Eaton Endurant User manual

Service Manual
Endurant™12-Speed
Automated Transmission
TRSM0950 EN-US
March 2019

© 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved
Table of Contents TRSM0950
General Information
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . .1
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . .3
Serial Tag Information and Model Nomenclature . . . . .5
Service Procedures
Removal
Oil Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Linear Clutch Actuator (LCA) Removal . . . . . . . . . . . . .9
Transmission Control Module (TCM) Removal . . . . . .13
Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . .17
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Fluid Pressure Sensor (FPS) Removal . . . . . . . . . . . .21
Output Speed Sensor Removal . . . . . . . . . . . . . . . . . .23
Mechatronic Transmission Module (MTM) Removal .27
Release Bearing and Clutch Release Yoke Removal . .31
Upper Countershaft Cover Removal . . . . . . . . . . . . . .35
Input Shaft Cover Removal . . . . . . . . . . . . . . . . . . . . .37
Lower Countershaft Cover and Inertia Brake
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Output Yoke Removal . . . . . . . . . . . . . . . . . . . . . . . . .43
Rear Bearing Cover Removal . . . . . . . . . . . . . . . . . . .45
Harness Bracket Removal . . . . . . . . . . . . . . . . . . . . . .49
Rear Housing Assembly Removal . . . . . . . . . . . . . . . .51
4-Bolt PTO Cover Removal . . . . . . . . . . . . . . . . . . . . .55
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Main Housing Removal . . . . . . . . . . . . . . . . . . . . . . . .59
8-Bolt PTO Cover Removal . . . . . . . . . . . . . . . . . . . . .65
Main Shaft and Countershaft Removal . . . . . . . . . . . .67
Disassembly/Assembly
Output Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . .75
Inertia Brake Disassembly/Assembly . . . . . . . . . . . . .77
Input Shaft Pilot Bearing Wear Sleeve
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . .81
Input Shaft Cover Disassembly/Assembly . . . . . . . . . .87
Main Shaft Disassembly/Assembly . . . . . . . . . . . . . . .91
Input Shaft Disassembly/Assembly . . . . . . . . . . . . . .101
Main Housing Disassembly/Assembly . . . . . . . . . . .107
Rear Housing Assembly Disassembly/Assembly . . .117
Clutch Housing Disassembly/Assembly . . . . . . . . . .129
Installation
Rear Bearing Cover Installation . . . . . . . . . . . . . . . . .137
Output Yoke Installation . . . . . . . . . . . . . . . . . . . . . .141
Lower Countershaft Cover and Inertia Brake
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Input Shaft Cover Installation . .. . . . . . . . . . . . . . . .147
Upper Countershaft Cover Installation . . . . . . . . . . .149
Mechatronic Transmission Module (MTM)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Fluid Pressure Sensor (FPS) Installation . . . . . . . . . .159
Output Speed Sensor Installation . . . . . . . . . . . . . . .161
Linear Clutch Actuator (LCA) Installation . . . . . . . . .165
Release Bearing and Clutch Release Yoke
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Transmission Control Module (TCM) Installation . . .169
Main Shaft and Countershaft Installation . . . . . . . . .173
Main Housing Installation . . . . . . . . . . . . . . . . . . . . .185
8-Bolt PTO Cover Installation . . . . . . . . . . . . . . . . . .191
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . .193
Rear Housing Installation . . . . . . . . . . . . . . . . . . . . .197
4-Bolt PTO Cover Installation . . . . . . . . . . . . . . . . . .201
Harness Bracket Installation . . . . . . . . . . . . . . . . . . .203
Clutch Installation .. . . . . . . . . . . . . . . . . . . . . . . . . .205
Transmission Installation . . . . . . . . . . . . . . . . . . . . .211
Oil Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Appendix
Oil Level Inspection Procedure . . . . . . . . . . . . . . . . .217
Manually Vent Linear Clutch Actuator (LCA) . . . . . . .219
Input Shaft Disassembly/Assembly using
Input Shaft Press (RR1085TR) . . . . . . . . . . . . . . . . .221
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . .229
Oil Leak Inspection Process . . . . . . . . . . . . . . . . . . .231
Inspection Precautions . . . . . . . . . . . . . . . . . . . . . . .233
Torque Specifications . . . . . . . . . . . . . . . . . . . . .235
Handling, Inspection and Cleaning of Parts . . . . . . .237
Recycling Parts and Oil . . . . . . . . . . . . . . . . . . . . . . .239
Roadranger Specialty Tools . . . . . . . . . . . . . . . . . . .241
Change Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 1
TRSM0950 General Information |Warnings and Cautions
Warnings and Cautions
The alert symbols, signal words (DANGER,
WARNING and CAUTION) and statements
throughout this manual indicate the potential
severity of a situation. Ensure to read, understand
and follow each statement to avoid vehicle dam-
age, component damage, personal injury, severe
injury and/or death.
DANGER: Indicates an immediate hazard. Failure to follow
the indicated procedures will cause major vehicle compo-
nent damage, severe injury or death.
WARNING: Indicates an immediate hazard. Failure to follow
the indicated procedures may result in major vehicle com-
ponent damage, severe injury or death.
CAUTION: Indicates a potential hazard. Failure to follow the
indicated procedures could result in minor or moderate
component damage and/or personal injury.
The NOTICE and Note statements through out this manual
provide additional details required to avoid damaging a
component or incorrectly completing a repair. Ensure to
read, understand and follow each statement to properly
complete a repair.
NOTICE: Indicates component or property damage could
result if you do not follow the indicated procedure.
Note: Indicates additional detail that will aid in the repair of
a component.
While working on a vehicle:
WARNING: Do not modify transmission components or
systems. Modification (altering, substituting, relocating) of
transmission components may result in major vehicle com-
ponent damage, severe injury or death.
WARNING: Do not modify transmission service tools. Mod-
ification (altering, substituting, relocating) of transmission
service tools may result in major vehicle component dam-
age, severe injury or death.
WARNING: Read, understand and follow each statement
regarding cap screw installation and torque specification
requirements. Failure to install and torque cap screws to
specification may result in major vehicle component dam-
age, severe injury or death.
WARNING: When working on vehicle components, keep
body parts clear of sharp objects and pinch points. Failure
to keep clear of sharp objects and pinch points may result
in severe injury or death.
WARNING: Use appropriate lifting devices and equipment
when working with heavy vehicle components. Failure to do
so may result in major vehicle component damage, severe
injury or death.
CAUTION: Do not work on the vehicle immediately after
operation. Working on a hot vehicle component could result
in personal injury.
Compressed Air System
WARNING: The vehicle air system operates approximately
between 60 - 140 PSI. Refer to OEM guidelines regarding
vehicle system operation and service. Failure to follow OEM
guidelines may result in major vehicle component damage,
severe injury or death.
!
!
!
!
!
!
!
!
!
!

2© 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Warnings and Cautions |General Information TRSM0950
Before starting a vehicle:
• Sit in the driver’s seat.
• Confirm vehicle parking brake is applied.
• Confirm Neutral is selected on the driver interface
device.
• Ensure vehicle has adequate fuel level.
• Do not operate the vehicle if the Alternator lamp is
on or if gauge indicates low voltage with the engine
running.
When parking the vehicle or leaving the cab:
1. Safely come to a complete stop.
2. Continue to depress and hold service brake.
3. Select Neutral on the driver interface device.
4. Apply vehicle parking brake.
WARNING: Apply vehicle parking brake and follow
vehicle manufacturer parking instructions. Failure to follow
these instructions could cause unintended vehicle move-
ment and may result in major vehicle component damage,
severe injury or death.
5. Turn ignition key Off and allow the engine to shut to
down.
Before working on a vehicle or leaving the cab
with engine running:
1. Safely come to a complete stop.
2. Continue to depress and hold service brake.
3. Select Neutral on the driver interface device.
4. Apply vehicle parking brake.
WARNING: Apply vehicle parking brake and follow
vehicle manufacture parking instructions. Failure to follow
these instructions could cause unintended vehicle move-
ment and may result in major vehicle component damage,
severe injury or death.
5. Chock wheels.
To avoid damage to the transmission during
towing:
When towing a vehicle equipped with the Endurant Trans-
mission, do not allow the output shaft of the transmission
to rotate. If the vehicle is towed with the drive wheels still in
contact with the road surface, the vehicle axle shafts or
driveline must be removed or disconnected prior to towing
vehicle.
NOTICE: Internal transmission damage can result from
improper vehicle towing.
!
!
Preferred
Must remove vehicle axle shafts or driveline prior to towing

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 3
TRSM0950 General Information |How to Use This Manual
How to Use This Manual
This publication is divided into three sections: General
Information, Service Procedures and Appendix.
General Information
This section contains basic chapters such as Transmission
Overview, How to Use This Manual and Serial Tag and
Model Nomenclature.
Service Procedures
To find the information you need, simply locate the proce-
dure in the Table of Contents, turn to the page specified and
follow the procedure.
The Service Procedures are divided in three sections;
Removal, Disassembly/Assembly and Installation. Removal
instructs how to remove the part or assembly from the
transmission. Disassembly instructs how to take an assem-
bly apart. Assembly instructs how to put together an
assembly. Installation instructs how to install the part or
assembly in the transmission. Not all parts have a disas-
sembly/assembly section.
A Component Identification diagram is included at the
beginning of each procedure for Removal, Disassem-
bly/Assembly and Installation. Below the Component
Identification diagram is a numerical listing for each part
with the part name.
Appendix
This section contains information such as Lubrication
Specifications, Inspection, Tool Specifications, and Torque
Specifications.

4© 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
How to Use This Manual |General Information TRSM0950

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 5
TRSM0950 General Information |Serial Tag Information and Model Nomenclature
Serial Tag Information and Model Nomenclature
Transmission model designation and other transmission identification information are stamped on the serial tag. To identify the
transmission model and serial number, locate the tag on the lower right side of the clutch housing.
When calling for service assistance or parts, have the model and serial numbers handy.
NOTICE: Do not remove or destroy the transmission identification tag.
Model Number
The model number gives basic information about the transmission and is explained below. Use this number when calling for ser-
vice assistance or replacement parts.
Serial Number
The serial number is the sequential identification number of the transmission. Before calling for service assistance, write the
number down as it may be needed.
GearRatio Set (A / B / C / D)
E
Eaton
Endurant
DesignLevel
UnitsforTorque (F = ft-lb; N = Nm)
X X F1
Forward Speeds
12 CE O
-
Overdrive
Torque Capacity
(XX * 100 + 50 ft-lb)

6© 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Serial Tag Information and Model Nomenclature |General Information TRSM0950

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 7
TRSM0950 Removal |Oil Drain Procedure
Oil Drain Procedure
Special Instructions
None
Special Tools
None
Component Identification
1. Oil Drain Plug - 6 mm Hex
1

8© 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Oil Drain Procedure |Removal TRSM0950
Procedure – Oil Drain
1. Locate the Oil Drain Plug on the back of the rear hous-
ing.
2. Place a suitable container under the Oil Drain Plug.
Note: If reusing oil, use a clean container free of con-
tamination and debris.
3. Remove the Oil Drain Plug with a 6 mm hex key and
drain the oil.
4. If PTO-equipped, remove PTO and drain the oil.
5. Inspect Oil Drain Plug and O-ring for damage. If dam-
aged, replace the Oil Drain Plug, O-ring is serviced with
plug.
6. Install the Oil Drain Plug and torque to 24.5-29.5 Nm
(18-22 lb-ft).
NOTICE: Do not over-torque drain plug or transmission
damage may occur.

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 9
TRSM0950 Removal |Linear Clutch Actuator (LCA) Removal
Linear Clutch Actuator (LCA) Removal
Special Instructions
Drain the vehicle air system.
Special Tools
None
Component Identification
1. Mechatronic Transmission Module (MTM) Housing
2. Linear Clutch Actuator (LCA)
3. LCA Cap Screws (x4) - T45 Torx
23
1

10 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Linear Clutch Actuator (LCA) Removal |Removal TRSM0950
Procedure – Removal
Note: Linear Clutch Actuator (LCA) is removable with trans-
mission in chassis.
1. Key off.
2. Disconnect the 20-Way TCM Vehicle Harness Connec-
tor from the TCM by depressing the lock tab and lifting
up on the lever.
3. Loosen the 4 LCA cap screws 1-2 turns each with a
T45 Torx.
Note: Residual air pressure in the LCA cylinder
exhausts between the LCA and MTM housing when the
cap screws are loosened.
4. Remove the 4 LCA cap screws
5. Remove the LCA from the Mechatronic Transmission
Module (MTM).
NOTICE: Ensure the key is off and 20-Way TCM Vehicle
Harness is disconnected prior to removing the LCA
from the MTM.
Note: LCA piston rod end is seated in the release yoke
socket; pull to release rod end from socket.

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 11
TRSM0950 Removal | Linear Clutch Actuator (LCA) Removal
6. Inspect the plastic socket insert in the release yoke
through the LCA opening using a flashlight to verify
none of the fingers are missing or damaged.
Note: If the plastic insert is damaged, replace the
release yoke assembly.

12 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Linear Clutch Actuator (LCA) Removal |Removal TRSM0950

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 13
TRSM0950 Removal |Transmission Control Module (TCM) Removal
Transmission Control Module (TCM) Removal
Special Instructions
None
Special Tools
• ServiceRanger
Component Identification
1. Transmission Control Module (TCM) Cover - 10 or 13 mm Nuts
2. Transmission Control Module (TCM)
3. Mechatronic Transmission Module (MTM)
4. Transmission Control Module (TCM) Jackscrew - 7 mm
3
2
4
1

14 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Transmission Control Module (TCM) Removal |Removal TRSM0950
Procedure – Removal
NOTICE: Do not allow contamination into the connectors on
the TCM or Mechatronic Transmission Module (MTM).
Note: Transmission Control Module (TCM) is removable
with transmission in chassis.
1. Connect ServiceRanger and create a Service Activity
Report.
2. Key off.
3. Disconnect the negative battery cable.
NOTICE: Leaving battery cable connected may damage
TCM.
4. Disconnect the 20-Way TCM Vehicle and Body Harness
Connectors from the TCM by depressing the lock tab
and lifting up on the lever.

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 15
TRSM0950 Removal | Transmission Control Module (TCM) Removal
5. Unscrew the 4 nuts on the TCM Cover and remove
TCM Cover.
Note: TCM Cover nuts are 10 or 13 mm.
6. Unscrew the 7 mm jackscrew, lift and remove the TCM
from the MTM.
7. Inspect the TCM Seal for damage.
NOTICE: Replace the TCM Seal if damaged.
8. If replacing the TCM, transfer the TCM Seal to the new
TCM.

16 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 2019.04.4
Transmission Control Module (TCM) Removal |Removal TRSM0950

2019.04.4 © 2018 Eaton Cummins Automated Transmission Technologies. All rights reserved 17
TRSM0950 Removal |Transmission Removal
Transmission Removal
Special Instructions
Manually Vent Linear Clutch Actuator (LCA).
Special Tools
• Transmission Jack Adapter Plate (RR1067TR)
• 2 cap screws and washers (M10 x 1.5 x 30 mm,
minimum class 8.8)
Component Identification
Procedure – Removal
1. Perform “Manually Vent Linear Clutch Actuator (LCA)”
on page 219.
2. Refer to OEM guidelines for transmission removal.