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SERVICE BULLETIN

Number: SB324013
Date: 02/14/06
Model: T200, T300
(Does not apply to Mack Trucks Australia)

Rear-Mounted Range Shift Cylinder Rebuild Procedures


During mid-November 2005, the special service tools needed for rebuilding the two-position
range shift cylinders used on T200 and T300 series transmissions were made available.
These service tools are shown in the following illustration.
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Figure 1 — Range Shift Cylinder Seal Installation Tools

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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Figure 2 — Shift Cylinder Assembly

Key Part No. Description


1 561KC23 Seal, shift rail (consists of O-ring and Teflon® seal ring)
2 561KC22 Seal, piston (consists of O-ring and Teflon® seal ring)
3 89KB21 Wiper ring, shift cylinder
4 55KC421 Housing, shift cylinder
5 56AX558 O-ring, housing-to-cover
6 414KB3113 Cover, cylinder housing
7 6AX1642 Bolt
8 591KC3194 Piston/shift rail assembly
9 629KB251 Gasket

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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

1. O-Ring 2. Teflon® Seal

Cylinder rebuild procedures using these service tools are as follows:

Although the rear-mounted range shift arrangement used with


the T200 and T300 short compound transmissions is similar in
design to the arrangement used with the T2130, T2180, T313
and T318 long compound transmissions, the shift cylinder
assemblies are not interchangeable.

Cylinder Removal
1. Disconnect both air lines from the cylinder.
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Figure 4 — Air Lines Disconnected from Cylinder

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2. Remove the rear case top cover.
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Figure 5 — Removing Rear Case Top Cover


3. Remove the shift fork locking bolt.
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Figure 6 — Removing Shift Fork Locking Bolt


4. Remove the four bolts that secure the shift cylinder to the rear case.
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Figure 7 — Removing Shift Cylinder Bolts

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5. Remove the shift cylinder cover and O-ring.
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Figure 8 — Removing Shift Cylinder Cover

6. While holding the shift fork, slide the shift cylinder from the rear of the transmission.
Remove the shift cylinder-to-rear case gasket.

To facilitate removing the shift cylinder, use a plastic mallet to


lightly tap on the piston to loosen the shift rail from the fork.
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Figure 9 — Removing Shift Cylinder

SB324013 — Page 5 of 20
Cylinder Rebuild
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Figure 10 — Shift Cylinder — Exploded View

Key Qty. Part No. Description


1 1 561KC23 O-ring and seal, shift rail
2 1 561KC22 O-ring and seal, piston
3 1 89KB21 Wiper ring

1. Remove the piston/shift rail assembly from the cylinder housing.


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Figure 11 — Removing Piston/Shift Rail Assembly from Cylinder Housing

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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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Figure 12 — Removing Teflon® Seal and O-Ring Expander

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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Figure 13 — Forming Teflon® Seal into Kidney Shape

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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Figure 15 — Positioning Tool in Shift Rail Bore


7. Press the plunger down to fully extend the nose. This positions the seal inside the shift
rail bore over the O-ring.
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Figure 16 — Installing Teflon® Seal

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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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Figure 17 — Seal Properly Installed in Shift Rail Bore


9. Align the relief of the range shift cylinder Teflon® seal installer/sizer (tool No. J 47358)
with the “V” fold of the seal, and then gently insert the tool into the bore. DO NOT twist
the tool as it is being installed.
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Figure 18 — Inserting Teflon® Seal Installer/Sizer (Tool No. J 47358)

Using a piece of crocus cloth to polish and remove any sharp


edges from the installer/sizer tool will ensure that the seal will
not be damaged as it is being installed.

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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Figure 20 — Removing Wiper Ring from Piston Groove

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13. Using a small screwdriver, remove the Teflon® seal and O-ring expander from the
second piston groove.
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Figure 21 — Removing Teflon® Seal and O-Ring from Piston Groove

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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Figure 22 — Installing O-Ring in Lower (Wide) Piston Groove

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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Figure 23 — Installing Teflon® Seal

16. Install the wiper ring into the upper (thin) piston groove.
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Figure 24 — Installing Wiper Ring in Upper (Thin) Piston Groove

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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 25 — Piston Assembled in Seal Sizer/Piston Installer (Tool No. J 47359)


18. Slide the piston into the tool until it bottoms on the flat surface.
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Figure 26 — Inserting Range Shift Piston into Seal Sizer/Piston Installer (Tool No. J 47359)

It is recommended that the piston assembly be allowed to


remain in the seal sizer/piston installer tool for approximately 15
minutes before proceeding with the final assembly. This will
properly size the O-ring and seal to the piston, and make final
installation easier.

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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

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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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Figure 30 — Installing Piston into Range Shift Cylinder Housing

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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Figure 31 — Installing Shift Fork

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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Figure 32 — Installing Shift Cylinder Gasket

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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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Figure 33 — Installing Shift Cylinder Assembly

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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Figure 34 — Tapping Piston into Place to Align Locking Bolt Hole

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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Figure 35 — Installing Shift Fork Locking Screw


6. Apply a small amount of MACK O-ring Lubricant (part No. 243SX41) to the
circumference of the shift cylinder housing.
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Figure 36 — Applying O-Ring Lubricant to Shift Cylinder

7. Install the shift cylinder end cover O-ring.


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Figure 37 — Installing Range Shift Cylinder End Cover O-Ring

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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Figure 38 — Installing End Cover and Tightening Mounting Bolts


9. Install the air line fittings into the ports in the cylinder housing and the cylinder end
cover.
10. Apply a bead of Dow-Corning Silastic® 732RTV (part No. 342SX32) to the edges of the
top cover opening in the rear case housing.
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Figure 39 — Applying Silastic® Sealant to Top Cover Opening

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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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Figure 40 — Top Cover Mounting Bolt Hole


11. Install the top cover. Be sure to install the transmission lifting eye at the right-rear
corner of the top cover. Tighten the top cover bolts to 23–36 lb-ft (33–49 N•m).
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Figure 41 — Cover Plate Installed

1. Transmission Lifting Eye

12. Reconnect the air lines to the shift cylinder.

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