Professional Documents
Culture Documents
Number: SB324013
Date: 02/14/06
Model: T200, T300
(Does not apply to Mack Trucks Australia)
1. Range Shift Cylinder Seal Inserter 3. Range Shift Piston Seal Sizer/Piston Installer
(Tool No. J 47357) (Tool No. J 47359)
2. Range Shift Cylinder Seal Installer/Sizer
(Tool No. J 47358)
SB324013 — Page 1 of 20
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2006
The shift cylinder is comprised of a housing, cover and piston/shift rail assembly.
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SB324013 — Page 2 of 20
The seal rings used on the shift rail and piston consist of an O-ring which acts as an
expander, and a Teflon® seal that fits around the inside diameter of the O-ring. The Teflon®
seal is contoured to fit the O-ring.
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Figure 3 — O-Ring
Cylinder Removal
1. Disconnect both air lines from the cylinder.
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SB324013 — Page 3 of 20
2. Remove the rear case top cover.
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SB324013 — Page 4 of 20
5. Remove the shift cylinder cover and O-ring.
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6. While holding the shift fork, slide the shift cylinder from the rear of the transmission.
Remove the shift cylinder-to-rear case gasket.
SB324013 — Page 5 of 20
Cylinder Rebuild
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SB324013 — Page 6 of 20
2. Using a small screwdriver, remove the Teflon® seal and O-ring from the shift rail bore
inside the cylinder housing.
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3. Install a new O-ring (part of O-ring and seal assembly part No. 561KC23) into the
groove in the shift rail bore.
4. Form the Teflon® seal (part of O-ring and seal assembly part No. 561KC23) into a
kidney shape as shown in the figure below.
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SB324013 — Page 7 of 20
5. With the nose of the range shift cylinder Teflon® seal inserter (tool No. J 47357)
retracted, place the seal in the nose the tool and then push the fold outward to make it
sit as flat as possible in the nose.
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Figure 14 — Inserting Teflon® Seal in Nose of Insertion Tool (Tool No. J 47357)
6. Position the nose of the seal inserter in the cylinder housing shift rail bore.
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SB324013 — Page 8 of 20
8. Remove the tool and then push on the seal with your finger to make sure it is seated
against the O-ring. Also, push on the “V” fold of the seal to make sure it is seated, and
to remove some of the fold.
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SB324013 — Page 9 of 20
10. Continue gently pushing the tool into the bore until the flat end of the tool is flush with
the inside bottom of the cylinder.
Examine the seal as the tool is being pushed into place. If the
seal moves out of position on the O-ring, or if the fold or a portion
of the fold becomes kinked, immediately remove the tool and
reseat the seal against the O-ring before reattempting to use the
tool to seat the seal.
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Figure 19 — Installer/Sizer Tool Fully Inserted and End Flush with Bottom of Cylinder
11. After the tool has been fully inserted, leave the tool in place while the remaining
cylinder rebuild procedures are performed. This allows the Teflon® seal to form to the
circumference of the shift rail bore.
12. Remove the wiper ring from the piston groove.
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SB324013 — Page 10 of 20
13. Using a small screwdriver, remove the Teflon® seal and O-ring expander from the
second piston groove.
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14. Install a new O-ring (part of O-ring and seal assembly part No. 561KC22) into the lower
(wide) piston groove.
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SB324013 — Page 11 of 20
15. Carefully install the Teflon® seal (part of O-ring seal assembly part No. 561KC22) over
the O-ring. Work the seal over the O-ring by hand as much as possible. Once the seal
is in position, slide a small screwdriver under the section of the seal that is not in
position, and pry the seal into position.
Be sure the screwdriver does not have any sharp edges on the
blade or nicks on the shank. DO NOT over-stretch the Teflon®
seal, and make sure that the seal lips seat over each side of the
O-ring.
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16. Install the wiper ring into the upper (thin) piston groove.
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SB324013 — Page 12 of 20
17. Place the range shift piston seal sizer/piston installer (tool No. J 47359) flange-side
(pilot end) down on a clean flat surface.
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Figure 26 — Inserting Range Shift Piston into Seal Sizer/Piston Installer (Tool No. J 47359)
SB324013 — Page 13 of 20
19. Using a piece of crocus cloth, polish the end of the shift rail and around the setscrew
hole to remove any sharp edges or burrs. This will prevent damaging the seal as the
piston assembly is installed into the cylinder. Be sure to clean any debris from the shift
rail after polishing with the crocus cloth.
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Figure 27 — Polishing Shift Rail and Setscrew Hole with Crocus Cloth
20. Remove the piston assembly from the seal sizer/piston installer tool.
21. Carefully clamp the range shift cylinder assembly in a vise. DO NOT remove the range
shift cylinder Teflon® seal installer/sizer from the cylinder assembly. The tool will be
pushed from the shift rail bore as the piston assembly is being installed. Place the
range shift piston seal sizer/piston installer with the flanged-side (pilot end) on the
cylinder housing.
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Figure 28 — Placing Seal Sizer/Piston Installer (Tool No. J 47359) on Cylinder Housing
SB324013 — Page 14 of 20
22. Align the shift fork locking bolt hole in the shift rail with the air line fitting port in the
cylinder housing.
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Figure 29 — Aligning Shift Fork Locking Bolt Hole with Air Fitting Port in Cylinder Housing
23. Carefully push the piston assembly through the installation tool until it seats inside the
cylinder housing bore. Be sure to catch the range shift Teflon® seal installer/sizer as it
is being pushed from the shift rail bore.
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SB324013 — Page 15 of 20
Shift Cylinder Installation
1. Position the shift fork in the rear case with the tips of the fork inserted into the groove of
the sliding hub. The shift fork is marked with an “R”. Install the fork with the “R” facing
the rear of the transmission. When properly installed, the wider portion at the top of the
fork is facing the rear of the transmission.
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2. Install a cylinder housing gasket (part No. 629KB251) onto the cylinder housing
assembly. The red silicone bead on the gasket must face the transmission case.
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SB324013 — Page 16 of 20
3. Install the shift cylinder onto the rear case with the shift rail entering the shift fork bore.
Make sure that the shift fork locking bolt hole in the rail is facing up.
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4. After the cylinder has been seated against the rear case, use a light plastic mallet to
tap the piston further into the cylinder until the locking bolt hole in the shift rail aligns
with the hole in the shift fork.
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SB324013 — Page 17 of 20
5. Once the locking bolt holes are in alignment, install the bolt and tighten to 35–50 lb-ft
(48–68 N•m).
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SB324013 — Page 18 of 20
8. Install the cylinder housing end cover and the four bolts that secure the housing
assembly to the transmission rear case. Tighten the bolts to 27–33 lb-ft (37–45 N•m).
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SB324013 — Page 19 of 20
On certain earlier manufactured transmissions, there was no top
cover mounting bolt hole at the flange center location of the rear
case (refer to the illustration below), even though the top cover
had a bolt hole. This bolt hole was added to the rear case on
later transmissions.
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SB324013 — Page 20 of 20