Eaton Fuller Solo Clutches 25.

00
14-Inch Dual Disc Clutch Installation

Installation
1. Do the clutch pre-installation procedures in Sub-
ject 110.
2. If not already in place, install two 3/8–16 x 3
guide studs in the two upper mounting holes of
the flywheel. See Fig. 1.

03/01/94 f250216a
03/01/94 f250034a
Fig. 2, Install the Intermediate Plate
Fig. 1, Guide Studs, Installed
disc marked PRESSURE PLATE SIDE facing the
3. If the clutch is new, remove any protective coat- pressure plate, install the rear driven disc. See
ing applied to the pressure plate and the inter- Fig. 3.
mediate plate.
9. Make sure that the ceramic buttons on each disc
4. Insert an aligning tool through the splines of the are as closely aligned as possible. See Fig. 4.
front disc and, with the side marked FLYWHEEL
SIDE facing the flywheel, install the front driven NOTE: Aligning the discs aids the function of
disc on the flywheel. the separator pins.
IMPORTANT: The drivestraps of the intermedi- 10. With the aligning tool still in place, slide the
ate plate must face the pressure plate. cover assembly over the aligning tool and the
two guide studs until it rests against the interme-
5. Install the intermediate plate assembly over the diate plate assembly.
two guide studs and slide it forward until it
touches the flywheel. Make sure the side marked 11. Install the clutch mounting capscrews, as follows.
PRESSURE PLATE SIDE faces the pressure See Fig. 5 for the tightening sequence.
plate. See Fig. 2.
6. Make sure the separator pins protrude toward NOTICE
the flywheel side. The pins should be flush on If the capscrews are not tightened in sequence, it
the pressure-plate side. may cause permanent damage to the clutch
7. Remove the aligning tool. cover and create an out-of-balance condition.
8. Insert the aligning tool through the splines of the 11.1 Start six 3/8–16 (grade 5 or better) mount-
rear driven disc and, with the side of the rear ing capscrews with lockwashers, and
tighten them finger-tight.

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25.00 Eaton Fuller Solo Clutches
14-Inch Dual Disc Clutch Installation

7
2
3
6

5
4
1
8
06/16/97 f250442a

Fig. 5, Tightening Sequence

13. Follow a crisscross pattern to remove the four

06/12/97 f250436 shipping bolts from the clutch cover. See Fig. 6.
Fig. 3, Position the Rear Disc, Solo

2
1

E
06/12/97 f250439 RE
PL
AC

1. Front Ceramic Button

2. Rear Ceramic Button

Fig. 4, Driven Disc Alignment

11.2 Remove the guide studs and replace them

with the two remaining mounting cap- 03/02/2010 f250676
screws, as above.
11.3 Tighten the eight capscrews progressively. Fig. 6, Installed Shipping Bolts
The final torque is 30 to 35 lbf·ft (40 to 47 NOTE: Retain the four shipping bolts. These
N·m).
bolts will be needed in the future to secure the
12. Remove the aligning tool. clutch assembly during removal and installation.

120/2 Business Class M2 Workshop Manual, Supplement 18, September 2010

Eaton Fuller Solo Clutches 25.00
14-Inch Dual Disc Clutch Installation

WARNING
Wear safety goggles when tapping the pins. If 1
any of the metal parts were to chip, flying pieces
of metal could cause eye injury.
NOTE: Only a small portion of each separator
pin is visible through the access hole. See 3
Fig. 7 and Fig. 8.
14. To ensure that all four separator pins are flush
against the flywheel, insert a 1/4-inch (6-mm)
diameter flat-nose punch through the access
holes and lightly tap each of them toward the 2
flywheel. See Fig. 9.
06/12/97 f250438
NOTE: Only a small portion of the pin is visible through
the access hole.
1. Access Hole 3. Separator Pin
2. Clutch Cover

Fig. 8, Separator Pin Access

RE
PL
AC
E

06/02/97 f250417

Fig. 7, Separator Pin Access Holes

NOTE: Do this step to ensure that all four pins

are flush against the flywheel. This allows an
equal gap on all sides of the intermediate plate
during clutch disengagement. 06/17/97 f250437
15. Using a clean cloth, remove all grease from the
Fig. 9, Setting the Separator Pins
input shaft.
16. Lubricate the release fork fingers. See Fig. 10. 17. Shift the transmission into gear so that during
assembly the transmission input shaft can be
rotated into line with the clutch driven-disc hub
splines.
18. Install the clutch brake, if equipped.

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25.00 Eaton Fuller Solo Clutches
14-Inch Dual Disc Clutch Installation

1
2

08/20/2009 f250672

1. Release Fork Finger 3. Release Fork

2. Release Bearing 4. Input Shaft

Fig. 10, Release Fork

NOTICE
Do not excessively force the transmission into
the clutch assembly or engine housing. If it does
not enter freely, investigate the cause of the
problem and then make any necessary changes.
Do not let the transmission drop or hang unsup-
ported in the driven discs. If this should occur,
the rear disc will become bent or distorted, caus-
ing the clutch to drag (not release).
19. Install the transmission and attach the clutch link-
age. For instructions, see Group 26.
20. Lubricate the release bearing. Eaton Fuller rec-
ommends a lithium-base grease that can operate
up to at least 325°F (163°C) and meets the NLGI
Grade 1 or 2 specification.

120/4 Business Class M2 Workshop Manual, Supplement 18, September 2010

Eaton Fuller Solo Clutches 25.00
15.5-Inch Clutch Installation

Installation
1. Do the clutch pre-installation procedures in Sub-
ject 110 before installing the clutch.
2. If not already installed, insert two 7/16–14 x 5
guide studs in the upper mounting holes of the

E
LAC
flywheel. See Fig. 1. Rotate the flywheel to level

REP
the guide studs.

06/02/97 f250419

Fig. 2, Inserting an Aligning Tool

03/01/94 f250034a

Fig. 1, Installing the Guide Studs

3. If installing a new clutch, remove the protective

coating from the pressure plate and the interme-
diate plate.
4. Set the clutch cover upright, and insert a spline
aligning tool through the release bearing sleeve.
See Fig. 2.
5. Install the rear driven disc and intermediate
plate, as follows.
5.1 Install the rear driven disc on the aligning
tool, with the side stamped INTERMEDI-
ATE PLATE SIDE facing away from the
clutch cover. See Fig. 3. 04/23/2003 f250608
5.2 Place the intermediate plate in the clutch
Fig. 3, Installing the Rear Driven Disc
cover. Align the drive lugs of the plate with
the notches in the cover. See Fig. 4. 6. Install the front driven disc on the aligning tool,
5.3 Make sure the separator pins protrude with the side stamped INTERMEDIATE PLATE
toward the flywheel side. See Fig. 4. The SIDE facing the intermediate plate. See Fig. 5.
pins should be flush on the pressure-plate
side.

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25.00 Eaton Fuller Solo Clutches
15.5-Inch Clutch Installation

WARNING
The clutch assembly is heavy. It should be re-
moved and installed only with a lifting device. If
A the assembly is lifted incorrectly or dropped, it
could cause serious personal injury.
7. Position the clutch over the two guide studs, and
slide the assembly forward until contact is made
with the flywheel surface. See Fig. 6.

03/03/2010 f250677
The separator pins should protrude to the flywheel side.
A. Flywheel Side

Fig. 4, Positioning the Intermediate Plate

E
LAC
REP

06/02/97 f250422

Fig. 6, Positioning the Clutch Cover

8. Install the mounting capscrews, as follows.

8.1 Start six 7/16–14 x 2-1/4 (grade 5 or bet-
ter) mounting capscrews with lockwash-
ers, and tighten them finger-tight.
8.2 Tap the aligning tool to make sure it is
centered and seated in the pilot bearing.
See Fig. 7.
8.3 Remove the two guide studs and replace
them with the two remaining 7/16–14 x
2-1/4 mounting capscrews and lockwash-
ers.
04/23/2003 f250610
9. Tighten the eight mounting capscrews progres-
Fig. 5, Installing the Front Driven Disc sively, in a crisscross pattern as shown in Fig. 8.
Final torque is 40 to 50 lbf·ft (54 to 68 N·m).

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Eaton Fuller Solo Clutches 25.00
15.5-Inch Clutch Installation

• causing permanent damage to the clutch

cover.
10. Following a crisscross pattern, remove and retain
the four shipping bolts from the clutch cover. See
Fig. 9.
RE
PL
AC
E

06/02/97 f250423

Fig. 7, Tap Aligning Tool

E
AC
PL
RE

6 2

4 03/02/2010 f250676
7
Fig. 9, Installed Shipping Bolts
8
E

NOTE: These bolts will be needed to secure

LAC

3
REP

future clutch assemblies during removal and in-

stallation.
11. Remove the aligning tool.
1 5 NOTE: Do not be concerned if the release bear-
ing housing touches the clutch cover.
05/29/2003 f250426a

Fig. 8, Tightening Sequence

WARNING
Wear safety goggles when tapping the pins. If
any of the metal parts were to chip, flying pieces
NOTICE of metal could cause eye injury.
Failure to tighten the bolts according to this pro- 12. To ensure that all four separator pins are flush
cedure can have the following effects: against the flywheel, insert a 1/4-inch (6-mm)
• preventing the clutch cover from centering into diameter flat-nose punch through the access
the pilot area of the flywheel; holes and lightly tap each of them toward the
flywheel. See Fig. 10 and Fig. 11.
• causing the clutch assembly to be out-of-
balance with the flywheel; NOTE: Failure to perform this step properly may
cause the clutch to drag or not release.

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25.00 Eaton Fuller Solo Clutches
15.5-Inch Clutch Installation

NOTE: For lubrication of the release fork fin-

gers, Eaton Fuller recommends a lithium-base
grease that can operate up to at least 325°F
(163°C) and meets the NLGI Grade 1 or 2
specification.
14. Lubricate the release fork fingers. See Fig. 12.

1
2

RE
PL
AC
E

08/20/2009 f250672
06/02/97 f250417
1. Release Fork Finger 3. Release Fork
Fig. 10, Separator Pin Access Holes 2. Release Bearing 4. Input Shaft

Fig. 12, Release Fork

15. Shift the transmission into gear so that during

assembly the transmission input shaft can be
rotated into line with the clutch driven-disc hub
splines.
16. Install the clutch brake.

NOTICE
Do not excessively force the transmission into
REPLACE

the clutch assembly or engine housing. If it

doesn’t enter freely, investigate the cause of the
1 problem and then make any necessary changes.
Don’t let the transmission drop or hang unsup-
ported in the driven discs. If this should occur,
the rear disc will become bent or distorted, caus-
ing the clutch to drag (not release).
17. Install the transmission and attach the clutch link-
06/02/97 f250416 age.
1. Pin Access Hole 18. Lubricate the release bearing as needed; for in-
structions and recommended lubricants, see
Fig. 11, Tapping A Separator Pin Group 25 of the Business Class M2 Mainte-
nance Manual.
13. Using a clean cloth, remove all grease from the
input shaft.

130/4 Business Class M2 Workshop Manual, Supplement 18, September 2010

Eaton Fuller Solo Clutches 25.00
Resetting the Clutch

When there is excessive free pedal, try resetting the a hand tool to tighten them until the gap is re-
clutch. moved and the bolts are snug.
For a 15.5-inch clutch, install four 7/16–14 x
Resetting 1-3/4 shipping bolts (if available) or hexhead ma-
chine screws into the four clutch cover holes,
NOTE: This procedure requires two persons; and use a hand tool to tighten them until the gap
one under the vehicle with access to the wear is removed and the bolts are snug.
indicating tab, and the other in the vehicle to 6. Remove the bolts.
operate the clutch pedal.
7. Press the clutch pedal all the way down, and
1. Park the vehicle on a level surface. Shut down squeeze the clutch brake five times to reposition
the engine, set the parking brake, and chock the the bearing.
tires.
NOTE: The release bearing travel tool A02–
2. Inside the cab, press the clutch pedal all the way 12419 may be used in the following step. This
down, and hold it there until instructed to release tool is available through the PDCs.
it later in this procedure.
8. Measure the distance between the clutch brake
3. Through the clutch cover inspection panel, use and the release bearing. It should be between
moderate force to slide the wear indicating tab 0.49 and 0.56 inch (12.5 to 14.2 mm). If it is not
leftward until it is at the NEW position on the in- within this range, refer to the literature available
dicator. See Fig. 1. If the tab does not move, use on the Roadranger website, www.roadranger-
the clutch reset tool as described later in this .com.
subject.
If you are using the release bearing travel tool
A02–12419 (see Fig. 3) for this measurement,
position it so that the legs at the blue 0.56-inch
1 (14.3-mm) end straddle the transmission input
shaft. If it fits loosely, the gap is too wide. If it
E does not fit in the gap, try inserting the green
AC
PL 0.50-inch (12.7-mm) end. If the green end of the
NE RE
W tool fits, snug or loose, then no adjustment is
needed. If the gap is too wide or the green end
2 does not fit in the gap, refer to literature available
on the Roadranger website, www.roadranger-
.com.

Using the Clutch Reset Tool

06/04/97 f250428
See Table 1 for more information about the clutch
With the clutch pedal down, set the tab to the "NEW"
position on the indicator. reset tool.
1. Clutch Cover 2. Wear Indicating Tab 1. While an assistant holds down the clutch pedal,
insert the tip of the clutch reset tool through the
Fig. 1, Resetting the Wear Indicating Tab access panel and position it under the bearing.
Align the tool so that the threaded bolt extends
4. Release the clutch pedal. into the slot in the cam. See Fig. 4.
5. Through the clutch inspection cover, remove the
gap between the sleeve and the pin, as follows. NOTICE
See Fig. 2.
Use the clutch reset tool carefully. Do not use
For a 14-inch clutch, install four 3/8–16 x 1-1/4 heavy force on it; heavy force can break the cam.
shipping bolts (if available) or hexhead machine
screws into the four clutch cover holes, and use

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25.00 Eaton Fuller Solo Clutches
Resetting the Clutch

1
1

1
A

2
1 3
1
4

08/02/2006 f250655

NOTE: The bell housing is shown transparent to provide a clear view of clutch components.
A. Gap Between the Sleeve and the Pin
1. Bolt 3. Pin 4. Access Panel
2. Sleeve

Fig. 2, Removing the Gap Between the Sleeve and the Pin

If the cam does not move, go to the next step.

3. Loosen the transmission, and install 1/4" spacers
A B between the flywheel housing and bell housing.
4. While an assistant holds down the clutch pedal,
A B use the clutch reset tool to move the tab to the
NEW position.
03/26/96 f580133 5. Once the tab is in the NEW position, release the
A. 0.50 inch (12.7 mm) B. 0.56 inch (14.3 mm) clutch pedal and remove the spacers.
6. Tighten the transmission mounting bolts; see
Fig. 3, Release Bearing Travel Tool A02–12419 Group 26 for torque values.
2. Using the tool, carefully try to move the cam to- 7. Resume the resetting procedure.
ward the NEW position.
If the cam moves easily, resume the resetting
procedure.

140/2 Business Class M2 Workshop Manual, Supplement 18, September 2010

Eaton Fuller Solo Clutches 25.00
Resetting the Clutch

08/02/2006
1 f250656

1. Clutch Reset Tool 3. Access Panel

2. Threaded Bolt

Fig. 4, Resetting the Clutch with the Clutch Reset Tool

Clutch Reset Tool

Tool Description Eaton Tool Part Code

Clutch Reset Tool CLPI-SOLOTOOL

f580427

Table 1, Clutch Reset Tool

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Eaton Fuller Solo Clutches 25.00
Troubleshooting

Troubleshooting Tables
Problem—The Clutch Does Not Release Completely
Problem—The Clutch Does Not Release Completely
Possible Cause Remedy
The clutch pedal height is incorrect. Make adjustments to obtain the following settings:
• 1/2 to 9/16 inch (12.7 to 14.3 mm) release bearing travel;
• 1/2 to 1 inch (12.7 to 25.4 mm) clutch brake squeeze.
For clutches with mechanical linkage, also make adjustments to obtain 0.105
to 0.145 inch (2.7 to 3.7 mm) release yoke free-travel. (Clutches with hydraulic
linkage will have constant contact between the yoke and clutch bearing pads.)
The bushing in the release bearing sleeve Replace the clutch cover.
assembly is damaged.
The clutch cover assembly is not properly Re-seat the clutch cover assembly into the flywheel. Use a crisscross pattern
seated into the flywheel. when tightening the mounting bolts.
The intermediate plate and/or pressure Replace any damaged parts.
plate is cracked or broken.
The cross shafts protrude through the re- Check for protruding cross shafts. Repair or replace as necessary.
lease yoke (a side-loading condition ex-
ists).
The release yoke fingers are bent or worn Install a new release yoke.
(a side-loading condition exists).
The engine housing and bell housing are Check for loose transmission mounting bolts. Tighten the transmission mount-
misaligned (a side-loading condition ex- ing bolts to the proper torque.
ists).
The clutch linkage is set up improperly (a Thoroughly examine the clutch linkage and adjust as necessary.
side-loading condition exists).
The driven discs are distorted or warped. Replace any distorted or warped driven discs. If the transmission is allowed to
hang unsupported during clutch installation, the driven discs may become dis-
torted.
The driven discs are installed backwards, Install new driven discs. Also, check the clutch cover for any damage. Replace
or the front and rear driven discs were the clutch cover if damaged.
switched with each other.
The input shaft spline is worn. Replace the input shaft. Also, check the driven disc hubs for wear. Replace
the driven discs if worn.
The input shaft spline is coated with Clean and dry the input shaft spline before installation.
grease, anti-seize compound, etc.
The input shaft splines are twisted. Select a new driven disc and slide it along the full length of the splines. If the
disc does not slide freely, replace the input shaft.
The input-shaft bearing cap is worn. Replace the input-shaft bearing.
The flywheel pilot bearing fits either too Check the pilot bearing for proper fit and replace it if worn.
tight or too loose in the flywheel and/or
end of input shaft.
The pilot bearing is dry or damaged. Replace the pilot bearing.

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25.00 Eaton Fuller Solo Clutches
Troubleshooting

Problem—The Clutch Does Not Release Completely

Possible Cause Remedy
The separator pins are bent, damaged or Be sure to use the proper tool when setting the separator pins. Also, take
incorrectly set. great care when handling the intermediate plate. For procedures, see the
appropriate clutch installation subject.
The clutch brake is damaged and/or not Install a new clutch brake.
functioning.
The driven disc faces are coated with oil Replace the driven disc assemblies. Cleaning the old driven discs is not
or grease. recommended.
There is foreign material (dirt, chaff, salt, Remove the foreign material and make sure the clutch inspection cover is
etc.) inside the clutch cover. installed.

Problem—The Clutch Rattles or Is Noisy

Problem—The Clutch Rattles or Is Noisy
Possible Cause Remedy
There is excessive flywheel runout. Repair or replace the flywheel. For procedures, see the engine manufacturer’s
manual.
There is corrosion between the input shaft Clean the mating parts between the input shaft and driven discs to ensure that
spline and the driven disc hubs. the discs slide freely over the input shaft spline.
The engine idle is too fast. Readjust engine idle to proper idling speed.
The clutch release bearing is dry or Lubricate the clutch release bearing. If the noise persists, install a new clutch
damaged. cover.
The flywheel pilot bearing is dry or Replace the flywheel pilot bearing.
damaged.
The bridge of the release yoke is hitting Check for a worn, broken or missing clutch brake. Also, check the release
the clutch cover (an over-stroking yoke and input-shaft bearing cap for wear. Replace any worn parts.
condition exists).
The release yoke fingers are hitting the Check if the release bearing, clutch cover, or release yoke fingers are worn or
clutch cover. broken. Replace worn parts.
The clutch inspection cover is not Re-install the clutch inspection cover.
installed.
The sleeve bushings are worn. Investigate for any side-loading conditions on the release bearing housing. If
there is a side-loading condition, determine its cause. Also, before installing
the new clutch, make sure that the side-loading condition has been corrected.
The clutch linkage is rattling excessively. Clean, lubricate and reassemble or replace missing/worn parts.
An idle gear rattle is coming from the Specify low-vibration driven discs. Check the engine for correct idle speed.
transmission. For procedures, consult the engine manufacturer’s manual.
The damper spring cover of the driven Install the correct clutch assembly.
disc assembly is interfering with the
flywheel.

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Eaton Fuller Solo Clutches 25.00
Troubleshooting

Problem—The Clutch Vibrates

Problem—The Clutch Vibrates
Possible Cause Remedy
The flywheel is loose. Retighten the flywheel mounting bolts to the proper specifications.
The universal joints are worn. Replace the worn parts.
The driveshaft is not properly phased. Investigate and correct the phasing of the driveshaft.
The driveshaft is not balanced. Balance and straighten the driveshaft.
The driveline angles are incorrect. Shim the drivetrain components to equalize universal joint angles.
The flywheel is not balanced. Balance the flywheel.
The pilot area of the clutch is not Ensure that no dirt, burrs, etc., are preventing the clutch cover from
completely seated into the flywheel. completely seating into the flywheel mounting surface.
The engine mounts are loose, damaged, Replace any worn or damaged parts. Retighten all bolts to proper
or worn out. specifications.
The engine is misfiring. The engine is not in tune. To correct the problem, see the engine
manufacturer’s manual.
There is excessive flywheel runout. Repair or replace the flywheel. For procedures, see the engine manufacturer’s
manual.

Problem—The Clutch Needs Frequent Adjustments

Problem—The Clutch Needs Frequent Adjustments
Possible Cause Remedy
The clutch specification is incorrect. Check the clutch specifications in Subject 400. Install a new clutch with the
proper specifications, if necessary.
The cross shafts and/or clutch linkage Investigate the entire clutch linkage system to determine if it is binding or
system is worn. operating sporadically and/or worn excessively.
The clutch driven discs are worn down to Install a new clutch.
the rivets.
The crankshaft has excessive end play. Repair or replace the crankshaft. Consult the engine manufacturer’s manual
for procedures.

Problem—The Clutch Slips

Problem—The Clutch Slips
Possible Cause Remedy
The clutch is overloaded. Verify that the proper clutch has been specified for the particular vehicle
application.
The release mechanism is binding. Free up the release mechanism and linkage. Also, check the clutch linkage
adjustment.
The driven disc faces are coated with oil Replace the driven disc assembly.
or grease.
The driver is riding the clutch pedal. Use correct driving procedures.
The input shaft spline is worn. Replace the input shaft.

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25.00 Eaton Fuller Solo Clutches
Troubleshooting

Problem—The Clutch Grabs or Chatters

Problem—The Clutch Grabs or Chatters
Possible Cause Remedy
The clutch is worn out. Replace the clutch and all worn components.
The linkage system is not operating freely. Check the clutch linkage for binding or excessive wear. Replace all worn
parts.
The driven disc faces are coated with oil Replace the driven disc assembly.
or grease.
The engine mounts are loose. Retighten the engine mounts to manufacturer’s specifications.
The release yoke fingers and/or the Replace all the worn parts.
release bearing wear pads are worn
excessively.

300/4 Business Class M2 Workshop Manual, Supplement 18, September 2010

Eaton Fuller Solo Clutches 25.00
Specifications

Clutch Torque Values

Description Size Grade Torque: lbf·ft (N·m)
Mounting Bolts, Clutch Cover to Flywheel on 14-inch clutch 3/8–16 x 1-1/4 5 30–35 (40–47)
Mounting Bolts, Clutch Cover to Flywheel on 15.5-inch clutch 7/16–14 x 2-1/4 5 40–50 (54–68)
Table 1, Clutch Torque Values

Minimum Flywheel Bores

Disc Type Minimum Flywheel Bore in inch (mm)
10-Spring 8.562 (217.48)
9-Spring 9.750 (247.65)
8-Spring 7.250 (184.15)
7-Spring 9.750 (247.65)
6-Spring 9.750 (247.65)
Table 2, Minimum Flywheel Bores

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Clutch Linkage 25.01
General Information

General Information
The clutch linkage transfers the motion of the clutch
pedal to the clutch release bearing.
Free play in the clutch pedal is required to ensure
that the fingers of the release bearing do not run
against the release bearing. There should not be any
play or looseness in the connections and joints of the
clutch linkage.
There are two types of clutches: the pull-type and the
push-type.
• On push-type clutches, depressing the clutch
pedal moves the release bearing toward the
engine flywheel. As the clutch is depressed,
the pressure plate moves away from the driven
disc assembly, and the clutch is disengaged.
As the clutch pedal is released, the release
bearing and clutch levers move away from the
engine flywheel. This locks the driven disc be-
tween the friction surfaces of the pressure
plate and the engine flywheel. The clutch is
then engaged.
• On pull-type clutches, depressing the clutch
pedal moves the release bearing away from
the pressure plate, disengaging the clutch. As
the clutch pedal is released, the pressure plate
is forced toward the engine flywheel until the
driving and driven discs turn at the same
speeds, engaging the clutch.
IMPORTANT: On pull-type clutches, release
bearing and release fork clearance are internal
clutch adjustments, and can not be adjusted by
adjusting the clutch linkage. For internal clutch
adjustments, see the clutch manufacturer’s ser-
vice literature.

Business Class M2 Workshop Manual, Supplement 4, March 2003 050/1

Clutch Linkage 25.01
Clutch Linkage Adjustment

Adjustment If this measurement is 0.125 to 0.145 inch (3.2 to

3.8 mm), no further work is needed. See Fig. 2.
1. Observe the following points before beginning If the measurement is incorrect, do all of the re-
clutch linkage adjustment: maining steps.

• If the clutch pedal free play is less than 1

3/4 inch (19 mm), adjust the clutch inter-
nally, not at the linkage. See Fig. 1.
• Be sure internal clutch adjustments are 2
correct before making adjustments to the
clutch linkage.
• Adjust the clutch linkage only after repair 3
or replacement of the clutch or clutch link-
age components.
• If the cab is equipped with an air suspen-
sion, be sure the air springs are properly
inflated. If the air springs are not inflated,
A
the clutch linkage can’t be adjusted cor- 10/31/2002 f250595
rectly. A. Clearance Between Release Yoke and Release
Bearing: 0.125 inch (3.2 mm) minimum
1. Release Yoke 3. Transmission
2. Release Bearing

Fig. 2, Clutch Adjustments

7. Disconnect the clutch linkage. See Fig. 3.

7.1 Remove the nut that attaches the clutch
rod to the upper lever arm.
A
7.2 Disconnect the clutch rod from the upper
lever arm.
09/12/2002 B f250597
7.3 Loosen the jam nut on the clutch rod.
Clutch pedal free play should be about one inch (25
mm) from the top end of the pedal stroke. 8. Adjust the clutch linkage.
A. Clutch Pedal Free Play 8.1 Hold the clutch rod in the same position.
B. End of Free Play; Start of Disengagement Adjust the rod length in or out, as needed.
Shorten the rod to increase the clearance.
Fig. 1, Clutch Pedal Free Play Lengthen the rod to decrease the clear-
2. Raise the hood, apply the parking brakes, and ance.
chock the front tires. 8.2 Attach the rod end to the upper lever arm.
3. Remove the clutch inspection cover from the bot- 8.3 Tighten the nut on the upper lever arm 23
tom of the bell housing. to 29 lbf·ft (31 to 39 N·m).
4. Be sure the clutch pedal is all the way up, 8.4 Tighten the jam nut on the clutch rod 12 to
against the upper stop. 15 lbf·ft (16 to 20 N·m).
5. Check the internal clutch adjustment. For proce-
NOTE: Each complete turn of the rod equals
dures, see the clutch manufacturer’s manual.
about .04 inch (1 mm) of movement. After
6. Measure the distance between the release yoke lengthening the linkage, at least 3/8 inch
and the release bearing.

Business Class M2 Workshop Manual, Supplement 4, March 2003 100/1

25.01 Clutch Linkage
Clutch Linkage Adjustment

3
2

4 1

5
6

7 8

09/12/2002 f250596
1. Clutch Pedal 6. Jam Nut
2. Return Spring 7. Clutch Rod
3. Spring Bracket 8. Lower Lever Arm Nut
4. Upper Lever Arm 9. Lower Lever Arm
5. Upper Lever Arm Nut

Fig. 3, Clutch Linkage

(9.5 mm) of thread must remain engaged in

the clutch rod (nine turns of the rod end).
9. Measure the distance between the release yoke
and the release bearing. If this measurement is
0.125 to 0.145 inch (3.2 to 3.8 mm), go to the
next step. If the measurement is not within these
limits, go back to the "Disconnect the clutch link-
age" step and adjust the linkage until it is correct.
10. Install the inspection cover on the bottom of the
bell housing.
11. Check the clutch pedal free play. See Fig. 1.
12. Remove the chocks from the front tires.

100/2 Business Class M2 Workshop Manual, Supplement 4, March 2003

Clutch Linkage 25.01
Specifications

Description Torque in lbf·ft (N·m)

Jam Nut 12 to 15 (16 to 20)
Upper Lever Arm Nut 23 to 29 (31 to 39)
Table 1, Torque Values, Clutch Linkage Adjustment

Business Class M2 Workshop Manual, Supplement 4, March 2003 400/1

Clutch Hydraulic System 25.02
General Information

General Information
The hydraulic clutch control system consists of a 1
pedal unit and a slave cylinder, connected by a hy-
draulic hose that is fastened with quick-disconnect 6
5
clips. See Fig. 1. The hydraulic system is self-
adjusting, and it uses DOT 4 brake fluid.
The pedal unit includes a hydraulic subassembly,
composed of the master cylinder and reservoir, which A
can be removed from the pedal unit for service pur-
poses; see Subject 110 for instructions.

Principles of Operation
When the clutch pedal is pressed, the fluid in the
master cylinder is forced through a hydraulic line to
the slave cylinder. The fluid pressure moves the 2
slave cylinder piston, pushing the plunger rod and
clutch release lever, which disengages the clutch.
3
Clutches
The hydraulic system has been designed to work
with three types of clutches: adjustment-free, manu-
ally adjusted, and self adjusting. Check the adjust-
ment of manually adjusted clutches regularly. 4

NOTICE 2

Operating a vehicle with a manually adjusted

clutch that is incorrectly adjusted could result in
failure of the clutch or clutch brake. 06/22/2011 f250685

The SACHS 365 mm (adjustment-free) and 395 A. Hydraulic Subassembly

XTend (self-adjusting) are push-type clutches that are 1. Pedal Unit 4. Slave Cylinder
part of the hydraulic clutch systems for the MBT520 2. Clip 5. Master Cylinder
and MBT660 medium-duty transmissions. They do 3. Hydraulic Hose 6. Reservoir
not need to be manually adjusted. For removal and
installation procedures, see Subject 130 for the Fig. 1, Components, Hydraulic Clutch Control
SACHS 365 mm, and Subject 180 for the 395
XTend. be maintained between 1/2 and 9/16 inch (12.7 and
14.3 mm). For the adjustment procedure, see Sub-
Eaton Stamped Angle-Spring and Easy-Pedal ject 190.
clutches are optional with some Eaton transmissions.
These clutches are manually adjusted. When com-
bined with a hydraulic clutch system, there is no
"free pedal" to tell the driver when the clutch needs
adjustment. Periodic inspection and manual adjust-
ment is required to maintain proper release bearing
travel and prevent premature clutch wear. Release
bearing travel is the clearance between the rear sur-
face of the release bearing housing and the forward
surface of the clutch brake disc. This distance must

Business Class M2 Workshop Manual, Supplement 20, September 2011 050/1

Clutch Hydraulic System 25.02
Pedal Unit Removal and Installation

Removal 4.1 Using a drain pan or other suitable con-

tainer, collect the fluid that drains from the
pedal unit, not more than 0.5 quarts (0.5
WARNING liters).

Clutch hydraulic fluid (DOT 4 brake fluid) is haz- 4.2 Allow the open end of the drain hose to
ardous. It may be a skin irritant and can cause remain over the drain pan.
blindness if it gets in your eyes. Always wear 4.3 Press down on the pedal several times,
safety glasses when handling clutch hydraulic until no more fluid drains from the pedal
fluid or bleeding hydraulic lines. If you get clutch unit.
hydraulic fluid on your skin, wash it off as soon
as possible. 4.4 Cover the hose to avoid contamination of
the hydraulic fluid.
1. Shut down the engine. 5. Disconnect the clutch control electrical connector
2. Apply the parking brakes, chock the front and located under the dash above the clutch pedal.
rear tires, and open the hood. 6. Remove the rubber pedal pad from the pedal.
3. Using a flat-head screwdriver, remove the quick- Retain the pedal pad for later installation.
disconnect clamp that attaches the hydraulic 7. Loosen the four mounting plate capscrews at-
hose to the pedal unit. See Fig. 1. Retain the taching the pedal unit to the frontwall.
clamp for later installation.
8. After bracing the pedal unit so that it does not
fall, remove the four mounting plate capscrews.
Retain the capscrews for later installation.
1
WARNING
Do not attempt to disassemble the preloaded as-
sist spring. Sudden release of the assist spring
could cause property damage and serious per-
sonal injury.
9. Remove the pedal unit from the vehicle. Drain
any remaining fluid and discard the gasket.
2 IMPORTANT: Handle the pedal unit carefully to
prevent spillage.
3
Installation
A 1. Mount the pedal unit on the frontwall, as re-
moved. Install a new gasket.
09/12/2001 f261135 2. Install the four mounting plate capscrews and
A. To Slave Cylinder tighten them 13 lbf·ft (18 N·m).
1. Frontwall 3. Hydraulic Hose
2. Pedal Unit
3. Fit the rubber pedal pad over the pedal.
4. Connect the hydraulic hose to the pedal unit.
Fig. 1, Pedal Unit and Hose
5. Install the clamp, as removed.
4. Drain the hydraulic fluid from the entire system.
5.1 Install the clamp in the recessed area on
the nozzle of the master cylinder.

Business Class M2 Workshop Manual, Supplement 3, January 2002 100/1

25.02 Clutch Hydraulic System
Pedal Unit Removal and Installation

5.2 Snap the hydraulic hose into place.

5.3 Tug on the hose to make sure it is in-
stalled correctly. The hose should not pull
out easily.
NOTE: Don’t force the hose into the master
cylinder. If the clamp is incorrectly installed,
the hose will not snap into place.

WARNING
Use only approved clutch hydraulic fluid (DOT 4
brake fluid). Do not mix different types of brake
fluid. The wrong fluid will damage the rubber
parts of the system, causing loss of clutch func-
tion and the risk of serious personal injury.
6. Fill the reservoir with approved DOT 4 hydraulic
brake fluid and bleed the system according to
the procedures in Subject 140.
7. Connect the clutch control electrical connector,
and check the function of the clutch actuation
system according to the procedures under the
heading "Clutch Actuation System Check" in
Troubleshooting, 300.

100/2 Business Class M2 Workshop Manual, Supplement 3, January 2002

Clutch Hydraulic System 25.02
Hydraulic Subassembly Replacement

Replacement
1. Place a suitable container under the master cyl-
inder to collect the fluid that will drain as the
hose is removed from the master cylinder.
2. Use a flat-tip screwdriver to remove the quick-
disconnect clip that locks the hydraulic hose into
the master cylinder. See Fig. 1. Remove the
hose and, with the end pointing upwards to pre-
vent fluid spillage, secure it temporarily to a safe
point on the vehicle. Retain the clip for later in-
stallation. 1
2
3
4
5
6
7
8
9
10/21/2002 f250598
1. Piston 6. Hydraulic Body
3 2. Lip Seal 7. Base
3. Reservoir O-Ring 8. Screw
4. Reservoir 9. Clip
5. Body O-Ring

Fig. 2, Hydraulic Subassembly

2
5. Pull carefully on the hydraulic subassembly until
1 it comes loose from the pedal unit. Discard the
old hydraulic subassembly.
6. Carefully remove the lip seal from the piston of
the master cylinder. Discard the lip seal.
NOTE: Avoid damaging the piston.
7. Lubricate a new lip seal and mount it on the pis-
ton. See Fig. 3.

05/07/2007 f250661 NOTICE

1. Hydraulic Hose
2. Quick-Disconnect Clip Use only the special grease provided in the as-
3. Master Cylinder sembly kit. Do not use mineral oil or any other
lubricant which could damage the seals and
Fig. 1, Quick-Disconnect Clip at the Master Cylinder cause loss of clutch function.

3. Drain the fluid from the master cylinder. 8. Lubricate the new O-rings and the O-ring seats
in the new reservoir and hydraulic body.
4. Remove the two screws that attach the hydraulic
subassembly to the mounting plate. See Fig. 2. 9. Put the reservoir and hydraulic body together
with the O-rings properly seated and lubricated.

Business Class M2 Workshop Manual, Supplement 20, September 2011 110/1

25.02 Clutch Hydraulic System
Hydraulic Subassembly Replacement

13. Fill the reservoir with approved DOT 4 hydraulic

brake fluid and bleed the system as instructed in
Subject 130.
14. Check the function of the clutch actuation system
as instructed in Subject 300.

B
06/24/2011 f250689

A. Correct Installation
B. Incorrect Installation

Fig. 3, Hydraulic Subassembly

10. While holding the reservoir and hydraulic body

together, insert the base over the hydraulic body.
11. Install the screws, and tighten them to 44 lbf·in
(500 N·cm).
12. Install the quick-disconnect clip and hydraulic
hose, as follows.
12.1 Insert the clip arms into the recessed
areas on the nozzle of the master cylinder.
12.2 Snap the hydraulic hose into place.
12.3 Tug on the hose to make sure it is in-
stalled correctly. The hose should not pull
out.
IMPORTANT: Do not force the hose into the
slave cylinder. If the clip is incorrectly in-
stalled, the hose will not snap into place.

WARNING
Use only approved clutch hydraulic fluid (DOT 4
brake fluid). Do not mix different types of brake
fluid. The wrong fluid will damage the rubber
parts of the system, causing loss of clutch func-
tion and the risk of serious personal injury.

110/2 Business Class M2 Workshop Manual, Supplement 20, September 2011

Clutch Hydraulic System 25.02
Slave Cylinder Replacement

Replacement 8. Mount the slave cylinder on the gear case, as

removed.

WARNING 8.1 Make sure that the pushrod is attached to

the clutch fork and inserted into the push-
Clutch hydraulic fluid (DOT 4 brake fluid) is haz- rod bore in the slave cylinder.
ardous. It may be a skin irritant and can cause 8.2 Push the slave cylinder against the gear
blindness if it gets in your eyes. Always wear case to compress the internal spring.
safety glasses when handling clutch hydraulic
fluid or bleeding hydraulic lines. If you get clutch 9. Install the four slave cylinder mounting cap-
hydraulic fluid on your skin, wash it off as soon screws and tighten them 13 lbf·ft (18 N·m).
as possible. 10. Connect the hydraulic hose to the slave cylinder.
1. Shut down the engine. 11. Install the clamp, as removed.
2. Apply the parking brakes, chock the front and 11.1 Install the clamp in the recessed area on
rear tires, and open the hood. the nozzle of the master cylinder.
3. Using a flat-head screwdriver, remove the quick- 11.2 Snap the hydraulic hose into place.
disconnect clamp that attaches the hydraulic
11.3 Tug on the hose to make sure it is in-
hose to the slave cylinder. Retain the clamp for
stalled correctly. The hose should not pull
later installation.
out easily.

WARNING NOTE: Don’t force the hose into the master

cylinder. If the clamp is incorrectly installed,
Never remove the slave cylinder from the gear the hose will not snap into place.
case while it is still connected to the hydraulic
hose and the system is filled with hydraulic fluid.
Depressing the pedal in this situation could re-
WARNING
lease, at high speed, the metal pushrod inside Use only approved clutch hydraulic fluid (DOT 4
the cylinder, causing component damage and se- brake fluid). Do not mix different types of brake
rious personal injury. fluid. The wrong fluid will damage the rubber
4. Drain the hydraulic fluid from the entire system. parts of the system, causing loss of clutch func-
See Fig. 1. For detailed procedures, see Sub- tion and the risk of serious personal injury.
ject 100. 12. Fill the reservoir with approved DOT 4 hydraulic
5. Loosen the four M8 slave cylinder mounting cap- brake fluid. Flush and bleed the system accord-
screws attaching the slave cylinder to the bell ing to the procedures in Subject 140.
housing. 13. Check the function of the clutch actuation system
6. After bracing the slave cylinder so that it does according to the procedures under the heading
not fall, remove the four slave cylinder mounting "Clutch Actuation System Check" in Trouble-
capscrews. Retain the capscrews for later instal- shooting, 300.
lation.
IMPORTANT: Handle the slave cylinder carefully
to prevent spillage.
7. Remove the slave cylinder from the gear case.
Drain any remaining fluid.
IMPORTANT: Be sure to mount the slave cylin-
der with the bleed valve on top of the unit and
horizontal to the ground, as shown in Fig. 1.

Business Class M2 Workshop Manual, Supplement 3, January 2002 120/1

25.02 Clutch Hydraulic System
Slave Cylinder Replacement

1
2
3

1
2
3

6
10
8

12/11/2001 f250582
Mount the slave cylinder with the bleed valve on top of the unit and horizontal to the ground.
1. Clamp Mounting Bolt, 1/4–20 6. Hydraulic Hose
2. Steel-Plated Washer 7. Slave Cylinder
3. Locknut, 1/4–20 8. Bleed Valve
4. Bell Housing Standoff Bracket 9. Bell Housing
5. Slave Cylinder Standoff Bracket 10. Slave Cylinder Mounting Capscrew, M8

Fig. 1, Clutch Slave Cylinder

120/2 Business Class M2 Workshop Manual, Supplement 3, January 2002

Clutch Hydraulic System 25.02
SACHS 365 mm Clutch Removal and Installation

Special Tools
A special tool is used for this procedure. See
Table 1.

Special Tool
Tool Description Manufacturer Part Number

Clutch Centering Pin Kent-Moore J-45719

f580335

Table 1, Special Tool

NOTE: To check tool availability, and to order NOTE: Do not grease the guide of the release
tools, call SPX Kent-Moore at 1-800-328-6657. bearing. Greasing it would attract dirt particles
that lead to excessive wear.
Removal 2. Insert the centering pin (Table 1) into the pilot
bearing. Then, with the clutch disc assembly ori-
1. Remove the transmission from the engine. ented so the side marked "flywheel side" faces
the flywheel, center the disc assembly on the
• For instructions for the Mercedes-Benz Au- flywheel.
tomated Transmission, see Sec-
tion 26.03, Subject 100. IMPORTANT: Do not remove the centering pin
until the clutch is completely installed.
• For instructions for the Mercedes-Benz
Manual Transmission, see Sec- 3. Install "guide pins" at the 10 o’clock and 2
tion 26.04, Subject 100. o’clock positions to ensure proper centering of
the clutch cover assembly. See Fig. 2.
2. Insert the centering pin (Table 1) through the
clutch disc and into the pilot bearing. "Guide pins" are long, headless capscrews that
are temporarily installed in the flywheel to sup-
IMPORTANT: The clutch is under tension. If one port the weight of the clutch, allowing you to
capscrew is loosened too much, it places too align it precisely with the flywheel. Without guide
much tension on the cover assembly. pins, proper clutch installation is extremely diffi-
3. Remove the cover assembly. See Fig. 1. In a cult. If necessary, cut off the heads of two 6-inch
star pattern, incrementally loosen the capscrews; (15 cm) capscrews to make a set.
take care not to loosen any one capscrew too 4. Install the cover assembly, as follows.
much before loosening the next one.
IMPORTANT: Never allow the diaphragm
4. Remove the clutch disc assembly. spring to rest on the centering pin.
4.1 Slide the clutch cover assembly onto the
Installation guide pins, and position it inside the
raised rim of the flywheel. See Fig. 3.
1. Grease the splines of the input shaft and the hub
of the disc assembly. Remove any excess 4.2 Ensure the cover assembly is situated
grease. completely within the rim of the flywheel

Business Class M2 Workshop Manual, Supplement 15, March 2009 130/1

25.02 Clutch Hydraulic System
SACHS 365 mm Clutch Removal and Installation

4
3
2

09/23/2005 f250626
1. Disc Assembly 4. Clutch Capscrews, 3/8–16 x 5. Input Shaft
2. Cover Assembly 13/16 6. Release Bearing
3. Washer

Fig. 1, Clutch Assembly

and not overlapping it. Use a flashlight to more tension on one side of the clutch
help verify the positioning if needed. than the other.
4.3 Install and hand-tighten six of the eight 5. When all capscrews have been tightened, re-
capscrews using the sequence shown in move the centering pin.
Fig. 4 (skipping the guide pin positions). 6. Install the transmission on the engine.
4.4 Remove the two guide pins, then install • For instructions for the Mercedes-Benz Au-
and hand-tighten the remaining two cap- tomated Transmission, see Sec-
screws. tion 26.03, Subject 100.
4.5 Using the sequence shown in Fig. 4, • For instructions for the Mercedes-Benz
tighten the eight clutch capscrews pro- Manual Transmission, see Sec-
gressively: first to 20 lbf·ft (27 N·m), and tion 26.04, Subject 100.
finally to 37 lbf·ft (50 N·m). Do not put

130/2 Business Class M2 Workshop Manual, Supplement 15, March 2009

Clutch Hydraulic System 25.02
SACHS 365 mm Clutch Removal and Installation

6 2
2
2

4
7

8 3
1

11/02/2005 f250625
1. Centering Pin 2. Guide Pin 08/20/2008 1 5 f250668

Fig. 2, Centering the Clutch Fig. 4, Capscrew Tightening Sequence

2
08/20/2008 f250669
1. Flywheel 2. Flywheel Rim

Fig. 3, Flywheel Rim

Business Class M2 Workshop Manual, Supplement 15, March 2009 130/3

Clutch Hydraulic System 25.02
Fluid Filling and Bleeding

5. Pressurize the reservoir to fill the system. Open

WARNING the bleed valve on the bleed tank of the adaptor.
Hydraulic clutch control fluid (DOT 4 brake fluid) NOTE: The hydraulic system holds approxi-
is hazardous. It may be a skin irritant and can mately 0.5 quart (0.5 liter) of fluid. It may need
cause blindness if it gets in your eyes. Always to be refilled during the bleeding process to pre-
wear safety glasses when handling it or bleeding vent air from re-entering the system.
hydraulic lines. If you get it on your skin, wash it
off as soon as possible. 6. Bleed the hydraulic system as follows.
6.1 Remove the cap from the bleed valve of
NOTICE the slave cylinder. See Fig. 2. On the
valve, install a transparent drain hose con-
Do not spill hydraulic clutch control fluid on the nected to a catch bottle. The hose needs
cab paint. Clean it off immediately if any is to fit the bleed valve tight enough so it
spilled. Brake fluid can damage paint. does not fall off when fluid is pumped out.
6.2 Open the bleed valve on the slave cylin-
Filling der.
The hydraulic system holds approximately 0.5 quart
(0.5 liter) of fluid. Use new DOT 4 brake fluid from a
tightly sealed container to fill the system until the
fluid level is between the MIN and MAX lines marked
on the side of the reservoir. 1

Bleeding 2

The hydraulic clutch control can be bled by using a

pressure adaptor or manual bleeding. Pressure
bleeding can be done by one person and manual
bleeding requires two.

Pressure Bleeding
A pressure bleeder hose (J-29532) and a bleed
adaptor (J-35798) for the fluid reservoir are available
through SPX Kent-Moore Tools and may be used to
complete the pressure bleeding procedure. To order
these parts, call Kent-Moore at 1-800-328-6657.
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. Open the hood.
3. Prepare the pressure bleeding equipment ac-
06/27/2011 f250688
cording to the manufacturer’s instructions. Use
new DOT 4 brake fluid from a tightly sealed con- 1. Frontwall 2. Reservoir
tainer. Pressurize the bleed adaptor to 15 psi
(103 kPa). Fig. 1, Master Cylinder, Hydraulic Clutch Control

4. Remove the reservoir cap (see Fig. 1) and install 6.3 When the draining fluid is clear and free of
the pressure bleed adaptor on the reservoir. air bubbles, close the bleed valve.

Business Class M2 Workshop Manual, Supplement 20, September 2011 140/1

25.02 Clutch Hydraulic System
Fluid Filling and Bleeding

1
2
3

1
2
3

6
10
8

12/11/2001 f250582
1. Clamp Mounting Bolt, 1/4–20 6. Hydraulic Hose
2. Steel-Plated Washer 7. Slave Cylinder
3. Locknut, 1/4–20 8. Bleed Valve
4. Bell Housing Standoff Bracket 9. Bell Housing
5. Slave Cylinder Standoff Bracket 10. Slave Cylinder Mounting Capscrew, M8

Fig. 2, Slave Cylinder, Hydraulic Clutch Control

140/2 Business Class M2 Workshop Manual, Supplement 20, September 2011

Clutch Hydraulic System 25.02
Fluid Filling and Bleeding

7. Disconnect the transparent hose. Tighten the

bleed valve 88 lbf·in (1000 N·cm) and install the
cap on the slave cylinder bleed valve.
8. Check the fluid level in the reservoir. If neces-
sary, add or drain fluid to bring the fluid level to
between the MIN and MAX lines marked on the
side of the reservoir. Install the reservoir cap.
9. Depress the clutch pedal a few times. There
should be resistance over the full pedal stroke.

Manual Bleeding
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires.
2. Open the hood.
NOTE: The hydraulic system holds approxi-
mately 0.5 quart (0.5 liter) of fluid. It may need
to be refilled during the bleeding process to pre-
vent air from re-entering the system.
3. Remove the reservoir cap (see Fig. 1) and fill
the reservoir with new DOT 4 brake fluid from a
tightly sealed container.
4. Remove the cap from the bleed valve of the
slave cylinder. See Fig. 2. On the valve, install a
transparent drain hose connected to a catch
bottle. The hose needs to fit the bleed valve tight
enough so it does not fall off when fluid is
pumped out.
5. Open the slave cylinder bleed valve. Observe the
flow of clutch hydraulic fluid through the drain
hose.
6. Have an assistant slowly pump the clutch pedal
to purge the fluid/air mixture.
7. When the draining fluid is clear and free of air
bubbles, close the bleed valve.
8. Disconnect the transparent hose. Tighten the
bleed valve 88 lbf·in (1000 N·cm) and install the
cap on the slave cylinder bleed valve.
9. Check the fluid level in the reservoir. If neces-
sary, add or drain fluid to bring the fluid level to
between the MIN and MAX lines marked on the
side of the reservoir. Install the reservoir cap.
10. Depress the clutch pedal a few times. There
should be resistance over the full pedal stroke.

Business Class M2 Workshop Manual, Supplement 20, September 2011 140/3

Clutch Hydraulic System 25.02
Release Bearing and Yoke Assembly
Replacement

Replacement 5. Install the bearing onto the release yoke.

NOTE: Do not grease the guide of the release
1. Remove the transmission from the engine. bearing. It is made from an advanced composite
• For instructions for Eaton Fuller Transmis- with embedded lubricating elements, and greas-
sions, see Section 26.00, Subject 100. ing it would attract dirt particles that lead to ex-
• For instructions for the Mercedes-Benz Au- cessive wear.
tomated Transmission, see Sec- 6. Install the transmission on the engine.
tion 26.03, Subject 100.
• For instructions for Eaton Fuller Transmis-
• For instructions for the Mercedes-Benz sions, see Section 26.00, Subject 100.
Manual Transmission, see Sec-
tion 26.04, Subject 100. • For instructions for the Mercedes-Benz Au-
tomated Transmission, see Sec-
2. Remove the release bearing from the release tion 26.03, Subject 100.
yoke. See Fig. 1.
• For instructions for the Mercedes-Benz
IMPORTANT: The clips that secure the bearing Manual Transmission, see Sec-
to the bearing guide must be handled carefully. tion 26.04, Subject 100.
Repositioning or damaging these clips can lead
to premature clutch failure. See Fig. 2.
3. Remove the two capscrews that attach the re-
lease yoke to the bell housing. Remove the re-
lease yoke from the transmission.

2 3
10/27/2005 f250631

A Handle the release bearing carefully. Do not bend or

reposition the clips.
Fig. 2, Release Bearing Clip
4

09/28/2005 f250624
A. Position the stop pin at 12 o’clock between the
arms of the release yoke.
1. Release Bearing 3. Release Yoke
2. Capscrew 4. Input Shaft

Fig. 1, Release Yoke Installation

4. Install the release yoke. Tighten the two cap-

screws 33 lbf·ft (45 N·m).
IMPORTANT: Position the release bearing with
the stop pin located at 12 o’clock between the
two arms of the release yoke. See Fig. 1.

Business Class M2 Workshop Manual, Supplement 9, March 2006 150/1

Clutch Hydraulic System 25.02
Hydraulic Hose Replacement

Replacement parts of the system, causing loss of clutch func-

tion and the risk of serious personal injury.
1. Park the vehicle on a level surface, shut down 8. Fill the reservoir with approved DOT 4 hydraulic
the engine, and set the parking brake. Chock the brake fluid and bleed the system as instructed in
tires. Subject 130.
2. Open the hood. 9. Check the function of the clutch actuation system
as instructed in Subject 300.
WARNING
Clutch hydraulic fluid (DOT 4 brake fluid) is haz-
ardous. It may be a skin irritant and can cause 1
blindness if it gets in your eyes. Always wear
safety glasses when handling clutch hydraulic 6
5
fluid or bleeding hydraulic lines. If you get clutch
hydraulic fluid on your skin, wash it off as soon
as possible.
3. Using a flat-tip screwdriver, remove the quick- A
disconnect clip that attaches the hydraulic hose
to the slave cylinder. Retain the clip. See Fig. 1.
4. Drain the hydraulic fluid from the entire system.
5. At the quick-disconnect clip that attaches the hy-
draulic hose to the master cylinder, note the po-
sition of the clip for later installation, then remove
it using a flat-tip screwdriver. See Fig. 2. 2

6. Route the new hydraulic hose between the slave

cylinder and the master cylinder.
3
7. Install the quick-disconnect clip and hydraulic
hose, as follows.
7.1 Insert the clip arms into the recessed
areas on the nozzle of the master cylinder.
4
IMPORTANT: Do not force the hose into the
slave cylinder. If the clip is incorrectly in-
stalled, the hose will not snap into place. 2

7.2 Snap the hydraulic hose into place.

7.3 Tug on the hose to make sure it is in-
06/22/2011 f250685
stalled correctly. The hose should not pull
out. A. Hydraulic Subassembly
1. Pedal Unit 4. Slave Cylinder
7.4 Insert the clip at the slave cylinder, and 2. Clip 5. Master Cylinder
install the hose as described above. 3. Hydraulic Hose 6. Reservoir

WARNING Fig. 1, Components, Hydraulic Clutch Control

Use only approved clutch hydraulic fluid (DOT 4

brake fluid). Do not mix different types of brake
fluid. The wrong fluid will damage the rubber

Business Class M2 Workshop Manual, Supplement 20, September 2011 160/1

25.02 Clutch Hydraulic System
Hydraulic Hose Replacement

05/07/2007 f250661

1. Hydraulic Hose
2. Quick-Disconnect Clip
3. Master Cylinder

Fig. 2, Quick-Disconnect Clip at the Master Cylinder

160/2 Business Class M2 Workshop Manual, Supplement 20, September 2011

Clutch Hydraulic System 25.02
Clutch Switch Replacement

Replacement
1
1. Park the vehicle on a level surface, shut down
the engine, and set the parking brake. Chock the
tires. A

2. Open the hood.

3. Disconnect the clutch control switch located 2
under the dash and above the clutch pedal, as
follows. See Fig. 1.
3.1 Retract the secondary lock. See Fig. 2.
3.2 Depress the latch to unlock the switch
05/31/2007 f545018
connector, then separate the clutch control
switch from the wire harness. A. Retract the secondary lock, then depress the latch
to release the connector.
4. Remove the screw that holds the switch assem-
bly to the pedal unit, and remove the switch. 1. Secondary Lock 2. Latch

5. Mount the new switch assembly on the connec- Fig. 2, Clutch Control Switch Connector
tor and tighten the M5 screw 23 lbf·in (260
N·cm).
6. Check the function of the clutch actuation system
as instructed in Subject 300.

2
3
1

06/22/2011 f250687
1. Frontwall
2. Clutch Control Switch
3. Screw

Fig. 1, Clutch Control Switch

Business Class M2 Workshop Manual, Supplement 20, September 2011 170/1

Clutch Hydraulic System 25.02
SACHS 395 XTend Clutch Removal and
Installation

Special Tools
A special tool is used for this procedure. See
Table 1.

Special Tool
Tool Description Manufacturer Part Number

Clutch Centering Pin Kent-Moore J-45719

f580335

Table 1, Special Tool

NOTE: To check tool availability, and to order

tools, call SPX Kent-Moore at 1-800-328-6657.

Removal
1. Remove the transmission from the engine.
• For instructions for the Mercedes-Benz Au-
tomated Transmission, see Sec-
tion 26.03, Subject 100.
• For instructions for the Mercedes-Benz
Manual Transmission, see Sec-
tion 26.04, Subject 100.
2. Insert the centering pin (Table 1) through the
clutch disc and into the pilot bearing.
IMPORTANT: Do not remove the stop bolt. Also, 09/26/2005 f250628
forgetting to loosen this bolt may cause internal
Fig. 1, Stop Bolt
components to dislodge and render the clutch
unusable. NOTE: If a SACHS 395 XTend cover assembly
3. Loosen the stop bolt about two turns. See Fig. 1 is covered with oil (e.g. defective shaft seal) or
for the stop bolt location. grease, do not reinstall it—even if it has been
cleaned.
IMPORTANT: The clutch disc is under tension. If
one capscrew is loosened too much, it places
excessive tension on the cover assembly. Installation
4. Remove the cover assembly. See Fig. 2. Loosen NOTE: When replacing a SACHS 365 mm
the capscrews in a star pattern, taking care not clutch with a 395 XTend, replace the flywheel as
to loosen any one capscrew too much before
loosening the next one.
well. For instructions, see the manufacturer’s
service literature.
5. Remove the clutch disc assembly.

Business Class M2 Workshop Manual, Supplement 15, March 2009 180/1

25.02 Clutch Hydraulic System
SACHS 395 XTend Clutch Removal and
Installation

4
3
2

09/26/2005 f250627
1. Disc Assembly 3. Washer 5. Input Shaft
2. Cover Assembly 4. Clutch Capscrews, M10 x 80 6. Release Bearing

Fig. 2, Clutch Assembly

1. Grease the splines of the input shaft and the hub IMPORTANT: Do not remove the centering pin
of the disc assembly. Remove any excess until the clutch is completely installed.
grease.
3. Install guide pins at the 10 o’clock and 2 o’clock
NOTE: Do not grease the guide of the release positions to ensure proper centering of the clutch
bearing. It is made from an advanced composite cover assembly. See Fig. 3.
with embedded lubricating elements, and greas- "Guide pins" are long, headless capscrews that
ing it would attract dirt particles that lead to ex- are temporarily installed in the flywheel to sup-
cessive wear. port the weight of the clutch, allowing you to
2. Insert the centering pin (Table 1) into the pilot align it precisely with the flywheel. Without guide
bearing. Then, with the clutch disc assembly ori- pins, proper clutch installation is extremely diffi-
ented so the side marked "flywheel side" faces cult. If necessary, cut off the heads of two 6-inch
the flywheel, center the disc assembly on the (15 cm) capscrews to make a set.
flywheel. 4. Install the cover assembly, as follows.

180/2 Business Class M2 Workshop Manual, Supplement 15, March 2009

Clutch Hydraulic System 25.02
SACHS 395 XTend Clutch Removal and
Installation

IMPORTANT: Never allow the diaphragm

spring to rest on the centering pin.
2
4.1 Slide the clutch cover assembly onto the 2
guide pins, and position it inside the
raised rim of the flywheel. See Fig. 4.
4.2 Ensure the cover assembly is situated
completely within the rim of the flywheel.
Use a flashlight to help verify the position-
ing if needed.
4.3 Install and hand-tighten six of the eight
capscrews using the sequence shown in
Fig. 5 (skipping the guide pin positions).
4.4 Remove the two guide pins, then install 1
and hand-tighten the remaining two cap-
screws.
4.5 Using the sequence shown in Fig. 5,
tighten the eight clutch capscrews pro-
11/03/2005 f250629
gressively: first to 20 lbf·ft (27 N·m), and
finally to 33 lbf·ft (44 N·m). Do not put 1. Centering Pin 2. Guide Pin
more tension on one side of the clutch
than the other. Fig. 3, Centering the Clutch

4.6 If the clutch was previously mounted and 2

the stop bolt loosened for removal, tighten
the stop bolt to 26 to 32 lbf·ft (35 to 43
N·m). If it is a new clutch, do not tighten
the stop bolt.
5. When all capscrews have been tightened, re-
move the centering pin.
6. Install the transmission on the engine.
• For instructions for the Mercedes-Benz Au-
tomated Transmission, see Sec-
tion 26.03, Subject 100.
• For instructions for the Mercedes-Benz
Manual Transmission, see Sec- 1
tion 26.04, Subject 100.
2
08/20/2008 f250669
1. Flywheel 2. Flywheel Rim

Fig. 4, Flywheel Rim

Business Class M2 Workshop Manual, Supplement 15, March 2009 180/3

25.02 Clutch Hydraulic System
SACHS 395 XTend Clutch Removal and
Installation

6 2

4
7

8 3

08/20/2008 1 5 f250668

Fig. 5, Capscrew Tightening Sequence

180/4 Business Class M2 Workshop Manual, Supplement 15, March 2009

Clutch Hydraulic System 25.02
Hydraulic Clutch Adjustment

General Information If the blue 0.56-inch (14.3-mm) end can’t be in-

serted in the gap, then try to insert the green
0.50-inch (12.7-mm) end.
Most hydraulically actuated clutches are auto-
adjusting and require no manual adjustment under If the green end of the tool can’t be inserted in
normal operating conditions. Eaton Easy-Pedal and the gap, adjustment is needed. Go to the next
Stamped Angle Spring clutches are manually ad- step.
justed models, and require periodic inspection and
adjusting to maintain proper clutch clearance and If the green end of the tool fits — snugly or
achieve maximum clutch disc life. Approximately 75 loosely — then no adjustment is needed. Nothing
percent of Business Class® M2 vehicles equipped more needs to be done. Install the clutch inspec-
with non-synchronized transmissions and hydrauli- tion cover and remove the chocks from the tires.
cally actuated clutches are equipped with manually
adjusted clutches. This combination of components
(hydraulic actuation and manual adjustment) does
not allow the driver to feel when the clutch must be
3
adjusted, because the clutch pedal has no free
travel.
Release bearing travel is the clearance between the
rear surface of the release bearing housing and the
forward surface of the clutch brake disc. This dis-
tance must be maintained between 1/2 and 9/16 inch
(12.7 and 14.3 mm).

Clutch Adjustment
1. Apply the parking brakes and chock all the tires.
2. Remove the clutch inspection cover from the bell
housing. See Fig. 1.
3. Slide the clutch brake tight against the transmis-
sion input-shaft bearing cap.
IMPORTANT: Release bearing travel tool A02-
1 2
12419-000 is available through the PDCs. One 06/22/2005 f261355
end of the tool has green tape on it and is 0.50 1. Clutch Inspection Cover
inch (12.7 mm) in diameter; the other end has 2. Hydraulic Slave Cylinder
3. Transmission
blue tape on it and is 0.56 inch (14.3 mm) in
diameter. See Fig. 2. Fig. 1, View from Underneath the Vehicle Looking
4. Measure the release bearing travel. See Fig. 3 Forward
for the correct dimension to measure. Using both
ends of the release bearing travel tool, check this 5. Turn the engine flywheel until the lockstrap is
gap as follows: aligned with the clutch inspection-cover opening.
6. Release the clutch by depressing the pedal.
Position the tool so that the legs at the blue
Block the pedal in the released position, or have
0.56-inch (14.3-mm) end straddle the transmis-
someone assist you by holding the pedal down
sion input shaft. If the tool fits loosely, the gap is
during the adjustment procedure.
too wide and adjustment is needed. Go to the
next step. NOTE: An open-end wrench is not recom-
mended for the following step.

Business Class M2 Workshop Manual, Supplement 9, March 2006 190/1

25.02 Clutch Hydraulic System
Hydraulic Clutch Adjustment

A B

A B

03/26/96 f580133

A. Green End (0.50 inch or 12.7 mm)

B. Blue End (0.56 inch or 14.3 mm)

Fig. 2, Release Bearing Travel Tool A02-12419-000

1 2

09/15/95 f250309

Fig. 4, Adjustment with Kwik-Adjust (bell housing

shown removed)

release bearing moves toward the trans-

mission).
To increase the gap: If clearance between
A the release bearing housing and the clutch
10/14/94 f250199a
brake is less than 1/2 inch (12.7 mm), turn
A. Clearance between release bearing housing and the adjustment bolt counterclockwise (the
clutch brake (release bearing travel) must be 1/2 to release bearing moves toward the en-
9/16 inch (12.7 to 14.3 mm). gine).
1. Release Bearing Housing
2. Clutch Brake 7.4 When the adjustment is complete, make
sure the adjustment bolt is locked (pulled
Fig. 3, Release Bearing Travel Measurement up flush with the mounting bolts).
NOTE: On Easy-Pedal 2000 clutches, each
7. Adjust the clutch, using a 5/8-inch box-end or
complete turn of the adjustment bolt represents
socket wrench on the adjustment bolt. See
Fig. 4. about 0.125 inch (3 mm) of release bearing
movement. On earlier Easy-Pedal models, each
7.1 Insert the 5/8-inch box-end or socket complete turn of the adjustment bolt represents
wrench through the inspection cover open- about 0.02 inch (0.5 mm) of release bearing
ing. movement.
7.2 To begin the adjustment, release the ad- 8. After adjusting, release the pedal and check the
justment bolt by pressing down on the bolt clearance between the release bearing housing
head. and the clutch brake. When the adjustment is
NOTE: Normal wear increases the gap be- correct, the green end of the tool should go in
tween the release bearing and the transmis- and the blue should not (clearance of 1/2 to 9/16
sion. See Fig. 3, dimension A. inch, or 12.7 to 14.3 mm).
9. Install the clutch inspection cover on the bell
7.3 To decrease the gap: If clearance between housing.
the release bearing housing and the clutch
brake is more than 9/16 inch (14.3 mm), 10. Remove the chocks from the tires.
turn the adjustment bolt clockwise (the

190/2 Business Class M2 Workshop Manual, Supplement 9, March 2006

Clutch Hydraulic System 25.02
Troubleshooting

Diagnostic Checks
IMPORTANT: If any problems are noticed during
these diagnostic checks, take corrective action
using the information under the heading
"Troubleshooting Tables." 1 3
2
When repairing any components, bleed the clutch
hydraulic system before restoring the vehicle to ser-
vice. This will prevent air from remaining in the sys- A
tem. 3
2
Clutch Switch Check
1. Shut down the engine.
2. Apply the parking brakes, chock the front and
rear tires, and open the hood. B
3
3. Disconnect the clutch control switch connector 1
located under the dash just above the clutch
pedal.
4. To check the upper position switch, do a continu- 08/21/2003 f544352
ity check between pin 2 and pin 3 of the connec- A. Upper Position Switch–The switch is open when
tor. See Fig. 1. the pedal is pressed down about four inches (10
cm).
4.1 With the pedal not pressed, the circuit B. Lower Position Switch–The switch closes when the
should be closed (continuity should be pedal is pressed down to the floor.
present). 1. Pin 1 3. Pin 3
4.2 With the pedal pressed down about 4 2. Pin 2
inches (10 cm), the circuit should be open Fig. 1, Clutch Switch
(no indication of continuity).
5. To check the lower position switch, do a continu- Clutch Actuation System Check
ity check between pin 1 and pin 3 of the connec-
tor. WARNING
5.1 With the pedal not pressed, the circuit
should be open (no indication of continu- Air in the clutch hydraulic system can prevent
ity). the gears from engaging properly, and cause a
serious accident resulting in personal injury.
5.2 With the pedal pressed down all the way
to the floor, the circuit should be closed 1. Shut down the engine.
(continuity should be present).
2. Apply the parking brakes and chock the front and
6. If either check gives an incorrect result, replace rear tires.
the clutch switch.
3. Do the "Clutch Actuation System Leak Check."
4. Press the pedal all the way to the floor several
times and check the action of the pedal. The
pedal should be easy to operate and return with-
out difficulty to its original position. It should feel
firm and responsive, not soft or spongy.

Business Class M2 Workshop Manual, Supplement 9, March 2006 300/1

25.02 Clutch Hydraulic System
Troubleshooting

5. With both the brake and the clutch pedals NOTE: This step requires two persons.
pressed down, start the engine.
3. Have one person press down on the clutch pedal
5.1 If the engine does not start, take correc- while the other person checks the clutch hydrau-
tive action using the information under the lic system for signs of leakage.
heading "Troubleshooting Tables."
5.2 If the clutch does not disengage properly, Clutch Incomplete
take corrective action using the informa-
tion under the heading "Troubleshooting
Disengagement Check
Tables." NOTE: Do this check only on vehicles with syn-
6. Remove the chocks from the front and rear tires. chronized transmissions.
1. Chock the front tires and apply the parking
7. Test drive the vehicle.
brake.
7.1 Check for proper clutch functioning while
2. Put the gear shift lever in neutral.
shifting gears.
3. Start the engine.
7.2 If the clutch makes noise when shifting out
of neutral into another gear, do the "Clutch 4. Press the clutch pedal all the way to the floor.
Incomplete Disengagement Check."
5. Shift the transmission into 1st gear.
7.3 With cruise control on, press the clutch
pedal down. If cruise control does not de- 6. With the clutch pedal still on the floor, shift into
activate, take corrective action using the 2nd gear.
information under the heading "Trouble- 7. Listen for noise and feel for difficult shifting. If
shooting Tables." there is noise or difficulty in getting the gears to
shift, the clutch is not completely disengaged.
Clutch Actuation System Leak Take corrective action using the information un-
der the heading "Troubleshooting Tables."
Check
1. Shut down the engine. Troubleshooting Tables
2. Apply the parking brakes, chock the front and
rear tires, and open the hood.
Problem–The Clutch Pedal Feels Soft or Spongy
Problem–The Clutch Pedal Feels Soft or Spongy
Possible Cause Remedy
There is air in the hydraulic system. Bleed the hydraulic system. See Subject 140 for instructions.
There is a hydraulic fluid leak. Check the fluid level. Check for leakage and replace any components found to
be leaking. Fill and bleed the hydraulic system.

Problem–The Clutch Pedal Is Unusually Hard To Operate

Problem–The Clutch Pedal Is Unusually Hard To Operate
Possible Cause Remedy
The clutch is damaged. Remove the clutch and inspect it for damage. Replace the clutch if damaged,
or make any necessary repairs. For the SACHS 365 mm clutch, see
Subject 130. For the SACHS 395 XTend clutch, see Subject 180.
The clutch is not functioning properly. Check clutch function and make any necessary repairs. See the instructions
under the heading "Clutch Actuation System Check."

300/2 Business Class M2 Workshop Manual, Supplement 9, March 2006

Clutch Hydraulic System 25.02
Troubleshooting

Problem–The Clutch Pedal Is Unusually Hard To Operate

Possible Cause Remedy
The return or assist spring is broken. Replace the pedal unit. See Subject 100 for instructions.

WARNING
Do not attempt to disassemble the preloaded assist spring. Sudden
release of the assist spring could cause property damage and serious
personal injury.
The pedal assembly is worn or jammed. Replace the pedal unit. See Subject 100 for instructions.
The master cylinder has components that Replace the hydraulic subassembly. See Subject 110 for instructions.
are jammed or broken.

Problem–The Clutch Does Not Completely Disengage; Shifting Is Difficult and Noisy
Problem–The Clutch Does Not Completely Disengage; Shifting Is Difficult and Noisy
Possible Cause Remedy
There is air in the hydraulic system. Bleed the hydraulic system. See Subject 140 for instructions.
There is a hydraulic fluid leak. Check the fluid level. Check for leakage and replace any components found to
be leaking. Fill and bleed the hydraulic system.
Components of the pedal unit are Replace the pedal unit. See Subject 100 for instructions.
defective.
The slave cylinder is defective. Replace the slave cylinder. See Subject 120 for instructions.
The slave cylinder is loose. Tighten the M8 slave cylinder mounting capscrews 12 lbf·ft (16 N·m).
The wrong type of brake fluid was used. Replace the complete system. Fill only with approved DOT 4 brake fluid.

Problem–The Clutch Is Slipping

Problem–The Clutch Is Slipping
Possible Cause Remedy
The clutch is worn. Replace the clutch. For the SACHS 365 mm clutch, see Subject 130. For the
SACHS 395 XTend clutch, see Subject 180.
Contamination (e.g. oil, grease, etc.). Replace the clutch. For the SACHS 365 mm clutch, see Subject 130. For the
SACHS 395 XTend clutch, see Subject 180.
The clutch actuation system is Check the clutch actuation system. See the procedures under the heading
"preloading." "Clutch Actuation System Check."

Problem–The Clutch Switch Does Not Activate

Problem–The Clutch Switch Does Not Activate
Possible Cause Remedy
The switch contacts are damaged or worn. Replace the clutch switch assembly. See Subject 170 for instructions.
The switch wiring is damaged. Repair the wiring. See Section 54.03 for instructions.
The switch cam is damaged. Replace the pedal unit. See Subject 100 for instructions.

Business Class M2 Workshop Manual, Supplement 9, March 2006 300/3

25.02 Clutch Hydraulic System
Troubleshooting

Problem–The Clutch Pedal Does Not Return

Problem–The Clutch Pedal Does Not Return
Possible Cause Remedy
The return or assist spring is broken. Replace the pedal unit. See Subject 100 for instructions.

WARNING
Do not attempt to disassemble the preloaded assist spring. Sudden
release of the assist spring could cause property damage and serious
personal injury.

Problem–Cruise Control or Engine Brake Does Not Deactivate When the Clutch Pedal Is Pressed Down
Problem–Cruise Control or Engine Brake Does Not Deactivate When the Clutch Pedal Is Pressed Down
Possible Cause Remedy
The upper position switch is damaged. Check switch function and make any necessary repairs. See the instructions
under the heading "Clutch Switch Check."
There has been an external electrical See Section 54.03 for instructions.
failure.

Problem–Starter Does Not Operate

Problem–Starter Does Not Operate
Possible Cause Remedy
The lower position switch is damaged. Check switch function and make any necessary repairs. See the instructions
under the heading "Clutch Switch Check."
There has been an external electrical See Section 54.03 for instructions.
failure.

300/4 Business Class M2 Workshop Manual, Supplement 9, March 2006

Clutch Hydraulic System 25.02
Specifications

For fastener torque values, see the tables below.

Description Size Grade/Class Torque: lbf·ft (N·m) Torque: lbf·in (N·cm)

Bleed Screw M7 — — 88 (1000)
Clutch Capscrews 3/8–16 5 37 (50) —
Clutch Switch Mounting Screw M5 — — 23 (260)
Hydraulic Sub-Assembly Retainer — — — 44 (500)
Pedal Unit Mounting Plate Capscrews M8 8.8 13 (18) —
Release Yoke Mounting Capscrews — — 33 (45) —
Slave Cylinder Mounting Capscrews M8 10.9 13 (18) —
Standoff Bracket Mounting Capscrews 1/4–20 8 10 (14) —
Table 1, Torque Values, SACHS 365 mm Clutch

Description Size Grade/Class Torque: lbf·ft (N·m) Torque: lbf·in (N·cm)

Bleed Screw M7 — — 88 (1000)
Clutch Capscrews M10 10.9 33 (45) —
Clutch Switch Mounting Screw M5 — — 23 (260)
Hydraulic Sub-Assembly Retainer — — — 44 (500)
Pedal Unit Mounting Plate Capscrews M8 8.8 13 (18) —
Release Yoke Mounting Capscrews — — 33 (45) —
Slave Cylinder Mounting Capscrews M8 10.9 13 (18) —
Standoff Bracket Mounting Capscrews 1/4–20 8 10 (14) —
Stop Bolt — — 29 (41) —
Table 2, Torque Values, SACHS 395 XTend Clutch

Business Class M2 Workshop Manual, Supplement 9, March 2006 400/1

Clutch Hydraulic System 25.02
Special Tools

Special Tools
Tool Description Manufacturer Part Number

Clutch Centering Pin Kent-Moore J-45719

f580335

Clutch Release Bearing Travel Tool PDC A02-12419-000

f580133a

Table 1, Special Tools

Business Class M2 Workshop Manual, Supplement 9, March 2006 500/1

Eaton Fuller Manual Transmission 26.00
Removal and Installation

Removal 4.3 Remove the midship bearing bracket. See

Fig. 4.
1. Park the vehicle on a level surface. Shut down 4.4 Support the disconnected driveshaft and
the engine, set the parking brake, and chock the chain it out of the way. See Fig. 5.
rear tires.
5. Drain the transmission fluid. See Fig. 6 for the
2. From inside the cab, remove the shift lever and location of the drain plug.
shift tower from the transmission top cover. See
Fig. 1. 6. Remove the transmission temperature sensor
and fitting from the transmission top cover.
2.1 Before removing the shift lever, place the
transmission in high gear. 7. Remove the fuel lines and the fuel line standoff
bracket from the transmission. See Fig. 7.
2.2 If installed, disconnect any electrical con-
nector(s) on the shift lever. 8. Unplug the electrical connector on the speedom-
eter sensor. Disconnect any other sensors (neu-
2.3 Remove the four M6 screws from the re- tral start switch, back-up switch, etc.), if installed.
taining ring around the shift lever boot.
Remove the retaining ring and boot from
the cover plate.
WARNING
2.4 Remove the eight M6 screws from the Do not press down on the clutch pedal after re-
spring nuts in the cover plate. Remove the moving the slave cylinder. Clutch hydraulic fluid
cover plate from the cab floor. (DOT 4 brake fluid) may squirt out, causing per-
sonal injury and damage to the vehicle.
2.5 Remove the four 3/8–16 shift tower
mounting capscrews from the shift tower. 9. Remove the bolts attaching the clutch slave cyl-
Remove the shift tower and shift lever inder to the mounting flange on the bell housing.
from the transmission top cover. See Move the slave cylinder out of the way. See
Fig. 2. Fig. 8.
3. If necessary to replace the shift lever or compo- 10. Remove the battery cable bracket(s) around the
nents of the shift linkage, disassemble the shift transmission and move the battery cables out of
linkage. the way. See Fig. 9.
3.1 If necessary to replace the shift lever, re- 11. Remove the exhaust pipe hanger bracket from
move the M10 shift linkage flange screw the gear case. See Fig. 10.
attaching the shift lever to the shift linkage 12. If the vehicle is equipped with optional dual fuel
adaptor. Remove the end of the shift lever tanks, remove the fuel cross-over line and its
from the shift linkage adaptor on the trans- support between the tanks.
mission.
13. Support the transmission with a jack. See
3.2 If necessary to replace the shift linkage Fig. 11.
adaptor, remove the M10 shift linkage
flange screw attaching the shift linkage 13.1 Except for the top two, remove all the
adaptor to the shift tower. Remove the bolts attaching the transmission bell hous-
shift linkage adaptor from the shift tower. ing to the engine flywheel housing.
4. From underneath the vehicle, disconnect the 13.2 Position a transmission jack under the
driveshaft from the transmission. transmission and raise its support plates
against the base of the transmission.
4.1 Support the midship bearing.
13.3 Adjust the support plates to cradle the
4.2 Remove the bolts from the U-joint end transmission.
caps and slide the front of the driveshaft
out of the transmission output yoke. See 13.4 Using a chain, secure the transmission to
Fig. 3. the jack.

Business Class M2 Workshop Manual, Supplement 8, September 2005 100/1

26.00 Eaton Fuller Manual Transmission
Removal and Installation

4
3
5

8 9

13
10

11

12

08/26/2003 f261269
1. Shift Knob 5. Boot 10. Shift Linkage Adaptor
2. Retaining Ring Screw, M6 (4 6. Floor Covering 11. Shift Linkage Flange Screw, M10
qty.) 7. Cover Plate Screw, M6 (8 qty.) (2 qty.)
3. Shift Lever 8. Cover Plate 12. Shift Tower
4. Retaining Ring 9. Insulation 13. Spring Nut, 1/4–20 (8 qty.)

Fig. 1, Shift Lever and Boot

13.5 Remove the last two bolts attaching the

bell housing to the flywheel housing. CAUTION
Do not allow the rear of the transmission to drop,
and do not allow the transmission to hang un-
supported. Keep the flange of the bell housing

100/2 Business Class M2 Workshop Manual, Supplement 8, September 2005

Eaton Fuller Manual Transmission 26.00
Removal and Installation

1
1 2 3 4 3
2

06/05/2001 f261005

1. Transmission
2. Output Yoke
3. Driveline
08/15/2003 f261270
1. Shift Tower Mounting Capscrew, 3/8–16 (4 qty.) Fig. 3, Output Yoke
2. Shift Tower
3. Shift Linkage Adaptor
4. Shift Lever 1
2
Fig. 2, Shift Linkage Connection 3
parallel (all the way around) to the flange of the
flywheel housing until the input shaft is clear of
the flywheel. Taking these precautions will pre-
vent damage to the input shaft, flywheel, and
clutch.
14. Remove the transmission. See Fig. 12.
14.1 Pull the transmission and jack straight
back until the transmission input shaft is
clear of the clutch.
4
14.2 Pull the transmission away from the ve- 08/14/2003 f261272
hicle. If there is not enough clearance to 1. Midship Bracket 3. Driveshaft
allow it to go straight out the back, use the 2. Midship Bearing 4. Jack
space behind the front wheel on the driv-
er’s side. Fig. 4, Midship Bearing Bracket

Business Class M2 Workshop Manual, Supplement 8, September 2005 100/3

26.00 Eaton Fuller Manual Transmission
Removal and Installation

08/21/2003
3 f261271
01/28/99 f261007 1. Socket Wrench
2. Transmission Top Cover
Fig. 5, Support the Driveline 3. Gear Case
4. Bracket
Fig. 7, Fuel Line Standoff Bracket

1.1 Align the jack and the transmission behind

the engine. Make sure the fingers of the
release yoke are rotated to clear the re-
lease bearing housing.
1.2 Coat the splines of the input shaft with
antiseize compound.
1.3 Raise the transmission and adjust the
angle of the jack until the bell housing and
05/14/2003 f261250 the flange of the flywheel housing are par-
allel.
Fig. 6, Transmission Drain Plug
1.4 Push the transmission and jack straight
Installation forward.
NOTE: Before installing, coat the threads of
IMPORTANT: Before installing the transmission, each bolt with Loctite 262 (or equivalent
make sure that the rear tires are chocked and thread-locking compound).
that the transmission is securely chained to the
1.5 Install the capscrews holding the bell
support plates on the transmission jack. housing to the flywheel housing. Use a
crossover pattern. Do a final tightening of
1. Install the transmission. See Fig. 13.
the capscrews to 33 lbf·ft (45 N·m).

100/4 Business Class M2 Workshop Manual, Supplement 8, September 2005

Eaton Fuller Manual Transmission 26.00
Removal and Installation

2 4 2
3
1
08/19/2003 f261275

1. Gear Case 2. Hanger Bracket

Fig. 10, Exhaust Pipe Hanger Bracket

11/11/2003 f261273 1
1. Hydraulic Line 3. Mounting Screw
2. Slave Cylinder 4. Bell Housing
Fig. 8, Hydraulic Clutch Slave Cylinder 2

1 1
3
4 3 2

08/15/2003 f261274
08/25/2003 f261276
1. Battery Cable Bracket
2. Engine Flywheel Housing 1. Transmission 3. Jack
3. Bell Housing 2. Chain
4. Bell Housing-to-Flywheel Housing Bolt Fig. 11, Supporting the Transmission
Fig. 9, Battery Cable Brackets
1.6 While installing the bell housing-to-
flywheel housing capscrews, also install
the battery cable brackets, as removed.

Business Class M2 Workshop Manual, Supplement 8, September 2005 100/5

26.00 Eaton Fuller Manual Transmission
Removal and Installation

08/14/2003 f261279

Make sure the fingers of the release yoke are rotated to

clear the release bearing.
1. Bell Housing
2. Release Yoke
3. Input Shaft
01/29/99 f261013 4. Input Shaft Splines

Fig. 12, Remove the Transmission Fig. 13, Install the Transmission

1.7 Remove the chain securing the transmis- 4.3 Install the bolts and nuts on the midship
sion to the jack; then remove the jack. bearing bracket. Tighten the nuts 95 lbf·ft
(129 N·m).
2. Through the inspection opening in the bell hous-
ing, make sure the fingers of the release yoke 5. Install the fuel line standoff bracket and connect
are inserted into the embossed area on the re- the fuel lines to the bracket.
lease bearing housing. See Fig. 14. 6. Connect the electrical connectors. Connect the
3. If the vehicle is equipped with the optional dual electrical cable to the speedometer sensor.
fuel tanks, install the fuel cross-over line and its 7. If necessary, assemble the shift linkage. See
support between the tanks. Tighten the clamps Fig. 1.
40 lbf·ft (54 N·m) and the mounting bolts 95 lbf·ft
(129 N·m). 7.1 Before installing, apply three to four drops
of Loctite 262 (or equivalent thread-locking
4. Connect the driveshaft. compound) halfway down the threads of
4.1 Slide the front of the driveshaft into the both shift linkage flange screws.
transmission output yoke. 7.2 Attach the shift linkage adaptor to the shift
4.2 Install the U-joint end caps on the output tower. Tighten the M10 shift linkage flange
yoke. Tighten the bolt heads 50 lbf·ft (68 screw 25 lbf·ft (34 N·m).
N·m) for 3/8-inch end cap bolts and 110 7.3 Fit the shift lever onto the remaining hole
lbf·ft (149 N·m) for 1/2-inch end cap bolts. in the shift linkage adaptor. Tighten the
other M10 shift linkage flange screw 25
lbf·ft (34 N·m).

100/6 Business Class M2 Workshop Manual, Supplement 8, September 2005

Eaton Fuller Manual Transmission 26.00
Removal and Installation

spacer points inboard as shown in Fig. 15.

Tighten the four mounting bolts 15 lbf·ft (20 N·m).
1
2 2

3 1

09/02/2003 f261278
08/14/2003 f261277 The tab on the spacer must face inboard.
The finger of the release yoke must fit as shown into 1. Slave Cylinder 3. Boot
the embossed area of the release bearing housing. 2. Spacer 4. Plunger (inside boot)
1. Bell Housing
2. Embossed Area of Release Bearing Housing Fig. 15, Slave Cylinder Installation
3. Finger of Release Yoke
10. If necessary, bleed the hydraulic clutch system.
Fig. 14, Release Yoke Alignment For detailed instructions, see Section 25.02,
Subject 140.
8. From inside the cab, install the shift tower and
shift lever, as removed, on the transmission top 11. Clean the transmission drain plug and install it
cover. See Fig. 2. on the transmission, along with a new aluminum
gasket. Tighten the drain plug 50 lbf·ft (68 N·m).
8.1 If removed, connect any electrical connec-
tors to the shift lever. 12. Add transmission fluid until it is level with the
lower edge of the fill opening. See Fig. 16 for the
8.2 Install the cover plate, with spring nuts correct level. See Group 26 of the Business
inserted, on the cab floor. Tighten the Class® M2 Maintenance Manual for approved
eight M6 cover plate screws 60 lbf·in (680 transmission lubricants and lubricant capacities.
N·cm).
8.3 Install the rubber boot and the metal re-
taining ring. Tighten the four M6 retaining
ring screws 60 lbf·in (680 N·cm).
8.4 Check the position of the shift lever to be
sure it is still positioned in high gear, as
removed, and that the gears shift nor-
mally. 10/05/94 A B f260006b

8.5 Tighten the four 3/8–16 shift tower mount- A. Full

B. Low
ing capscrews 30 to 35 lbf·ft (40 to 47
N·m). Fig. 16, Transmission Fluid Level Checking
9. From underneath the vehicle, fasten the clutch 13. Clean the transmission fill plug and install it on
slave cylinder, with the plunger fully extended to the transmission, along with a new aluminum
contact the release yoke, to the mounting flange gasket. Tighten the plug as follows:
on the bell housing. Make sure the tab on the

Business Class M2 Workshop Manual, Supplement 8, September 2005 100/7

26.00 Eaton Fuller Manual Transmission
Removal and Installation

• 25 to 35 lbf·ft (34 to 48 N·m) for Eaton

Fuller transmissions with 3/4-inch pipe
threads.
• 60 to 75 lbf·ft (81 to 102 N·m) for Eaton
Fuller transmissions with 1-1/4-inch pipe
threads.
14. Remove the chocks from the rear tires.

100/8 Business Class M2 Workshop Manual, Supplement 8, September 2005

Eaton Fuller Manual Transmission 26.00
Specifications

Torque Values, Eaton Fuller Transmissions

Torque: Torque:
Description Size Grade
lbf·ft (N·m) lbf·in (N·cm)
Bell Housing-to-Timing Case Capscrews M10 x 1.5 8.8 33 (45) —
Clutch Slave Cylinder Bracket Mounting Bolts M8 8.8 15 (20) —
Fuel Cross-Over Line Mounting Bolts — — 95 (129) —
Fuel Cross-Over Line Mounting Clamps — — 40 (54) —
Midship Bearing Bracket Capscrews 3/4–11 — 95 (129) —
Shift Lever Cover Plate Screws M6 8.8 — 60 (680)
Shift Lever Retaining Ring Screws M6 8.8 — 60 (680)
Shift Linkage Flange Screws M10 x 1.5 8.8 25 (34) —
Shift Tower Mounting Capscrews 3/8–16 — 30-35 (40-47) —
Transmission Fluid Drain Plug — — 50 (68) —
Transmission Fluid Fill Plug (with 3/4-inch pipe fittings) — — 25-35 (34-47) —
Transmission Fluid Fill Plug (with 1-1/4-inch pipe fittings) — — 60-75 (81-102) —
3/8–24 — 50 (68) —
U-Joint End Cap Bolts
1/2–20 — 110 (149) —
Table 1, Torque Values, Eaton Fuller Transmissions

Business Class M2 Workshop Manual, Supplement 8, September 2005 400/1

Allison Automatic Transmission 26.01
Removal and Installation

Removal bracket so the driveshaft can be moved far

enough back.
1. Park the vehicle on a level surface, shut down 5.4 Support the disconnected driveshaft and
the engine, apply the parking brake, and chock tie it to the frame rail.
the tires.
6. Disconnect the three electrical connections to the
2. Disconnect the batteries. transmission. See Fig. 2. For instructions, see
3. Remove the transmission drain plug from the Subject 120.
bottom of the transmission and drain the auto-
matic transmission fluid (ATF). Install the drain A
plug and tighten it 18 to 24 lbf·ft (25 to 32 N·m).
4. Support the driveline with a jack stand between
the midship bearing and rear axle.
5. Disconnect the driveline from the transmission, 1
as follow.
5.1 Loosen the bolts that attach the midship
bearing bracket, so the driveshaft can
slide to the rear. See Fig. 1.

3
4
04/14/93 f260116a
A. To bulkhead connector
1. Transmission Wiring Harness
2. Engine Speed Sensor
3. Transmission Control Connector
4. Output Speed Sensor

Fig. 2, Transmission Electrical Connections

7. Remove the ATF fill/dipstick tube, as follows.

08/10/93 f260063
7.1 Remove the capscrew and clamp that
Fig. 1, Midship Bearing Fastener hold the fill/dipstick tube.

5.2 Remove the transmission yoke U-joint end 7.2 Pull the fill/dipstick tube out of the trans-
caps or lock straps. Separate the driveline mission case.
from the transmission output yoke. 7.3 Plug the hole with a clean shop towel to
5.3 Remove the driveline companion flange prevent entry of foreign material.
from the transmission companion flange. 8. Disconnect the flexplate from the transmission,
as follows.
NOTE: It may be necessary to remove the
mounting bolts from the midship bearing

Business Class M2 Workshop Manual, Supplement 10, September 2006 100/1

26.01 Allison Automatic Transmission
Removal and Installation

8.1 Remove the capscrews that attach the

ring gear access cover, then remove the
cover. See Fig. 3.

08/04/94 f260111a
09/27/2001 f261137
Fig. 3, Ring Gear Access NOTE: Rear-mounted hoses shown, but hoses may be
attached at the front of the transmission.
NOTE: For easier access on Mercedes-Benz 1. ATF Cooler Hoses
engines, first remove the three bolts that
hold the exhaust pipe to the turbocharger Fig. 4, Fluid Cooler Lines
exhaust elbow, then lower the exhaust pipe.
8.2 Using a screwdriver, turn the ring gear
until one of the capscrews that attach the
flexplate adapter to the torque converter
can be removed. Continue turning the ring
gear and removing the capscrews through
the access hole until all 12 are removed.
9. Disconnect the transmission fluid cooler lines
from the transmission, and drain the remaining
ATF. See Fig. 4.
10. Place a piece of plywood on a transmission jack
to support the transmission.
11. Slide the jack into place under the transmission.
Secure the transmission with a chain. Anchor the
chain with bolts at the front lifting bosses on the
top of the transmission. See Fig. 5. 08/04/94 f260112a
12. If equipped, remove the two bolts that attach the
transmission to the rear overslung transverse Fig. 5, Chain Around Transmission
support spring. Remove the spring. See Fig. 6. 15. Move the transmission jack to the rear. Lower
13. Remove the 12 transmission-flange bolts. See the jack and lift the vehicle, as needed, so the
Fig. 7. transmission clears the frame rail and any at-
tached components. Support the vehicle frame
14. Remove the muffler support bracket that is sup-
with jack stands.
ported by two of the companion-flange bolts.

100/2 Business Class M2 Workshop Manual, Supplement 10, September 2006

Allison Automatic Transmission 26.01
Removal and Installation

transmission is securely chained to the trans-

mission jack.
1. Raise the vehicle frame with a hydraulic jack to
obtain adequate clearance for installing the
transmission. Place jack stands under the front
of the vehicle.
2. With the transmission on a jack, roll the trans-
1 mission into place behind the flexplate. Remove
the jack stands, and lower the vehicle frame.
3 3. Raise the jack until the transmission lines up with
2
the flexplate.
4 4. Push the transmission toward the engine until it
seats squarely against the engine flywheel hous-
ing, with the bolt holes in the transmission hous-
ing aligned with those in the flywheel housing.
NOTE: No force is required. If interference is
09/04/2001 f261110 encountered, move the transmission away from
1. Bracket Bolts the engine and correct the problem.
2. Transmission L-Bracket
3. Transverse Support Spring 5. Install the transmission-flange bolts finger-tight.
4. Transmission 6. Install the 12 flexplate adapter capscrews, as
follows.
Fig. 6, Transverse Support Bracket
6.1 Turning the ring gear for access, install all
the capscrews through the access hole.
Don’t tighten them now.
Be careful not to drop the capscrews in-
side the flywheel housing. The transmis-
sion must be removed to get them out.
IMPORTANT: Install all capscrews before
tightening any of them to prevent cocking of
the flexplate adapter.
6.2 Tighten the capscrews, in a star pattern,
to the following specifications based on
the model number:
• 1000 and 2000 Families: 6 bolts to
46 lbf·ft (62 N·m)
08/04/94 f260117a
• 3000 Family: 6 bolts to 50 lbf·ft (68
Fig. 7, Transmission-Flange Bolts N·m)

16. Roll the transmission jack rearward, and remove • 4000 Family: 12 bolts to 27 lbf·ft (37
the transmission. N·m)
6.3 Install the access cover and its cap-
Installation screws. There are four capscrews on Cat-
erpillar engines, three capscrews on
Mercedes-Benz engines, and two on
IMPORTANT: Before installing the transmission,
Cummins and Detroit Diesel engines.
make sure the rear tires are chocked and the

Business Class M2 Workshop Manual, Supplement 10, Septermber 2006 100/3

26.01 Allison Automatic Transmission
Removal and Installation

7. Tighten the 12 M10 transmission-flange bolts 38 15.2 Install the fill/dipstick tube and clamp.
to 45 lbf·ft (51 to 61 N·m) in a star pattern. See Tighten the self-tapping screw until it is
Fig. 7. firmly seated, approximately 18 to 21 lbf·ft
8. If previously removed, install the transverse sup- (24 to 28 N·m).
port spring at the rear of the transmission. Install 16. Install the standoff bracket on the right side of
the two bolts and washers. Tighten the bolts 136 the transmission.
lbf·ft (184 N·m). See Fig. 6.
Make sure the air line and the wiring harness are
9. Remove the chain that holds the transmission to securely attached to the standoff bracket.
the transmission jack.
17. Connect all electrical lines to the transmission,
10. Lower the transmission jack and remove it. as follows.
11. Connect the transmission fluid cooler hoses to 17.1 Connect the transmission control connec-
the transmission, and tighten the fittings to the tor.
applicable values in Table 1. See Fig. 4.
17.2 Connect the cable to the output speed
12. Install the muffler bracket. sensor.
13. Connect the driveshaft, as follows. 17.3 Connect the cable to the engine speed
13.1 Slide the front of the driveshaft into the sensor.
transmission output yoke. 17.4 Using tie straps, secure the cables where
13.2 Install the transmission yoke U-joint end necessary.
caps and lock straps. 18. Fill the transmission with ATF.
13.3 If the midship bearing bracket bolts and 19. Connect the batteries.
nuts were removed, install them. Tighten
the nuts 95 lbf·ft (129 N·m). 20. Start the engine, and check for any leaks. Repair
leaks as needed.
14. On Mercedes-Benz engines, if the exhaust pipe
was disconnected from the turbocharger exhaust 21. Check the ATF level. Add fluid as needed.
elbow, connect the pipe and tighten the bolts 60 22. Remove the chocks from the tires.
lbf·ft (81 N·m).
23. Road test the vehicle, and check for correct
15. Install the ATF fill/dipstick tube, as follows. transmission operation.
15.1 Inspect the fill/dipstick tube seal. Replace
it if damaged.

Series/Family Description SAE Size Torque: lbf·ft (N·m)

1000 and 2000 Front Ports 12 25–35 (34–47)
Non-retarder, Front Ports 12 25–35 (34–47)
3000 Non-retarder, Rear Ports 16 40–50 (54–68)
Retarder, Rear Ports 16 40–50 (54–68)
Non-retarder, Front Ports 16 40–50 (54–68)
4000 Non-retarder, Rear Ports 16 40–50 (54–68)
Retarder, Rear Ports 20 50–60 (68–81)
Table 1, Torque Values for Transmission Fluid Cooler Hoses

100/4 Business Class M2 Workshop Manual, Supplement 10, September 2006

Allison Automatic Transmission 26.01
ATF Cooler Replacment (stand-alone unit)

NOTE: If the vehicle is equipped with the inte-

gral radiator/cooler, see Section 20.01 for re-
placement instructions.

Replacement
1. Park the vehicle on a level surface, shut down
the engine, apply the parking brake, and chock
the tires.
1
WARNING
Drain the coolant system only when the coolant 2
10/05/2001 f261140
and engine are cool. Draining it when these are
1. Cooler Fitting (welded to cooler)
hot could cause severe personal injury due to 2. Transmission Hose
scalding.
2. With the engine cool, loosen the surge tank cap Fig. 1, ATF Hose Connection at Transmission Cooler
to release cooling system pressure.
3. Place a suitable container under the radiator.
Open the drain petcock at the bottom of the ra-
diator and drain the cooling system. Close the
drain petcock.
4. Remove the two radiator hoses at the transmis-
sion cooler, draining any excess engine coolant
into a pan.
1
CAUTION
3
The transmission fluid hoses at the cooler have
quick-connect fittings. DO NOT attempt to un- 10/05/2001 2 4 f261141
screw the fitting at the cooler. It is welded to the
1. Retaining Clip
cooler. See Fig. 1. If the fittings at the cooler are 2. Cooler Fitting (welded to cooler)
turned, internal cooler leakage will occur which 3. Safety Collar
can cause transmission failure. 4. Transmission Hose
5. Disconnect the coolant hoses from the fittings at
both sides of the automatic transmission fluid Fig. 2, Safety Collar Removal
(ATF) cooler.
can tear the internal O-ring at the cooler fitting. If
5.1 Pull back the safety collar on the hose the O-ring tears and leaks ATF, the cooler will
fitting accessing the retaining clip. See have to replaced.
Fig. 2.
5.3 Over a drain pan, pull the cooler hose out
5.2 Using a small flat-head screw driver, re- of the fitting. See Fig. 4. Catch the ATF by
move the retaining clip from the cooler directing the disconnected end of each
fitting. See Fig. 3. Discard the clip. hose into a drain pan. When the ATF
stops draining, plug the hoses.
CAUTION Protect the ends of the cooler hoses,
wrapping them in shop towels or similar
Protect the ends of the cooler hoses. Failure to
material.
do so can cause damage to the hose end, which

Business Class M2 Workshop Manual, Supplement 0, January 2002 110/1

26.01 Allison Automatic Transmission
ATF Cooler Replacment (stand-alone unit)

1 CAUTION
DO NOT reuse the retaining clips. Use a new re-
taining clip each time the hoses are removed.
Failure to do so could result in the cooler hoses
coming out of the cooler during vehicle opera-
tion, leaking ATF and causing permanent damage
to the transmission. New retaining clips are avail-
able from the PDCs.
3 8.1 Install a new retaining clip in the fitting at
the cooler. The clip should be completely
4 seated as it was before the hose was re-
10/05/2001 2 f261142 moved.
1. Retaining Clip 8.2 Carefully insert the end of the transmis-
2. Cooler Fitting (welded to cooler)
3. Safety Collar
sion hose into the cooler fitting until the
4. Transmission Hose end seats at the retaining clip. See Fig. 5.
Gently pull the hose to make sure it is
Fig. 3, Retaining Clip Removal fully seated.

1
2 3

10/05/2001 1 f261143
10/05/2001 2 f261144

1. Cooler Fitting (welded to cooler) 1. Retaining Clip

2. Transmission Hose End (protect when removed) 2. Cooler Fitting (welded to cooler)
3. Transmission Hose
Fig. 4, Cooler Hose Removal
Fig. 5, Transmission Hose Installation
6. Remove the four fasteners that attach the ATF
cooler to the mounting bracket assembly, and 8.3 Push the safety collar back up and around
remove the ATF cooler. Drain the ATF cooler into the cooler fitting and retaining clip. See
a drain pan. Fig. 1.

7. Hold the ATF cooler in place; then install the fas- 9. Install the two radiator hoses and tighten the
teners on the mounting bracket. Tighten the fas- hose clamps.
teners 28 lbf·ft (38 N·m). 10. Fill the coolant system and install the surge tank
8. Attach the transmission hoses to the fittings at cap.
both sides of the cooler. 11. Start the engine and operate the transmission for
1 or 2 minutes, then add the correct ATF to the
transmission as needed. For instructions and lu-
bricant specifications, see Group 26 of the
Business Class M2 Maintenance Manual.

110/2 Business Class M2 Workshop Manual, Supplement 0, January 2002

Allison Automatic Transmission 26.01
ATF Cooler Replacment (stand-alone unit)

12. Check the coolant level and add as needed.

13. Remove the tire chocks.

Business Class M2 Workshop Manual, Supplement 0, January 2002 110/3

Allison Automatic Transmission 26.01
Transmission ECU Replacement

A new transmission control module (TCM) was intro- 6. Place the new TCM over the mounting posts,
duced by Allison Transmissions in mid-2006. This and install the washers and nuts. Tighten the
control — known as "fourth generation" — replaced nuts 24 lbf·in (271 N·cm).
the previous electronic control unit (ECU) that is
IMPORTANT: Be careful when attaching the 80-
commonly referred to as "WTEC III". Replacement
procedures for both are provided below. way connector to the TCM. Do not bend the
pins.
Fourth Generation TCM 7. Connect the electrical harness to the TCM.
Replacement 8. Connect the batteries.
9. Close the hood and remove the chocks from the
1. Park the vehicle on a level surface, shut down tires.
the engine, set the parking brake, and chock the
tires.
WTEC III ECU Replacement
2. Disconnect the batteries.
3. Open the hood and locate the TCM attached to 1. Park the vehicle on a level surface, shut down
the frontwall panel. the engine, set the parking brake, and chock the
tires.
4. Disconnect the electrical harness from the TCM.
See Fig. 1. 2. Disconnect the batteries.
3. Locate the ECU either on the frame or behind
the left fender, and disconnect the black, gray,
and blue harness connectors from the ECU.
4. Remove the nuts, washers, and spacers from
each ECU mounting post, and remove the ECU.
See Fig. 2.

4
3 5
1 1
1 6
2

2
4
1

3
08/28/2001 f543869
1. Mounting Post
05/01/2006 f261363
2. Blue Harness Connector Port
1. Mounting Post 3. Black Harness Connector Port
2. Harness Connector 4. ECU
3. TCM 5. Gray Harness Connector Port
4. Mounting Plate 6. ECU Access/Mounting Plate

Fig. 1, Allison Fourth Generation Transmission TCM Fig. 2, Allison WTEC III Transmission ECU
5. Remove the nuts and washers from each TCM 5. Place the new ECU over the mounting posts and
mounting post, then remove the TCM. install the spacers, washers, and nuts. Tighten
the nuts firmly.

Business Class M2 Workshop Manual, Supplement 10, September 2006 120/1

26.01 Allison Automatic Transmission
Transmission ECU Replacement

6. Connect the blue, black, and gray electrical har-

nesses to the appropriate ports on the ECU.
7. Remove the chocks from the tires.

120/2 Business Class M2 Workshop Manual, Supplement 10, September 2006

Transmission Shift Control, Freightliner SmartShift 26.02
General Information

General Information 5 6 7
The SmartShift™ transmission shift control is an elec- 4 8
3
tronic transmission control device. It is applicable to
automated mechanical transmissions and is required
with the Mercedes-Benz AGS Automated Gear Shift
transmission, and the Eaton® Fuller® UltraShift™ 9
transmission. It replaces either the typical floor- 1
mounted shift lever or dash-mounted pushbutton 2
10
control. 11
12
The SmartShift control mounts to the right-hand side 01/24/2003 f270120
of the steering column and is operated by the driver’s
To upshift manually, pull the control up (towards you). To
right hand. There are two versions of the control: downshift manually, push the control down (away from
• See Fig. 1 for the AGS control. you).
1. SmartShift Control
5 2. Slide Switch (forward driving mode switch)
6 3. MAN Position (of slide switch)
7
4 4. AUTO Position (of slide switch)
3 8 5. Upshift Direction
6. Reverse Position (of selector switch)
7. Selector Switch
8. Neutral Lock Button
9 9. Neutral Position (of selector switch)
1 10. Drive Position (of selector switch)
2 11. Low Position (of selector switch)
10
12. Downshift Direction
11
11/11/2002 f270080 Fig. 2, SmartShift Control (for UltraShift transmission)
To upshift manually, pull the control up (towards you). To space is increased and access to the sleeper is im-
downshift manually, push the control down (away from proved by removing the shift lever from the floor. Be-
you). cause of the steering column mounting, the transmis-
1. SmartShift Control sion control is within fingertip reach of the steering
2. Slide Switch (forward driving mode switch) wheel, which enhances safety.
3. MAN Position (of slide switch)
4. AUTO Position (of slide switch) In automatic drive mode, forward drive gears are
5. Upshift Direction shifted automatically, without driver interaction. On
6. Reverse Position (of selector switch) SmartShift, a slide switch allows the driver to choose
7. Selector Switch between automatic and manual forward driving
8. Neutral Lock Button modes. In manual mode the driver has direct control
9. Neutral Position (of selector switch)
10. Drive Position (of selector switch)
over gear shifts.
11. Downshift Direction Manual gear shifts are accomplished by a momen-
tary pull or push on the control in the plane perpen-
Fig. 1, SmartShift Control (for AGS transmission)
dicular to the steering wheel. See Fig. 3. All shifts
• See Fig. 2 for the UltraShift control. into reverse (R) are done manually.
SmartShift accepts driver requests for transmission Pull upward (toward you) on the control to upshift
functions and transmits them through hard wiring to and push downward (away from you) to downshift.
the transmission control unit (TCU). SmartShift is a The control is spring-loaded and returns to mid-
true shift-by-wire system. position when released after an upshift or downshift.
SmartShift offers two main advantages over conven- The selector switch is located at the end of the con-
tional transmission control devices. Usable cab trol. There are two different versions:

Business Class M2 Workshop Manual, Supplement 6, September 2004 050/1

26.02 Transmission Shift Control, Freightliner SmartShift
General Information

2
1

3
4

01/29/2003 f270121
1. Upshift (in manual mode, pull upward)
2. Steering Wheel
3. Downshift (in manual mode, push downward)
4. Steering Column

Fig. 3, SmartShift Control Operation

• For AGS, the selector switch has three posi-
tions (R, N, D). See Fig. 1.
• For UltraShift, the selector switch has four po-
sitions (R, N, D, L). See Fig. 2.
Embedded in the selector switch is a small neutral
lock button to prevent accidental shifts into gear from
neutral (N). Any time you shift through N, press the
neutral lock button to move the switch from N to an-
other gear, such as drive (D), low (L), or reverse (R).
When shifting to N, it is not necessary to press the
neutral lock button.

050/2 Business Class M2 Workshop Manual, Supplement 6, September 2004

Transmission Shift Control, Freightliner SmartShift 26.02
Replacement

Replacement
1. Shut down the engine, set the parking brakes,
and chock the rear tires.
2. Remove the steering column covers. For detailed
procedures, see Section 46.02, Subject 110.
3. Disconnect the electrical connector from the
SmartShift module.
4. Remove the three mounting capscrews and
washers that attach the bracket assembly to the
steering column. See Fig. 1.

3
1

5
2

04/21/2004 f261319
1. Mounting 3. SmartShift Lever
Capscrew(s) 4. Bracket Assembly
2. Washer(s) 5. Steering Column

Fig. 1, SmartShift Lever Replacement

5. Remove the bracket assembly from the vehicle
with the SmartShift lever attached.
6. Position the new bracket assembly on the steer-
ing column. Install the mounting capscrews and
washers. Tighten the capscrews 80 lbf·in (900
N·cm).
7. Connect the electrical connector to the Smart-
Shift module.
8. Install the steering column covers, as removed.
9. Remove the chocks from the rear tires.

Business Class M2 Workshop Manual, Supplement 6, September 2004 100/1

Transmission Shift Control, Freightliner SmartShift 26.02
Troubleshooting

General Information 5 6
The following information is provided to help deter- 3 4 7
mine whether a potential transmission problem is ac-
tually the transmission or possibly the Freightliner
SmartShift® Transmission Shift Control.
8
Resistance checks at the SmartShift connector can 1
help determine connection problems. 2 9
DataLink Software can be used to test the SmartShift 10
11
control. The tests require a ServiceLink computer 11/23/99 f270082
connected to the vehicle. If the tests confirm the shift 1. SmartShift Control
control is defective, this subject also includes con- 2. Slide Switch (forward driving mode switch)
nector resistance checks to rule out wiring issues. 3. MAN Position (on slide switch)
4. AUTO Position (on slide switch)
For transmissions other than Mercedes-Benz Auto- 5. Upshift Direction
mated Gear Shift (AGS), follow the procedures below 6. Reverse Position (on selector switch)
for resistance checking and Freightliner SmartShift 7. Selector Switch
testing using DataLink Monitor and dash displays. 8. Neutral Position (on selector switch)
For AGS transmissions, see Section 26.03, Sub- 9. Drive Position (on selector switch)
ject 302. 10. Low Position (on selector switch)
11. Downshift Direction
To determine which transmission is installed on the
vehicle, check the shift pattern decal on the dash or Fig. 1, SmartShift Control (with Eaton Fuller AutoShift)
visor.
NOTE: SmartShift controls designed for one 2 3
transmission model should not be used with
4
other models of transmission.
SHIFT
UP
For Eaton Fuller AutoShift, the four-position selector PULL

switch is marked "R-N-D-L". A slide switch is present. Smart

Shift
See Fig. 1.
PUSH 5
For ZF Meritor SureShift, the three-position selector 1 SHIFT
DOWN

switch is marked "R-N-F" (older models) or "R-N-D" 6

(newer models). In addition, there is no slide switch. 7
See Fig. 2.
11/23/99 f270081
For ZF Meritor FreedomLine and Mercedes-Benz NOTE: Newer SureShift models have a "D" (for drive) in
AGS, the three-position selector switch is marked place of the "F" (for forward).
"R-N-D". A slide switch is present. See Fig. 3. 1. SmartShift Control
2. Upshift Direction
3. Reverse Position (on selector switch)
4. Selector Switch
5. Neutral Position (on selector switch)
6. Forward Position (on selector switch)
7. Downshift Direction

Fig. 2, SmartShift Control (with ZF Meritor SureShift)

Business Class M2 Workshop Manual, Supplement 11, March 2007 300/1

26.02 Transmission Shift Control, Freightliner SmartShift
Troubleshooting

5
2. Remove the screws that secure the steering col-
6 umn trim panels, and separate the forward and
7
4 rear panels to access the shift control. See
3 8 Fig. 4.
3. Disconnect the electrical connector from the plug
on the shift control unit. See Fig. 5.
9
1
2
10

11
11/11/2002 f270080 2
1. SmartShift Control
2. Slide Switch (forward driving mode switch)
3. MAN Position (on slide switch)
4. AUTO Position (on slide switch)
5. Upshift Direction
6. Reverse Position (on selector switch)
7. Selector Switch
8. Neutral Lock Button
9. Neutral Position (on selector switch)
10. Drive Position (on selector switch)
11. Downshift Direction

Fig. 3, SmartShift Control (with ZF Meritor 1

FreedomLine and Mercedes-Benz AGS)

Shift Control Resistance

Checking 07/23/99 f270067
1. Steering Column Panel Capscrews
Parts 2. Shift Control

Fig. 4, Steering Column Panel

Parts for Wire Extension*
4. Assemble the wire extension from the parts in
Part Number Description Qty.
Table 1 to allow for easy resistance testing, as
PAC12110847 Metri-Pack Terminal 3 follows.
PAC12047767 Connector Terminal 3 4.1 Crimp the connector terminals at the end
48-02493-184 18GA GTX Wire, Yellow 3 ft x 3 of each 3-foot (1-meter) wire.
PAC12047781 3-Pin Connector 1 4.2 Assemble the 3-pin connector with the
PAC12047783 Connector Lock 1 connector terminals and connector lock.
* Parts are available through the PDCs.
4.3 Crimp the Metri-Pack terminals on the
Table 1, Parts for Wire Extension other end of the wires.
5. Plug the wire extension into the plug on the shift
Procedure control unit. See Fig. 6 for SmartShift terminal
positions.
1. Shut down the engine, apply the parking brake,
and chock the tires.
NOTE: Using this new wire extension prevents
the need to remove the shift control.

300/2 Business Class M2 Workshop Manual, Supplement 11, March 2007

Transmission Shift Control, Freightliner SmartShift 26.02
Troubleshooting

Resistance on SmartShift Controls at B and C

(Except Meritor SureShift)
1
Selector Switch Position Reading: kOhm
R 2.947–3.067
N 0.347–0.361
D 0.606–0.630
L* 1.65–1.72
* Applies to four-position (R-N-D-L) controls only.

2 Table 2, Resistance on SmartShift Controls at B and

C (Except Meritor SureShift)

3
Resistance on SmartShift Controls at A and C
(Except Meritor SureShift)
01/24/2007 f261387 Slide Switch + Lever
Reading: kOhm
Position
1. Shift Control
2. Steering Wheel Manual 2.865–2.981
3. Electrical Connector Manual + Up 0.531–0.553

Fig. 5, SmartShift Components Manual + Down 1.150–1.197

Auto 11.27–11.73
Table 3, Resistance on SmartShift Controls at A and
C (Except Meritor SureShift)

Resistance on the SmartShift Control, Meritor

SureShift
Selector Switch + Lever
Reading: kOhm
Position
R 10.2–10.6
C N 1.65–1.71
B
A F or D 2.65–2.75
11/08/2005 f261085a R + Up 4.14–4.3
R + Down 6.07–6.31
Fig. 6, SmartShift Terminal Positions
Table 4, Resistance on SmartShift Controls at A and
6. Check the resistance at the other end of the C (Meritor SureShift)
wires. See Fig. 7.
Use Table 2 and Table 3 for all SmartShift appli- 7. After checking the resistance, unplug the wire
cations except Meritor SureShift. extension, and reconnect the electrical connec-
tor.
Use Table 4 for Meritor SureShift applications.
8. Install the steering column trim panels.
9. Remove the chocks from the tires.

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26.02 Transmission Shift Control, Freightliner SmartShift
Troubleshooting

SureShift™, click on SmartShift with Meritor

SureShift.
NOTE: The DLM template for the SureShift
transmission will not work with the ZF Meritor
FreedomLine transmission. For further diagnos-
tic assistance on FreedomLine transmissions,
1 use Meritor’s TransSoft software.
6. Go directly to the appropriate heading in this
A subject, "SmartShift Control Testing for Eaton
AutoShift" or "SmartShift Control Testing for ZF
Meritor SureShift and FreedomLine".

2
SmartShift Control Testing for
Eaton AutoShift
The AutoShift DataLink Monitor template (see Fig. 8)
will display the current vehicle status and will reflect
change in status. Vehicle information is retrieved
from the transmission ECU on the datalink. The
monitor can also be used to verify readings on the
instrument panel.
3 To test the shift control using the datalink, the
vehicle can be placed into a mode that allows
the gears to be shifted without the engine run-
05/16/2002 f270075 ning. The following step explains how to enter
A. Plug the newly assembled wire extension into the that mode.
plug on the shift control unit.
1. Turn the ignition OFF, then turn the ignition back
1. Shift Control Unit ON, but don’t start the engine. The transmission
2. Digital Multimeter (set to ohms) controller will still be in the Engine ON mode,
3. Metri-Pack Terminals (at wire ends) thereby allowing the gears to be shifted.
Fig. 7, Resistance Checking at Shift Control 2. Test the operation of the shift control for Reverse
(R) and Neutral (N), as follows.
SmartShift Control Checking 2.1 Select R on the selector switch. In the
Using DataLink Monitor (DLM) Range Selected field of the template an R
should be displayed.
1. With the wheels chocked, start the engine. 2.2 Select N on the selector switch. In the
2. Connect the service computer to the engine and Range Selected field of the template an N
start ServiceLink. should be displayed.
3. Click on the Transmission icon on the left 3. Test the operation of the shift control for Drive
screen. (D), as follows.
4. Click on the Templates tab. An overview of 3.1 Select D on the selector switch and turn
available templates will be shown. the slide switch (reading "Automatic/
Manual") to Automatic. In the Range Se-
5. If the vehicle is equipped with Eaton® Fuller® Au- lected field of the template, a D should be
toShift™, click on SmartShift with Eaton Auto- displayed.
Shift. If the vehicle is equipped with ZF Meritor™

300/4 Business Class M2 Workshop Manual, Supplement 11, March 2007

Transmission Shift Control, Freightliner SmartShift 26.02
Troubleshooting

DataLink Monitor

ECU Range Gear Battery Voltage

Software Selected Attained
Version: (Lever): (Trans.):

Gear Actuator Up−Shift Req. Ign. Switch

Shaft Speeds [rpm] Switched Batt. (Ign.)

Input Main Output
OFF OFF

3000
Rail Actuator Down−Shift Req. Ign. Interrupted

2500
OFF OFF
2000
Shift Finger Rail Position Shift Finger Gear Position
1500
0 0
0 25 50 75 100 0 25 50 75 100
1000

500
FAULTS
0 MID PID/SID FMI SID ? STATUS OCC CNT
0 0 0

Version 1.1, January 2000

02/19/2001 f610457

Fig. 8, DataLink Monitor Template for Eaton Fuller AutoShift

3.2 With the selector switch still on D, toggle 4.2 Push and hold the shift control lever. The
the slide switch from Automatic to Manual Down-Shift Req. field will turn green and
and back. Confirm that the Range Se- read ON for 3 seconds.
lected field shows a D while in Automatic
NOTE: A blinking display indicates that the
and an H (High) while in Manual.
transmission is attempting to shift into the gear
3.3 While in Manual mode, change the selec- position. A solid display shows the current gear
tor switch to L (Low) and confirm that the position attained.
Range Selected field changes from H to L.
5. When the selector switch is in any position but N
4. Test upshifting and downshifting, as follows. (Neutral), the Ign. Interrupt field on the Monitor
4.1 With the selector switch on D, pull and template will read YES.
hold the shift control lever. The Up-Shift
Req. field will turn green and read ON for
3 seconds.

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26.02 Transmission Shift Control, Freightliner SmartShift
Troubleshooting

SmartShift Control Testing for ZF NOTE: The DLM template for the SureShift
transmission will not work with the FreedomLine
Meritor SureShift and transmission. For further diagnostic assistance
FreedomLine on FreedomLine transmissions, use Meritor’s
TransSoft software.
The SmartShift control test for a ZF Meritor SureShift
system can be performed by using the dash-mounted
gear display. The SureShift DataLink Monitor (DLM) WARNING
template can be used if further testing of the system
For SureShift transmissions, do not depress the
is necessary, for example, to confirm dash display
clutch pedal during these tests. Doing so could
readings or gear positions. See Fig. 9.
result in the vehicle moving, possibly causing
vehicle damage or personal injury.

DataLink Monitor

Model Range Gear Position

100

s/n Low
75

Trans Shaft Speeds [rpm] Gear Selected 50

Input Output Software
3000 25
2500 Gear Attained
0
2000 0
1500
Rail Position
1000
500 0
0 0 25 50 75 100
0 0

FAULTS Trans ECU Voltage

MID PID/SID FMI SID ? STATUS OCC CNT

Version 1.2, February 2001

01/11/2001 f610466

Fig. 9, DataLink Monitor Template for ZF Meritor SureShift

300/6 Business Class M2 Workshop Manual, Supplement 11, March 2007

Transmission Shift Control, Freightliner SmartShift 26.02
Troubleshooting

Make sure all tires are chocked and the parking

brake is set before performing the following
tests. These tests require the vehicle to be
started, and precautions need to be taken to en-
sure the vehicle will not move.
1. Test the operation of the shift control for Reverse
(R) and Neutral (N), as follows.
1.1 Move the selector switch to R. Confirm
that the display is changing from N to RL
(Reverse Low), the default reverse gear.
The display will change to CL (Clutch)
after one second. Repeat this step if the
reading disappeared quickly.
1.2 Pull the shift control lever once to upshift
to High Reverse. Confirm the display
changes to RH (Reverse High).
2. Test the operation of the shift control for F or D,
as follows.
2.1 Move the selector switch to F (Forward) or
Drive (D).
2.2 Test upshifting and downshifting. Push,
then pull, the shift control lever through all
the gears and verify that each gear dis-
plays correctly on the dash display.
If the display or the DLM template does not confirm
the SmartShift control position, the shift control
should be tested. See the shift control resistance
checking procedure herein.

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
General Information

General Information rear of the hydraulic body are a hydraulic pump and
an electric motor.
Mercedes-Benz AGS Automated Gear Shift transmis- The TCU is the electronic center of the AGS. It con-
sions are fully automated manual transmissions that trols gear changes and monitors the positions of the
were installed on M2 vehicles for years. In 2010, the clutch and the shift mechanism. It receives requests
name changed to Freightliner AMT3™ Automated- from the shift lever to change drive modes and
Manual Transmission, and new model numbers were gears. It broadcasts error messages to the J1587
applied. See Table 1 for model numbers. databus. It communicates to the engine, antilock
brakes, and bulkhead module over the J1939 net-
NOTE: In this workshop manual, the term "AGS work.
transmission" refers collectively to the transmis-
sion models in Table 1, and the information in The hydraulic body distributes hydraulic fluid to the
this section applies equally to those models. clutch, x-y actuator, and accumulator. The hydraulic
pump is driven by an electric motor with its own con-
An AGS transmission gear case holds 9.5 quarts (9.0 nection to the power distribution module, protected
liters) of oil. MobilTrans SHC® DC is the approved by a 40-amp fuse.
oil.
The hydraulic pump comes on automatically when
No clutch pedal is needed to change gears. The the ignition is turned on, producing a distinctive hum-
clutch is activated by a hydraulic system that also ming noise that is a characteristic of this transmis-
controls the shifting mechanism. After any service, sion. When the noise stops, the hydraulic system is
the clutch must be recalibrated. pressurized.
The hydraulic system is a self-contained AGS unit The hydraulic reservoir holds about 1.05 quarts (one
that attaches to the left-hand side of the gear case. liter) of hydraulic fluid. The only fluid used in this sys-
See Fig. 1. tem is Pentosin. No other fluid can be substituted.
The AGS unit has four major components: Both high-pressure and low-pressure hydraulic fit-
• The x-y actuator, which controls the move- tings are not threaded. They can be removed by
ments of the shift mechanism pressing a brass ring against a soft O-ring and
thereby compressing it enough to break the seal and
• The reservoir, which holds the supply of hy- open the line. See Fig. 2 for the line removal tools.
draulic fluid
Certain fasteners used on this transmission contain
• The pressure accumulator, which maintains a small amounts of chemical in micro-capsules embed-
maximum hydraulic pressure of 1230 psi (8500 ded in the thread. This chemical has sealant and/or
kPa) thread-locking properties. These fasteners must be
• The central unit, which controls both electrical replaced at every service for the micro-encapsulated
and hydraulic inputs chemical to keep its properties.
The central unit of the AGS contains the transmission IMPORTANT: Do not use Loctite® or sealant on
control unit (TCU) and the hydraulic body. On the these fasteners.

Transmission Model Numbers

Mercedes-Benz AGS Freightliner AMT3 Engine Rating Drive
MBT520-6DA AMT3-520-6DA 520 lbf·ft Direct Drive
MBT660-6OA AMT3-660-6OA 660 lbf·ft Overdrive
Table 1, Transmission Model Numbers

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
General Information

Principles of Operation
A shift can be requested either manually, by pushing
or pulling the SmartShift lever, or automatically. The
AGS judges when to shift automatically through infor-
mation provided by rotational speed (rpm) sensors.
One sensor reads input shaft speed (this sensor is
located aft of the central unit, on the countershaft).
Two rear sensors read output shaft speed and direc-
tion of rotation.
When a shift is requested, hydraulic pressure disen-
gages the clutch. A position sensor attached to the
clutch release bearing housing ensures smooth dis-
engagement and engagement.
The x-y actuator moves the shift rod in two dimen-
sions (this is why it is called x-y actuation). With the
clutch disengaged, the actuator uses hydraulic pres-
sure to move the shift rod until it is over the correct
shift rail. Then it turns the shift rod a precise amount
so that the shift finger can engage the shift rail for
the correct gear. Two shift position sensors, a gear
position sensor and a rail position sensor, assure
correct positioning of the shift rod and the shift rail.
From this point on, the mechanism operates in ex-
actly the same way as in any other Mercedes-Benz
manual transmission. The notch in the shift rail con-
tacts the shift fork, which moves the synchro slide
onto the correct gear wheel.

050/2 Business Class M2 Workshop Manual, Supplement 20, September 2011

Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
General Information

1
2

4
03/17/2004 f270125
1. X-Y Actuator
2. Reservoir
3. Accumulator
4. Central Unit

Fig. 1, AGS Unit Components

06/02/2004 f580377
NOTE: The tool with the large opening (top) is used to
disconnect the low-pressure hoses. The tool with the
small opening (bottom) is used to disconnect the high-
pressure lines.
Fig. 2, Hydraulic Fitting Disconnect Tools

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
Transmission Removal and Installation

Removal mounting bolts from the bell housing except for

the top two. See Fig. 3.
1. Park the vehicle on a level surface. Shut down 7. Remove the two screws attaching the splash
the engine, set the parking brake, and chock the guard to the TCU. See Fig. 4.
rear tires. 8. Remove the main vehicle harness (X1 connec-
IMPORTANT: To prevent loss of hydraulic fluid, tor) and electric motor harness (X3 connector).
depressurize the hydraulic system before re- Remove tie straps as necessary. See Fig. 5.
moving the transmission. 9. Support the transmission with a jack. See Fig. 6.
2. Depressurize the hydraulic system. For detailed 9.1 Position a transmission jack under the
procedures, see Subject 160. transmission and raise its support plates
3. Disconnect the batteries. against the base of the transmission.
4. Disconnect the driveshaft from the transmission. 9.2 Adjust the support plates to cradle the
See Fig. 1. transmission.
9.3 Using a chain, secure the transmission to
3
the jack.
10. Remove the top two transmission mounting bolts
attaching the timing case to the bell housing.

CAUTION
4
Do not allow the rear of the transmission to drop,
and do not allow the transmission to hang un-
supported. Keep the flange of the bell housing
parallel (all the way around) to the flange of the
2 timing case, until the input shaft is clear of the
flywheel. Taking these precautions will prevent
damage to the input shaft, flywheel, and clutch.
1 5
01/29/2004 f410504 11. Remove the transmission. See Fig. 7.
1. U-Joint 4. Drive Shaft
2. Midship Bracket 5. Jack 11.1 Pull the transmission and jack straight
3. Midship Bearing back until the transmission input shaft is
clear of the engine.
Fig. 1, Midship Bearing 11.2 If necessary, lower the jack supporting the
4.1 Support the driveline with a jack under- transmission. It might also be necessary
neath the aft midship bearing. to jack up the truck to get enough clear-
ance to allow the transmission to pass.
4.2 Remove the bolts from the aft midship
bearing bracket. IMPORTANT: Watch closely the clearance
between the bell housing and the frame rail.
4.3 Remove the forward midship bracket.
11.3 Pull the transmission out through the
4.4 Remove the transmission yoke U-joint space behind the cab.
from the transmission.
4.5 Support the disconnected driveshaft. Installation
5. Remove the cab floor plate and cover plate. See
Fig. 2. IMPORTANT: Before installing the transmission,
6. Remove all brackets attached to the transmission
make sure that the rear tires are chocked and
mounting bolts. Remove all the transmission

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
Transmission Removal and Installation

5
3
4

2
6
1

01/30/2004 f261297

1. Cover Plate 4. Washer 6. Cab Floor

2. Mounting Bolt, Cover Plate 5. Floor Plate 7. Spring Clip
3. Mounting Bolt, Floor Plate

Fig. 2, Floor Access

1 1
2
2

3
3
4 3

4
06/02/2004 f270129
02/09/2004 f544401
1. TCU Mounting Bolt
1. Bell Housing 2. TCU
2. Transmission Mounting Bolt 3. Splash Guard
3. Battery Clamp 4. Splash Guard Mounting Bolt
4. Battery Cables
Fig. 4, TCU Splash Guard
Fig. 3, Battery Cable Brackets

100/2 Business Class M2 Workshop Manual, Supplement 20, September 2011

Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
Transmission Removal and Installation

1
2
2

02/17/2004 f544407
1. X3 Connector
2. Electric Motor Harness
3
Fig. 5, Harness Connector

that the transmission is securely chained to the

support plates on the transmission jack.
1. Align the input shaft so that its splines engage
the clutch. 02/12/2004 f261299
1. Chain 3. Jack
1.1 Align the jack and the transmission behind 2. Transmission
the engine.
1.2 Raise the transmission and adjust the Fig. 6, Supporting the Transmission
angle of the jack until the bell housing and
2.1 Install the M10 transmission mounting
the timing case flange are parallel.
bolts holding the bell housing to the timing
1.3 Push the transmission and jack straight case. Use a crossover pattern.
forward.
2.2 While installing the transmission mounting
NOTE: The AGS transmission automatically bolts, also install the all the bracket(s) on
selects neutral when shut off. To make sure the bell housing, as removed.
the clutch and input shaft are properly 2.3 Remove the chain securing the transmis-
aligned, this substep requires two persons. sion to the jack; then remove the jack.
1.4 While one person continues to push the 2.4 Do a final tightening of the mounting bolts
transmission forward, the other person to 33 lbf·ft (45 N·m).
uses channel locks or other locking pliers
to grip the input shaft and twist it slightly. 3. Connect the X1 and X3 electrical connectors. Be
sure the yellow safety slide on the X1 connector
1.5 When the input shaft and the clutch are snaps into place.
aligned, work the transmission further to-
wards the engine and line up the bolt 4. Install the cab floor plate and cover plate. See
Fig. 2.
holes in the flywheel housing with those in
the bell housing. 5. Connect the driveshaft.
2. Install the transmission.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
Transmission Removal and Installation

03/17/2004 f261318

Fill the reservoir to the level indicated by the arrow.

Fig. 8, Hydraulic Fluid Fill Level

edge of the fill opening. See Fig. 9 for the loca-

tion of the fill plug and Fig. 10 for the correct
level. See Group 26 of the Business Class® M2
Maintenance Manual for approved transmission
lubricants and lubricant capacities.

01/29/99 f261013

Fig. 7, Remove the Transmission

5.1 Slide the front of the driveshaft into the

transmission output yoke.
5.2 Install the U-joint end caps on the output
yoke. Tighten the bolt heads 50 lbf·ft (68
N·m) for 3/8-inch end cap bolts and 110
lbf·ft (149 N·m) for 1/2-inch end cap bolts.
5.3 Install the bolts and nuts on the midship
bearing brackets. Tighten the nuts 91 lbf·ft
(123 N·m).
6. Check the hydraulic fluid level and add more 06/02/2004 f261323
Pentosin if needed. See Fig. 8. For detailed pro- The fill plug is located on the left-hand side of the rear
cedures, see Subject 150. gear case, just behind the accumulator.
IMPORTANT: Use only Pentosin in the hydraulic Fig. 9, Fill Plug
reservoir. No other fluid can be substituted.
10. Clean the transmission fill plug and install it on
7. Connect the batteries. the transmission, along with a new aluminum
8. Bleed the hydraulic system and recalibrate the gasket. Tighten the fill plug 42 lbf·ft (57 N·m).
transmission according to the procedures in Sub- 11. Remove the chocks from the rear tires.
ject 130.
9. Check the transmission fluid level. If low, add
transmission fluid until it is level with the lower

100/4 Business Class M2 Workshop Manual, Supplement 20, September 2011

Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
Transmission Removal and Installation

10/05/94 A B f260006b

A. Full B. Low

Fig. 10, Transmission Fluid Level Checking

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
AGS Transmission Control Unit Replacement

IMPORTANT: To successfully replace the trans- 5

mission control unit (TCU) on the vehicle, there
must be at least 2-3/4 inches (70 mm) clear-
ance between the TCU and the frame rail.

Replacement
1. Park the vehicle on a level surface. Shut down
the engine, set the parking brake, and chock the
rear tires.
2. Disconnect the batteries. 4
3. Before starting the replacement procedure, clean
all screws and fittings by spraying with a light 1 2 2
penetrating oil. 02/11/2004 3 f544402

4. Remove the two mounting capscrews attaching Remove the eight Torx screws (arrows) attaching the
TCU to the hydraulic body.
the splash guard to the TCU. See Fig. 1.
1. X1 (main vehicle) Connector
2. Safety Slide
3. X2 (transmission) Connector
4. X3 (electric motor) Connector
2 5. Tie Strap
1
Fig. 2, TCU

IMPORTANT: When cutting tie straps at the top

of the TCU, use extreme care. Do not cut the
3 wires in the electrical harness.
6. Remove the eight Torx® screws attaching the
TCU to the hydraulic body. Pull the TCU straight
4 back until all the internal connections are disen-
gaged.
4 NOTE: Expect some resistance as the internal
5 connections disengage.
6
7. Install the new TCU on the hydraulic body. See
7 Fig. 3.
06/02/2004 f544406
1. TCU 4. Cable Clamp 7.1 Align the new seal ring in the groove pro-
2. Front Hanger 5. Clamp Mounting Bolt vided in the inside of the new TCU.
Bracket 6. Battery Cable
3. Cable Bracket 7. Splash Guard
7.2 Coat the seal ring with enough bearing
grease to ensure that the seal ring will not
Fig. 1, Area of TCU
fall out of its groove during installation.
7.3 Make sure all spade connectors are
5. Disconnect the X1 (main vehicle), X2 (transmis- straight.
sion), and X3 (electric motor) electrical connec-
tors from the base and aft side of the TCU. See 7.4 Square up the TCU on the hydraulic body
Fig. 2. Remove tie straps and clamps as using the guide pins on the inside of the
needed. TCU. This will ensure that the internal
connectors line up properly.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
AGS Transmission Control Unit Replacement

1
2

03/03/2004 f544403

When installing the new TCU, be sure to align the guide

pins (arrows).
1. TCU 2. Seal Ring

Fig. 3, TCU Seal Ring

7.5 Check that the seal ring does not get

pinched along the line where the TCU
meets the hydraulic body.
NOTE: Make sure the TCU is seated firmly
on the hydraulic body before installing the
mounting screws. Do not use the screws to
pull the TCU into position.
7.6 Install the mounting screws and tighten
them 44 to 53 lbf·in (500 to 600 N·cm).
8. Attach the electrical connectors. Be sure the yel-
low slide on the X1 and X2 connector snaps into
place. See Fig. 2.
9. Replace tie straps and cable clamps as needed.
10. Install the splash guard. Tighten the mounting
capscrews 17 lbf·ft (23 N·m). See Fig. 1.
11. Recalibrate the transmission according to the
procedures in Subject 130.
12. Remove the chocks from the rear tires.

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AGS Transmission Sensor Replacement

Replacement Shift Position Sensors

The shift position sensors, shown in Fig. 2, are inte-
IMPORTANT: Depressurize the hydraulic system gral to the x-y actuator and cannot be replaced with-
before replacing any of the hydraulic out replacing the x-y actuator. Replacement of the
components—such as the Clutch Position Sen- x-y actuator requires removing the transmission from
sor, Gear Position Sensor, Rail Position Sensor, the vehicle. For detailed procedures, see Sub-
and Fluid Level Sensor. ject 170.
For detailed hydraulic system depressurization proce-
dures, see Subject 160. For a diagram of transmis- Fluid Level Sensor
sion sensors, see Fig. 1.
1. Clean around the area of the reservoir cap. Take
care not to introduce dirt into the reservoir.
Clutch Position Sensor
2. If not already done, depressurize the hydraulic
The clutch position sensor is integral to the clutch system. For detailed procedures, see Sub-
actuator and cannot be replaced without replacing ject 160.
the clutch actuator. For detailed procedures, see
Subject 210.

1 7

02/10/2004 f261298
1. Clutch Position Sensor 4. Fluid Level Sensor 6. Output Shaft Speed Sensor #2
2. Gear Position Sensor 5. Output Shaft Speed Sensor #1 7. Input Shaft Speed Sensor
3. Rail Position Sensor

Fig. 1, Transmission Sensors

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
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AGS Transmission Sensor Replacement

5. Insert a new cap with probe into the hydraulic

reservoir.
1 6. Attach the electrical connector to the new cap
and make sure the new cap is tightly fastened.

2 Speed Sensors
1. Park the vehicle on a level surface. Shut down
the engine, set the parking brake, and chock the
rear tires.
2. Unscrew the electrical connector from the sen-
sor. See Fig. 4 for the input shaft speed sensor
and Fig. 5 for the two output shaft speed sen-
f544410
sors.
02/17/2004
1. Gear Position Sensor
2. Rail Position Sensor 1

Fig. 2, Shift Position Sensors

3. Remove the electrical connector from the reser-

voir cap. See Fig. 3.

02/17/2004 f544409
2 3 1. Input Shaft Speed Sensor
2. Accumulator

Fig. 4, Input Shaft Speed Sensor

10/20/2003 f261291 3. Using a wrench, remove the sensor from the rear
1. Reservoir 3. Connector gear case.
2. Cap 4. Install a new sensor on the rear gear case.
Tighten the sensor 28 lbf·ft (38 N·m).
Fig. 3, Fluid Level Sensor
5. Install the electrical connector on the end of the
3.1 Insert a small screwdriver into the opening sensor.
at the top of the connector.
6. Remove the chocks from the rear tires.
3.2 Pull back (aft) on the clip until it releases.
A click can be heard when it releases.
3.3 Remove the connector from the plug on
the reservoir cap.
4. Unscrew the reservoir cap and remove the cap
and probe from the hydraulic reservoir.

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AGS Transmission Sensor Replacement

4
2

02/19/2004 f261308
1. Output Shaft Speed Sensor #2
2. Connector, Sensor #2
3. Connector, Sensor #1
4. Output Shaft Speed Sensor #1

Fig. 5, Output Shaft Speed Sensors

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
AGS Transmission Bleeding and Recalibration

Bleeding NOTE: As the hydraulic pump builds pres-

sure, you may hear it humming.
IMPORTANT: Bleed the hydraulic system after 2.1 Turn on the ignition, and wait one minute.
any repair. Then turn off the ignition, and wait one
1. Shut down the engine, set the parking brake, minute. Verify that the current gear indica-
and chock the rear tires. tor is blank.

NOTE: To gain access to the reservoir cap, it 2.2 Again, turn on the ignition, and wait one
may be more convenient to open the floor ac- minute. Then turn off the ignition, and wait
one minute. Verify that the current gear
cess plate. See Subject 100 for procedures. indicator is blank.
2. Clean around the area of the bleed screw and
3. Verify that the current gear indicator is blank. Set
the reservoir cap. Keep the reservoir cap clean
the selector switch on the SmartShift control to
and take care not to introduce dirt into the reser-
"N" (neutral). See Fig. 1.
voir.
3. With the hydraulic system depressurized (for de- 1
tailed procedures, see Subject 160), remove the
plastic cap from the bleed screw. Insert a clear
hose onto the bleed valve on the bell housing.
2
Remove the reservoir cap and place the other
end of the hose inside the hydraulic reservoir.
IMPORTANT: Do not start the engine.
4. Turn on the ignition switch and put the transmis-
sion into 1st gear.
5. Slowly open the bleed screw. Allow the hydraulic
fluid to circulate until no air bubbles are visible
and the fluid is clear.
6. Tighten the bleed screw 13 lbf·ft (17 N·m).
7. Remove the bleed hose and install the reservoir
10/13/2003 f270079
cap.
Make sure the current gear indicator is blank and the
8. Install the plastic cap on the bleed screw. selector switch is set to "N".
9. Recalibrate the transmission using the procedure 1. Current Gear Indicator
under the heading "Recalibration" in this subject. 2. SmartShift Control

10. Check the hydraulic fluid level and add more Fig. 1, Ready to Recalibrate
Pentosin as needed. See Subject 150 for proce-
dures. NOTE: For the recalibration procedure to suc-
ceed, the selector switch must remain in neutral
Recalibration until instructed differently later in this procedure.
4. With the selector switch in neutral, pull the
IMPORTANT: Use this procedure when a new SmartShift lever up (towards you) and hold it
transmission is installed, the TCU is replaced, there until instructed to release it later in this pro-
and to correct complaints of rough shifting. cedure.
1. Shut down the engine and set the parking brake. 5. While holding the SmartShift lever up, turn on
the ignition. When the letter "X" displays on the
2. Pressurize the hydraulic pump, as follows. current gear indicator, recalibration is in
progress. See Fig. 2. Do not start the engine at
this time.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
AGS Transmission Bleeding and Recalibration

displays "N", proceed to the next step. If it

flashes "SM-N", turn off the ignition, wait
two minutes or until the display clears, and
proceed to the next step.
• If the current gear indicator flashes "SM-X",
stop, and repeat the recalibration proce-
dure from the beginning.
8. If necessary, turn on the ignition and wait for the
letter "N" to display on the current gear indicator.
Now select "D" on the SmartShift control, and
wait for the numeral "1" to display on the current
gear indicator. Then select "R" and wait for "R" to
display on the current gear indicator.
02/24/2004 f610679a
IMPORTANT: If the current gear indicator dis-
Fig. 2, Recalibration In Progress plays "SM" or any other problem occurs, repeat
the recalibration procedure from the beginning.
NOTE: If the letter "X" does not appear, turn off
the ignition, wait one minute, and try again.
6. Wait for the letter "N" to display on the current
gear indicator and the audible alert to sound.
See Fig. 3. Start the engine within 10 seconds.

10/13/2003 f610679

Fig. 3, Neutral Display

7. The next time the alert sounds, release the

SmartShift lever and shut down the engine. Wait
two minutes, turn on the ignition, and do one of
the following:
• If the current gear indicator displays "N",
proceed to the next step.
• If the current gear indicator flashes "SM-
N", turn off the ignition and wait two min-
utes for the display to clear. Then turn on
the ignition. If the current gear indicator

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Accumulator Replacement

Special Tool
A special tool is required for this procedure. See
Table 1.

Special Tool for Accumulator Replacement

Tool Description Manufacturer Part Number

Accumulator Torque Adaptor Kent-Moore J-47291

f580381

Table 1, Special Tool for Accumulator Replacement

Replacement
4
1. Shut down the engine, set the parking brake and
chock the rear tires.
IMPORTANT: Depressurize the hydraulic system A
before replacing any hydraulic components.
2. Depressurize the hydraulic system. For detailed 2
procedures, see Subject 160.

WARNING 1

This system is under extremely high pressure.

Do not attempt to loosen the accumulator until
the system has been depressurized. Hydraulic
fluid could spray out at high speed, causing a 3
personal injury.
07/19/2004 f261326
3. Using a socket wrench and the accumulator
To obtain the correct torque, set the torque adaptor at a
torque adaptor (Table 1), loosen the M30 fitting 90-degree angle to the wrench.
on the accumulator.
A. 90-degree Angle
4. Remove the accumulator from the hydraulic body 1. Fitting, M30 4. Torque Wrench
of the AGS central unit. 2. Accumulator
5. Install the accumulator. See Fig. 1. 3. Accumulator Torque
Adaptor
5.1 Position the new accumulator on the
threaded hole and screw it onto the hy- Fig. 1, Install the Accumulator
draulic body.
IMPORTANT: If the torque adaptor is not set
5.2 Assemble the torque wrench and the ac-
at a 90-degree angle to the wrench, the M30
cumulator torque adaptor (Table 1) with
the torque adaptor set at a 90-degree fitting will not receive the correct torque.
angle to the wrench.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
Accumulator Replacement

5.3 Using the torque wrench and adaptor as-

sembly, tighten the M30 fitting 55 lbf·ft (75
N·m).
6. Check the hydraulic fluid level and add more
Pentosin if needed. For detailed procedures, see
Subject 150.
IMPORTANT: Use only Pentosin in the hydraulic
reservoir. No other fluid can be substituted.
7. Start the engine and allow the system to pressur-
ize. Shift back and forth a few times from drive to
reverse and back to neutral.
NOTE: The first few shifts after draining and re-
filling the hydraulic system will take longer than
usual.
8. Check the hydraulic system for leaks and repair
if necessary. When done, shut down the engine.
9. Remove the chocks from the rear tires.

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Hydraulic Fluid Reservoir Replacement

Special Tool
A special tool is required for this procedure. See
Table 1.

Special Tool for Hydraulic Fluid Reservoir Replacement

Tool Description Manufacturer Part Number

Low-Pressure Hose Disconnect Tool Kent-Moore J-47202

f580379a

Table 1, Special Tool for Hydraulic Fluid Reservoir Replacement

Replacement 3.1 Place a receptacle under the reservoir to

catch the drained fluid.
1. Shut down the engine, set the parking brake and 3.2 Pull out the spring clips that secure the
chock the rear tires. low-pressure hydraulic hoses to the fittings
IMPORTANT: Depressurize the hydraulic system at the base of the reservoir.
before replacing any hydraulic components. 3.3 Using the low-pressure hose disconnect
2. Depressurize the hydraulic system. For detailed tool (Table 1), remove the two low-
procedures, see Subject 160. pressure hydraulic hoses from the reser-
voir.
3. Drain the hydraulic fluid. See Fig. 1.
3.4 Allow the hoses to drain into the container
and cap them when fluid no longer drains
out.
4. Carefully remove the inverted-Torx® M8 fastener
at the base of the reservoir. Discard this fastener.
See Fig. 2.
2
1

3
1
4 2

3
02/18/2004 f261301
4
Install the spring clips in the slots provided in the base
of the reservoir. 02/24/2004 f261306
1. Low-Pressure Hose 3. Return Hose 1. Reservoir 3. Fastener, M8
2. Reservoir 4. Spring Clip 2. Lip of Gear Case 4. Hydraulic Fitting

Fig. 1, Hydraulic Hoses Fig. 2, Fastener, Reservoir Base

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
Hydraulic Fluid Reservoir Replacement

5. Remove the electrical connector from the reser- 7. Remove the reservoir from the transmission.
voir cap. See Fig. 3. 8. Position the new reservoir in the transmission.
Install the two M6 fasteners that fasten it to the
gear box and tighten them 71 lbf·in (800 N·cm).
1 9. Attach the electrical connector to the reservoir
cap. Tug lightly on the connector to make sure it
has snapped into place.
10. Install a new M8 fastener into the groove at the
base of the reservoir. See Fig. 2. Tighten the M8
fastener 11 lbf·ft (18 N·m).
2 3 IMPORTANT: Do not use Loctite® or sealant on
this fastener.
11. Install the low-pressure hydraulic hoses at the
base of the reservoir. See Fig. 1.
10/20/2003 f261291
11.1 Install the spring clips in the slots pro-
1. Reservoir 3. Fluid Level Sensor vided.
2. Reservoir Cap
11.2 Insert the two hydraulic hoses through the
Fig. 3, Reservoir Cap spring clips until they snap into place. Tug
lightly on the lines to make sure they are
5.1 Insert a small screwdriver into the opening securely fastened.
at the top of the connector.
NOTE: After depressurizing, wait five minutes
5.2 Pull back (aft) on the clip until it releases. before checking the hydraulic fluid level. This
A click can be heard when it releases. will allow any foam in the fluid to settle.
5.3 Remove the connector from the plug on 12. Check the hydraulic fluid level. Add Pentosin as
the reservoir cap. needed until the level reaches the joint between
6. Remove the two inverted-Torx M6 fasteners fas- the upper and lower sections of the reservoir.
tening the top of the reservoir to the transmission See Fig. 5.
gear box. See Fig. 4.

1
2

03/17/2004 f261318

Fill the reservoir to the level indicated by the arrow.

10/16/2003 f270127
Fig. 5, Hydraulic Fluid Fill Level
1. Fastener, M6 2. Reservoir
IMPORTANT: Use only Pentosin in the hydraulic
Fig. 4, Fasteners, Reservoir Top reservoir. No other fluid can be substituted.

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Hydraulic Fluid Reservoir Replacement

13. Start the engine and allow the system to pressur-

ize. Shift back and forth a few times from drive to
reverse and back to neutral.
NOTE: The first few shifts after draining and re-
filling the hydraulic system will take longer than
usual.
14. Check the hydraulic system for leaks and repair
if necessary. When done, shut down the engine.
15. Remove the chocks from the tires.

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
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AGS Hydraulic System Depressurization

IMPORTANT: Depressurize the hydraulic system

before removing the transmission or replacing
any hydraulic components.

Depressurization
Normal Procedure
1. Shut down the engine and set the parking brake.
2. Connect ServiceLink to the vehicle. Start the
"AGS Procedures" template and follow the in-
structions on the screen to depressurize the sys-
tem. See Fig. 1.
2.1 Press the "Start Communications" button.
2.2 Select "Start Diagnostic Mode."
2.3 Select the "Reduce Hyd Pressure" button
to depressurize the system.
3. Turn off the ignition switch. Wait for the system
to depressurize. When the system depressurizes,
the accumulator will dump its fluid into the reser-
voir, causing an obvious rise in the reservoir
level.
IMPORTANT: If the reservoir level fails to rise,
or any other problem prevents the system from
depressurizing, use the alternate procedure. Do
not use the alternate procedure unless the nor-
mal procedure fails.
4. Disconnect ServiceLink from the vehicle.

Alternate Procedure
NOTE: The pressure-limiting valve is designed
to be opened a limited number of times. Do not
use it routinely to depressurize the system.
1. Open the pressure-limiting valve embedded in
the forward side of the x-y actuator. Loosen the
M6 adjusting screw carefully one quarter-turn.
See Fig. 2.
IMPORTANT: Do not loosen the adjusting screw
more than one quarter-turn. If the pressure-
limiting valve is opened wider than that, it can
cause the accumulator to discharge.
2. Close the M6 adjusting screw when depressur-
ization is complete. Tighten it 62 to 71 lbf·in (700
to 800 N·cm).

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
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AGS Hydraulic System Depressurization

File Help

1
Note: You first must start
Start communication with communication with the AGS ECU before
Transmission entering into diagnostic mode. The
AGS ECU will kick you out of
diagnostic mode without first
establishing this contact.
2 3

Start
Reduce complete
Start Diagnostic Mode Hyd learning
Pressure procedure

Start clutch
Start last
offset
Exit Diagnostic Mode learning
learning
procedure
procedure

02/25/2004 f060184

NOTE: This screen is provisional and subject to change.

1. Start Communications 2. Start Diagnostic Mode 3. Reduce Hydraulic Pressure

Fig. 1, ServiceLink Depressurization Screen

02/19/2004 f261309
If the normal procedure fails, open the pressure-limiting
valve by turning the adjusting screw (arrow).
Fig. 2, Alternate Procedure

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Transmissions 26.03
X-Y Actuator Replacement

Special Tool
A special tool is required for this procedure. See
Table 1.

Special Tool for X-Y Actuator Replacement

Tool Description Manufacturer Part Number

High-Pressure Line Disconnect Tool Kent-Moore J-47201

f580379

Table 1, Special Tool for X-Y Actuator Replacement

Replacement
1. Shut down the engine, set the parking brake and
chock the rear tires. 2
NOTE: Replacement of the x-y actuator requires
removing the transmission from the vehicle.
2. Remove the transmission from the vehicle. For
detailed procedures, see Subject 100.
1
IMPORTANT: Depressurize the hydraulic system
before replacing any hydraulic components. 3
3. If not already done, depressurize the hydraulic
system. For detailed procedures, see Sub-
ject 160.
4. Remove the AGS assembly from the transmis-
sion. For detailed procedures, see Subject 200.
5. Before starting the replacement procedure, clean 03/10/2004 f261317
all screws and fittings by spraying with a light 1. High-Pressure Line Disconnect Tool
penetrating oil. 2. Metal Ring
3. High-Pressure Hydraulic Line
6. Using the high-pressure hydraulic line disconnect
tool (Table 1), remove the high-pressure hydrau-
Fig. 1, Removing the High-Pressure Hydraulic Lines
lic lines from the actuator. See Fig. 1.
6.1 Mark each line and attachment point with 6.3 Carefully pull the line away from the at-
a paint pen for ease of installation. tachment point and pull it free of the ac-
tuator.
6.2 Place the high-pressure line tool in front of
the metal ring. Use the tool to pull on the
line and shake it slightly until the line
CAUTION
comes free. Be careful not to bend or damage the lines or the
O-rings when removing them.

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26.03 Transmissions
X-Y Actuator Replacement

NOTE: Make sure the actuator is seated firmly 8.1 The lines snap into place with an audible
on the mounting flange. Do not use the mount- click. When the installation is correct, the
ing capscrews to pull the actuator into position. outermost O-ring is no longer visible. See
Fig. 3.
7. Install the four M8 mounting capscrews finger-
tight in the actuator. Make sure they are firm all 8.2 Tug lightly on each line to make sure it is
around. Then tighten them 17 lbf·ft (23 N·m). locked in place.
9. Install the connectors for the two position sen-
CAUTION sors on the actuator.
Do not twist or bend the hydraulic lines. This will 10. Install the AGS assembly on the transmission.
make installation more difficult and could dam- For detailed procedures, see Subject 200.
age the lines. 11. Install the transmission on the vehicle. For de-
8. Install the hydraulic lines in the actuator, as re- tailed procedures, see Subject 100.
moved. See Fig. 2.

06/02/2004 f261324
1. Rail Select Line (high) 3. X-Y Actuator 5. Rail Select Line (low)
2. Gear Select Line (fore) 4. Gear Select Line (aft) 6. Hydraulic Body

Fig. 2, Install the Hydraulic Lines

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X-Y Actuator Replacement

02/18/2004 f261304
The outermost O-ring (arrow) is not visible when the line
is installed correctly.
Fig. 3, Snap the Lines Into Place

12. Start the engine and allow the system to pressur-

ize. Shift back and forth a few times from drive to
reverse and back to neutral.
NOTE: The first few shifts after draining and re-
filling the hydraulic system will take longer than
usual.
13. Check the hydraulic system for leaks and repair
if necessary. When done, shut down the engine.
14. Check the hydraulic fluid level and add more
Pentosin as needed. For detailed procedures,
see Subject 150.
IMPORTANT: Use only Pentosin in the hydraulic
reservoir. No other fluid can be substituted.
15. Remove the chocks from the rear tires.

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
AGS Transmission Harness Replacement

Replacement 5.3 Remove the connector from the plug on

the reservoir cap.
NOTE: This procedure can be done with the 6. Unscrew the electrical connectors from the gear
transmission either installed on, or removed and rail position sensors on the x-y actuator.
from, the vehicle. Mark the cap and plug of each connector with a
paint pen.
1. Disconnect the batteries.
7. Unscrew the electrical connector from the input
2. Remove the two mounting capscrews that attach shaft speed sensor on the left-hand side of the
the splash guard to the TCU. See Fig. 1. rear gear case just aft of the accumulator. Mark
the cap and plug of the connector with a paint
pen.
8. Unscrew the electrical connectors from the two
2
output shaft speed sensors on the aft end of the
1 rear gear case. Mark the cap and plug of each
connector with a paint pen.
9. Cut tie straps as needed to remove the harness
from the transmission.
3
IMPORTANT: Be careful to color-code each con-
nector. If the connectors are not installed in the
correct locations, the transmission will not oper-
4 ate properly.
10. Lay the old harness next to the new harness on
4 a table. Match up each connector on the new
5 harness with the corresponding connector on the
6 old harness. Use paint pens to mark each con-
7 nector on the new harness with the color of its
06/02/2004 f544406 corresponding connector on the old harness.
1. TCU 4. Cable Clamp 11. Install the X2 (transmission) connector on the aft
2. Front Hanger 5. Clamp Mounting Bolt side of the TCU. Make sure the yellow safety
Bracket 6. Battery Cable
3. Cable Bracket 7. Splash Guard
slide snaps into place.
12. Install the two mounting capscrews that attach
Fig. 1, Area of TCU the splash guard to the TCU.
3. Remove the X2 (transmission) connector from 13. Install the new harness, matching each connec-
the transmission control unit (TCU). tor by color. Install new tie straps as needed.
4. Unscrew the electrical connector cap from the 14. Connect the batteries. Start the engine and
clutch position sensor plug on the bell housing. check the electrical system for proper operation.
See Fig. 2. Mark the cap of the connector and
the plug with a paint pen.
5. Remove the electrical connector from the reser-
voir cap.
5.1 Insert a small screwdriver into the opening
at the top of the connector.
5.2 Pull back (aft) on the clip until it releases.
A click can be heard when it releases.

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AGS Transmission Harness Replacement

1 7

02/10/2004 f261298
1. Clutch Position Sensor 4. Fluid Level Sensor 6. Output Shaft Speed Sensor #2
2. Gear Position Sensor 5. Output Shaft Speed Sensor #1 7. Input Shaft Speed Sensor
3. Rail Position Sensor

Fig. 2, Transmission Sensors

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AGS Central Unit Replacement

Special Tool
A special tool is required for this procedure. See
Table 1.

Special Tool for X-Y Actuator Replacement

Tool Description Manufacturer Part Number

High-Pressure Line Disconnect Tool Kent-Moore J-47201

f580379

Table 1, Special Tool for X-Y Actuator Replacement

Replacement CAUTION
1. Shut down the engine, set the parking brake and Be careful not to bend or damage the lines or the
chock the rear tires. O-rings when removing them.
NOTE: Replacement of the x-y actuator requires NOTE: The central unit has two parts: in front is
removing the transmission from the vehicle. the transmission control unit (TCU), and behind
2. Remove the transmission from the vehicle. For it is the hydraulic body.
detailed procedures, see Subject 100. 7. Still using the high-pressure hydraulic line dis-
IMPORTANT: Depressurize the hydraulic system connect tool, remove the high-pressure hydraulic
before replacing any hydraulic components. lines from the central unit. See Fig. 1.

3. If not already done, depressurize the hydraulic NOTE: There are five lines that connect to
system. For detailed procedures, see Sub- the hydraulic body of the central unit. One
ject 160. line connects to the clutch and four lines
4. Remove the AGS assembly from the transmis-
connect to the x-y actuator.
sion. For detailed procedures, see Subject 200. 7.1 Mark each line and attachment point with
a paint pen for ease of installation. On the
CAUTION top of the hydraulic body, remove the
outer lines first.
Make sure the AGS assembly is well supported
before working on the hydraulic lines. If neces- IMPORTANT: Don’t use the tool as a lever.
sary, call another person to help support it. The Work it in until it is fully engaged and then
weight of the assembly components could cause wiggle until the line comes free.
damage to the lines. 7.2 Place the high-pressure line tool in front of
5. Before starting the replacement procedure, clean the metal ring. Press down to compress
all screws and fittings by spraying with a light the locking device, and then pull outward
penetrating oil. and shake the tool slightly until the line
comes free.
6. Using the high-pressure hydraulic line disconnect
tool (Table 1), remove the four high-pressure 7.3 Once all the lines are unlocked, carefully
hydraulic lines from the x-y actuator. For proce- separate the central unit from the rest of
dures, see Subject 170. the AGS assembly.

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AGS Central Unit Replacement

3 4

2 2

1
3

1
01/13/2005 f544421
03/10/2004 f261317 1. TCU 3. X-Y Actuator
1. High-Pressure Line Disconnect Tool 2. Hydraulic Body 4. Hydraulic Line
2. Metal Ring
3. High-Pressure Hydraulic Line Fig. 2, Hydraulic Lines on the Central Unit

Fig. 1, Using the High-Pressure Line Disconnect Tool

CAUTION
Do not twist or bend the hydraulic lines. This will
make installation more difficult and could dam-
age the lines.
8. Install the hydraulic lines in the central unit, as
removed. See Fig. 2.
8.1 The lines snap into place with an audible
click. When the installation is correct, the
outermost O-ring is no longer visible. See
Fig. 3.
8.2 Tug lightly on each line to make sure it is
locked in place.
02/18/2004 f261304
9. Install the high-pressure hydraulic lines on the The outermost O-ring (arrow) is not visible when the line
x-y actuator, as removed. For procedures, see is installed correctly.
Subject 170.
Fig. 3, Snap the Lines Into Place
10. Install the AGS assembly on the transmission.
For detailed procedures, see Subject 200. NOTE: The first few shifts after draining and re-
11. Install the transmission on the vehicle. For de- filling the hydraulic system will take longer than
tailed procedures, see Subject 100. usual.
12. Start the engine and allow the system to pressur- 13. Check the hydraulic system for leaks and repair
ize. Shift back and forth a few times from drive to if necessary. When done, shut down the engine.
reverse and back to neutral.

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AGS Central Unit Replacement

14. Check the hydraulic fluid level and add more

Pentosin as needed. For detailed procedures,
see Subject 150.
IMPORTANT: Use only Pentosin in the hydraulic
reservoir. No other fluid can be substituted.
15. Remove the chocks from the rear tires.

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
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AGS Assembly Removal and Installation

Special Tools
Special tools are required for this procedure. See
Table 1.

Special Tools for AGS Assembly Installation

Tool Description Manufacturer Part Number

Shift Finger Alignment Fork Kent-Moore J-47204

f580380

Shift Mechanism End Guide Kent-Moore J-47203

f580382

Table 1, Special Tools for AGS Assembly Installation

Removal 6. Remove the electrical connectors from the clutch

position sensor at the bell housing, and from the
three speed sensors on the rear gear case. Mark
1. Shut down the engine, set the parking brake and
both the cap and plug of the connector with a
chock the rear tires.
paint pen for ease of installation.
NOTE: Replacement of the AGS assembly re- 7. Remove the high-pressure clutch hydraulic line
quires removing the transmission from the ve- from the bell housing. For procedures, see Sub-
hicle. ject 120.
2. Remove the transmission from the vehicle. For 8. Remove the accumulator. For detailed proce-
detailed procedures, see Subject 100. dures, see Subject 140.
IMPORTANT: Depressurize the hydraulic system 9. Remove the hydraulic fluid reservoir. For detailed
before replacing any hydraulic components. procedures, see Subject 150.
3. If not already done, depressurize the hydraulic NOTE: The central unit has two parts: in front is
system. For detailed procedures, see Sub- the TCU and behind it is the hydraulic body.
ject 160.
10. Remove the four inverted-Torx® capscrews that
4. Remove the two mounting capscrews attaching attach the central unit to the transmission. See
the splash guard to the transmission control unit Fig. 1. See Fig. 2.
(TCU). See Subject 110 for instructions.
11. Remove the four inverted-Torx capscrews that
5. Disconnect the X1 (main vehicle) and X3 (elec- attach the x-y actuator to the transmission. See
tric motor) electrical connectors from the base Fig. 2.
and aft side of the TCU. Mark both the cap and
plug of the connector with a paint pen for ease of NOTE: The two upper capscrews are 110 mm
installation. Remove tie straps and clamps as long; the two lower capscrews are 60 mm long.
needed. 12. Remove the x-y actuator assembly from the front
gear case.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
AGS Assembly Removal and Installation

12.2 Remove the sheet metal shift cover at the

end of the shift cover housing. See Fig. 3.
3
Tap the shift cover with a drift to dislodge
2 it, and then pull it out of the shift cover
housing with pliers. Discard this shift
cover.
4

1
03/03/2004 f544422
1
Remove the four inverted-Torx capscrews (arrows) that
attach the central unit to the transmission.
1. Transmission Control Unit (TCU)
03/10/2004 f261316
2. Hydraulic Body
3. Low-Pressure Return Hose 1. Setscrew Hole 2. Shift Cover
4. Low-Pressure Supply Hose
Fig. 3, Removing the Shift Cover
Fig. 1, AGS Central Unit Mounting Capscrews
12.3 Pull the actuator assembly, complete with
the shift rod, out of the front gear case.
IMPORTANT: If there is difficulty in separat-
ing the x-y actuator from the gear case, in-
stall the shift mechanism end guide on the
end of the shift rod. Then use a rubber mal-
let to pound gently on the end guide until the
actuator comes free.
13. Carefully remove the entire AGS assembly from
the transmission.
14. If necessary due to wear, file around the set-
screw bore at the end of the shift rod. When fin-
ished filing, be sure to remove any metal scraps,
shavings, or other residue.
02/19/2004 f261305
Remove the four large inverted-Torx capscrews (arrows)
Installation
that attach the x-y actuator to the transmission.
1. Using the shift finger alignment fork (Table 1),
Fig. 2, X-Y Actuator Mounting Capscrews align the shift finger. See Fig. 4. Leave the fork
in place until the shift rod is installed in the front
12.1 From the right-hand side of the transmis-
gear case. Screw the shift mechanism end guide
sion, remove the setscrew that holds the
(Table 1) onto the shift rod.
end of the shift rod.

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Transmissions 26.03
AGS Assembly Removal and Installation

1 2

3 1

2
3

02/18/2004 f261307 06/03/2004 f261325

1. Shift Finger 3. Shift Rod 1. End Guide 3. Setscrew
2. Alignment Fork 4. Removal Cord 2. Shift Cover Housing
Fig. 4, Align the Shift Finger Fig. 5, Install the Setscrew
NOTE: Turn the shift rod to make sure the 2.6 When the shift rod is all the way in, un-
countersunk bore for the setscrew is rotated at screw the end guide.
a 90-degree angle away from the shift finger.
2.7 Turn the shift rod until the indent on the
2. Install the actuator assembly in the front gear end of the shift rod is at the 9 o’clock po-
case. sition. See Fig. 6.
2.1 Clean the mating surface between the ac-
tuator assembly and the front gear case.
Coat the mating surface with Loctite® 509 2
or equivalent sealing compound.
2.2 Insert the actuator assembly into the front
gear case. Make sure that the removal 1
cord attached to the end of the alignment
fork is accessible.
3
NOTE: For ease of entry, it helps to tip the
shift fork slightly downwards and to the rear.
2.3 When the shift rod is in far enough to en-
gage the shift finger, there will be about a
two-inch (50-mm) gap between the back
of the x-y actuator and the mating surface
on the front gear case. Use the removal 03/10/2004 f261315
cord to pull out the alignment fork. The indent (arrow) must be at the 9 o’clock position.
1. Setscrew Hole 3. End of Shift Rod
2.4 Set the x-y actuator against the mating 2. Shift Cover Housing
surface. If necessary, turn the shift rod in
a clockwise direction until the setscrew Fig. 6, Indent at Shift Rod End
bore is visible through the hole provided.
2.5 Install the M12 setscrew in the counter- 2.8 Before tightening, make sure the setscrew
sunk bore in the shift rod, but do not is firmly seated in the shift rod. Tighten the
tighten it yet. See Fig. 5. setscrew 22 lbf·ft (30 N·m).

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
AGS Assembly Removal and Installation

2.9 Press a new shift cover onto the shift

cover housing.
3. Install the hydraulic fluid reservoir. For detailed
procedures, see Subject 150.
4. Install the accumulator. For detailed procedures,
see Subject 140.
5. Install the high-pressure clutch hydraulic line, as
removed.
6. Coat the threads of the four inverted-Torx actua-
tor mounting capscrews with Loctite 509 or
equivalent thread-locking compound. Install the
four capscrews on the x-y actuator and tighten
them 17 lbf·ft (23 N·m).
7. Coat the threads of the four inverted-Torx central
unit mounting capscrews with Loctite 509 or
equivalent thread-locking compound. Install the
four capscrews on the central unit and tighten
them 17 lbf·ft (23 N·m).
8. Connect all the electrical connectors, as re-
moved.
9. Bleed the hydraulic system. For procedures, see
Subject 130.
10. Add Pentosin as needed until the level reaches
the joint between the upper and lower sections of
the reservoir. For detailed procedures, see Sub-
ject 150.
IMPORTANT: Use only Pentosin in the hydraulic
reservoir. No other fluid can be substituted.
11. Install the splash guard before installing the
transmission. Tighten the mounting screws 17
lbf·ft (23 N·m). See Subject 110 for instructions.
12. Install the transmission on the vehicle. For de-
tailed procedures, see Subject 100.
13. Start the engine and allow the system to pressur-
ize. Shift back and forth a few times from drive to
reverse and back to neutral.
NOTE: The first few shifts after draining and re-
filling the hydraulic system will take longer than
usual.
14. Check the hydraulic fluid level and add more
Pentosin as needed. For detailed procedures,
see Subject 150.
15. Check the hydraulic system for leaks and repair
if necessary. When done, shut down the engine.
16. Remove the chocks from the rear tires.

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Freightliner AMT3 and Mercedes-Benz Automated-Manual
Transmissions 26.03
Clutch Actuator Replacement

Replacement 4. Loosen the clutch actuator mounting capscrews,

but do not remove them yet.
NOTE: Replacement of the clutch actuator re- 5. Lift up the spring clip from the hydraulic line and
quires removing the transmission from the ve- carefully pull the hydraulic line straight out, using
hicle. a minimum of force. See Fig. 2.
1. Remove the transmission from the vehicle. For 6. Remove the clutch actuator (release bearing
detailed procedures, see Subject 100. housing and concentric slave cylinder). See
Fig. 3.
2. If not already done, depressurize the hydraulic
system. For detailed procedures, see Sub- 6.1 Remove both 30-mm hexhead hydraulic
ject 160. fittings from the bell housing.
3. Unlock the electrical connector cap from the 6.2 Remove the clutch actuator mounting cap-
clutch position sensor. See Fig. 1. Turn the lock screws that attach the clutch actuator to
collar on the connector plug 90 degrees counter- the bell housing.
clockwise and remove it. Then remove the con- 6.3 Slide the clutch actuator off the transmis-
nector plug and the position sensor wire from the sion input shaft.
bell housing.

1 7

02/10/2004 f261298
1. Clutch Position Sensor 4. Fluid Level Sensor 6. Output Shaft Speed Sensor #2
2. Gear Position Sensor 5. Output Shaft Speed Sensor #1 7. Input Shaft Speed Sensor
3. Rail Position Sensor

Fig. 1, Transmission Sensors

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
26.03 Transmissions
Clutch Actuator Replacement

1
3
3
5
4
5 4
2
6

7
2 6

1
02/23/2004 f261312
1. Mounting Plate Capscrew
2. Connector Plug
3. 30-mm Hexhead Hydraulic Bleed Fitting 03/17/2004 f261313
4. Bleed Screw 1. Lip of Bell Housing
5. Spring Clip 2. Input Shaft
6. 30-mm Hexhead Hydraulic Pressure Fitting 3. Clutch Actuator Mounting Capscrew
7. Hydraulic Line 4. Release Bearing Housing
5. Concentric Slave Cylinder
Fig. 2, Clutch Components on Bell Housing 6. Position Sensor Connector
7. Clutch Position Sensor
7. Slide the clutch actuator onto the input shaft. In-
stall the clutch actuator on the bell housing. Fig. 3, Clutch Actuator
7.1 Install new clutch actuator mounting cap-
screws and tighten 17 lbf·ft (23 N·m).
IMPORTANT: Do not use Loctite® or sealant
on these fasteners.
7.2 Connect the hydraulic line and the fitting
that attaches it to the bell housing. Make
sure the spring clip engages properly.
7.3 Install the bleed screw and the fitting that
attaches it to the bell housing.
7.4 Attach the sensor wire, connector, and
connector plug assembly to the bell hous-
ing. Lock the electrical connector cap onto
the connector plug.
7.5 Tighten all hydraulic fittings 37 lbf·ft (50
N·m).
8. Install the transmission in the vehicle. For de-
tailed procedures, see Subject 100.

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Transmissions 26.03
General Troubleshooting

IMPORTANT: Always use ServiceLink when at- But in most cases, the J1587 fault code is the start-
tempting to diagnose problems with the AGS ing point for the troubleshooting procedures. See
(Automated Gear Shift) transmission. Table 1 to find information for SID fault codes. See
Table 2 to find information for PID fault codes.
How To Start Before starting any procedures, use ServiceLink to
depressurize the AGS hydraulic system. For detailed
To gain a baseline for troubleshooting when there is procedures, see Subject 160.
no definite problem, when the malfunction is erratic
or intermittent, or to determine the general health of Fault Code Guide
the electrical system, start with the electrical pre-test
in Subject 301. To troubleshoot a given fault code, look up the sub-
In a few cases there will be a definite problem and ject number in Table 1 (for SIDs) and Table 2 (for
no J1587 fault code will be sent (engine will not PIDs). Follow the procedures for that fault code until
crank, no information on gear display, fluid level the fault is corrected.
fault). For these problems, see the appropriate table
in Subject 301.

Fault Code Guide (MID 130 SIDs)

SID FMI Text Message Failure Reason Procedure
18 02 Prim Selector Erratic The shift lever does not shift gears. See Subject 302.
33 03 MultiPress Ind Short Hi The hydraulic pressure sensor circuit is shorted to power. See Subject 303.
33 04 MultiPress Ind Short Lo The hydraulic pressure sensor circuit is shorted to ground. See Subject 303.
33 05 MultiPress Ind OPEN The hydraulic pressure sensor circuit is open. See Subject 303.
52 05 Hydraulic Sys OPEN The hydraulic pump circuit is open. See Subject 304.
The hydraulic pressure does not increase even though the
52 07 Hydraulic Sys NoRESPONSE See Subject 304.
hydraulic pump is activated.
52 11 Clutch Act Not Known The hydraulic pump temperature is too high. See Subject 304.
55 00 Clutch Act HIGH The clutch is too hot. See Subject 305.
55 07 Clutch Act NoRESPONSE The clutch does not operate properly. See Subject 305.
55 13 Clutch Act Calibrate The clutch needs to be calibrated. See Subject 305.
231 02 SAE J1939 Datalink Erratic The J1939 datalink is not communicating properly. See Subject 306.
231 09 SAE J1939 Datalink UPDATE The J1939 datalink has timed out. See Subject 306.
The J1939 datalink is not communicating with the
231 12 SAE J1939 Datalink Bad See Subject 306.
transmission.
251 00 POWER SUPPLY HIGH The power supply voltage is too high. See Subject 307.
251 01 POWER SUPPLY Low The power supply voltage is too low. See Subject 307.
There is no power to the transmission with the engine
251 05 POWER SUPPLY OPEN See Subject 307.
running.
251 14 POWER SUPPLY RSRVD The power supply is not properly grounded. See Subject 307.
253 02 Calibration Memory Erratic The transmission needs to be recalibrated. See Subject 308.
253 12 Calibration Memory Bad The transmission needs to be recalibrated. See Subject 308.
253 13 Calibration Memory Calibrate The transmission needs to be recalibrated. See Subject 308.
253 14 Calibration Memory RSRVD The transmission needs to be recalibrated. See Subject 308.

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 Freightliner AMT3 and Mercedes-Benz Automated-Manual
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General Troubleshooting

Fault Code Guide (MID 130 SIDs)

SID FMI Text Message Failure Reason Procedure
254 04 Controller Short Lo The TCU is shorted to ground. See Subject 309.
254 05 Controller OPEN The TCU has an open circuit. See Subject 309.
254 11 Controller Not Known The TCU AUTO mode software module has an error. See Subject 309.
254 12 Controller Bad The TCU has a hardware problem. See Subject 309.
254 13 Controller Calibrate The TCU has a software memory problem. See Subject 309.
Table 1, Fault Code Guide (SIDs)

Fault Code Guide (MID 130 PIDs)

PID FMI Text Message Failure Reason Procedure
33 02 Erratic The clutch position sensor gives invalid data. See Subject 310.
33 03 Short Hi The clutch position sensor circuit is shorted to power. See Subject 310.
33 04 Short Lo The clutch position sensor circuit is shorted to ground. See Subject 310.
33 05 OPEN The clutch position sensor circuit is open. See Subject 310.
The clutch position sensor gives incorrect resistance
33 14 RSRVD See Subject 310.
readings.
59 02 Shift FNGR Gear Erratic The shift rod position sensor gives invalid data. See Subject 311.
59 03 Shift FNGR Gear Short Hi The gear position sensor circuit is shorted to power. See Subject 311.
59 04 Shift FNGR Gear Short Lo The gear position sensor circuit is shorted to ground. See Subject 311.
59 05 Shift FNGR Gear OPEN The gear position sensor circuit is open. See Subject 311.
59 14 Shift FNGR Gear RSRVD The gear position sensor gives incorrect resistance readings. See Subject 311.
60 02 Shift FNGR Rail Erratic The rail position sensor circuit gives invalid data. See Subject 312.
60 03 Shift FNGR Rail Short Hi The rail position sensor circuit is shorted to power. See Subject 312.
60 04 Shift FNGR Rail Short Lo The rail position sensor circuit is shorted to ground. See Subject 312.
60 05 Shift FNGR Rail OPEN The rail position sensor circuit is open. See Subject 312.
60 14 Shift FNGR Rail RSRVD The rail position sensor gives incorrect resistance readings. See Subject 312.
The output shaft speed sensor is not providing accurate
64 09 Dir Switch Update See Subject 313.
directional information.
The output shaft speed sensor is not providing accurate
64 11 Dir Switch Not Known See Subject 313.
directional information.
158 00 Volts (BattSw) HIGH The voltage in the ignition power circuit is too high. See Subject 314.
158 01 Volts (BattSw) Low The voltage in the ignition power circuit is too low. See Subject 314.
161 02 In shaft SPEED Erratic The input shaft speed sensor circuit gives invalid data. See Subject 315.
161 03 In shaft SPEED Short Hi The input shaft speed sensor circuit is shorted to power. See Subject 315.
161 04 In shaft SPEED Short Lo The input shaft speed sensor circuit is shorted to ground. See Subject 315.
161 05 In shaft SPEED OPEN The input shaft speed sensor circuit is open. See Subject 315.
The input shaft speed sensor circuit is broadcasting an
161 08 In shaft SPEED Update See Subject 315.
abnormal frequency.

300/2 Business Class M2 Workshop Manual, Supplement 20, September 2011