3).

2

T

ON

FR

3

Figure 9-1. Axle Access and Coolant Draining

9-174

Proterra Operating Company, Inc.

10. Remove and retain the skid-plate (4) and fasteners (5) using a 15 mm socket/
wrench.

12. Remove and retain both motor bridge harness brackets/bolts (8) using a 13
mm socket/wrench.

11. Remove and retain all six axle covers (6) and fasteners (7) using 10 and 13
mm sockets/wrenches.

13. Disconnect the ECU harness connector (9).
14. Remove and retain the ECU bracket/ECU (10) and fasteners (11) using a 10
mm socket/wrench.

7
10
6

9

11

T

ON

FR

6

7
8

8

6
7
4

5

Figure 9-3. Harness Brackets & ECU bracket/ECU Removal
Figure 9-2. Skid-Plate and Axle Covers Removal

Proterra Operating Company, Inc.

9-175

Gearbox Oil Draining and Filter Inspections
15. Drain both gearboxes into a suitable oil drain pan by removing the oil drain
plugs (12) using a 21 mm socket/wrench.
16. Re-install the oil drain plugs (12) using a 21 mm socket/wrench and torque to
18 ft-lbs (24 Nm).

14

12
13

Figure 9-5. Oil Strainers and Oil Filters

12

Figure 9-4. Gearbox Oil Draining

17. Verify the oil module torque stripes are present on the oil filter caps (13) and
oil strainer caps (14). If no torque stripes are present, apply torque stripes
before proceeding to the next step.
18. Remove and inspect both oil filter caps and oil filters (13). Replace the oil
filters if swollen or disintegrating (see examples in figure).
19. Apply degreaser to a rag and clean the threads on both the oil filter caps and
in the oil module. Reinstall both oil filters and oil filter caps (13) and realign the
torque stripes.
20. If the oil filters were disintegrating, also remove and inspect both strainer caps
and strainers (14). Clean the strainers as needed.
Apply degreaser to a rag and clean the threads on both the strainer caps and in
the oil module. Reinstall both oil strainer caps (14) and realign the torque
stripes.

9-176

Figure 9-6. Oil Strainer and Oil Filter Examples

Proterra Operating Company, Inc.

Traction Motor Removals
21. Locate each gearbox serial number tag (X). No snap ring replacement is
necessary on gearboxes where the “CUST:” line (15) includes “063900”.
NOTE: “CUST: PROTERRA - 063900” indicates that the gearbox was
manufactured with the new snap ring; no snap ring replacement is necessary
on the gearbox.

16

15

22. Mark each traction motor for proper curb-side or street-side re-installation.

P / N:
CUS T: P ROTE RRA - 063900
S / N:
RATI O :
D AT E:

FRONT

23. Mark each traction motor coolant hose (16) for proper re-installation and
disconnect from each traction motor.
24. Disconnect the low-voltage connectors (17) from each traction motor.
25. Remove all brackets (18) from each traction motor using a 15 mm socket/
wrench.
26. Remove and retain the traction motor ground cables and ground cable
fasteners (19) using a 15 mm socket/wrench.

17
18

18
19

Figure 9-7. Traction Motor Removals (1 of 3)

Proterra Operating Company, Inc.

9-177

27.Remove and retain the phase cable box guard (20) and the phase cable box
cover (21) from each traction motor using a 3 mm hex-head wrench.

30. Place a properly rated transmission jack or other suitable lifting device
underneath the traction motor and secure with a ratchet strap.

28. Mark each phase cable on each traction motor for proper re-installation.
Remove and retain the phase cable fasteners (22) using a 13 mm socket on
each traction motor.

31. Remove and retain the eight traction motor stud locknuts and spacers (26)
using a 10 mm flexible ratchet wrench.

29. Disconnect the cord grip caps (23) on each traction motor using the 30 mm
Crow’sFoot tool (see the Tools table). Pull the phase cables (24) out of the
phase cable junction boxes.
Remove and retain the three phase cable ground clips (25).

32. Carefully pry the traction motor (27) away from the gearbox and gently lower
to a stable location.
33. Record both the gearbox and traction motor serial numbers on the vehicle’s
maintenance log.

20

21

22
25
24

22

23

27

Figure 9-8. Traction Motor Removals (2 of 3)

26

Figure 9-9. Traction Motor Removals (3 of 3)

9-178

Proterra Operating Company, Inc.

Street-Side Gearbox Snap Ring Replacement
ATTENTION: Each gearbox front housing cover must be re-installed on the same
gearbox it was removed from or gear damage may occur.
34. Mark each gearbox for proper curb-side or street-side re-installation.
35. Unplug the temperature sensor (28).
36. Mark both the inlet (29) and outlet (30) gearbox oil hoses for proper reinstallation and disconnect from the gearbox front housing cover using a 7/8”
wrench.
37. Cut the cable-tie securing the breather hose (31) to the brake cannister.

38. Remove and discard the thirteen gearbox front housing cover mounting bolts
(32) using a 13 mm socket/wrench. Retain the washers.
39. Remove and discard the ten gearbox mounting bolts (33) from the gearbox
using a 19 mm socket/wrench. Retain the washers.
CAUTION: Do not pry the front housing cover side-to-side. Internal gearing
damage can occur if the front housing cover is removed improperly at an angle.
CAUTION: Pry the gearbox front housing cover only at the three pry-bar locations
shown.
40. Carefully pry the gearbox front housing cover (34) away from the gearbox with
multiple pry-bars at the pry-bar locations shown, ensuring the housing cover
comes horizontally straight out and place onto a workbench.

31

Pry-Bar Location

29

33

32

30

34

28

Pry-Bar Location
(Both sides)

Figure 9-11. Gearbox Front Housing Cover Disconnection
Figure 9-10. Gearbox Front Housing Cover Disconnection Preparation

Proterra Operating Company, Inc.

9-179