MT 600 Service Manual SM1317 199907

SM1317EN
Service
Manual
Allison Transmission
AUTOMATIC MODELS
MT 640, MT(B) 643
MT 650, MT(B) 653
AUGUST 1996
REVISED 199907
Division of General Motors Corporation
P.O. Box 894 Indianapolis, Indiana 46206-0894
Printed in the U.S.A.
Copyright 1996 General Motors Corp.
INTRODUCTION
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Amojell is a registered trademark of the Amoco Oil Company.
DEXRON is a registered trademark of General Motors Corporation.
Biobor JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.

Dykem is a registered trademark of the Dykem Company.
Loctite is a registered trademark of the Loctite Corporation.
Teflon is a registered trademark of the DuPont Corporation.
Permatex is a registered trademark of the Loctite Corporation.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by letter suffix to the publication number. Check with your
Allison Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of Transmissions Truck, Tractor, etc.
ii
IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cautions described in this Service Manual. These Warnings and Cautions advise against the
use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. It is, however, important to understand
that these Warnings and Cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in which
service might be done or of the possible hazardous consequences of each way. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special
tools should be used when and as recommended.
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
iii
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
When checking the transmission fluid level, be sure that the parking brake and/
or emergency brakes are set and properly engaged, and the wheels are blocked.
Unexpected and possible sudden movement may occur if these precautions are
not taken.
While conducting a stall check, the vehicle must be positively prevented from
moving. Apply the parking and service brake, and block the wheels securely.
Warn personnel to keep clear of the vehicle and its travel path. Failure to do so
can cause serious injury.
Do not burn discarded Teflon seals; toxic gases are produced by burning.
Never dry bearings with compressed air. A spinning bearing can disintegrate
allowing balls or rollers to become lethal flying projectiles. Also, spinning a
bearing without lubrication can damage the bearing.
Do not position the transmission so that its rear end is lower than its front end.
The components in the rear of the transmission are not secured. These
components could fall out and cause personal injury and/or damage to the parts.
Certain control valve body components are spring-loaded and must be
restrained while retaining pins or bolts are removed.
The main-pressure regulator valve spring is under approximately 65 lbs (290 kN)
compression.
Hydraulic fluid under 40 psi (280 kPa) pressure may be trapped in the output
retarder accumulators. Personal injury can occur if this pressure is accidently
released.
Accumulator piston springs are highly compressed. Use extreme caution during
removal of the accumulator cover. Personal injury can occur if the bolts are
removed without properly relieving the spring force.
The retarder piston return spring is highly compressed. Use extreme caution
during removal of the spring. Personal injury can occur if proper removal
procedures are not followed.
iv
MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

Paragraph
Page
Section 1. GENERAL INFORMATION

11. SCOPE OF MANUAL
a. Coverage . . . . . . . . . . . . . . . . . . . . . . . . . .11
b. Illustrations . . . . . . . . . . . . . . . . . . . . . . . .11
c. Maintenance Information . . . . . . . . . . . . .11
12. SUPPLEMENTARY INFORMATION . . . .11
13. ORDERING PARTS
a. Transmission Nameplate . . . . . . . . . . . . .11
b. Parts Catalog. . . . . . . . . . . . . . . . . . . . . . .11
14. GENERAL DESCRIPTION
a. Number of Speeds . . . . . . . . . . . . . . . . . .11
b. Torque Converter and Lockup Clutch . . .11
c. Planetary Gearing, Clutches . . . . . . . . . . .16
d. Output Retarder . . . . . . . . . . . . . . . . . . . .16
15. OPERATING INSTRUCTIONS . . . . . . . . . .16
16. SPECIFICATIONS AND DATA . . . . . . . . .16
Section 2. DESCRIPTION AND OPERATION

21. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
22. DESIGNATION OF CLUTCHES AND
PLANETARY GEAR SETS
a. Clutch Designations . . . . . . . . . . . . . . . . .21
b. Planetary Gear Set Designations . . . . . . .21
23. MOUNTING
a. To Engine . . . . . . . . . . . . . . . . . . . . . . . . .21
b. To Vehicle . . . . . . . . . . . . . . . . . . . . . . . .21
c. Output Retarder Mount. . . . . . . . . . . . . . .22
24. INPUT DRIVE . . . . . . . . . . . . . . . . . . . . . . . .22
25. TRANSMISSION HOUSING . . . . . . . . . . . .22
26. TORQUE CONVERTER
a. Description . . . . . . . . . . . . . . . . . . . . . . . .22
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . .22
27. LOCKUP CLUTCH
a. Description . . . . . . . . . . . . . . . . . . . . . . . .22
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . .23
28. OIL PUMP ASSEMBLY
a. Description . . . . . . . . . . . . . . . . . . . . . . . .23
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . .23
29. OIL PUMP AND FRONT SUPPORT
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . .23
210. FORWARD CLUTCH AND TURBINE SHAFT
a. Description . . . . . . . . . . . . . . . . . . . . . . . .23
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . .23
Paragraph
Page
211. FOURTH CLUTCH

a. Description . . . . . . . . . . . . . . . . . . . . . . . 24
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 24
212. THIRD CLUTCH, CENTER SUPPORT, AND
SECOND CLUTCH
a. Description . . . . . . . . . . . . . . . . . . . . . . . 24
b. Operation of Third Clutch . . . . . . . . . . . 24
c. Operation of Second Clutch . . . . . . . . . . 25
213. FIRST CLUTCH
a. Description . . . . . . . . . . . . . . . . . . . . . . . 25
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 25
214. PLANETARY GEAR UNIT
a. Description . . . . . . . . . . . . . . . . . . . . . . . 25
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 26
215. LOW CLUTCH (MT 650, 653 Only)
a. Description . . . . . . . . . . . . . . . . . . . . . . . 26
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 26
216. LOW PLANETARY GEARING
(MT 650, 653 Only)
a. Description . . . . . . . . . . . . . . . . . . . . . . . 27
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
217. GOVERNOR DRIVE
a. Description (MT 650, 653). . . . . . . . . . . 27
b. Description (MTB 653) . . . . . . . . . . . . . 27
c. Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
218. SPEEDOMETER DRIVE/SPEED
SENSOR WHEEL
a. Description . . . . . . . . . . . . . . . . . . . . . . . 27
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 27
219. MODULATOR
a. Vacuum Modulator. . . . . . . . . . . . . . . . . 28
b. Mechanical Modulator . . . . . . . . . . . . . . 28
c. Electric Modulator . . . . . . . . . . . . . . . . . 28
220. CONTROL VALVE ASSEMBLIES
a. Description . . . . . . . . . . . . . . . . . . . . . . . 28
b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 28
221. OIL PAN AND FILTER
a. Description . . . . . . . . . . . . . . . . . . . . . . . 28
b. Function . . . . . . . . . . . . . . . . . . . . . . . . . 28

Paragraph
Page
222. REAR COVER

a. Description . . . . . . . . . . . . . . . . . . . . . . . .29
b. Function . . . . . . . . . . . . . . . . . . . . . . . . . .29
223. OUTPUT RETARDER
a. Description . . . . . . . . . . . . . . . . . . . . . . . .29
b. Function . . . . . . . . . . . . . . . . . . . . . . . . . .29
224. HYDRAULIC SYSTEM
a. System Functions . . . . . . . . . . . . . . . . . . .29
b. System Schematics . . . . . . . . . . . . . . . . . .29
c. Filter, Pump Circuit . . . . . . . . . . . . . . . . .29
d. Main-Pressure Circuit (Red). . . . . . . . . . .29
e. Converter-In (Yellow), Converter-Out
(Orange), Lubrication (Green)
Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .210
f. Selector Valve, Forward Regulator
Circuit (Red and Blue) MT 640, 643 . . .210
g. Selector Valve, Forward Regulator
Circuit (Red and Blue) MT 650, 653 . . .210
h. Governor Circuit (Green and White) . . .210
i. Modulator Pressure Circuit (Red and
Green) . . . . . . . . . . . . . . . . . . . . . . . . . . .211
j. Trimmer Regulator Valve (Green and
Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . .212
k. Trimmer Valves . . . . . . . . . . . . . . . . . . .212
l. Lockup Circuit . . . . . . . . . . . . . . . . . . . .212
m. Priority Valve . . . . . . . . . . . . . . . . . . . . .213
n. 21 Inhibitor Valve MT 650, 653 . . .213
o. Clutch Circuits, Hold Regulator
Circuits, Drive Ranges . . . . . . . . . . . . . .213
p. Automatic Upshifts. . . . . . . . . . . . . . . . .215
q. Automatic Downshifts . . . . . . . . . . . . . .215
r. Downshift and Reverse Inhibiting . . . . .215
225. RETARDER HYDRAULIC CIRCUIT
COMPONENTS
a. Circuit Schematic . . . . . . . . . . . . . . . . . .215
b. Priority Valve . . . . . . . . . . . . . . . . . . . . .215
c. Driver Retarder Control . . . . . . . . . . . . .216
d. Retarder Valve . . . . . . . . . . . . . . . . . . . .216
e. Cutoff Valve . . . . . . . . . . . . . . . . . . . . . .216
f. Retarder Pressure Regulator Valve . . . .216
g. Charging Valve. . . . . . . . . . . . . . . . . . . .216
226. RETARDER HYDRAULIC CIRCUIT
FUNCTION
a. Retarder Valve Off (Vehicle Moving) . . .216
b. Retarder Valve Partially Applied . . . . . .216
c. Retarder Valve Fully Applied . . . . . . . .217
vi
Paragraph
227. TORQUE PATHS THROUGH THE

TRANSMISSION
a. Converter Operation . . . . . . . . . . . . . . .
b. Lockup Operation . . . . . . . . . . . . . . . . .
c. Neutral Operation (MT 640, 643) . . . .
d. First Range Operation
(MT 640, 643) . . . . . . . . . . . . . . . . . . .
e. Second Range Operation
(MT 640, 643) . . . . . . . . . . . . . . . . . . .
f. Third Range Operation
(MT 640, 643) . . . . . . . . . . . . . . . . . . .
g. Fourth Range Operation
(MT 640, 643) . . . . . . . . . . . . . . . . . . .
h. Reverse Range Operation
(MT 640, 643) . . . . . . . . . . . . . . . . . . .
i. Neutral Operation (MT 650, 653) . . . .
j. First Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
k. Second Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
l. Third Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
m. Fourth Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
n. Fifth Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
o. Reverse Range Operation
(MT 650, 653) . . . . . . . . . . . . . . . . . . .
Page
217
217
218
219
220
221
222
223
224
225
226
227
228
229
230
Section 3. PREVENTIVE MAINTENANCE

31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
32. INSPECTION AND CARE . . . . . . . . . . . . . 31
33. IMPORTANCE OF PROPER
TRANSMISSION FLUID LEVEL
a. Effects of Improper Fluid Level . . . . . . . 31
b. Foaming and Aerating . . . . . . . . . . . . . . 31
34. DIPSTICK MARKINGS . . . . . . . . . . . . . . . 31
35. TRANSMISSION FLUID LEVEL CHECK
PROCEDURE
a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 32
b. Cold Check . . . . . . . . . . . . . . . . . . . . . . . 32
c. Hot Check . . . . . . . . . . . . . . . . . . . . . . . . 33
36. KEEPING TRANSMISSION FLUID
CLEAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Paragraph
Page
37. TRANSMISSION FLUID

RECOMMENDATIONS
a. Recommended Automatic Transmission
Fluid and Viscosity Grade . . . . . . . . . . . .34
38. TRANSMISSION FLUID AND FILTER
CHANGE INTERVALS . . . . . . . . . . . . . . . .34
39. TRANSMISSION FLUID CONTAMINATION
a. Examine at Fluid Change . . . . . . . . . . . . .35
b. Metal Particles . . . . . . . . . . . . . . . . . . . . .35
c. Coolant Leakage . . . . . . . . . . . . . . . . . . . .35
d. Auxiliary Filter . . . . . . . . . . . . . . . . . . . . .36
310. TRANSMISSION FLUID AND FILTER
CHANGE PROCEDURES
a. Fluid Change Procedure (Standard
Configuration, 4.3 and 5.1 Inch Pan) . . . .36
b. Fluid Change Procedure (External
Access Heavy-Duty Configuration,
7.14 Inch Pan). . . . . . . . . . . . . . . . . . . . . .38
c. Governor Filter Change Procedures . . . . .38
311. BREATHER. . . . . . . . . . . . . . . . . . . . . . . . .310
312. LINKAGE
a. Shift Selector Lever and Control
Linkage . . . . . . . . . . . . . . . . . . . . . . . . . .310
b. Mechanical Actuator Adjustment. . . . . .311
c. Other Linkage Adjustments . . . . . . . . . .311
313. ADJUSTMENT OF SHIFT POINTS
a. Calibrated on Test Stand or in Vehicle . . .311
b. Location of Adjusting Components . . . .311
c. Checks Before Adjusting Shift Points. . . . .311
d. Calibration by Road Test Method . . . . .312
e. Calibration by Speedometer Readings
Method . . . . . . . . . . . . . . . . . . . . . . . . . .312
f. Calibration by Test Stand Method . . . . .312
Paragraph
Page
d. Stall Test Procedures Vehicles

With Smoke-Controlled Engines . . . . . 327
e. Neutral Cool-Down Check Procedure. . . 328
f. Results. . . . . . . . . . . . . . . . . . . . . . . . . . 328
316. PRESERVATION AND STORAGE
a. Storage, New Transmissions . . . . . . . .
b. Preservation Methods . . . . . . . . . . . . . .
c. Storage, One Year Without
Transmission Fluid . . . . . . . . . . . . . . . .
d. Storage, One Year With
Transmission Fluid . . . . . . . . . . . . . . . .
e. Restoring Transmission to Service. . . .
328
328
328
328
329
317. REPLACEMENT OF COMPONENTS WHILE

TRANSMISSION IS IN THE VEHICLE
CHASSIS
a. Replacement of Selector Shaft Seal . . . 329
b. Removal of Output Flange . . . . . . . . . . 330
c. Removal of Dust Shield and Output
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . 330
d. Removal of Output Shaft Bearing . . . . 330
e. Removal of Governor and Speedometer
Drive Gear . . . . . . . . . . . . . . . . . . . . . . 331
f. Install Governor and Speedometer Drive
Gears, Rear Bearing, Oil Seal, and Dust
Shield . . . . . . . . . . . . . . . . . . . . . . . . . . 331
g. Installation of Output
Flange MT 640, 643 . . . . . . . . . . . . 331
h. Installation of Output Flange
MTB 643, MT(B) 650, 653 . . . . . . . . . 333
318. TROUBLESHOOTING BEFORE
REMOVAL OR OPERATION OF
TRANSMISSION . . . . . . . . . . . . . . . . . . . 333
REMOVAL AND DURING OPERATION
a. Determine Cause of Trouble . . . . . . . . 333
b. Proper Engine Tuning. . . . . . . . . . . . . . 333
b. Stall Test Preparation . . . . . . . . . . . . . . .327
320. OUTPUT RETARDER TROUBLESHOOTING BEFORE REMOVAL

a. High Speed Mode Pressure Function
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
b. Static Mode Pressure Function Test. . . 334
c. Stall Test Procedures Vehicles

Without Smoke-Controlled Engines . . .327
321. TROUBLESHOOTING TRANSMISSION

REMOVED FROM VEHICLE . . . . . . . . . 334
314. OIL COOLER . . . . . . . . . . . . . . . . . . . . . . .326

315. TRANSMISSION STALL TEST
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . .326
vii

Paragraph
Page
322. TROUBLESHOOTING PROCEDURES

a. Troubleshooting Information . . . . . . . . .334
b. Fluid Pressures . . . . . . . . . . . . . . . . . . . .334
c. Increasing Pump Volume . . . . . . . . . . . .334
Section 4. GENERAL OVERHAUL

INFORMATION
41. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
42. TOOLS AND EQUIPMENT
a. Improvised Tools and Equipment . . . . . .41
b. Special Tools . . . . . . . . . . . . . . . . . . . . . .41
c. Mechanics Tools, Shop Equipment . . . .41
43. REPLACEMENT PARTS
a. Ordering Information . . . . . . . . . . . . . . . .42
c. Parts Normally Replaced . . . . . . . . . . . . .42
Paragraph
Page
c. External Pipe Plugs, Hydraulic

Fittings . . . . . . . . . . . . . . . . . . . . . . . . .
d. Oil-Soluble Grease . . . . . . . . . . . . . . . .
e. Lip-Type Seals . . . . . . . . . . . . . . . . . . .
f. Butt-Joint Sealrings . . . . . . . . . . . . . . .
g. Interference-Fit Parts . . . . . . . . . . . . . .
h. Sleeve-Type Bearings and Bushings . .
i. Bearings (Ball or Roller) . . . . . . . . . . .
j. Clutch Snaprings. . . . . . . . . . . . . . . . . .
415
416
416
416
417
417
417
417
47. REMOVING (OR INSTALLING)

TRANSMISSION
a. Drain Transmission Fluid . . . . . . . . . . .
b. Check Linkages and Lines . . . . . . . . . .
c. Retain Torque Converter . . . . . . . . . . .
d. Clean Transmission . . . . . . . . . . . . . . .
e. Transmission Installation . . . . . . . . . . .
417
417
417
417
418
48. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . 418

49. SPRING SPECIFICATIONS. . . . . . . . . . . 418
44. CAREFUL HANDLING . . . . . . . . . . . . . . . .42
410. TORQUE SPECIFICATIONS. . . . . . . . . . 418
45. CLEANING AND INSPECTION

a. Dirt-Free Assembly . . . . . . . . . . . . . . . .412
b. Cleaning Parts. . . . . . . . . . . . . . . . . . . . .412
c. Cleaning Bearings. . . . . . . . . . . . . . . . . .412
d. Inspecting Bearings . . . . . . . . . . . . . . . .412
e. Keeping Bearings Clean . . . . . . . . . . . . .412
f. Inspecting Cast Parts, Machined
Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . .412
g. Inspecting Bushings, Thrust Washers . . . .413
h. Inspecting Oil Seals, Gaskets . . . . . . . . .413
i. Inspecting Gears . . . . . . . . . . . . . . . . . . .413
j. Inspecting Shafts. . . . . . . . . . . . . . . . . . .414
k. Inspecting Splined Parts . . . . . . . . . . . . .414
l. Inspecting Threaded Parts . . . . . . . . . . .414
m. Inspecting Snaprings . . . . . . . . . . . . . . .415
n. Inspecting Springs . . . . . . . . . . . . . . . . .415
o. Inspecting Clutch Plates . . . . . . . . . . . . .415
p. Inspecting Swaged, Interference-Fit
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .415
q. Inspecting Balls in Clutch Housings . . . .415
r. Inspecting Seal Contact Surfaces . . . . . .415
411. SELECTIVE PARTS . . . . . . . . . . . . . . . . . 418
46. ASSEMBLY PROCEDURES

a. Clutches, Pistons. . . . . . . . . . . . . . . . . . .415
b. Parts Lubrication. . . . . . . . . . . . . . . . . . .415
viii
Section 5. DISASSEMBLY OF
TRANSMISSION
51. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
52. GENERAL INFORMATION . . . . . . . . . . . 51
53. MOUNTING TRANSMISSION IN HOLDING
FIXTURE OR OVERHAUL STAND. . . . . 51
a. Mounting of Transmission in TableMounted Holding Fixture . . . . . . . . . . . . 51
b. Mounting of Transmission in Overhaul
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
54. PREPARATION FOR DISASSEMBLY
(MTB Series Only)
a. Relieving Trapped Hydraulic Pressure. . 51
b. Removing Hose Assemblies, Fittings,
and Brackets . . . . . . . . . . . . . . . . . . . . . . 52
55. REMOVAL OF TORQUE CONVERTER, OIL
PAN, AND FILTER
a. Removal of Torque Converter . . . . . . . . 52
b. Removal of Oil Pan and Filter (Standard
Configuration). . . . . . . . . . . . . . . . . . . . . 52
c. Removal of Oil Pan and Filter (HeavyDuty Configuration) . . . . . . . . . . . . . . . . 53

Paragraph
Page
56. REMOVAL OF HYDRAULIC COMPONENTS

(MT(B) 640, 643)
a. Modulated Lockup Valve Body . . . . . . . .53
b. Tube Adapter . . . . . . . . . . . . . . . . . . . . . .54
c. Control Valve Assembly . . . . . . . . . . . . .54
57. REMOVAL OF HYDRAULIC CONTROL
COMPONENTS (MT(B) 650, 653)
a. Modulated Lockup Valve Body . . . . . . . .54
b. Low Shift Valve Assembly . . . . . . . . . . .54
c. Control Valve Assembly . . . . . . . . . . . . .55
58. REMOVAL OF OIL PUMP AND FRONT
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . .55
59. REMOVAL OF FORWARD, FOURTH, AND
THIRD CLUTCHES, AND CENTER
SUPPORT
a. Forward Clutch . . . . . . . . . . . . . . . . . . . . .56
b. Fourth Clutch . . . . . . . . . . . . . . . . . . . . . .56
c. Third Clutch . . . . . . . . . . . . . . . . . . . . . . .56
d. Center Support . . . . . . . . . . . . . . . . . . . . .56
510. REMOVAL OF GOVERNOR, GEAR UNIT,
SECOND CLUTCH, AND FIRST CLUTCH
a. Governor . . . . . . . . . . . . . . . . . . . . . . . . . .57
b. Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . .58
c. Second Clutch. . . . . . . . . . . . . . . . . . . . . .58
d. First Clutch . . . . . . . . . . . . . . . . . . . . . . . .58
511. REMOVAL OF GEAR UNIT, SECOND
CLUTCH, FIRST CLUTCH, AND
GOVERNOR (MTB 643, MT(B) 650, 653)
a. Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . .58
b. Second Clutch. . . . . . . . . . . . . . . . . . . . . .58
c. First Clutch . . . . . . . . . . . . . . . . . . . . . . . .59
d. Governor . . . . . . . . . . . . . . . . . . . . . . . . . .59
512. REMOVAL OF REAR COVER (MT 640, 643,
650, 653)
a. Positioning . . . . . . . . . . . . . . . . . . . . . . . .59
b. MT 640, 643 Rear Cover . . . . . . . . . . . . .59
c. MT 650, 653 Rear Cover . . . . . . . . . . . . .59
513. REMOVAL OF OUTPUT RETARDER
(MTB 643, 653)
a. Retarder Control Valve Assembly . . . . .510
b. Retarder Housing . . . . . . . . . . . . . . . . . .510
c. Retarder Adapter Housing . . . . . . . . . . .512
Paragraph
Page
514. REMOVAL OF LOW CLUTCH, LOW

PLANETARY, AND LOW GEAR ADAPTER
HOUSING (MT(B) 650, 653)
a. Low Clutch . . . . . . . . . . . . . . . . . . . . . . 512
b. Low Planetary Carrier . . . . . . . . . . . . . 512
c. Low Clutch Adapter Housing. . . . . . . . 512
Section 6. REBUILD OF SUBASSEMBLIES

61. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . 61
b. Procedures. . . . . . . . . . . . . . . . . . . . . . . . 61
62. GENERAL INFORMATION FOR REBUILD
OF SUBASSEMBLIES . . . . . . . . . . . . . . . . 61
63. TORQUE CONVERTER ASSEMBLY
a. Check the End Play. . . . . . . . . . . . . . . . .
b. Disassembly . . . . . . . . . . . . . . . . . . . . . .
c. Rebuilding Stator Assembly. . . . . . . . . .
d. Rebuilding Torque Converter Turbine
Assembly . . . . . . . . . . . . . . . . . . . . . . . .
e. Rework of Converter Pump Hub . . . . . .
f. Assembly . . . . . . . . . . . . . . . . . . . . . . . .
61
62
64
66
68
68
64. MODULATED LOCKUP VALVE BODY

ASSEMBLY
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 610
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 610
65. LOW SHIFT VALVE ASSEMBLY
(MT(B) 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 611
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 611
66. CONTROL VALVE ASSEMBLY
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 611
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 613
67. RETARDER CONTROL VALVE ASSEMBLY
(MTB Series Only)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 615
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 616
68. OIL PUMP AND FRONT SUPPORT
ASSEMBLY
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 616
b. Rework of Front Support Sealring
Grooves. . . . . . . . . . . . . . . . . . . . . . . . . 618
c. Assembly . . . . . . . . . . . . . . . . . . . . . . . 618
ix

Paragraph
Page
69. FORWARD CLUTCH AND TURBINE SHAFT

a. Disassembly . . . . . . . . . . . . . . . . . . . . . .623
b. Rework of Rotating Sealring Bore,
Forward Clutch . . . . . . . . . . . . . . . . . . . .624
c. Assembly . . . . . . . . . . . . . . . . . . . . . . . .626
610. FOURTH CLUTCH
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .628
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .628
611. CENTER SUPPORT ASSEMBLY
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .630
b. Rework Center Support Anchor Bolt
Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . .630
c. Rework of Center Support for One
Piece Thrust Bearing Race Assembly. . .631
d. Rework of Non-Eccentric Center
Support to Eccentric Support . . . . . . . . . 6-31
e. Assembly . . . . . . . . . . . . . . . . . . . . . . . .632
Paragraph
Page
618. OUTPUT RETARDER HOUSING

(MTB 643, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 648
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 649
619. RETARDER ADAPTER HOUSING
(MTB 643, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 652
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 655
620. LOW CLUTCH ADAPTER HOUSING AND
FIRST CLUTCH PISTON (MT(B) 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 656
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 657
621. TRANSMISSION HOUSING
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 657
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 658
622. GOVERNOR
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 659
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 659
612. GEAR UNIT AND MAIN SHAFT ASSEMBLY

(MT(B) 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .634
b. Installing Replacement Sun Gear Shaft
Bushings . . . . . . . . . . . . . . . . . . . . . . . . .636
c. Assembly . . . . . . . . . . . . . . . . . . . . . . . .636
623. CLUTCH STACK MEASUREMENT

a. Methods . . . . . . . . . . . . . . . . . . . . . . . .
b. Forward Clutch . . . . . . . . . . . . . . . . . . .
c. Fourth Clutch . . . . . . . . . . . . . . . . . . . .
d. Low Clutch MT 650, 653 . . . . . . . .
e. First Clutch . . . . . . . . . . . . . . . . . . . . . .
f. Second and Third Clutches. . . . . . . . . .

(MT 640, 643)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .639
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .639
624. PLANETARY CARRIER ASSEMBLIES

a. Assembly Inspection. . . . . . . . . . . . . . . 661
b. Removal of Pinion Components. . . . . . 662
c. Replacing Bushing in Front and Low
Planetary Carrier Assemblies . . . . . . . . 662
d. Rework Center Carrier for Non-Rotating
Thrust Washers . . . . . . . . . . . . . . . . . . . 665
e. Installation of Pinion Components . . . . 665

(MTB 643)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .641
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .642
615. OUTPUT SHAFT (MT 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .642
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .643
616. REAR COVER ASSEMBLY (MT 650, 653)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .643
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .645
617. REAR COVER ASSEMBLY (MT 640, 643)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . .647
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . .647
659
660
660
660
660
661
Section 7. ASSEMBLY OF TRANSMISSION

71. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
72. GENERAL INFORMATION FOR
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . 71
73. INSTALLATION OF CLUTCHES, CENTER
SUPPORT, PLANETARY GEARING, AND
REAR COVER OR RETARDER
a. Selecting Center Support Snapring . . . . 71
b. Second Clutch Clearance . . . . . . . . . . . . 72

Paragraph
Page
c. Rear Cover MT 640, 643. . . . . . . . . . .73

d. Output Retarder MTB 643 . . . . . . . . .73
e. First Clutch Clearance MT(B) 640,
643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
f. Low Clutch Clearance
MT(B) 650, 653 . . . . . . . . . . . . . . . . . . . .76
g. Low Clutch Planetary MT(B) 650,
653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
h. Rear Cover, Governor
MT 650, 653 . . . . . . . . . . . . . . . . . . . . . . .78
i. Output Retarder MTB 653 . . . . . . . . .79
j. First Clutch Clearance
MT(B) 650, 653 . . . . . . . . . . . . . . . . . . .710
k. Gear Unit Assembly
MT(B) 640, 643 . . . . . . . . . . . . . . . . . . .711
l. Gear Unit Assembly
MT(B) 650, 653 . . . . . . . . . . . . . . . . . . .712
m. Second Clutch. . . . . . . . . . . . . . . . . . . . .712
n. Center Support . . . . . . . . . . . . . . . . . . . .712
o. Third Clutch Clearance. . . . . . . . . . . . . .713
p. Fourth Clutch . . . . . . . . . . . . . . . . . . . . .714
q. Forward Clutch and Turbine Shaft. . . . .714
74. INSTALLATION OF OIL PUMP AND
FRONT SUPPORT . . . . . . . . . . . . . . . . . . .715
75. INSTALLATION OF HYDRAULIC
CONTROL COMPONENTS
a. Control Valve Assembly
MT(B) 640, 643 . . . . . . . . . . . . . . . . . . .716
b. Tube Adapter MT(B) 640, 643 . . . . .717
c. Control Valve Assembly
MT(B) 650, 653 . . . . . . . . . . . . . . . . . . .717
d. Low Shift Valve Body
MT(B) 650, 653 . . . . . . . . . . . . . . . . . . .718
e. Valve Tubing MT(B) 650, 653 . . . . .719
f. Modulated Lockup Valve Assembly . . .719
Paragraph
Page
77. INSTALLING RETARDER EXTERNAL

COMPONENTS (MTB 643, 653)
a. Retarder Valve Body . . . . . . . . . . . . . . 722
b. Hose Assemblies, Fittings, and
Brackets . . . . . . . . . . . . . . . . . . . . . . . . 722
78. INSTALLING GOVERNOR AND
GOVERNOR COVER . . . . . . . . . . . . . . . . 723
79. INSTALLATION OF OUTPUT
COMPONENTS (MT 640, 643, 650, 653)
a. Governor and Speedometer Drive
Gears, Ring Bearing . . . . . . . . . . . . . . . 724
b. Oil Seal, Dust Shield . . . . . . . . . . . . . . 725
710. REMOVAL OF TRANSMISSION FROM
OVERHAUL STAND AND INSTALLATION
OF NEUTRAL START SWITCH
a. Supporting Transmission . . . . . . . . . . . 726
b. Installing PTO Cover . . . . . . . . . . . . . . 726
711. CHECKING SHIFT POINTS . . . . . . . . . . 727
712. POWER TAKEOFF COMPONENTS
a. Establishing PTO Backlash . . . . . . . . . 727
b. New Installation . . . . . . . . . . . . . . . . . . 727
Section 8. WEAR LIMITS AND SPRING DATA

81. WEAR LIMITS DATA
a. Maximum Variations . . . . . . . . . . . . . . . 81
b. Cleaning and Inspection . . . . . . . . . . . . . 81
82. SPRING DATA . . . . . . . . . . . . . . . . . . . . . . 81
Section 9. CUSTOMER SERVICE

91. OWNER ASSISTANCE . . . . . . . . . . . . . . . 91
92. SERVICE LITERATURE . . . . . . . . . . . . . . 92
76. INSTALLATION OF OIL FILTER, PAN,

TORQUE CONVERTER
a. Oil Filter (Standard Configuration) . . . .720
b. Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . .720
c. Oil Filter Canister (Heavy-Duty
Configuration) . . . . . . . . . . . . . . . . . . . .721
d. Oil Pan and Filter (Heavy-Duty
Configuration) . . . . . . . . . . . . . . . . . . . .721
e. Torque Converter . . . . . . . . . . . . . . . . . .721
xi

LIST OF FOLDOUT ILLUSTRATIONS
(Back of Service Manual)
CROSSSECTION VIEWS
Foldout
1
2
Model MT(B) 640, 643 Automatic Transmission

Model MT(B) 650, 653 Automatic Transmission
SCHEMATIC VIEWS
Foldout
3
4
5
Model MT(B) 640, 643 Transmission Hydraulic System

Model MT(B) 650, 653 Transmission Hydraulic System
Model MTB 643, 653 Output Retarder Hydraulic System
EXPLODED VIEWS
Foldout
6
7,A
7,B
8,A
8,B
9,A
9,B
10,A
10,B
11,A
11,B
12,A
12,B
13
14
15,A
15,B
16
17,A
17,B
18,A
18,B
19,A
19,B
xii
Torque Converter and Lockup Clutch

Oil Pump and Front Support Assembly
Forward Clutch and Turbine Shaft Assembly
Fourth Clutch Assembly
Third Clutch, Center Support, and Second Clutch
Gear Unit Assembly MT(B) 640, 643
Gear Unit Assembly MT(B) 650, 653
Transmission Housing, Standard Oil Filter and Oil Pan Configurations
Heavy-Duty Oil Filter and Oil Pan Configuration
First Clutch and Rear Planetary Ring Gears
Low Clutch, Planetary, and Adapter Housing MT(B) 650, 653
Rear Cover Components MT 640, 643
Output Shaft and Rear Cover Components MT 650, 653
Control Valve Body Assembly MT(B) 640, 643
Control Valve Body Assembly MT(B) 650, 653
Modulated Lockup Valve Body Assembly
Low Shift Valve Body Assembly MT(B) 650, 653
Parking Brake Assemblies
Retarder Accumulators and Governor
Retarder Control Valve
Retarder Housing
Retarder Clutch
MTB 643 Retarder Adapter
MTB 653 Retarder Adapter
Section 1 GENERAL INFORMATION

11.
SCOPE OF MANUAL
3. Required tools and fixtures are available as

outlined in the Service Manual.
a. Coverage
1. This Service Manual describes the operation,
maintenance, and overhaul procedures for the
MT 640, MT(B) 643, MT 650, and MT(B) 653
Series automatic transmissions (Figures 11
through 18). Descriptions of the major components of the transmissions, the function and
operation of the hydraulic system, wear limits,
and inspection procedures are included. Torque
specifications are given with each assembly
step and on the exploded view foldouts at the
back of this manual.
2. Because of similarities between models, instructions apply generally to all models. Where
procedures vary between models, instructions
identify specific models.
b. Illustrations. Overhaul procedures are illustrated
mainly by photographs. Line drawings are used to supplement detailed assembly procedures; cross sections
show torque paths and the relationship of assembled
parts. Cross sections, color-coded hydraulic schematics, and exploded views are on foldouts at the back of
the manual. The foldouts may be opened for reference
while studying the text.
4. Reasonable and prudent maintenance practices are utilized.

NOTE:
Service organizations and individuals are encouraged to contact their local Allison Transmission Distributor for information and guidance on any of the
tasks outlined herein.
12. SUPPLEMENTARY INFORMATION

Supplementary information will be issued, as required,
to cover any improvements made after publication of
this manual. Check with your dealer or distributor to
ensure you have the latest information.
13. ORDERING PARTS

a. Transmission Nameplate. The nameplate (Figure 19) is located on the right-rear side of the transmission. The nameplate shows the transmission serial
number, part number (assembly number), and model
designation, all three of which must be supplied when
ordering replacement parts or requesting service information.
c. Maintenance Information. Each task outlined in

this Service Manual has been successfully accomplished by service organizations and individuals. It is
not expected that every service organization or individual will possess the required special tooling, training, or experience to perform all the tasks outlined.
However, any task outlined herein may be performed
if the following conditions are met:
b. Parts Catalog. Do not order by illustration item

numbers on exploded views in this manual. All replacement parts should be ordered from your distributor or dealer. Parts are listed in the current Parts Catalog PC1316EN.
1. The organization or individual has the required

knowledge of the task through:
a. Number of Speeds. The MT(B) 640, 643 have

four forward speeds and one reverse. The MT(B) 650,
653 have five forward speeds and one reverse. Shifting
within the forward ranges selected by the operator is
fully automatic.
Formal
instruction in an Allison or
Distributor training facility.
On-the-job instruction by an Allison or
Distributor representative.
Experience in performing the task.
2. The work environment is suitable to prevent

contamination or damage to transmission parts
or assemblies.
14. GENERAL DESCRIPTION
b. Torque Converter and Lockup Clutch. An

Allison three-element torque converter (Foldout 1 or
2) transmits power from the engine to the transmission
gearing. The torque converter serves as both a fluid
coupling and a torque multiplier. MT 600 Series
transmissions also include a lockup clutch in the
torque converter assembly.
11

BREATHER
TRANSMISSION
HOUSING
REAR COVER
MOUNTING PAD
PARKING BRAKE
MOUNTING PAD
OUTPUT SHAFT
NEUTRAL START
SWITCH PLUG
SPEEDOMETER
DRIVE OPENING
SELECTOR SHAFT
GOVERNOR COVER
MAIN PRESSURE
GOVERNOR PRESSURE
GOVERNOR FILTER
FILL TUBE OPENING
MODULATOR
ACTUATOR OPENING
OIL PAN
H00042.01
Figure 11. Model MT 640 or MT 643 Automatic Transmission Left-Rear View
TO COOLER PORT
TORQUE
CONVERTER
PTO COVER
FROM
COOLER
PORT
NAMEPLATE
DRAIN PLUG
FILL TUBE OPENING
CONVERTER
RESTRAINING
STRAP
OIL PAN
H00041
Figure 12. Model MT 640 or MT 643 Automatic Transmission Right-Front View
12
GENERAL INFORMATION
TRANSMISSION HOUSING
ADAPTER HOUSING
SPEEDOMETER
DRIVE OPENING
BREATHER
REAR COVER
FLANGE NUT
PARKING BRAKE
MOUNTING PAD
GOVERNOR FILTER
SELECTOR SHAFT
NEUTRAL START
SWITCH PLUG
GOVERNOR COVER
MAIN PRESSURE
FILL TUBE OPENING
GOVERNOR PRESSURE
MODULATOR
ACTUATOR
OPENING
H00001.01
Figure 13. Model MT 650 or MT 653 Automatic Transmission Left-Rear View
TO COOLER
MOUNTING PAD
PTO COVER
BRAKE MOUNTING
PAD
NAMEPLATE
TORQUE
CONVERTER
FROM COOLER
DRAIN PLUG
OIL PAN
FILL TUBE OPENING
H00002
Figure 14. Model MT 650 or MT 653 Automatic Transmission Right-Front View
13

TO RETARDER
CLUTCH
ADAPTER HOUSING
FROM CONVERTER
RETARDER HOUSING
FROM EXTERNAL
FILTER TO LUBE
TO EXTERNAL FILTER
ACCUMULATOR
REGULATING VALVE ASSEMBLY
CHECK VALVE
RETARDER VALVE BODY
H00003
Figure 15. Model MTB 643 Automatic Transmission Right-Rear View
TO RETARDER CLUTCH
BREATHER
SPEEDOMETER PORT
OUTPUT FLANGE NUT
OUTPUT FLANGE
FILL TUBE
OPENING
GOVERNOR COVER
Figure 16. Model MTB 643 Automatic Transmission Left-Rear View
14
H00004
GENERAL INFORMATION
RETARDER CONTROL
AIR PRESSURE
TO EXTERNAL
FILTER
MOUNTING
PADS
CONVERTER
RESTRAINING
STRAP
CHECK
VALVE
FROM COOLER
PORT
TO COOLER
PORT
FROM EXTERNAL
FILTER TO LUBE
H00136.1
Figure 17. Model MTB 653 Automatic Transmission Right-Front View

TO RETARDER CLUTCH
ADAPTER HOUSING
RETARDER HOUSING
FROM CONVERTER
REAR SUPPORT
MOUNTING PAD
FROM EXTERNAL FILTER

TO LUBE
TO EXTERNAL FILTER
REGULATING
VALVE ASSEMBLY
ACCUMULATOR
RETARDER VALVE BODY

H00009
Figure 18. Model MTB 653 Automatic Transmission Right-Rear View
15
AGR
ICULTURA
WORKERS
OF
AM
ERI
CA
UNITE
DA
ILE AEROSPAC
ENT
OB
EM
OM
IM
UAW
933
UT
PART NO.
SERIAL NO.
XXXXX
MODEL
NO.
AN
PL
DIVISION OF
GENERAL MOTORS
CORPORATION
INDIANAPOLIS
INDIANA
d. Output Retarder. The MT 600 Series retarder

provides power absorption to slow vehicle forward
motion. It is located at the rear of the transmission as
an integral part of the transmission (Foldout 1 or 2).
The overall transmission length, from the flywheel
housing mounting face to the output flange face, remains essentially the same with the addition of the
output retarder.
XXXXXXX
XX XXXX X
15. OPERATING INSTRUCTIONS
V01251
Figure 19. Transmission Nameplate
c. Planetary Gearing, Clutches. The MT(B) 640,

643 have three planetary gear sets that produce four forward speeds and one reverse speed. The planetaries are
controlled by five hydraulically-actuated clutches. The
MT(B) 650, 653 have four planetary gear sets that produce five forward speeds and one reverse speed. The
planetaries are controlled by six hydraulically-actuated
clutches. All gearing is in constant mesh.
Refer to Operators Manual OM1334EN for operating

instructions.
16. SPECIFICATIONS AND DATA

The specifications and data shown in Table 11 are applicable to MT(B) 640, 643, 650, and 653 transmissions.
Table 11. Specifications and Data

INPUT RATINGS MT(B) 643/653
Value
General Truck
Transit & Airport

Shuttle Bus
Emergency
Equipment
School Bus &

Motorhome
Agricultural
Hauler &
Spreader
Unit
4000
4000
4000
4000
4000
rpm
3000
2200
500
3000
2200
500
3000
2200
500
3000
2200
500
3000
2200
500
rpm
rpm
rpm
Input Power
Maximum net
250 (186)
210 (156)
250 (186)
250 (186)
250 (186)
hp (kW)
Input Torque
Maximum net
640 (868)
590 (800)
640 (868)
640 (868)
640 (868)
lb ft (Nm)
Turbine Torque
Maximum net
1210 (1640)
1210 (1640)
1210 (1640)
1210 (1640)
1210 (1640)
lb ft (Nm)
73280 (33240)
73280 (33240)
42000 (19051)
N/A
Parameter
Input Speed
Maximum full load governed speed
MT 643, 653
Maximum full load governed speed
MTB 643
Minimum full load governed speed
Minimum idle speed in drive
Gross vehicle weight (GVW)

Gross combination vehicle weight (GCW)
16
55000 (24948) 42000 (19051) 55000 (24948)

N/A
42000 (19051) 80000 (36288)
lb (kg)
lb (kg)
GENERAL INFORMATION
Table 11. Specifications and Data (contd)
Mounting:
Transmission to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission to vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retarder to vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation (viewed from input):
Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output (in forward ranges) . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque converter:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall torque ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lockup clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive range and sequences:
MT 640, 643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MT 650, 653 (Third range hold option) . . . . . . . . . . . . . . . .
MT 650, 653 (Second range hold option) . . . . . . . . . . . . . . .
Drive range and shift control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift modulation:
Diesel models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAE 2 automotive flywheel housing

Two side mounting pads on input housing
(optional use)
Two top mounting pads or two rear mounting pads
Flexplate
Clockwise
Clockwise
Single-stage, 3-element, multiphase
TC 350-3.04:1; TC 360-2.86:1; TC 3702.40:1; TC 378-2.27:1; TC 380-1.82:1
Automatic in selected ranges
Reverse, neutral 1234, 123, 12, 1
Mechanical (external)
Hydraulic valve body (internal control)
Air, mechanical, or electric
Vacuum or mechanical
Fluid-cooled, hydraulically-actuated, springreleased, self-compensating for wear
Planetary, straight-cut spur, constant mesh
Hydraulic System:
Fluid capacity (excluding external circuits) . . . . . . . . . . . . . . .
MT 640, 643 4.34 inch (110.2 mm) pan . . . . . . . . . .
MT 650, 653 5.10 inch (129.5 mm) pan . . . . . . . . . .
MTB 643 4.34 inch (110.2 mm) pan . . . . . . . . . . . . .
MTB 653 5.10 inch (129.5 mm) pan . . . . . . . . . . . . .
Fluid filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling circuit filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Fill
After Rebuild
U.S. Qts
21
21
22
22
Liters
20
20
21
21
Refill After
Servicing
U.S. Qts
12
15
12
15
Liters
11
14
11
14
Integral full-flow replaceable paper element

filter or permanent sump screen
Customer supplied full-flow filter with
bypass
Engine driven, positive displacement
DEXRON-III and Allison-approved C-4
Integral
17

Temperatures*:
Sump (max intermittent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250F (121C)
Sump (min continuous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100F ( 38C)
Converter-out (max intermittent) . . . . . . . . . . . . . . . . . . . . . . . . . 300F (149C)
Retarder operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330F (165C)
Normal operation (sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160200F (7193C)
Normal operation (converter-out) . . . . . . . . . . . . . . . . . . . . . . . . 180220F (82104C)
Fluid pressures:
Forward drive range (vehicle brakes applied)
Engine rpm MT 640
MT 640, 643
MT 650
MT 650, 653
(prior to S/N 47020) (eff. with S/N 47020) (prior to S/N 47285) (eff. with S/N 47285)
600
125 psi min.

(861 kPa)
125 psi min.

(861 kPa)
125 psi min.

(861 kPa)
125 psi min.

(861 kPa)
1200
137167 psi
(9451151 kPa)
158200 psi
(10891378 kPa)
187217 psi
(12891496 kPa)
158200 psi
(10891378 kPa)
Reverse drive range (vehicle brakes applied, driveline disconnected)

Engine rpm Main Pressure
2000
275326 psi
(18952245 kPa)
Reverse Pressure
Lube Pressure
275326 psi
(18952245 kPa)
15 psi min.
(103 kPa min.)
Speedometer drive:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MT 640, 643 drive gear data . . . . . . . . . . . . . . . .
MT 650, 653 drive gear data . . . . . . . . . . . . . . . .
MTB 643, 653 drive gear data . . . . . . . . . . . . . . .
Driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tone wheel or spiral gear

5 and 8 tooth lh helix angle or 16-tooth tone wheel
7, 8, and 11 tooth lh helix angle or 16-tooth tone wheel
17 tooth lh helix angle
Supplied by customer
Power takeoff:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting flange . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter driven
SAE 6-bolt, one opening
6 pitch, 64 teeth, 20 degree pressure angle
Right side (viewed from rear)
Parking brake provision:

Drum type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output retarder models . . . . . . . . . . . . . . . . . . . . .
Output flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 x 3 or 12 x 4
50 lb (23 kg)
None
Supplied by customer
* Temperature gauge kit available in Parts Catalog PC1316EN.
18
GENERAL INFORMATION
Dry weight (less parking brake):
MT 640, 643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MT 650, 653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MTB 643 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MTB 653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
510 lb (231 kg)

602 lb (273 kg)
638 lb (289 kg)
730 lb (331 kg)
TRANSMISSION RATIOS (Mechanical**):

MT(B) 640, 643
Range
Neutral
First
Second
Third
Fourth
Reverse
Clutch(es) Engaged
First
Forward and first
Forward and second
Forward and third
Forward and fourth
Fourth and first
Ratio
0
3.58:1
2.09:1
1.39:1
1.00:1
5.67:1
Clutch(es) Engaged
First
Forward and low
Forward and first
Forward and second
Forward and third
Forward and fourth
Fourth and first
Ratio
0
8.05:1
3.58:1
2.09:1
1.39:1
1.00:1
5.67:1
MT(B) 650, 653

Range
Neutral
First
Second
Third
Fourth
Fifth
Reverse
** Overall torque multiplication ratio of transmission (output stalled) is the product of the converter torque multiplication ratio (see torque converter) and
the mechanical (gear) ratio.
19

NOTES
110
Section 2 DESCRIPTION AND OPERATION

21.
SCOPE
This section describes the transmission components,

explains their functions, and details the hydraulic system and torque paths. Where features are common to
all models, no reference is made to models. Where
features are specific to a model, the model is noted.
b. Planetary Gear Set Designations (Figure 21).

The MT 640 and 643 have three planetary gear sets,
designated as front, center, and rear, while the MT 650
and 653 have four. The additional MT 650 and 653
gear set is the low planetary. Each gear set in the same
physical location has the same name, regardless of
model or clutch drive function.
23. MOUNTING
a. To Engine. Transmission housing 16 (Foldout
10,A) is machined to provide an SAE 2 mounting
flange. This flange is mated with an SAE 2 bolt circle
at the rear of the engine.
22. DESIGNATION OF CLUTCHES

AND PLANETARY GEAR SETS
a. Clutch Designations (Figure 21). The MT 640
and 643 have five clutches and the MT 650 and 653
have six. The additional MT 650 and 653 clutch is the
low clutch. Each clutch in the same physical location
has the same name, regardless of model or clutch drive
function.
b. To Vehicle. Two side-mount pads are provided at

the front of the transmission housing. Each pad has
four 12-13 threaded holes. A top-mount pad is provided on the transmission rear cover (MT 640, 643) or
adapter housing (MT 650, 653). This pad has two 58-11
threaded holes.
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CLUTCH
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FORWARD
CLUTCH
FOURTH
CLUTCH
THIRD
CLUTCH
SECOND
CLUTCH
FIRST
CLUTCH
LOW CLUTCH
(FIVE-SPEED MODELS ONLY)
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LOW GEAR SET

(FIVE-SPEED MODELS ONLY)
REAR GEAR SET
CENTER GEAR SET
V00752
Figure 21. Uniform Clutch and Gear Designations
21

c. Output Retarder Mount. Transmissions with the
output retarder require special attention when mounting. The additional weight of the retarder makes it necessary to overhang the transmission behind the engine
using rear support pads. Each rear pad in the retarder
housing has two M12 x 1.75-6H threaded holes that are
1.18 inches (30 mm) deep. Each top pad has one M14 x
2-6H threaded hole that is also 1.18 inches (30 mm)
deep. The converter housing side-mount pads cannot be
used with MTB 653 direct-mount units. Only remotemount units and MTB 643 direct-mount units may be
installed using the side-mount pad on the converter
housing with a rear support.
24. INPUT DRIVE

A flexplate assembly (supplied by the vehicle manufacturer) connects the engine to the torque converter
pump cover 6 (Foldout 6), which is the input member
of the transmission.

Transmission housing 16 (Foldout 10,A) is cast aluminum. It is machined to receive the clutches, rear cover,
adapter housing, front and center supports, control
valve, and oil pan. A power takeoff mounting pad is
provided on the right side.
26. TORQUE CONVERTER

a. Description (Foldout 6). The torque converter
consists of three elements: pump assembly 42, stator
assembly 24, and turbine assembly 20. These are
vaned elements which are cast aluminum. Pump assembly 42 is the input member and is driven by the engine. Turbine 20 is splined to the forward clutch and
turbine shaft assembly 2 (Foldout 7,B). Stator assembly 24 (Foldout 6) is the reaction (torque multiplying)
element. The stator is supported on freewheel roller
race 32, which is splined to valve and front support assembly 22 (Foldout 7,A). This stator arrangement provides an over-running clutch which permits the stator
to rotate freely in one direction and lockup in the opposite direction.
b. Operation (Foldout 6)
1. The torque converter assembly is continually
filled with fluid, which provides converter
cooling and lubrication. Transmission fluid is
22
the power transmitting medium in the torque

converter. When the engine drives the converter, the pump vanes throw fluid against the
turbine vanes. The impact of the fluid against
the turbine vanes rotates the turbine.
2. The turbine, splined to the turbine shaft, transmits torque to the transmission gearing. At engine idle speed, the impact of fluid against the
turbine vanes is minimal. At high engine speed
the impact of fluid on the turbine is much
greater, and high torque is produced.
3. Fluid thrown into the turbine flows to the stator
vanes. The stator vanes change the direction of
flow (when the stator is locked against rotation), and direct the fluid to the pump in a direction that assists the rotation of the pump.
The redirection of the fluid by the stator enables the torque converter to multiply the input
torque.
4. Greatest torque multiplication occurs when the
turbine is stalled, and the pump is rotating at its
highest speed. Torque multiplication decreases
as the turbine speed approaches pump speed.
5. When turbine speed approaches pump speed,
fluid flowing to the stator begins striking the
backs of the stator vanes. This rotates the stator
in the same direction as the turbine and pump.
At this point, torque multiplication stops and
the converter becomes, in effect, a fluid coupling.
6. The torque converter accomplishes three main
functions. It acts as a disconnect clutch because little torque is transmitted at engine idle
speed. It multiplies torque at low turbine/high
pump speed to give greater starting or driving
effort when needed. Finally, it acts as a fluid
coupling to efficiently transmit engine torque
to the transmission gearing during drive, other
than idle or starting.
27. LOCKUP CLUTCH

a. Description (Foldout 6). The lockup clutch consists of three main elements: piston 10, clutch plate 12,
and backplate 14. These elements are located between
the torque converter cover and the torque converter
turbine. The piston and backplate rotate with the con-
DESCRIPTION AND OPERATION

verter pump. The clutch plate is located between the
piston and the backplate and is splined to the converter
turbine.
2. Piston 16 is retained in housing and shaft assembly 3 by piston return spring 17, spring retainer 18, and snapring 19.
b. Operation (Foldout 6). The engagement of the

lockup clutch is controlled by the lockup relay valve
which derives its lockup signal from the modulated
lockup valve. Clutch-apply pressure compresses the
lockup clutch plate between the piston and backplate,
locking all three together. The converter pump and turbine are locked together and provide a direct drive
from the engine to the transmission gearing. As rotational speed of the output shaft decreases, the relay
valve automatically releases the lockup clutch. Refer
to Paragraph 224l for explanation of the hydraulic action.
3. The external tangs of clutch plates 22 engage

the slots in the housing and shaft assembly.
The internal splines of clutch plates 23 engage
forward clutch hub 21, which is splined to
main shaft assembly 33 (Foldout 9,A or 9,B).
Clutch plates 23 are held in place by fourth
clutch driving hub 24, which is retained by
snapring 25. PTO drive gear 13 is secured to
forward clutch housing 6 by snapring 12.
4. For transmissions after S/N 49489, housing 6
contains centrifugal valve 11, valve spring 10,
and valve plug 9. Pin 8 retains these parts in
the housing.
28. OIL PUMP ASSEMBLY

b. Operation (Foldout 7,B)
a. Description (Foldout 7,A). Oil pump assembly 4
consists of three main elements: drive gear 9, driven
gear 8, and pump body 7. The oil pump assembly is
bolted to front support assembly 22.
b. Operation (Foldout 7,A). When the torque converter rotates, its rear hub drives pump drive gear 9.
Gear 9 is in mesh with driven gear 8. As the gears rotate, they draw fluid into the oil pump and move the
fluid into the hydraulic system.
29. OIL PUMP AND FRONT

SUPPORT ASSEMBLY
Oil pump and front support assembly 1 (Foldout 7,A)
is bolted to the transmission housing. The front support provides the ground sleeve for the torque converter and supports the forward clutch and turbine
shaft. The rear side of the front support contains bores
for main-pressure regulator valve 13, converter-pressure regulator valve 25, and lockup valve 17.
210. FORWARD CLUTCH

AND TURBINE SHAFT
a. Description (Foldout 7,B)
1. Forward clutch and turbine shaft assembly 2
connects the converter turbine to the clutches
and gearing in the transmission.
1. Housing 6 rotates when the converter turbine

rotates. Fourth clutch driving hub 24 also rotates. Fourth clutch internal-splined plates 4
(Foldout 8,A) are splined to the driving hub
and rotate with it.
2. When hydraulic pressure is applied to the piston bore in forward clutch housing 6 (Foldout
7,B), piston 16 compresses plates 22 and 23
against fourth clutch driving hub 24. This locks
forward clutch hub 21 to forward clutch housing 6. Hub 21 is splined to main shaft assembly
33 (Foldout 9,A or 9,B).
3. The forward clutch is applied only in forward
range operation, and is always paired with another clutch (either first, second, third, fourth,
or low (MT 650, 653 only)). When the converter turbine rotates and the forward clutch is
applied, the main shaft assembly also rotates.
This drives components of the gear unit, which
drives the output shaft in any forward range.
The specific forward range depends upon
which additional clutch is applied.
4. In neutral or reverse operation, the forward
clutch is not applied. Torque from the converter turbine rotates only forward clutch housing 6 (Foldout 7,B) and fourth clutch driving
hub 24.
23

5. For transmissions after S/N 49489, centrifugal
valve 11 provides a safety feature to prevent
over-speeding the torque converter. When the
forward clutch housing exceeds a predetermined
rotational speed, the centrifugal valve lifts from
its seat and exhausts the forward clutch.
211. FOURTH CLUTCH

a. Description (Foldout 8,A)
1. The fourth clutch includes housing assembly
13, piston 9 or 10, piston return spring 8, four
internal-splined plates 4, four external-tanged
plates 5, spring retainer 7, snapring 6, backplate 3, and snapring 2.
(Foldout 7,B) drives main shaft assembly 33

(Foldout 9,A or 9,B). The result is direct drive to
the output shaft.
4. In reverse range operation, the fourth clutch
and the first clutch are applied (the forward
clutch is released). The fourth clutch operates
as described in Step (4). Engagement of the
first clutch (Foldout 11,A) causes an interaction between the planetaries that results in reverse rotation of the output shaft.
212. THIRD CLUTCH, CENTER

SUPPORT, AND SECOND CLUTCH
2. Piston 9 or 10 is installed in housing assembly

13 and is retained by spring 8, spring retainer
7, and snapring 6. External-tanged plates 5 engage slots in clutch housing assembly 13. Internal-splined plates 4 engage splines in fourth
clutch driving hub 24 (Foldout 7,B). Plates 4
and 5 are held in place by backplate 3 and
snapring 2.
3. The hub of clutch housing 13 splines onto sun
gear shaft 27 (Foldout 9,A or 9,B). The outer
splines of clutch housing 13 engage internalsplined plates 3 (Foldout 8,B) of the third
clutch.
b. Operation (Foldout 8,A)
1. Internal-splined clutch plates 4 rotate whenever turbine shaft 5 (Foldout 7,B) and forward
clutch housing 6 rotate.
2. When the fourth clutch is applied, piston 9 or 10
(Foldout 8,A) compresses plates 4 and 5 against
backplate 3, locking plates 4 and 5 together and,
in turn, to clutch housing 13. Clutch housing 13
rotates with the turbine shaft.
1. The third clutch is forward of center support

housing assembly 13, and the second clutch is
rearward of the center support housing assembly. Each clutch has six clutch plates.
2. The third clutch includes items 1 through 11.
The second clutch includes items 17 through
28. Center support housing assembly 13 serves
both clutches. The front side of the center support housing is bored to receive third clutch
piston 9. The rear side is bored to receive second clutch piston 19. Center support housing
assembly 13 includes passages which direct
fluid to both of these clutches, and provides
lubrication to the fourth clutch assembly.
3. External-tanged plates 4 and 26 engage slots in
the transmission housing and are always stationary. Internal-splined plates 3 of the third
clutch engage splines in fourth clutch housing
assembly 13 (Foldout 8,A). Internal-splined
plates 27 of the second clutch engage splines in
front planetary carrier assembly 4 (Foldout 9,A
or 9,B).
b. Operation of Third Clutch (Foldout 8,B)
3. The fourth clutch is engaged during fourth

range (MT 640, 643), fifth range (MT 650,
653), and reverse range operation. In fourth (or
fifth) range, the fourth and forward clutches are
engaged. Clutch housing 13 drives sun gear
and shaft assembly 23 (Foldout 9,A or 9,B) at
the same speed that forward clutch hub 21
24
1. When the third clutch is applied, piston 9 compresses plates 3 and 4 against backplate 2. This
locks plates 3 (which are splined to the fourth
clutch housing) to plates 4 which are stationary. This holds the fourth clutch housing stationary.

2. Sun gear shaft assembly 23 (Foldout 9,A or
9,B) is held stationary through the splines of
the clutch housing hub. This causes a reaction
within the planetary carrier assemblies which
produces a third (MT 640, 643) or fourth (MT
650, 653) range ratio at the output shaft. Input
torque for the gearing is transmitted through
the engaged forward clutch and the transmission main shaft.
c. Operation of Second Clutch (Foldout 8,B)
1. When the second clutch is applied, piston 19
compresses plate 26 and 27 against backplate
28. This locks plates 27, which are splined to
front planetary carrier 4 (Foldout 9,A or 9,B),
to plates 26 (Foldout 8,B) which are stationary.
2. The front planetary carrier is held stationary.
This causes a compound reaction within the
planetary gearing which produces a second
range (MT 640, 643) or third range (MT 650,
653) ratio at the output shaft. Input torque for
the gearing is transmitted through the engaged
forward clutch and transmission main shaft.
213. FIRST CLUTCH

1. The first clutch includes piston 11, six internalsplined plates 3, and six external-tanged plates 4.
2. In the MT 640, 643, piston 11 is positioned in
rear cover 6 (Foldout 12,A). In the MT 650,
653, piston 11 is positioned in adapter housing
3 (Foldout 11,B). The external tangs of plates 4
(Foldout 11,A) engage slots in the transmission
housing and are always held stationary. The
splines of plates 3 engage rear planetary ring
gear 5 (MT 650, 653) or 14 (MT 640, 643).
Piston 11 is retained by twenty-six piston return springs 10, retainer 9, and snapring 8.
1. When the first clutch is applied, piston 11 compresses plates 3 against plates 4. This locks internal-splined plates 3 to external-tanged plates
4, which are stationary. Plates 3 are splined to
ring gear 5 or 14, and hold the ring gear stationary.

2. The stationary ring gear causes a reaction within
the planetary gearing to produce either first
range (MT 640, 643), second range (MT 650,
653), or reverse, depending on the driving member in the gear set. In first range (MT 640, 643),
the driving member is rear planetary sun gear 37
(Foldout 9,A), which is driven by the transmission main shaft and the engaged forward clutch.
In second range (MT 650, 653), the driving
member is rear planetary sun gear 36 (Foldout
9,B). First (or second) range is produced by the
action of one planetary. In reverse range, the
driving member is sun gear shaft assembly 23
(Foldout 9,A or 9,B) which is driven by the engaged fourth clutch and the forward clutch
housing. Reverse range is accomplished by
compound action of two planetaries.
214. PLANETARY GEAR UNIT

NOTE:
Because gearing components for MT 640, 643 and
MT 650, 653 models are nearly identical, most references below are to the MT 640, 643 illustration
(Foldout 9,A). The MT 650, 653 gearing is shown in
Foldout 9,B.
1. The gear unit and main shaft assembly includes all of the gears in the transmission, except the rear planetary ring gear 5 or 14 (Foldout 11,A) and the low range gearing (Foldout
11,B).
2. Three planetary gear sets are included in the
assembly. These are called front planetary, center planetary, and rear planetary. The planetary
sets are so designated because of their positions in relation to the transmission and to each
other.
3. The front planetary includes sun gear 2, front
carrier assembly 4, and ring gear 14. The center planetary includes sun gear and shaft assembly 23, planetary carrier assembly 15, and
ring gear 32. The rear planetary includes sun
25

gear 37 and carrier assembly 40. Also included
is ring gear 14 (Foldout 11,A) for MT 640, 643
models or ring gear 5 for MT 650, 653 models.
4. The three planetaries are connected by sun
gear shaft assembly 23 (Foldout 9,A), main
shaft assembly 33, and planetary connecting
drum 30. This interconnection of planetary input, reaction, and output components produces
four forward speeds and one reverse speed.
1. The front planetary, together with the center
planetary, produces second range (MT 640,
643), or third range (MT 650, 653), when the
forward and second clutches are engaged.
2. The center planetary is active in second and third
(MT 640, 643), or third and fourth (MT 650,
653), and reverse ranges. In second range (third
range in MT 650, 653), it is compounded with the
front planetary, as described in Step (1).
3. The center planetary produces third range
(MT 640, 643), or fourth range (MT 650,
653), when the forward and third clutches are
engaged.
4. The center planetary is locked with the front
planetary and the rear planetary to produce
fourth range (MT 640, 643), or fifth range
(MT 650, 653), when the forward and fourth
clutches are engaged.
5. The center planetary is compounded with the
rear planetary to produce reverse range when
the fourth and first clutches are engaged.
6. The rear planetary is active in first range
(MT 640, 643), or second range (MT 650,
653), and reverse range operation.
7. The rear planetary is locked with the front and
center planetaries to produce fourth (or fifth)
range as explained in Step (4).
8. The rear planetary is compounded with the
center planetary to produce reverse range as
explained in Step (5).
26
9. The rear planetary acts alone to produce first

range (MT 640, 643), or second range (MT 650,
653), when the first and forward clutches are engaged.
NOTE:
In fourth range (MT 640, 643), or fifth range (MT 650,
653), all three planetaries rotate as a unit because the
forward and fourth clutches are engaged. This gives
direct drive through the transmission.
215. LOW CLUTCH (MT 650, 653 Only)

1. The low clutch includes piston 23, five internal-splined plates 18, and six external-tanged
plates 17.
2. The piston is housed in rear cover assembly 13
(Foldout 12,B). The external tangs of plates 17
(Foldout 11,B) engage slots in adapter housing
3 and are held stationary. The internal splines
of plates 18 engage the splines of planetary
carrier assembly 8. Piston 23 is retained by
twenty-six piston return springs 22, retainer
21, and snapring 20.
b. Operation (Foldout 11,B)
1. When the low clutch is released, internalsplined plates 18 are free to rotate. This allows
low planetary carrier assembly 8 to rotate. The
low clutch is released in neutral, reverse, second, third, fourth, and fifth range operation.
2. When the low clutch is applied, piston 23 compresses plates 17 and 18 against adapter housing 3. This locks internal-splined plates 18 to
external-tanged plates 17, which are stationary.
Plates 18, splined to low planetary carrier assembly 8, hold it stationary. This causes a reaction within the planetary which produces first
range ratio at the output shaft. Input torque for
the gearing is transmitted through the engaged
forward clutch and transmission main shaft.

216. LOW PLANETARY GEARING
(MT 650, 653 Only)
1. The low planetary gearing includes planetary
carrier assembly 8, sun gear 6, and ring gear
19. Sun gear 6 is splined to rear planetary ring
gear hub 6 (Foldout 11,A). Ring gear 19 (Foldout 11,B) is splined to output shaft assembly 1
(Foldout 12,B).
2. The low planetary is compounded with the rear
planetary to produce first range when the forward and low clutches are applied.
b. Operation (Foldout 11,B). The low planetary is inactive in all ranges except first range. The low planetary,
together with the rear planetary, produces first range
when the forward and low clutches are applied. Input
torque for the gearing is transmitted to the low sun
gear 6 by rear planetary ring gear hub 6 (Foldout
11,A). The low sun gear rotates low planetary pinions
12 (Foldout 11,B). The pinions rotate low planetary
ring gear 19. Carrier assembly 8 is anchored against
rotation.
217. GOVERNOR DRIVE

NOTE:
The description and operation of the governor drive
are identical for all models. Therefore, only the
MT(B) 650, 653 is described.
a. Description (MT 650, 653) (Foldout 12,B). Governor assembly 35 is a centrifugal (flyweight) governor driven by governor drive gear 8. The governor is
supported in a bore in rear cover 15 by pin 16, and is
retained in the rear cover by governor cover 39.
b. Description (MTB 653) (Foldout 17,A). Governor assembly 35 is a centrifugal (flyweight) governor
driven by governor drive gear 25 (Foldout 18,A). The
governor is supported in a bore in retarder housing 6
by bushing 4, and is retained in the retarder housing by
cover 39 (Foldout 17,A).
c. Operation (Foldout 12,B). Rotation of the governor causes the governor valve (Foldout 3) to travel
within its bore. When the valve moves to the left, governor pressure rises. When the valve moves to the
right, governor pressure falls. Governor pressure varies proportionally with output speed. Governor pressure, in combination with modulator pressure (Paragraph 224i) provides the automatic shifting in the
transmission. Refer to Paragraphs 224p and 224q
for additional information about automatic shift.
218. SPEEDOMETER DRIVE/SPEED

SENSOR WHEEL
NOTE:
The description and operation of the speedometer
drive or speed sensor wheel are identical for all models. Therefore, only the MT(B) 650, 653 is described.
a. Description
1. For the MT 650, 653 (Foldout 12,B), the
speedometer drive consists of drive gear 9, a
worm gear with a left-hand helix, or speed sensor wheel 10. The drive is concentric with the
output shaft and has no key or drive splines.
The gear is clamped between rotating parts
which cause the drive gear to rotate.
2. Speed sensor wheel 10 (Foldout 12,B) or 3
(Foldout 12,A) is provided for models
equipped with an electronic speedometer. The
16-tooth wheel provides a rotating pulse that
can be read by an electronic speed sensor.
3. For the MTB 653 (Foldout 18,A), the speedometer drive consists of drive gear 25 and
driven gear bushing 10. Drive gear 25 is a
worm gear with a left-hand helix. It is located
between the rotor hub and output shaft bearing
spacer 26. The gear is splined to the output
shaft and rotates at output shaft speed.
b. Operation
1. When the transmission output shaft rotates, the
drive gear or speed sensor wheel rotates.
2. For mechanical speedometers, the driven gear,
supplied by the vehicle manufacturer, rotates
clockwise (viewed at the cable connection in
the rear cover) during forward operation. Rear
cover assembly 13 (Foldout 12,B) supports the
driven gear.
27

3. For electronic speedometers, the speed sensor,
supplied by the vehicle manufacturer, reads the
output speed by counting the pulses produced by the teeth of the speed sensor wheel.
used with mechanically-controlled engines that

can provide a 12- or 24-volt (dc) signal to
stroke the modulator valve.
220. CONTROL VALVE ASSEMBLIES

219. MODULATOR
a. Vacuum Modulator. The position of the diaphragm in the modulator varies with vehicle speed,
load, and engine throttle opening. When the diaphragm moves, the modulator valve is affected, increasing or decreasing modulator pressure. Modulator
and governor pressures control the automatic selection
of transmission ranges.
b. Mechanical Modulator
1. The mechanical modulator is attached to the
transmission and activated by a cable.
2. The cable is connected to the fuel control lever
at one end and the modulator valve actuator at
the other. The fuel control lever moves the cable, controlling the modulator valve.
c. Electric Modulator
1. An electric modulator can be used with electronic or non-electronic engines any engine
which can provide an On/Off signal based on
throttle/pedal position.
2. The 12-volt modulator assembly and the 24-volt
modulator assembly utilize an electronic signal
to stroke the transmission modulator pin from
the closed-throttle position to the full-throttle
position. The result is step-modulation.
3. Step-modulation is a two-phase modulation
schedule which utilizes a closed-throttle shift
schedule until the throttle position is greater
than 8085 percent, and then remains at a fullthrottle shift schedule until the throttle position
is less than 6065 percent.
4. Electric modulators are compatible with an
electronically-controlled engine that can provide an On/Off signal based on throttle position.
Consult
the
respective
engine
manufacturer to identify the wire that provides
this signal. Electronic modulation can also be
28
a. Description. Control valve assemblies 1 (Foldout

13 or 14), 3 (Foldout 15,B), 1 (Foldout 15,A), and
valve and front support assembly 22 (Foldout 7,A)
contain the major valves in the transmission. These
valves and their related components control shifting
and lockup operation. The valve bodies (except valve
and front support assembly) are bolted to the bottom
of the transmission case, which is channeled to direct
the flow of fluid between the valve body, clutches, and
other components.
b. Operation. Refer to Paragraph 224 for operation of control valve assemblies.
221. OIL PAN AND FILTER

a. Description (Foldout 10,A or 10,B)
1. Oil pan 46 (Foldout 10,A) or 25 (Foldout 10,B)
is a pressed steel assembly which provides separate openings for draining the fluid and for
mounting the fill tube. The pan is bolted to the
bottom of the transmission housing.
2. Filter 14 (Foldout 10,B) is a paper element retained by a steel casing and can be serviced
without removal of the pan. Filter 30 (Foldout
10,A) is a paper element with detachable filter
tube 32. Filter 38 is a stainless steel screen with
integral filter tube. Filter 30 and 38 elements are
retained by a steel casing.
3. The input pump draws fluid from the sump
through the filter and directs it to the hydraulic
system.
b. Function (Foldout 10,A or 10,B)
1. Oil pan 46 (Foldout 10,A) or 25 (Foldout 10,B)
holds the entire supply of fluid for the transmission and covers the control valve assemblies and filter.
2. Filter 30 or 38 (Foldout 10,A), or 14 (Foldout
10,B), screens all fluid entering the hydraulic
system.

222. REAR COVER
a. Description (Foldouts 12,A and 12,B). Rear
cover 13 (Foldout 12,B) or 6 (Foldout 12,A) is made
of aluminum and is machined to receive the governor
assembly. The cover for the MT 640, 643 is machined
to receive first clutch piston 11 (Foldout 11,A). The
cover for the MT 650, 653 receives low clutch piston
23 (Foldout 11,B).
b. Function. The rear cover provides support for
output shaft assembly 50 (Foldout 9,A) or 1 (Foldout
12,B). A parking brake mounting face is provided on
the rear surface of the cover. The cover is the rear enclosure member and is bolted to the transmission
housing.
223. OUTPUT RETARDER

1. The output retarder consists of four main elements: rotor assembly 14, two stators, and a friction clutch. The rotor assembly is a vaned wheel,
splined to output shaft 11, and rotates continuously at output shaft speed. Front stator 4 is located on the forward side of the rotor and is
bolted to retarder adapter housing 7 (Foldout
19,A). The front stator consists of vanes cast into
a stationary ring. The rear stator is located to the
rear of the rotor assembly and consists of vanes
cast into retarder housing 6 (Foldout 18,A).
2. The clutch (Foldout 18,B) consists of five external-splined reaction plates 6, one backplate 15,
and six internal-splined friction plates 7. Four
reaction plates are splined to the ID of the front
stator. One reaction plate and the backplate are
splined to the ID of the rear stator. The six friction plates are splined to rotor hub 13.
3. The output retarder mounts directly to the rear
of the transmission housing on MTB 643 models and to the rear of the low clutch adapter
housing on MTB 653 models. The retarder
housing adapter (Foldout 19,A or 19,B) permits the retarder to be mounted to the transmission housing or low clutch adapter housing.
b. Function. The output retarder provides power absorption to slow vehicle forward motion. The retarder
housing replaces the transmission rear cover, encloses
the retarder components, and provides a mounting pad

for the retarder control valves. A speedometer drive
can be mounted on the retarder housing, but no provisions have been made to mount a parking brake on the
rear of the retarder housing.
224. HYDRAULIC SYSTEM

NOTE:
References to up, down, left, or right refer to positions or movements of components on Foldout 3, 4,
or 5.
a. System Functions. The hydraulic system generates, directs, and controls the pressure and flow of hydraulic fluid within the transmission. Hydraulic fluid
(transmission oil) is the power transmitting medium in
the torque converter. Its velocity drives the torque converter turbine. Its flow cools and lubricates the transmission. Its pressure operates the various control
valves and applies the clutches.
b. System Schematics (Foldouts 3, 4). Color-coded
foldouts of both MT 640, 643 and MT 650, 653 hydraulic systems are presented at the back of this manual. Each illustration represents the system as it would
function in neutral with the engine idling.
c. Filter, Pump Circuit. The input-driven pump
draws transmission fluid (blue) from the sump through
a filter. Fluid (red) discharged by the pump flows into
the bore of the main-pressure regulator valve.
d. Main-Pressure Circuit (Red)
1. Main pressure is regulated by the main-pressure regulator valve. Transmission fluid from
the pump flows into the valve bore, into an internal passage in the valve, and to the upper
end of the valve. Pressure at the upper end of
the valve forces the valve downward against
the spring until fluid (yellow) flows into the
converter-in circuit. When flow from the pump
exceeds the circuit requirement, the converter
regulator valve opens and allows the excess to
exhaust to sump.
2. Although main pressure is controlled primarily
by the spring at the bottom of the valve, it is
also affected by forward regulator pressure and
lockup pressure. These pressures are not
29

present at the regulator valve during reverse
operation and main pressure is regulated at a
higher value.
e. Converter-In (Yellow), Converter-Out
(Orange), Lubrication (Green) Circuit
1. This circuit originates at the main-pressure
regulator valve. Converter-in fluid flows to the
torque converter. Fluid must flow through the
converter continuously to keep it filled and to
carry off the heat generated by the converter.
The converter pressure regulator valve regulates converter-in pressure by exhausting excessive fluid to sump.
2. Converter-out fluid flows to an external cooler
(supplied by the vehicle or engine manufacturer). The flow of air or water over or through
the cooler removes the heat from the transmission fluid.
3. Lubrication fluid is directed through the transmission to components requiring continuous lubrication and cooling. Fluid in excess of that
required by the lubrication circuit escapes to
sump through the lubrication pressure regulator.
f. Selector Valve, Forward Regulator Circuit
(Red and Blue) MT 640, 643 (Foldout 3)
1. The selector valve is manually shifted to select
the operating range desired. It can be shifted to
any one of six positions: N (Neutral), R (Reverse), D (Drive), D3 (Drive 3), D2 (Drive 2),
and D1 (Drive 1). At each of these positions
the selector valve establishes the hydraulic circuit for operation in the selected range.
2. D, D3, D2, and D1 are forward ranges. The
lowest range attainable is first range. In D1,
D2, D3, or D position, the transmission starts
in first range (except on second range start).
Shifting within any range is automatic, depending upon vehicle speed and throttle position.
3. The forward regulator circuit originates at the
manual selector valve and terminates at the
main-pressure regulator valve. The circuit is
pressurized in every forward range, reducing
main pressure. In reverse, forward-regulator
210
pressure is not present, allowing high main

pressure to control the higher torque produced
in reverse operation.
g. Selector Valve, Forward Regulator Circuit
(Red and Blue) MT 650, 653 (Foldout 4)
1. The selector valve is manually shifted to select
the operating range desired. It can be shifted to
any one of six positions: N (Neutral), R (Reverse), D (Drive), D3 (Drive 3), D2 (Drive 2),
and D1 (Drive 1). At each of these positions
the selector valve establishes the hydraulic circuit for operation in the selected range.
2. D, D3, D2, and D1 are forward ranges. The
lowest range attainable is first range which is
present in D1 only. In D2, D3, or D position,
the transmission starts in second range. Shifting within any range is automatic, depending
on vehicle speed and throttle position. Later
MT 650 (after S/N 13800) and all MT 653
transmissions do not upshift in D2 position under normal operating conditions.
3. The forward regulator circuit originates at the
manual selector valve and terminates at the
main pressure regulator valve. The circuit is
pressurized in every forward range, reducing
main pressure. In reverse, forward-regulator
pressure is not present, allowing for high main
pressure to control the higher torque produced
in reverse operation. In earlier MT 650 models,
forward-regulator pressure was effective in
only third, fourth, and fifth ranges. It originated at the line that connects the 23 and 34
relay valves.
h. Governor Circuit (Green and White)
1. Main pressure is directed to the governor
valve. The speed of the transmission output
controls the position of the governor valve. The
position of the governor valve determines the
amount of pressure in the governor circuit.
When the transmission output is not rotating,
governor pressure is approximately 2 psi. Governor pressure varies with the output rpm.
2. In the MT 640 and 643, governor pressure is
directed to the 12, 23, and 34 shift signal

valves and modulated lockup valve. In earlier
models that do not include the modulated
lockup valve, governor pressure is directed to
the top of the lockup valve.
3. In the MT 650 and 653, governor pressure is
directed to the 23, 34, and 45 shift signal
valves, the 21 inhibitor valve, and the modulated lockup valve. In earlier models that do
not include the modulated lockup valve, governor pressure is directed to the top of the lockup
valve.
4. At the 21 inhibitor valve, governor pressure
acts upon the top of the valve. When governor
pressure is sufficient to push the valve downward, road speed is too high to permit a downshift to first range. A 21 shift cannot occur
until governor pressure (and road speed) is reduced. D1 pressure is blocked from reaching
the top of the 12 shift valve until road speed
(and governor pressure) is decreased to a value
that allows the inhibitor valve to move upward.
5. In second range start units, the presence of
governor pressure at the bottom of the 12
shift valve, and forward-regulator pressure on
the 12 modulator valve, plus the assistance of
spring force under the 12 shift valve, cause
the shift valve to move upward against its stop.
This allows main pressure to pass through the
12 shift signal valve to the 12 relay valve.
The 12 relay valve is forced downward in its
bore allowing apply pressure to be directed to
the second clutch, permitting second range
start.
i. Modulator Pressure Circuit (Red and Green)
NOTE:
The modulator varies modulator pressure with
throttle movement, and may be vacuum, air, mechanically, or electrically controlled. Refer to the
current MT1357EN, MT(B) 600 Series Mechanics
Tips, for details. Mechanical modulators are most
commonly used for diesel engine applications (Foldouts 3, 4). Vacuum modulators can be used only on
gasoline engine applications. Air, mechanical, and
electric modulators may be used with any engine.
1. The modulator valve produces a regulated

pressure which is derived from main pressure.
When the throttle is closed, a spring at the left
end of the valve moves the valve to the right.
When the throttle is opened, cam and spring
action move the valve to the left. When the
spring force at the left of the valve is in balance
with the spring force and modulator pressure at
the right of the valve, modulator pressure is
regulated.
2. When the throttle setting is increased, the
movement of the actuator cam forces the modulator valve to the left, reducing modulator
pressure. When the throttle setting is reduced,
the downward movement of the actuator cam
allows the spring at the left to push the valve to
another regulating position. Because the throttle setting varies with load and engine speed,
modulator pressure also varies. This varying
pressure is directed to the 12, 23, and 34
shift signal valves (MT 640, 643) or 23, 34,
and 45 shift signal valves (MT 650, 653),
trimmer regulator valve, and modulated lockup
valve. Earlier models do not include the modulated lockup valve.
3. At the shift signal valves, modulator pressure
assists governor pressure to overcome shift
valve spring force. Each one of the shift valves
and springs is calibrated so that the valves shift
in the proper sequence at the proper time. A
decrease in modulator pressure causes a downshift if governor pressure is not sufficient to
oppose the shift valve spring force. Modulator
pressure controls trimmer boost and the trimmer regulator valve.
4. At the modulated lockup valve, modulator
pressure assists governor pressure in moving
(or holding) the valve downward. The variation
in modulator pressure varies the timing of
lockup clutch engagement and release. The primary purpose of lockup modulation is to prolong the engagement of the lockup clutch (at
closed throttle) in lower ranges to provide
greater engine braking.
5. All modulated lockup valves are adjustable,
but not all transmissions have modulated
lockup. Adjustable lockup is adjusted by rotat-
211

ing the adjusting ring (Paragraph 313b) at the
bottom of the valve until the desired shift point
is attained.
j. Trimmer Regulator Valve (Green and Yellow)
NOTE:
Paragraphs 224j(1) and 224j(2) apply only to
transmissions built after S/N 13800.
1. The trimmer regulator valve reduces main
pressure to a regulated pressure. The regulated
pressure is raised or lowered by changes in
modulator pressure (red and green).
2. Trimmer regulator pressure is directed to the
lower sides of the first and second trimmer
plugs on some models, or to the lower sides of
the first, second, third, and fourth trimmer
plugs on models equipped with smooth shift.
This varies the clutch-apply pressure pattern of
the trimmer valves. A higher modulator pressure (closed throttle) reduces trimmer regulator
pressure, resulting in a lower initial clutch
pressure. A lower modulator pressure (open
throttle) results in higher regulator pressure
and a higher initial clutch-apply pressure.
4. When the clutch is released, the spring pushes

the trimmer components to the top of the valve
bore. In this position the trimmer is reset and
ready to repeat the action at the next application of that clutch.
l. Lockup Circuit
1. The modulated lockup valve and the lockup relay valve control lockup clutch engagement
and release.
1. The purpose of the trimmer valves is to avoid

shift shock. The valves reduce pressure to the
clutch-apply circuit during initial application,
then gradually return the pressure to operating
maximum. This applies the clutch gently, preventing harsh shifts.
2. The modulated lockup valve is actuated by

governor pressure or governor plus modulator
pressure. At full throttle, governor pressure
moves the valve downward. At part throttle,
governor and modulator pressures move the
valve downward. The purpose of the modulated lockup valve is to prolong lockup clutch
engagement while vehicle speed decreases
(closed throttle). This feature provides engine
braking action at speeds lower than the normal
lockup disengagement point.
2. Although each trimmer valve is calibrated for

the clutch it serves, all four trimmers function
in the same manner. Each trimmer includes
(top to bottom) an orificed trimmer valve, trimmer valve plug, one or two trimmer springs,
and a stop pin.
3. In its downward position, the modulated

lockup valve directs main pressure to the top of
the lockup valve. Main pressure pushes the
lockup valve downward. In its downward position, the valve directs main pressure to the
lockup clutch. This engages the clutch.
3. When any clutch (except forward clutch) is applied, clutch-apply pressure is sent to the top
end of the corresponding trimmer valve. Initially, the plug and valve are forced downward
against the spring until fluid escapes to exhaust. The escape of fluid, as long as it contin-
4. The position of the lockup valve affects the

volume of fluid flowing to the torque converter.
When the valve is upward (lockup clutch released), there is maximum flow to the converter. When the valve is downward (clutch
engaged), an orifice restricts converter-in flow.
k. Trimmer Valves
212
ues, reduces clutch-apply pressure. Fluid flows

through an orifice in the trimmer valve to the
cavity between the trimmer valve and the trimmer valve plug. Pressure in this cavity forces
the plug down to the stop. The pressure below
the trimmer valve acts upon a greater diameter
than at the upper end, and pushes the trimmer
valve to the upper end of the valve bore. This
reduces and then stops the escape of fluid to
the exhaust. When the escape of fluid stops,
clutch pressure is maximized. The plug remains downward until the clutch is released.

5. When the lockup clutch is engaged, a signal
pressure is sent to the main pressure regulator
valve. This signal pressure reduces main pressure to a lower pressure schedule.
6. On models with adjustable lockup, modulator
assistance at the modulated lockup valve is not
present. Lockup engagement is initiated by setting the adjusting ring (Paragraph 313b) to
the shift point specifications and with the assistance of governor pressure.
7. Earlier models, which do not have modulated
lockup, do not include the modulated lockup
valve. Governor pressure is directed to the top
of the lockup valve.
the 12 shift valve and move it downward to

the first range position.
3. While operating in first range, the 21 inhibitor
valve moves downward, if road speed and governor pressure exceed the safe limit for first
range operation. This blocks D1 pressure and
exhausts the cavity above the 12 shift valve.
The shift valve moves upward to give second
range operation.
o. Clutch Circuits, Hold Regulator Circuits,
Drive Ranges
1. There are five clutches in the MT 640, 643 and
six clutches in the MT 650, 653. The clutches
are applied as follows:
Range
m. Priority Valve
1. The priority valve ensures that the control system upstream from the valve will have sufficient pressure during shifts to perform its automatic functions. In later MT 643, 650 models
and all MT 653 models, first clutch pressure
can bypass the priority valve while in reverse.
2. Without the priority valve, the filling of a
clutch might momentarily require a greater
volume of fluid than the pump could supply
and still maintain pressure for the necessary
control functions.
n. 2-1 Inhibitor Valve MT 650, 653 (Foldout 4)
1. The 21 inhibitor valve prevents a downshift
from second range to first range when road
speed is too high. It protects the engine from
over-speeding during downgrade operation in
first range by making a 12 upshift if road
speed exceeds the safe limit for first range operation.
2. When road speed is great enough to produce a
governor pressure that pushes the 21 inhibitor
valve downward, D1 pressure to the 12 shift
valve is blocked. If a manual shift to D1 (Drive
1 or first range) is made, D1 pressure cannot
reach the 12 shift valve. The transmission remains in second range until road speed and
governor pressure decrease to a value that permits the 21 inhibitor valve to move upward.
In its upward position, D1 pressure can reach
Clutch(es) Applied
MT 640, 643
Neutral
First
First range
First and forward
Second range
Second and forward
Third range
Third and forward
Fourth range
Fourth and forward
Reverse range
First and fourth
MT 650, 653
Neutral
First
First range
Low and forward
Second range
First and forward
Third range
Second and forward
Fourth range
Third and forward
Fifth range
Fourth and forward
Reverse range
First and fourth
2. Each clutch has its own circuit. The first, second, third, and fourth clutches each connect to
a relay valve and to a trimmer valve. The forward clutch connects directly to the selector
valve and does not connect to a trimmer valve.
The low clutch (MT 650, 653 only) is not
trimmed because there is no automatic upshifting from, or downshifting, to this clutch.
3. The low clutch circuit (MT 650, 653 only) connects the clutch to the 12 shift valve. The 12
shift valve also receives 12 (low and first)
feed from the 23 relay valve. In N (Neutral),
the 12 shift valve is held upward by spring
213

pressure and cannot move downward unless
the Drive 1 line is charged. In the upward position, 12 (low and first) feed pressure is sent to
the first clutch.
4. The first clutch circuit (red and yellow) connects the clutch to the first trimmer valve and
to either the 12 relay valve (MT 640, 643) or
the 12 shift valve (MT 650, 653). In N (Neutral) the 12 shift valve is held upward by
spring pressure. The 12 shift valve cannot
move downward unless the 21 signal line is
charged. This does not occur in N (Neutral) because there is no governor pressure to shift the
21 inhibitor valve. Only the first clutch is applied, so the transmission output cannot rotate.
A bypass and check ball are provided between
the reverse and first trimmer passages to ensure
a rapid and more positive shift from first range
to reverse (MT(B) 643 with second range start)
or from first (low) range to reverse (MT(B)
653).
5. The first clutch is also applied in first range operation (MT 640, 643), second range operation
(MT 650, 653), and reverse range operation.
Shifting the selector from N (Neutral) to D,
D3, D2, or D1 charges the forward clutch circuit and applies the forward clutch. Shifting
from N (Neutral) to R (reverse) charges the
fourth clutch, while the first clutch remains
charged. In reverse, fourth clutch (reverse signal) pressure is also directed to the bottom of
12 relay valve (MT 640, 643) or 23 relay
valve (MT 650, 653). The pressure at this location prevents either relay valve from moving
downward.
6. When the circuits are charged, and the selector
valve is at D, the MT 640, 643 automatically
shifts from first to second, second to third, and
third to fourth. The MT 650, 653 automatically
shifts from second to third, third to fourth, and
fourth to fifth. These shifts occur as a result of
governor pressure and (if the throttle is not
fully open) modulator pressure.
7. The position of the selector valve determines
the highest range that can be reached automatically while the vehicle is moving. MT 640, 643
models that do not incorporate a second range
start automatically shift 12, 23, and 34
214
when the selector valve is in D4 (Drive 4) position. In D3 (Drive 3), automatic 12, 23 shifts
occur. In D2 (Drive 2), an automatic 12 shift
occurs. D1 (Drive 1) does not permit an upshift
to occur unless the transmission output overspeeds.
8. The positions of the selector valve in second
range start units is the same, only the transmission performance is altered. The transmission
always starts in second range when any forward range other than D1 (Drive 1) is selected.
When D4 (Drive 4) is selected, the transmission starts in second range and automatically
shifts 23 and 34. In D3 (Drive 3), an automatic 23 shift occurs. D2 (Drive 2) does not
permit an upshift to occur unless the transmission output overspeeds. D1 (Drive 1) is the
only position in which first range is available
and automatic upshifting is not permitted unless the transmission output overspeeds.
9. In the MT 650 or 653, in D (Drive), automatic
23, 34, and 45 shifts can occur. In D3
(Drive 3), automatic 23 and 34 shifts can
occur. In D2 (Drive 2) (before S/N 13800), an
automatic 23 shift can occur. Beginning with
S/N 13801, no automatic shift from D2 (Drive
2) can occur unless overspeed occurs. In D1
(Drive 1) no automatic shift can occur unless
the transmission output overspeeds.
10. The various drive ranges limit the highest
range attainable by introducing a pressure
which prevents governor pressure from upshifting the signal valves (unless governor
pressure is well above that normally attained).
This pressure is a regulated, reduced pressure
derived from the main-pressure circuit at the
hold regulator valve. Main pressure is directed
to the hold regulator valve through the hold
feedline when the selector lever is in D1 (Drive
1), D2 (Drive 2), or D3 (Drive 3) position. The
pressure produced in the hold regulator valve is
directed to the 34 shift valve (MT 640, 643)
or the 45 shift valve (MT 650, 653) when the
selector is in D3 (Drive 3). The hold pressure is
directed to the 23 and 34 (MT 640, 643) or
the 34 and 45 (MT 650, 653) shift signal
valve when the selector is in D2 (Drive 2) position. Beginning with S/N 13801, hold pressure

in the MT 650, 653 is directed to the 23, 34,
and 45 shift signal valves. In the MT 640, 643
and MT 650, 653 pressure is directed to all
shift signal valves when the selector is in D1
(Drive 1).
11. Hold regulator pressure at each shift signal
valve pushes the modulator valve upward and
exerts downward force on the shift valve.
When hold pressure is present, upshifts are inhibited except in extreme overspeed conditions.
p. Automatic Upshifts
1. When the transmission is operating in first
range (MT 640, 643) or second range (MT
650, 653), with the selector valve at D (Drive),
a combination of governor pressure and modulator pressure, or governor pressure alone, upshifts the transmission to second (MT 640,
643) or third (MT 650, 653) range. At closed or
part throttle, modulator pressure assists governor pressure. At full throttle, there is no modulator pressure and upshifts occur at a higher
road speed. When the throttle is closed, shifts
occur at lower road speeds.
2. Governor pressure depends upon rotation
speed of the transmission output. The greater
the output (vehicle) speed, the greater the governor pressure. When governor pressure is sufficient, the first upshift (12 for MT 640, 643
or 23 for MT 650, 653) occurs. Further increases in governor pressure (and vehicle
speed) cause the second upshift (23 for MT
640, 643 or 34 for MT 650, 653) and then the
third upshift (34 for MT 640, 643 or 45 for
MT 650, 653) to occur. Modulator pressure,
when present, assists governor pressure in
overcoming shift valve spring force.
3. In any automatic upshift, the shift signal valve
acts first. This directs a shift signal pressure to
the relay valve. The relay valve moves downward, exhausting the applied clutch and applying a clutch for the next higher range.
q. Automatic Downshifts
1. Automatic downshifts, like upshifts, are controlled by rear governor and modulator pressures. Downshifts occur in sequence as rear
governor pressure and/or modulator pressure

decrease. Low modulator pressure (open throttle) hastens downshifts; high modulator pressure (closed throttle) delays downshifts.
2. In any automatic downshift, the shift signal
valve acts first. This exhausts the shift signal
pressure holding the relay valve downward.
The relay valve then moves upward, exhausting the applied clutch and applying the clutch
for the next lower range.
r. Downshift and Reverse Inhibiting
1. As a result of calibrations of valve areas and
spring forces, the system inherently prevents
downshifts at too rapid a rate or shifts to reverse while moving forward. For example, if
the vehicle is traveling at a high speed in fourth
range and the selector valve is moved to D1
(Drive 1), the transmission will not immediately shift to first range (MT 640, 643). Instead
it will shift 4321 as speed decreases. The
transmission remains in fourth range if speed is
not decreased sufficiently to allow an automatic downshift.
2. The progressive downshift occurs because the
hold regulator pressure is calibrated, along
with the valve areas, to shift the signal valves
downward against governor pressure only
when governor pressure decreases to a value
corresponding to a safe downshift speed. If
speed is too great, governor pressure is sufficient to hold the shift signal valve upward
against D3 (Drive 3), D2 (Drive 2), or D1
(Drive 1) pressure (all of which are the regulated holding pressure originating in the hold
regulator valve). As governor pressure decreases, all shift signal valves move downward
in sequence.
225. RETARDER HYDRAULIC

CIRCUIT COMPONENTS
a. Circuit Schematic (Foldout 5). The schematic of
the retarder hydraulic circuit presented in the back of
this manual shows the circuit in the retarder-off condition.
b. Priority Valve. Main pressure supplied by the
transmission to the retarder passes through this valve.
215

The function of the valve is to protect the transmission
from low main pressure. During retarder operation the
valve remains open. If transmission main pressure
drops below 55 psi (379 kPa), the valve closes, permitting main pressure to increase. As main pressure increases above 55 psi (379 kPa), the priority valve
opens, allowing main pressure to charge the accumulators.
c. Driver Retarder Control. Retarder operation is
controlled by a driver-actuated air control. This control
is either a lever or a pedal. When the control is actuated, air pressure is applied to the top of the retarder
valve. This air pressure causes the retarder valve to
move downward to apply the retarder. The amount of
retarder application is determined by the amount of air
pressure applied by the driver through the retarder
control.
d. Retarder Valve. The retarder valve is a spooltype valve which directs the flow of fluid to and from
the retarder. Hydraulic pressure, supplemented by
spring force, moves the valve in the upward direction
while air pressure moves the valve in the downward
direction.
e. Cutoff Valve. The cutoff valve is located beneath
the retarder valve and regulates hydraulic pressure
throughout the system during partial retarder application. With a coiled spring under the cutoff valve and
the retarder valve above, regulated pressure and spring
force position the cutoff valve in its bore, directing a
reduced regulated pressure to the hydraulic system.
During full retarder valve application, the cutoff valve
is held at the bottom of its bore, directing maximum
regulated pressure into the retarder hydraulic system.
f. Retarder Pressure Regulator Valve. The regulator valve is the most complex valve in the control system. It provides regulated pressure for full clutch apply. It provides clutch pressure priority by closing off
the feed line from the retarder pressure regulator valve
to the charging valve during initial clutch fill. At low
vehicle speeds, it reduces retarder clutch pressure by
closing or regulating the feed line between the cutoff
valve and the retarder pressure regulator valve. This
provides a smooth transition from retarder to vehicle
service brakes.
216
g. Charging Valve. The charging valve regulates the

difference in pressure between clutch-apply pressure
and retarder-charging pressure. When vehicle output
speed is approximately l600 rpm or greater, the charging valve moves toward the stop (left) in its bore, directing regulated retarder-charging pressure to the retarder. Once the pressure on both sides of the clutchapply piston is balanced, the piston return spring force
moves the piston back into its bore (left), disengaging
the clutch. When the vehicle speed is reduced, the
charging valve moves to the right in its bore, against
spring pressure, exhausting retarder-charging pressure.
The lower retarder-charging pressure in front of the
piston permits the higher clutch pressure behind the
clutch piston to move the piston out of its bore (right),
engaging the clutch. The application of the clutch at
lower vehicle speeds ensures a smooth transition from
retarder to vehicle service brakes.
226. RETARDER HYDRAULIC

CIRCUIT FUNCTION
a. Retarder Valve Off (Vehicle Moving). The retarder valve is in the off position when positioned at
the top of its bore. Air pressure at the top of the valve
is zero and spring force at the bottom of the valve
holds it in the top of its bore. In this position, the valve
directs fluid from the cooler to the transmission lubrication circuit, from the transmission converter through
the retarder valve to the fluid cooler, and from the fluid
cooler to the transmission housing and the retarder
housing for lubrication. Main pressure from the priority valve passes through the retarder valve to the three
accumulator cylinders. This fluid pressure moves the
pistons leftward in their bores, holding the fluid in reserve until required.
b. Retarder Valve Partially Applied
1. The position of the retarder valve in its bore is
controlled by the amount of air pressure applied to the top of the valve. At partial apply,
the initial air pressure application forces the retarder and cutoff valves to the bottom of their
bores. Clutch pressure at maximum strength is
released at the regulator valve and directed to
the clutch-apply circuit. Fluid retained in the
three accumulator cylinders is released to the

clutch-apply circuit and retarder-charging pressure is directed to the clutch-apply circuit. The
simultaneous addition of fluid from these circuits fulfills the clutch-apply circuit demand in
the shortest length of time and sets up a balanced pressure in the retarder hydraulic system. With this balanced pressure on both sides
of the piston, spring force moves the piston
away from the clutch plates, disengaging the
clutch. The retarder and cutoff valves move upward in their bores until the force on the top of
the valve is equal to the force on the bottom.
The position of the retarder valve in its bore
determines the pressure in the retarder hydraulic system.
2. As vehicle output speed decreases, governor
pressure is reduced. The charging valve moves
rightward in its bore, exhausting retardercharging pressure and reducing retarder-in
pressure to the clutch valve plug. The loss of
pressure at the left end of the plug permits
spring force at the right end to move the plug
leftward. Regulated pressure at the right end of
the clutch valve moves the valve leftward, reducing the regulated pressure to the clutch-apply circuit. Since the pressure in the retarder
charging circuit is less than the pressure in the
clutch-apply circuit, the piston is forced to engage the clutch. The engaged clutch, supplemented by rotor rotation, retards vehicle
forward motion and permits a smooth transition from retarder to vehicle service brakes.
c. Retarder Valve Fully Applied
1. Full application of air pressure to the top of the
retarder valve moves both the retarder and cutoff valves to the bottom of their bores. The
valves are held in this position until the air
pressure at the top of the valve is relieved.
Maximum regulated pressure is released by the
regulator valve and is maintained throughout
the hydraulic system, changed only by governor pressure and output speed.
2. Partial application of air pressure to the top of
the retarder valve initially moves the retarder
and cutoff valves to the bottom of their bores,
releasing maximum regulated pressure

throughout the system. The pressure at the top
and bottom of the retarder and cutoff valves
become equalized, forcing the two valves upward in their bores to a position that permits
the cutoff valve to introduce reduced regulated
pressure to the hydraulic system. The capability of the partial application to release reduced
regulated pressure into the hydraulic system is
the primary difference between full and partial
retarder valve application.
227. TORQUE PATHS THROUGH

THE TRANSMISSION
a. Converter Operation. Power is transmitted hydraulically through the torque converter. The engine
drives the converter pump. The pump throws transmission fluid against the turbine vanes, imparting
torque to the converter turbine shaft. From the turbine, the fluid flows between the vanes of the stator,
and re-enters the converter pump where the cycle begins again. The torque path through the torque converter is identical in all drive situations and in neutral. When the engine is idling, impact of the fluid
upon the turbine blades is negligible. When the engine is accelerated, the impact is increased and the
torque directed through the turbine shaft can exceed
the engine torque (by an amount equal to the torque
ratio of the converter). Converter operation is illustrated in Figures 22, 23, 24, and 27 for the MT
640 and 643, and in Figures 28, 29, 210, 211,
and 214 for the MT 650 and 653.
b. Lockup Operation. Power is transmitted mechanically through the lockup clutch. Application of
the lockup clutch occurs automatically as a function of
governor pressure. When the clutch is applied, the
converter elements rotate as a unit at engine speed.
This provides a direct drive from the engine to the turbine shaft. Lockup operation is illustrated in Figures
25 and 26 for third and fourth ranges for the MT
640 and 643, and in Figures 212 and 213 for fourth
and fifth ranges for the MT 650 and 653.
217
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LOCKUP
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CENTER
PLANETARY
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CONNECTING DRUM
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FRONT PLANETARY
V00273.08
Figure 22. Model MT 640 or MT 643 Neutral Torque Path
c. Neutral Operation (MT 640, 643) (Figure 22).

Engine torque is transmitted through the torque converter as described in Paragraph 227a. Although the
first clutch is applied, the forward clutch is not en-
218
gaged and torque is not transmitted beyond the fourth

clutch hub. Two clutches must be applied to produce
output shaft rotation.
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CENTER
PLANETARY
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V00273.09
Figure 23. Model MT 640 or MT 643 First Range Torque Path
d. First Range Operation (MT 640, 643) (Figure

23). Engine torque is transmitted through the torque
converter as described in Paragraph 227a. The forward clutch and the first clutch are applied. Forward
clutch application locks the turbine shaft and the transmission main shaft together so that they rotate as a
unit. The first clutch application anchors the rear planetary ring gear against rotation. The rear sun gear is
splined to the transmission main shaft and rotates with

it, rotating the planetary pinions. The pinions are part
of the planetary carrier, which is splined to the output
shaft. With the rear planetary ring gear held stationary
by the applied first clutch and with the rear sun gear
rotating the pinions, the rear planetary carrier rotates
within the ring gear and drives the output shaft at a
speed reduction of 3.58:1.
219
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CONVERTER
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CLUTCH
THIRD
CLUTCH
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CLUTCH
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CENTER
PLANETARY
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V00273.10
Figure 24. Model MT 640 or MT 643 Second Range Torque Path
e. Second Range Operation (MT 640, 643) (Figure 24). Engine torque is transmitted through the
torque converter as described in Paragraph 227a. The
forward clutch and the second clutch are applied. Forward clutch application locks the turbine shaft to the
transmission main shaft so that they rotate together.
The rear sun gear is splined to both the transmission
main shaft and the center ring gear and all three parts
rotate as a unit. With the front planetary carrier anchored against rotation (by second clutch application),
220
the rotating center ring gear rotates the center sun gear.
The center sun gear is splined to the sun gear shaft to
which the front sun gear is splined. The rotating front
sun gear rotates the front carrier pinions whose carrier
is anchored. The front carrier pinions rotate the front
ring gear which, along with the center carrier, is
splined to the rear planetary carrier through a connecting drum. Rotation of the connecting drum drives the
output shaft, through the splines of the rear planetary
carrier, at a speed reduction of 2.09:1.
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PLANETARY
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V00273.11
Figure 25. Model MT 640 or MT 643 Third Range Torque Path
f. Third Range Operation (MT 640, 643) (Figure

25). Engine torque is transmitted through the lockup
clutch as described in Paragraph 227b. The forward
and third clutches are applied. Third clutch application
anchors the sun gear shaft against rotation, which prevents the integral center sun gear from rotating. Forward clutch application locks the turbine shaft and the
main shaft together so that they rotate as a unit. The
rear sun gear is splined to both the main shaft and the
center ring gear, and rotates at input speed. With the

center sun gear held stationary and the center ring gear
rotating, the ring gear drives the center planetary pinions. This rotates the center planetary carrier at a speed
reduction of 1.39:1. This carrier and the rear planetary
carrier are splined to the planetary connecting drum
and rotate as a unit. The output shaft, being splined to
the rear carrier, rotates at the same speed as the center
planetary carrier.
221
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V00273.12
Figure 26. Model MT 640 or MT 643 Fourth Range Torque Path
g. Fourth Range Operation (MT 640, 643) (Figure 26). Engine torque is transmitted through the
lockup clutch as described in Paragraph 227b. The
forward and fourth clutches are applied. With these
clutches applied, the transmission main shaft and center sun gear shaft are locked together and rotate as a
222
unit at input speed. With the center sun gear and rear
sun gear rotating at the same speed (locked together)
and their respective carriers splined to the planetary
connecting drum, all components rotate at the same
speed. The transmission output shaft is splined to the
rear carrier and produces an output ratio of 1.00:1.
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CONVERTER
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V00273.13
Figure 27. Model MT 640 or MT 643 Reverse Range Torque Path
h. Reverse Range Operation (MT 640, 643) (Figure 27). Engine torque is transmitted through the
converter as described in Paragraph 227a. Reverse
range is the only range in which the forward clutch is
not applied. In this range, the fourth clutch is applied
and rotates the sun gear shaft (with the front sun gear
splined to it) at input speed. The first clutch is also applied and anchors the rear ring gear against rotation.
The center sun gear rotates the center carrier pinions
which, in turn, rotate the center ring gear in the opposite direction. The center carrier is splined to the planetary connecting drum, which is splined to the rear
carrier. The reverse direction of rotation of the center
ring gear rotates the rear sun gear. This causes the rear
planetary pinions to drive the rear carrier in a reverse
direction, within the stationary ring gear. The transmission output shaft, splined to the rear carrier, rotates
in a reverse direction at a speed reduction of 5.67:1.
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CLUTCH
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CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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OUTPUT
SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.10
Figure 28. Model MT 650 or MT 653 Neutral Torque Path
i. Neutral Operation (MT 650, 653) (Figure 28).

Engine torque is transmitted through the torque converter as described in Paragraph 227a. Although the
first clutch is applied, the forward clutch is not en-
224
gaged and torque is not transmitted beyond the fourth

clutch hub. Two clutches must be applied to produce
output shaft rotation.
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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OUTPUT
SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.11
Figure 29. Model MT 650 or MT 653 First Range Torque Path
j. First Range Operation (MT 650, 653) (Figure

converter as described in Paragraph 227a. The forward clutch and the low clutch are applied. Forward
clutch application locks the turbine shaft and the transmission main shaft together so that they rotate as a
unit. Low clutch application anchors the low planetary
carrier against rotation. The rear planetary sun gear
(splined to the transmission main shaft) rotates the rear
planetary pinions; however, the rear planetary carrier
resists rotation because it is restrained by the output

shaft to which it is splined. This causes the rear planetary carrier ring gear to rotate. The low planetary sun
gear is splined to the rear planetary ring gear and rotates with it. The low planetary sun gear rotates the
pinions. Since the low planetary carrier is anchored
against rotation, the pinions rotate the low planetary
ring gear which, in turn, rotates the output shaft to
which it is splined, at a speed reduction of 8.05:1.
225
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
MAIN SHAFT
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REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.12
Figure 210. Model MT 650 or MT 653 Second Range Torque Path
k. Second Range Operation (MT 650, 653) (Figure 210). Engine torque is transmitted through the
torque converter as described in Paragraph 227a. The
forward clutch and the first clutch are applied. Forward clutch application locks the turbine shaft and the
transmission main shaft together so that they rotate as
a unit. First clutch application anchors the rear ring
gear against rotation. The rear sun gear is splined to
226
the main shaft and rotates with it, and rotates the planetary pinions. The pinions are part of the planetary carrier which is splined to the output shaft. With the rear
planetary ring gear held stationary by the applied first
clutch, and with the rear sun gear rotating the pinions,
the rear planetary carrier rotates within its ring gear
and drives the output shaft at a speed reduction of
3.58:1.
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.13
Figure 211. Model MT 650 or MT 653 Third Range Torque Path
l. Third Range Operation (MT 650, 653) (Figure

converter as described in Paragraph 227a. The forward clutch and the second clutch are applied. Forward clutch application locks the turbine shaft and the
transmission main shaft together so that they rotate as
a unit. Second clutch application anchors the front
planetary carrier against rotation. The rear sun gear is
splined to both the transmission main shaft and the
center planetary ring gear and all three rotate as a unit.
With the front planetary carrier anchored against rota-
tion by second clutch application, the rotating center

ring gear rotates the center sun gear. The center sun
gear is integral with the sun gear shaft to which the
front sun gear is splined. The rotating front sun gear
rotates the front carrier pinions whose carrier is anchored. The front carrier pinions rotate the front ring
gear which, along with the center carrier, is splined to
the rear planetary carrier through a connecting drum.
Rotation of the connecting drum drives the output
shaft through the splines of the rear planetary carrier at
a speed reduction of 2.09:1
227
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.14
Figure 212. Model MT 650 or MT 653 Fourth Range Torque Path
m. Fourth Range Operation (MT 650, 653) (Figure 212). Engine torque is transmitted through the
lockup clutch as described in Paragraph 227b. The
forward and third clutches are applied. Third clutch
application anchors the sun gear shaft against rotation,
which prevents the integral center sun gear from rotating. Forward clutch application locks the turbine shaft
and the main shaft together so that they rotate as a unit.
The rear sun gear is splined to both the main shaft and
228
the center planetary ring gear and rotates at input

speed. With the center sun gear held stationary, the
center ring gear drives the center planetary carrier pinions. This rotates the center planetary carrier at a speed
reduction of 1.39:1. This carrier and the rear planetary
carrier are splined to the planetary connecting drum
and rotate as a unit. The output shaft, splined to the
rear carrier, rotates at the same speed as the center
planetary carrier.
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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OUTPUT
SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.15
Figure 213. Model MT 650 or MT 653 Fifth Range Torque Path
n. Fifth Range Operation (MT 650, 653) (Figure

213). Engine torque is transmitted through the lockup
clutch as described in Paragraph 227b. The forward
and fourth clutches are applied. With the clutches applied, the transmission main shaft and center sun gear
shaft are locked together and rotate as a unit at input
speed. With the center sun gear and the rear sun gear
rotating at the same speed (locked together) and their
respective carriers splined to the planetary connecting
drum, all components rotate at the same speed. The
output shaft is splined to the rear carrier and produces
an output ratio of 1.00:1.
229
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TORQUE
CONVERTER
LOCKUP
CLUTCH
FOURTH
CLUTCH
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CLUTCH
SECOND
CLUTCH
FORWARD
CLUTCH
FIRST
CLUTCH
CENTER
PLANETARY
LOW CLUTCH
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SHAFT
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LOW PLANETARY
TURBINE SHAFT
Clutch Applied
Torque Path
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MAIN SHAFT
REAR PLANETARY
CONNECTING DRUM
SUN GEAR SHAFT
FRONT PLANETARY
V00272.16
Figure 214. Model MT 650 or MT 653 Reverse Range Torque Path
o. Reverse Range Operation (MT 650, 653) (Figure 214). Engine torque is transmitted through the
converter as described in Paragraph 227a. Reverse
range is the only range in which the forward clutch is
not applied. In reverse range, the fourth clutch is applied, rotating the sun gear shaft (with the front sun
gear splined to it) at input speed. The first clutch is
also applied and anchors the rear ring gear against rotation. The center sun gear rotates the center carrier
230
pinions, which rotate the center ring gear in the opposite direction. The center carrier is splined to the planetary connecting drum, which is splined to the rear
carrier. The reverse direction of rotation of the center
ring gear rotates the rear sun gear. This causes the rear
planetary pinions to drive the rear carrier in a reverse
direction, within the stationary ring gear. The transmission output shaft, splined to the rear planetary carrier, rotates in a reverse direction at a speed reduction
of 5.67:1.
Section 3 PREVENTIVE MAINTENANCE

31.
SCOPE
a. This section describes the routine and periodic

procedures required to maintain the transmission in
good operating condition. Topics covered include inspection, hydraulic system maintenance, storage procedures, linkage adjustment, and shift point adjustment. A troubleshooting chart is included at the back
of this section.
b. For transmission removal and installation guidelines, engine adaptation hardware specifications, and
road test checks, refer to the MT(B) 600 Series Mechanics Tips, MT1357EN.
32. INSPECTION AND CARE

a. Clean and inspect the exterior of the transmission
at regular intervals. The severity of service and operating conditions will determine the frequency of such inspections. Inspect the transmission for:
loose bolts (transmission and mounting com-
ponents)
transmission fluid leaks*
shift linkage freely positioned by transmission
detent
full (and ease of) movement of mechanical
modulator linkage
vacuum or air line and modulator for leaks
damaged or loose hydraulic lines
worn or frayed electrical connections
driveline U-joints and slip fittings
speedometer cable and fittings
PTO linkage and driveline
b. Check the transmission fluid level at the intervals

specified in the vehicle operators manual.
33. IMPORTANCE OF PROPER

TRANSMISSION FLUID LEVEL
a. Effects of Improper Fluid Level. Because the
transmission fluid cools, lubricates, and transmits hydraulic power, it is important that the proper fluid level
be maintained at all times. The transmission fluid is
used to apply clutches and to lubricate and cool the
components. If the fluid level is too low, the converter
and clutches will not receive an adequate supply of

fluid. If the level is too high, the fluid will aerate, the
transmission will overheat, and fluid may be expelled
through the breather or dipstick tube.
b. Foaming and Aerating
1. Transmission performance will be affected
when the fluid foams or aerates. The primary
causes of aeration are low fluid in the sump,
too much fluid in the sump, or a defective or
missing sealring on the intake pipe.
2. A low fluid level (indicated on the dipstick)
will not completely envelop the fluid filter.
Fluid and air are drawn in by the input pump
and directed to the clutches and converter,
causing converter cavitation noises and irregular shifting. Aeration also changes the viscosity
and color of the fluid to a thin milky liquid.
3. At normal fluid level (FULL mark on the dipstick), the fluid is slightly below the planetary
gear units. If the transmission is overfilled,
bringing the fluid level above the FULL mark,
the planetary units will run in the fluid, causing
it to become aerated. Overheating and irregular
shift patterns can occur when the fluid is aerated.
4. A defective sealring 31 or 39 (Foldout 10,A),
or 9 (Foldout 10,B) on the filter tube will cause
the input pump to draw air and fluid from the
sump, causing the fluid to become aerated.
34. DIPSTICK MARKINGS

Two dipstick variations are available for use with the
MT 600 Series transmissions. Differences in fill tube
placement and dipstick orientation may change the
markings slightly. Refer to Figures 31 through 34 for
typical dipstick markings and pan fluid levels.
NOTE:
The HOT RUN band for the 7.14 inch (181.36 mm)
pan is below the split line. The bottom of the HOT
RUN band is 1.75 inch (44.5 mm) below the split line
of the transmission and oil pan. The REF FILL
(COLD RUN) band is not provided with this configuration.
* Transmission fluid leaks require immediate attention.
31

35. TRANSMISSION FLUID LEVEL
CHECK PROCEDURE
1.80"
(46 mm)
1.50"
(38 mm)
0.75"
(19 mm)
WARNING!
When checking the transmission fluid level, be
sure that the parking brake and/or emergency
brakes are set and properly engaged, and the
wheels are blocked. Unexpected and possible
sudden movement may occur if these precautions
are not taken.
TOP OF OIL PAN
FULL
HOT RUN
ADD
COLD RUN
a. Preparation
3. Transmission input speed and fluid temperature significantly affect the fluid level. An increase in input speed lowers the fluid level; an
increase in fluid temperature raises the fluid
level. The fluid level must always be checked
with the engine at idle (600650 rpm) and the
transmission in N (Neutral).
TRANSMISSION
OIL PAN
SPLITLINE
CHECK IN NEUTRAL AT IDLE

USE DEXRON OIL
Figure 31. Fluid Levels for 4.3 Inch

Pan MT 640, 643, 650, 653
CHECK IN NEUTRAL AT IDLE

USE DEXRON OIL
2. Clean around the end of the fill tube before removing the dipstick. Dirt or foreign material
must not be allowed to enter the transmission
because it can cause valves to stick, cause undue wear of transmission parts, or clog passages. Check the fluid level by the following
procedures and record any abnormal level on
your maintenance records.
V00274
HOT
RUN
1. Always check the transmission fluid level at

least twice. Consistency is important in maintaining accuracy. If inconsistent dipstick readings persist, check for proper venting of the
transmission breather and/or fill tube. A
clogged breather can force fluid up into the fill
tube and cause an inaccurate reading. A dipstick that anchors inside the top end of an unvented fill tube can draw fluid up into the tube
during removal and give an inaccurate reading.
FULL
0.75"
(19 mm)
0.75"
(19 mm)
1.80"
(46 mm)
ADD
1.50"
(38 mm)
32
RUN
NOTE:
A Cold Check is performed with dipsticks similar
to those illustrated in Figures 32 and 34.
The fluid level rises as sump temperature increases.
DO NOT FILL above the REF FILL (COLD
RUN) band if the transmission fluid is below normal operating temperature.
COLD
b. Cold Check
V00275
Figure 32. Dipstick Markings for 4.3 Inch

Pan MT 640, 643, 650, 653
(Earlier and Later Models)
PREVENTIVE MAINTENANCE
1. Park the vehicle on a level surface, apply the
parking brake, and block the wheels.
2. Operate the engine at 10001500 rpm for one
minute to purge air from the system. Allow the
engine to idle. Shift to D (Drive) and then to R
(Reverse) to fill the hydraulic circuits with
fluid. Then, shift to N (Neutral). The sump
temperature should be 60120F (1650C).
3. After wiping the dipstick clean, check the fluid
level. If the fluid level is in the COLD RUN
(Figure 32) or REF FILL (Figure 34) bands,
the level is satisfactory for operating the transmission until the fluid is hot enough to perform
a Hot Check. If the fluid level is not within
these parameters, raise or lower the fluid level
to bring it within the band.
4. Perform a Hot Check at the first opportunity
after normal operating temperature is reached
(160200F (7193C) sump temperature;
180220F (82104C) converter-out temperature).
0.75"
(19 mm)
1.50"
2.22"
2.55"
(38 mm) (57 mm) (65 mm)
FULL
HOT RUN
REF FILL
ADD
V03275
Figure 33. Fluid Level for 5.10 Inch

Pan MT 643, 653
NOTE:
IDLE
IDLE
2.55"
1.50"
(64.8 mm)
(38.0 mm)
TRANSMISSION
OIL PAN
SPLITLINE
0.75"
(19.0 mm)
HOT
RUN
HOT
RUN
A Hot Check is performed with all dipstick designs

(Figures 32 and 34).
0.75"
(19.0 mm)
L AT
TRA
NEU
L AT
TRA
NEU
TRANSMISSION
OIL PAN
SPLITLINE
CK IN
CHE
CK IN
CHE
c. Hot Check
TOP OF
OIL PAN
1.50"
(38.0 mm)
2.22"
(57.1 mm)
REF
FILL
1. Operate the transmission until normal operating temperature is reached (160200F (71
93C) sump temperature; 180220F (82
104C) converter-out temperature). Shift to D
(Drive) and then to R (Reverse) to fill the hydraulic circuits with fluid.
5.10 in.
OIL PAN
7.14 in.
OIL PAN
V03276
2. Park the vehicle on a level surface and shift to

N (Neutral). Apply the parking brake, block
the wheels, and allow the engine to idle.
3. After wiping the dipstick clean, check the
fluid level. The safe operating level is anywhere between the FULL and ADD lines (Figure 32) or within the HOT RUN band
(Figures 32 and 34).
Figure 34. Dipstick Markings for 5.10 and 7.14 Inch Pan
(Later Models)
4. If the fluid level is outside of these parameters,

raise or lower the fluid level to bring it within
the correct markings on the dipstick.
33

36. KEEPING TRANSMISSION
FLUID CLEAN
Transmission fluid must be handled in clean containers
to prevent foreign material from entering the transmission. Lay the dipstick in a clean place while filling the
transmission.
in tubes, hoses, external filters, seals, etc., are

compatible with C-4 fluids.
CAUTION:
Disregarding minimum fluid temperature limits
can result in transmission malfunction or reduced transmission life.
CAUTION:
Containers or fillers that have been used to handle antifreeze or engine coolant solution must
never be used for transmission fluid. Antifreeze
and coolant solutions contain ethylene glycol
which, if introduced into the transmission, can
cause the clutch plates to fail.

RECOMMENDATIONS
a. Recommended Automatic Transmission
Fluid
1. Hydraulic fluids (oils) used in the transmission
are important influences on transmission performance, reliability, and durability. Use
DEXRON-III fluids for standard duty, onhighway applications. Use C-4 fluids (Allison
approved SAE 10W or SAE 30) for severe
duty and off-highway applications. Also use
type C-4 SAE 30 in all applications where the
ambient temperature is consistently above
95F (35C).
2. Some DEXRON-III fluids are also qualified
as type C-4 fluids. To ensure the fluid is qualified for use in Allison transmissions, check for
a DEXRON-III or C-4 fluid license, or approval numbers on the container, or consult the
lubricant manufacturer. Consult your Allison
Transmission dealer or distributor before using
other fluid types. Fluid types such as Type F,
and universal farm fluids may or may not be
properly qualified for use in your Allison transmission.
3. Before using type C-4 fluids, consult the vehicle manufacturer to ensure that materials used
34
b. Recommended Viscosity Grade. When choosing the optimum viscosity grade of fluid to use, duty
cycle, preheat capabilities, and/or geographical location must be taken into consideration. Table 31 lists
the minimum fluid temperatures at which the transmission may be safely operated. Preheat with auxiliary
heating equipment or by running the vehicle with the
transmission in N (Neutral) for a minimum of 20 minutes before attempting range operation.
Table 31. Operating Temperature
Requirements for Transmission Fluid
(Ambient Temperature Below Which Preheat is Required)
Viscosity Grade
Fahrenheit
Celsius
SAE 0W-20
31
35
DEXRON-III
22
30
20
15
SAE 30
32
SAE 40
50
10
SAE 10W
SAE 15W-40
38. TRANSMISSION FLUID AND

FILTER CHANGE INTERVALS
Transmission fluid and filter change frequency is determined by the severity of transmission service and
by the filter equipment installed. Table 32 is a general guide. More frequent changes may be required
when the fluid is visually contaminated, when operations subject the transmission to high levels of contamination or overheating, or if fluid analysis indicates that the fluid is oxidized beyond the limits
listed in Table 33.
Table 32. Transmission Fluid and Filter Change Intervals
Transmission
Application
Fluid Change
Internal Sump
Governor Filter
External Auxiliary
Filters**
On-Highway
25,000 miles
(40 000 km)
or 12 months*
Paper Filter:
25,000 miles (40 000 km) or
12 months*
Stainless Steel Screen: At
overhaul
25,000 miles
(40 000 km)
or 12 months*
After first 5000 miles (8 000

km) and at normal fluid
change intervals thereafter*
Off-Highway
1000 hours max

or 12 months*
Paper Filter: 1000 hours

maximum or 12 months*
Stainless Steel Screen: At
overhaul
1000 hours max

or 12 months*
After first 500 hours and at

normal fluid change intervals
thereafter*
* Whichever occurs first.
** When an Allison high-efficiency filter is used, the change interval is until the Change Filter light indicates the filter is contaminated or until it has
been in use for three years, whichever occurs first. No mileage restrictions apply.
Table 33. Fluid Oxidation Measurement Limits

Measurement
Viscosity
Limit
+/- 25% change from new
fluid
Carbonyl absorbance +0.3 A*/0.1 mm change from

new fluid
Total acid number
+3.0 change from new fluid
Solids
2% by volume maximum
* A = Absorbance units
b. Metal Particles. Metal particles in the fluid (except for the minute particles normally trapped in the
filter) indicate damage has occurred in the transmission. When these particles are found in the sump or on
the magnetic plate in the bottom of the pan, the transmission must be disassembled and closely inspected to
find the source. Metal contamination requires complete disassembly of the transmission and cleaning of
all internal and external circuits, cooler, and all other
areas where the particles could lodge. Refer to application of the auxiliary filter, Paragraph 39d.
Refer to SIL 17-TR-83 for fluid analysis techniques and data interpretation.
Consult your local industrial yellow pages for fluid analysis firms. Use
one fluid analysis firm as results from various firms cannot be accurately
compared. Refer to the Technician's Guide for Automatic Transmission
Fluid (GN2055EN) for additional information.

CONTAMINATION
a. Examine at Fluid Change. At each fluid change,
examine the fluid which is drained for evidence of dirt
or engine coolant (water). A normal amount of condensation will emulsify in the fluid during operation of
the transmission. If there is evidence of coolant, check
the cooler (heat exchanger) for leakage between the
coolant and fluid areas. Fluid in the coolant side of the
cooler (heat exchanger) is another sign of leakage.
This may indicate leakage from the engine oil system.
Any accumulation of sludge or soft dirt in the sump
should be removed.
CAUTION:
If excessive metal contamination has occurred,
inspection of the cooler and all bearings within
the transmission is recommended.
c. Coolant Leakage
1. If engine coolant leaks into the transmission
hydraulic system, immediate action must be
taken to prevent malfunction and possible serious damage. The transmission must be completely disassembled, inspected, and cleaned.
All traces of the coolant, and varnish deposits
resulting from coolant contamination, must be
removed. Clutch plates contaminated with ethylene glycol must be replaced.
2. A Gly-Tek test kit to detect glycol in transmission fluid can be obtained from Nelco
35

Company, 1047 McKnight Road South, St.
Paul, Minnesota 55119.
NOTE:
Some transmission fluids will give a positive indication because of additives in the fluid. When
test results are questionable, test a clean (unused)
sample of the same type or brand of fluid to confirm results.
5. Use one of the following recommended auxiliary filters:

Filter Assembly
Allison 29510923*
AC PM 16-1
AC PM 13-16
Fram HP 1-2
Purolator OF-15C-1
Purolator PER-20-10
*
d. Auxiliary Filter
NOTE:
Transmissions equipped with a stainless steel sump
screen must have an auxiliary filter in the external
transmission cooling circuit.
1. If a condition occurs that introduces debris into

the hydraulic system, completely clean up the
cooler and lines.
2. Repeated cleaning and flushing may not remove all debris. For models with retarder, replace the main cooler. For models without
retarder, installation of an auxiliary filter (Figure 35) in the cooler-out line (between cooler
and transmission) is required if such a filter
does not already exist. This requirement applies whether the transmission is overhauled or
replaced by a new or rebuilt unit.
3. If any doubt exists about the clean-up of the
cooler, replace the cooler.
4. The auxiliary filter must have a 40 micron or
finer filter element and a maximum filter pressure drop of 3 psi (21 kPa) at 8 gpm (30 liters/
minute) at 180F (82C). The finest filtration
allowed is a filter that removes 100 percent of
all particles larger than 6 micron. The maximum external circuit pressure drop at normal
operating temperature must not exceed 23 psi
(159 kPa) at 2000 rpm in N (Neutral).
36
Filter Element
Allison 29510922*
PF 141
PF 897
HP 1
OF-2C-1
PER-20
High-efficiency filter and element are available from your

authorized Allison distributor. Refer to SIL 12-TR-93
(latest revision).
6. Install the filter in the line from the cooler to

the transmission. Use No. 12 hose (minimum
ID of 58 inch (15.7 mm)) of sufficient length to
permit power pack movement. Hose fittings
must have a minimum ID of 0.484 inch (12.29
mm). The hose must meet SAE 100 R5 specifications, with an operating range of 40 to
330F (40 to 165C).
7. The total cooler circuit (to and from the cooler)
pressure drop must not exceed 23 psi (159 kPa)
in neutral, at 2000 rpm and normal operating
temperature. Filter bypass opening pressure on
units not equipped with a differential pressure
indicator (P switch) must be 59 psi (3462
kPa). The Allison high-efficiency filter has a
P switch that monitors pressure drop across
the filter and illuminates a warning light if the
P exceeds 8 psi (55 kPa). The filter bypass
valve will open if P exceeds 12 psi (82 kPa).
8. External auxiliary filter element change intervals can be determined according to Table 32,
Paragraph 38.
310. TRANSMISSION FLUID AND

FILTER CHANGE PROCEDURES
a. Fluid Change Procedure (Standard Configuration, 4.3 and 5.1 Inch Pan) (Foldout 10,A)
1. The transmission should be at the normal operating temperature of 160200F (7193C) to
assist draining. Shift the transmission to N
(Neutral) and turn off the engine.
2. Remove drain plug 43 and gasket 44 from the
right side of the pan. Allow the fluid to drain.
RADIATOR
FROM COOLER
ENGINE
TO COOLER
TRANSMISSION FLUID
FROM COOLER
COOLANT
COOLANT
TRANSMISSION
NAMEPLATE
TYPICAL COOLER
AUXILIARY
FILTER
TRANSMISSION FLUID TO COOLER

V03129
Figure 35. Installation of External Auxiliary Filter
NOTE:
Transmissions equipped with a stainless steel sump
screen do not require pan removal or filter replacement until overhaul, unless the transmission has
had a failure resulting in contamination of the fluid.
Steps (3) through (12) describe the procedure for
changing paper element or stainless steel screen
sump filters. Proceed to Step (13) if not replacing a
sump screen filter.
element with sump screen and integral filter

tube assembly 40. For 5.10 inch pan models,
remove spacer 37 if replacing a paper filter
with the sump screen assembly. For transmissions equipped with a sump screen filter, remove filter retaining bolt 42 and filter
assembly 40.
3. Remove pan 46, gasket 34 or 41, and the fill

tube from the transmission. Discard the gasket.
Clean the pan.
5. Check the current Parts Catalog PC1316EN for

the proper replacement filter. Keep filters in
their carton until ready for installation. If replacing a paper filter element with a stainless
steel sump screen, the transmission nameplate
must have the letters AA stamped into the
nameplate to indicate the modification.
4. For transmissions equipped with paper element

filter 33, remove washer-head screw 35 that retains the filter. Remove the filter and discard.
Filter tube 32 is not integral with the filter. Do
not discard the tube unless replacing the paper
6. Install filter tube 32 into a new paper filter element assembly 33 (if used). Install a new sealring 31 or 39 onto filter tube 32 or sump screen
filter assembly 40. Lubricate the sealring with
transmission fluid. Install the new filter, insert-
37

ing the filter tube into the hole in the bottom of
the transmission. Secure the filter with 516-18
x 58 inch washer-head screw 35 or 42. For 5.10
inch deep pans not upgraded to the sump
screen, secure the filter assembly and spacer 37
with a 516-18 x 114 inch washer-head screw.
Tighten the filter retaining screw to 1015 lb ft
(1420 Nm).
CAUTION:
Do not use gasket-type sealing compounds, fibrous greases, or nonsoluble, vegetable-base
cooking compounds any place inside the transmission or where they could be flushed into the
transmission hydraulic system.
7. Place gasket 34 or 41 onto the pan. Sealer or
cement may be applied only to the area of the
pan flange that is outside the raised bead of the
flange.
8. Install the gasket and pan 46, carefully guiding
them into place. Guard against dirt or foreign
material entering the pan. Retain the pan to the
housing with four 516-18 washer-head screws
48. Install screws by hand, one at a time, into
the corners of the pan.
9. Install the remaining seventeen washer-head
screws 48 by hand, carefully threading each
through the gasket and into the transmission.
Bottom all screws before tightening them.
10. Alternately tighten screws 180 degrees apart to
5 lb ft (6.7 Nm). Repeat the process, tightening the screws to 1520 lb ft (2027 Nm).
11. Install the fill tube at the side of the pan.
12. Check Dimension A (Figure 36) to determine
what oil pan boss is present. If Dimension A is
0.5700.580 inch (14.4814.73 mm), tighten
the tube fitting to 6575 lb ft (88102 Nm). If
Dimension A is 0.6700.680 inch (17.02
17.27 mm), tighten the tube fitting to 90100
lb ft (122136 Nm).
13. Install drain plug 43 and gasket 44. Tighten the
plug to 1520 lb ft (2027 Nm).
14. Replace the external auxiliary filter element
(cooler-out line), if present. Refer to Paragraph
39d.
38
15. Refill the transmission with transmission fluid.

Use approximately 12 U.S. quarts (11 liters) of
fluid for the 4.3 inch pan and 15 U.S. quarts
(14 liters) of fluid for the 5.10 inch pan. These
quantities of fluid will vary depending on external circuits.
16. Check the fluid level using the procedure described in Paragraph 35.
17. Refer to Table 32 and determine when the
next fluid and filter changes will be required. If
labels are available (Figure 37), fill in the appropriate dates and affix the labels in a conspicuous location in the vehicle.
b. Fluid Change Procedures (External Access
Heavy-Duty Configuration, 7.14 Inch Pan)
(Foldout 10,B)
1. The transmission should be at the normal operating temperature of 160200F (7193C) to
assist draining. Shift the transmission to N
(Neutral) and turn off the engine.
2. Remove drain plug 23 from rear or side of pan.
Allow the fluid to drain.
3. Remove bolt 21 and nut 22. Remove strap 20,
filter cover 19, spring 17, and retainer 16.
4. Remove filter 14. Discard the filter retainer
sealring 15 and filter cover sealring 18.
5. Install a new sealring 15 on filter retainer 16.
Install filter 14 and retainer into external access
canister 11.
6. Install a new filter cover sealring 18 onto the
lip of the pan. Install spring 17 into cover 19
and place over the filter retainer.
7. Install strap 20, 516-24 x 78 bolt 21, and nut 22
onto pan. Torque the bolt to 1114 lb ft (1519
Nm).
8. Refill the transmission with transmission fluid.
Use approximately 17 U.S. quarts (16 liters).
The quantity of fluid will vary depending on
external circuits.
A
Dimension A
0.5700.580 in. (14.4814.73 mm)
0.6700.680 in. (17.0217.27 mm)
Torque Specifications
65 75 lb ft (88102 Nm)
90 100 lb ft (122136 Nm)
NOTE: Except for Dimension A, the oil pan in Figure 36 does not represent all MT oil pan configurations.
V03277
Figure 36. Measuring the Length of Oil Pan Boss to Identify Torque Requirements
Next Transmission
Fluid Change is Due
Miles/km
or
Date
Next Transmission Internal
Filter Change is Due
Miles/km
V02883
Figure 37. Typical Fluid and Filter Change Reminder Labels
9. Check the fluid level using the procedure described in Paragraph 35. Refer to Paragraph
34 for dipstick calibration specifications.
10. Refer to Table 32 and determine when the
next fluid and filter changes will be required. If
labels are available (Figure 37), fill in the appropriate dates and affix the labels in a conspicuous location in the vehicle.
c. Governor Filter Change Procedures
1. MT 643, 653 Earlier Models. Remove the
pipe plug that retains the governor oil screen
(Figure 38). If the filter is undamaged, clean
and reinstall it. If damaged, install a new filter.

The open end must be installed first, into the
transmission rear cover. Install the pipe plug to
retain the filter. Tighten the plug to 45 lb ft
(5.56.7 Nm).
2. MT 643, 653 Later Models. For MT 643
(Foldout 12,A), remove hex plug 14, sealring
13, and governor filter 12 from the rear cover
(Figure 39). For MT 653 (Foldout 12,B), remove hex plug 22, sealring 21, and governor
filter 20. Install a new filter, a new sealring, and
the hex plug. Tighten the plug to 5070 lb ft
(6895 Nm).
39

3. MTB 643, 653 Models (Foldout 18,A). Remove 78-14 hex socket plug 15 and governor
filter 13 from the output retarder housing (Figure 310). Remove sealring 14 from the plug
and discard. Install a new filter. Install a new
sealring on the plug. Install the plug and
tighten it to 5070 lb ft (6895 Nm).
REAR
COVER
311. BREATHER
The breather is located at the top of the transmission
housing and prevents pressure buildup within the transmission. The breather must be kept clean and the passage
open. The prevalence of dust and dirt determines the frequency at which the breather requires cleaning. Use care
when cleaning the transmission. Spraying steam, water,
or cleaning solution directly at the breather can force the
water or solution into the transmission.
312. LINKAGE
a. Shift Selector Lever and Control Linkage
CAUTION:
Failure to obtain proper detent in D (Drive), N
GOVERNOR OIL SCREEN

H00005
Figure 38. MT 643, 653 Governor

Filter Earlier Models
(Neutral), or R (Reverse) can cause metering of

the clutch-apply fluid to either forward or
fourth (reverse) clutch. The resulting low apply
pressure and clutch slippage will affect transmission durability.
Manual selector shafts that are center drilled at
their outer ends require an M10 x 1.5-6G nut
(metric thread). Shafts that are undrilled require a 38-16 nut (standard inch series). Use of
the wrong nut will damage both the shaft and
nut. Torque for either nut is 1520 lb ft (2027
Nm). Excessive torque applied to the nut without holding the lever can damage the internal lever. Do not use an impact wrench.
RETARDER
7/8-14
HEX SOCKET PLUG
FILTER
REAR COVER
SEALRING
HEX HEAD PLUG
GOVERNOR FILTER
Figure 39. MT 643, 653 Governor

Filter Later Models
310
H00006
H00007
Figure 310. MTB 643, 653 Governor Filter
1. To install the shift selector lever and nut, refer to
MT 600 Series Mechanics Tips, MT1357EN.
2. Proper adjustment of the shift selector control
linkage is important as the shift selector detents must correspond exactly to those in the
transmission. Periodic inspections should be
made for bent or worn parts, loose threaded
connections, loose bolts, and accumulation of
grease and dirt. All moving joints must be kept
clean and well lubricated. For connecting and
adjusting the shift selector control linkage, refer to MT 600 Series Mechanics Tips,
MT1357EN, or the vehicle manual.
b. Mechanical Actuator Adjustment. The mechanical linkage must be properly adjusted for efficient
performance. For installing and adjusting the mechanical modulator control, refer to MT 600 Series Mechanics Tips, MT1357EN.
c. Other Linkage Adjustments. For adjustments to
other linkage, such as PTO, speedometer, etc., refer to
MT 600 Series Mechanics Tips, MT1357EN.
down-inhibit), and a trimmer regulator check.

If a test stand is not available, satisfactory calibration of shift points may be made after road
testing the vehicle.
b. Location of Adjusting Components
1. Shift points are changed by changing the positions of the adjusting rings that determine the
retaining force of valve springs in the main
control valve body. Refer to items 10, 17, 23,
29, and 46 (Foldout 13 or 14) and 14 (Foldout
15,B).
2. Special tool J 24314 is used to depress and rotate the adjusting rings. Clockwise rotation increases spring force and raises the shift point;
counterclockwise rotation reduces spring force
and lowers the shift point.
NOTE:
Each notch of adjustment alters the shift point approximately 40 output shaft rpm.
313. ADJUSTMENT OF SHIFT POINTS

c. Checks Before Adjusting Shift Points
NOTE:
Transmission shift points cannot be satisfactorily
adjusted if the transmission has the wrong governor
installed. Check the two- or three-digit code on the
head of the governor with the code shown in the
current Parts Catalog PC1316EN for the governor
listed for your transmission assembly number.
a. Calibrated on Test Stand or in Vehicle
1. Proper timing of shift speed points is necessary
for maximum transmission performance. Shifts
may be adjusted on the test stand when the
transmission is rebuilt or overhauled, or during
road testing of the vehicle.
2. A Kent Moore Valve and Governor Test Stand
(J 25000) or Aidco (Model 250) is designed to
check five principle transmission functions. It
performs a checking procedure on the governor, modulator, hold regulator, shift points (up-
1. For calibration during a road test or on a test

stand, warm up the transmission or test stand
setup to the normal operating temperature of
160200F (7193C).
2. Check the engine no-load governor setting, and
adjust if required, to conform to the transmissions engine speed requirements.
3. Check the engine for satisfactory performance
before checking shift points.
4. For diesel applications, check the linkage that
controls the mechanical or electrical modulator
valve actuator for proper travel, routing, and
operation. For most gasoline applications,
check the condition and routing of vacuum
modulator lines, hoses, and connections.
5. Check the selector linkage for proper range selection.
311

6. Provide accurate instrumentation for observing
speeds, temperatures, pressures, vacuum, etc.
5. Refer to Sections 5, 6, and 7 for procedures

covering removal and replacement of affected
components.
d. Calibration by Road Test Method

e. Calibration by Speedometer Readings Method
NOTE:
Before road test, determine the vehicle tachometer
error with a test tachometer. Make corrections for
error, as required, in subsequent tests.
1. When a tachometer is not available for checking shift points, the vehicle speedometer can
be used.
1. Note the full-load governed speed of the engine. This is the base speed from which checks
and adjustments are made.
2. Check the top speed of the vehicle in each selector hold position (first, second, and third
ranges for MT 640, 643; second, third, and
fourth ranges for MT 650, 653). Record the top
speed for each.
2. Subtract 200 rpm from the governed speed recorded and record the remainder as the desired speed for all automatic upshifts, except
the 12 shift of the MT 640, 643 and the 23
shift of the MT 650, 653. The latter two shifts
should occur at full-load governed speed, less
600 rpm.
3. For checking the shift points, place the selector

at D (Drive) so that all automatic shifts can occur. Drive the vehicle at full throttle from a
standing start until the 34 (MT 640, 643) or
45 (MT 650, 653) upshift occurs. Record the
mph at which each upshift occurs.
3. Drive the vehicle and check the engine speed

(at full throttle) at which each upshift occurs.
Each upshift should occur at the speeds specified in Step (2).
4. If an upshift speed does not reach the specified
rpm, the shift point may be raised by adjusting
(increasing) the spring force on the 12, 23,
34, or 45 shift signal valve. If the upshift
speed exceeds the specified rpm, or if upshift
does not occur at all, the spring force must be
reduced. Adjust the force only on springs for
valves that do not upshift at the proper speed.
NOTE:
If more than one shift signal valve spring requires
adjustment in the same direction, it may be necessary to adjust the spring force on the modulator
valve in the same direction. If not adjusted, the
closed throttle downshifts may be abnormally high
or low depending on the direction the shift signal
adjusting rings were rotated. If all full throttle upshift points are too low by approximately the same
amount, check adjustment of the modulator external linkage.
312
4. Compare the upshift speeds with the hold

speeds recorded in Step (2). The 23 upshift
in the MT 640, 643 should occur at approximately two mph below the top speed of second range; the 34 upshift two mph below the
top speed of third range. The 34 and 45 upshifts for the MT 650, 653 should occur approximately two mph below the top speeds of
third and fourth range, respectively. The 12
(MT 640, 643) and 23 (MT 650, 653) upshifts are not to be adjusted relative to hold
speed. The 21 downshift (MT 640, 643) or
32 downshift (MT 650, 653) at closed throttle should occur at 35 mph (48 km/h).
f. Calibration by Test Stand Method
1. Tables 34 through 310 provide detailed information required for adjusting shift points on
transmissions matched to engines having governed speeds from 2200 to 4000 rpm.
2. The adjustment procedures are as outlined in
Paragraph 313b, except the base for checks
and adjustments is output shaft speed instead
of engine governed speed. Individual output
shaft speed ranges are given for each shift.
Table 34. MT 640 Shift Points Without Modulated or Adjustable Lockup

Engine Governed Speed rpm
2200
2400
2600
2800
3000
3200
3400
3600
4000
MT Parts Book Group
S, AK**
Q, AJ**
12
530590
530590
570630
625685
685740
740795
795855
850910
9651020
23
8751015
8751015
9701110
11101250
12401380
12551400
14201565
14451590
16401780
3C3LU
10501400
11901600
11901600
13601615
13101600
15801870
15801870
17452155
21602450
Throttle
Position
Range
D
R
4
Closed
or
DR3
DR4
Shift
Transmission Output Speed (rpm) at Start of Shift
34
14751625
15801725
17251870
18702010
20852230
21602300
23002445
24452590
27352880
DR3
43
1560 Min
1850 Min
1910 Min
2020 Min
2370 Min
2440 Min
2550 Min
2720 Min
3090 Min
DR2
32
9451300
11901470
12801580
13401580
14501900
15301930
16202000
17302120
20802460
DR1
21
660760
700960
7401080
7751025
9101100
9301130
9601200
10401280
12001590
43*
150390
150390
250675
20675
225640
425780
555855
20590
570950
32*
370470
370470
390615
355640
445700
510780
550840
350700
600815
21
20300
20300
20470
20535
205530
285550
365550
20535
345550
DR4
* 42 downshift is acceptable.
** Prior to S/N 2410096186.
Governor Pressure Schedule:
Governor schedule testing requires main pressure to be 150 psi (1035 kPa) minimum and oil temperature to be 100 10F (38 5C).
Full
DR2
313
314
Table 35. MT 643 Shift Points with Modulated or Fixed Lockup

Engine Full-Load Governed Speed rpm
Red Mod/
Mod LU/
LU 34
MT Parts Book Group
CG
AK**
AZ
BR
530570
530570
440480
Range
D
R
DR2
Closed
or
Shift
12
2400
Std Mod/
Fixed LU/
LU 34
Red Mod/
Mod LU/LU
34/Special
Red Mod/Fixed
LU/LU 3rd/4th
Blocked
Red Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
Red Mod/
Mod LU/LU
34/2GS
Red Mod/
Mod LU/LU
34 (Sicca)
AJ**/EF
AS
AY
BP
550590
550590
475515
EH
530570
440480
530570
23
850930
915985
915985
915985
915985
700780
850930
9701050
9701050
9701050
9701050
3C3L
10601220
11951355
11951355
12451405
11801320
10601220
10601220
12301390
12301390
12301390
12751435
34
15001580
15001580
15001580
15001580
15001580
13201400
16451725
16451725
16451725
16451725
DR3
43
16401955
16401955
16401955
16401955
16401955
16401955
18252145
18252145
18252145
18252145
DR2
32
10001310
10001310
10001310
10001310
10001310
10001310
10001310
12151495
12151495
12151495
12151495
DR1
21
640730
640730
640730
640730
640730
640730
640730
715810
715810
715810
715810
43*
9901360
7401025
7401025
7401025
7401025
8051240
8051240
645805
8051240
8051240
32*
620725
635740
635740
635740
635740
400640
620725
670770
575700
670770
670770
LUConv
770970
520720
520720
755955
770970
670770
770970
530730
9451145
530730
475675
21
20320
20320
20320
20320
20225
20320
20380
20225
20225
DR3
4
Full
Red Mod/
Red Mod/
Mod LU/LU Mod LU/LU
34/2GS
34 (Volvo)
DR4
DR4
42 downshift is acceptable.
After S/N 2410096186.
Check for manual shift function only.
Lockup shift definition is 2C-2L.
Lockup signal pressure 140 psi (965 kPa) minimum after CL shift.
Red Mod/
Fixed LU/
LU 34
Throttle
Position
*
**
+
++
2200
Description
Table 35. MT 643 Shift Points with Modulated or Fixed Lockup (contd)
2400 (contd)
2500
Description
Red Mod/
Fixed LU/
LU 34
Red Mod/
Fixed LU/LU
34 Special
Std Mod/
Mod LU/
LU 34
Red Mod/
Mod LU/
LU 24
Std Mod/
Fixed LU/
LU 24
Red Mod/
Mod LU/LU
34/Special
Red Mod/
Mod LU/LU
34/(Hino)
MT Parts Book Group
CU
DQ
DU
DW
DJ
DP
DY
Throttle
Position
Range
D
4
Full
Closed
o
r
DR2
Std Mod/
Fixed LU/
LU 24
EC
12
550590
500545
550590
550590
550590
500545
500545
550590
580620
23
9701050
9701050
9701050
10851165
10851165
9701050
9701050
9701050
11351215
3C3L
12301390
12301390
12301390
790950 ++
790950 ++
12301390
12301390
12301390
790950 ++
34
16451725
16451725
16451725
16451725
16451725
16451725
16451725
17151795
DR3
43
18252145
18252145
18252145
18252145
18252145
18252145
19052225
18252145
DR2
32
12151495
12151495
12151495
12151495
12151495
12151495
12551530
12151495
12151495
DR1
21
715810
715810
715810
715810
715810
715810
730830
715810
715810
43*
8051240
8051240
645805
8051240
645805
8051240
8051240
690900
32*
670770
670770
575700
670770
615740
670770
670770
670770
635755
LUConv
9451175
9451175
180380
525725
670870
530730
530730
9451175
670870
21
20380
300410
20225
20380
20225
300410
300410
20380
20305
DR3
DR4
DR4
+ Check for manual shift function only.
++ Lockup shift definition is 2C-2L.
Shift
Red Mod/Fixed
LU/LU 3rd/4th
Blocked
315
316
2600
MT Parts Book Group

Throttle
Position
Range
D
R
4
Full
or
DR2
DR3
Std Mod/
Mod LU/
LU 34
Red Mod/
Mod LU/
LU 34/
2GS
Red Mod/
Mod LU/
LU 34
CF
AD
BA
BE/EG
Shift
Red Mod/ Red Mod/

Red Mod/
Fixed LU/ Mod LU/LU Mod LU/LU
LU 34
34/(RVI) 34/(Sicca)
BK
BE
BQ
Red Mod/
Mod LU/
LU 24
DA
Red Mod/
Red Mod/
Fixed LU/ Fixed LU/LU
LU 34
34/(Sterki)
Red Mod/
Fixed LU/
LU 3rd/4th
Blocked
DX
DK
435475
500545
570610
900980
12
560615
560615
23
9701110
9701110 10001080 10001080 10001080
570610
570610
570610
10001080
440480
570610
10001080 11801260
9701050
10001080
790950 ++ 12201380
3C3L
13951555 13951555 15001660 15001660 15001660
12301390
12751435
12301390
15001660
34
17251870 17251870 17601840 17601840 17601840
17601840
17601840 15101890 15051585
16451725
DR3
43
19052225 19052225 19052225 19052225 19052225
19052225
19052225 19052225 19052225
19052225
DR2
32
12551530 12551530 12551530 12551530 12251530
12251530
12551530 12901560 12551530
12551530
12251530
730830
730830
730830
13401645 10201430 9951360
8051240
DR4
DR1
Closed
Std Mod/
Fixed LU/
LU 34
DR4
21
730830
730830
730830
730830
730830
730830
43*
6751295
6751295
9701390
9701390
9701390
9701390
32*
520715
520715
660765
660765
660765
660765
660765
730860
630735
670770
660775
355555
605805
605805
12751475
530730
475675
520720
9351135
9451145
12751475
20245
20400
20400
20400
20320
110410
175330
300410
20400
LUConv 11801380
21
20245
730830
730830
Description
Engine Governed
Speed rpm
2700
2800
Description
MT Parts Book Group
Range
Shift
D DR2
12
23
4 DR3
or
3C3L
Red Mod/
Mod LU/
LU 34/
(Gillig)
Std Mod/
Fixed LU/
LU 24
Red Mod/
Fixed LU/
LU 34/
(Special)
Red Mod/
Fixed LU/
LU 3-4
CT
CK
BF
DH
DZ
EJ
700740
500545
700740
10501130 12201300 12201300 12201300 12201300 11501250 12801360 12201300 12201300 12801360
1220
1300
12201300
13601520 13951555 13951555 15001660 15001660 15601760
1500
1660
15001660
Red Mod/
Mod LU/
LU 34
Std Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
DG
AE
AM
AW
Red Mod/
Mod LU/
LU 34
Red Mod/
Mod LU/
LU 34
(Engessa)
BF
BN

620660
690750
690750
700740
680720
700740
9601120
700740
15001660 15001660
++
Full
DR4
++
34
18651940 19702050 19702050 19702050 19702050 19202000 19702050 19702050 19702050 19702050
1970
2050
19702050
DR3
43
19852305 20652390 20652390 20652390 20652390 20252445 20652390 20652390 20652390 20652390
2065
2390
20652390
DR2
32
13351600 13901650 13901650 13901650 13901650 12501660 13901650 13751640 13901650 13901650
1390
1650
13901650
DR1
21
43*
Closed
9601120
DR4
755915
745975
11051490 8001340
745975
745975
745975
790980
745975
745975
745975
745975
745975
745975
1285
1635
12851635
685810
735890
735890
765965
1310
1475
11501350
270540
300410
425595
8001340 12851635 12851635 9601320 12851635 8001340 12851635 8001340
32*
675780
600810
600810
735890
735890
730940
7751000
LUConv
605805
355555
11501350
605805
605805
705905
590790
21
265490
270540
270540
425595
310505
425595
317
600810
735890
12901490 10101225
+
425595
Throttle
Position
Red Mod/
Mod LU/
LU 24
Red Mod/
Fixed LU/
LU 34/
2GS
(Trolley)
Red Mod/
Mod LU/
LU 34/
2GS
318
3000
3200
Std Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
Red Mod/
Mod LU/
LU 34
Red Mod/
Mod LU/
LU 34/2GS
Std Mod/
Mod LU/
LU 24
Std Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
Red Mod/
Mod LU/
LU 34
MT Parts Book Group
AB
AL
BJ
EB
CE
AF
AN
BG
Throttle
Position
Range
D
DR2
Full
Closed
12
640700
640700
650690
640700
655710
655710
655710
23
12401380
12401380
12851345
12851345
13401480
12551400
12551400
12551400
3C3L
15601760
15601760
15351735
15351735
10001200 ++
16251825
16251825
15601760
34
20852230
20852230
21202200
21202200
20852230
21602300
21602300
21602300
DR3
43
23602820
23602820
23602820
23602820
23602820
23752905
23752905
23752905
DR2
32
13651770
13651770
13651770
13651770
13651770
14001800
14001800
14001800
DR1
21
8651055
8651055
8651055
8651055
8651055
9001045
9001045
9001045
43*
5951035
5951035
9551360
9551360
5951035
6901115
6901115
9801540
32*
525795
525795
685890
685890
600850
555795
555795
665910
LUConv
330530
12601510
690890
690890
510710
400600
13401590
705905
21
20320
20320
255465
20320
20320
20320
265485
R
4
or
Shift
DR3
DR4
DR4
Description
3400
Description
Std Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
MT Parts Book Group
AH
AP
Throttle
Position
Range
D
Full
4
or
Std Mod/Mod
LU/
LU 34
Red Mod/
Mod LU/
LU 34
Std Mod/
Fixed LU/
LU 34
Red Mod/
Mod LU/
LU 34
Std Mod/
Mod LU/
LU 34
Red Mod/
Mod LU/
LU 34
AG
BH
CL
DR
AC
DC
Shift
685740
685740
685740
850910
850910
850910
895950
880985
900965
23
14201565
14201565
14201565
14451590
14451590
14451590
14851625
15301670
16101720
3C3L
18952095
18952095
18952095
20552255
20402240
20552255
18352040
21052305
18902090
34
23002445
23002445
23002445
24452590
24452590
24452590
25752720
25902735
27202865
DR3
43
25253070
25253070
25253070
26753130
26753130
26753130
30553490
30553490
30553490
DR2
32
15251920
15251920
15251920
15752000
15752000
15752000
20102395
19602325
20102395
DR3
DR4
DR4
21
9501145
9501145
9501145
9801165
9801165
9801165
11551565
11351425
11551565
43*
8301375
8301375
10851735
415980
10251580
415980
10851735
8701330
12451965
32*
635920
635920
7051000
375775
660965
375775
7051000
460895
8101050
LUConv
385585
16351885
8701045
375575
740940
18052005
11551435
410610
11751375
21
20320
20320
305615
20320
215570
20320
305615
20370
315630
Lockup signal pressure 140 psi (965 kPa) minimum after CL shift
.
4000
12
DR1
Closed
Red Mod/
Mod LU/
LU 34
3800
DR2
3600
319
320
Table 36. MT 650 Shift Points without Modulated or Adjustable Lockup

2200
Throttle
Position
3000
3200
3400
3600
4000
Z**, P
Range
Shift
Low1
Check for Manual Shift Function Only
4
or
Closed
2800
D DR1DR2
R
Full
2600
DR2
12
530590
530590
570630
625685
685740
740795
795855
850910
9651020
23
8751015
8751015
9701110
11101250
12401380
12551400
14201565
14451590
16401780
3C3LU
10501400
11901600
11901600
13601615
13101600
15801870
15801870
17452155
21602450
34
14751625
15801725
17251870
18702010
20852230
21602300
23002445
24452590
27352880
DR3
43
1560 Min
1830 Min
1950 Min
2100 Min
2450 Min
2450 Min
2640 Min
2710 Min
2930 Min
DR2
32
9451300
11401450
12401540
14001700
15301990
16001860
16702030
19002200
19902370
DR2
21
660760
700960
7401080
7751025
9101100
9301130
9601200
10401290
12001590
DR1
1Low
320425
320425
300400
365510
365510
300550
300550
300550
43*
150390
150390
250675
20675
225640
425780
555855
20590
570950
DR4
32*
370470
370470
390615
355640
445700
510780
550840
350700
600815
21
20300
20300
20470
20535
205530
285550
365550
20535
345550
DR4DR1
1Low
DR3
DR4
** Prior to S/N 2410096186.
MT Parts Catalog Group
2400
Table 37. MT(B) 653 Shift Points with Modulated or Fixed Lockup
2200
Description

Throttle
Position
Closed
Red Mod/
Fixed LU/
LU 45
Red Mod/
Mod LU/
LU 45/
Special
Red Mod/
Fixed LU/
LU 45/
Retarder
CH,CX,DL
DV
CY
Red Mod/
Mod LU/
LU 45
Red Mod/
Mod LU/
LU 45
Std Mod/
Fixed LU/
LU 45
Std Mod/
Mod LU/
LU 45
Std Mod/
Mod LU/
LU 45/
(Volvo)
Red Mod/
Fixed LU/
LU 45
Std Mod/
Mod LU/
LU 45/
Retarder
Z**/EL
AT
BZ,CA,EE
CM
CV,CZ
DB,CQ
550590
550590
550590
Range
Shift
DR1DR2
12
D
R
5
or
DR4
23
530570
460500
530570
530570
550590
550590
550590
34
850930
730810
850930
850930
9701050
9701050
9701050
9701050
9701050
9701050
ConvLU
10451205
11601320
10601220
10451205
12651425
12901450
12901450
12901450
12651425
12501410
45
15401620
13601440
15401620
15401620
16451725
16451725
16451725
16451725
16451725
16451725
DR4
54
16101920
16101920
16201950
16101920
17802135
17802135
17802135
19302275
17802135
17402060
DR3
43
10451330
10301320
9801320
10451330
12401495
12401495
12401495
11851465
12401495
11151415
DR2
32
295340
190355
340400
295340
325390
325390
325390
370430
325390
340390
54*
7901180
665890
7501050
7901180
9701340
6951010
6951010
520765
9701340
7951210
43*
540700
450640
610730
540700
630775
525685
525685
440610
630775
650755
LUConv
8101010
545665
8401040
425625
580780
10751275
325525
325525
10701270
545745
32
200410
100335
30330
240410
300430
160360
160360
160360
300430
20370
DR5
DR5
DR5DR1
21
** After S/N 2410096186.
Full
2400
321
322
Table 37. MT(B) 653 Shift Points with Modulated or Fixed Lockup (contd)
2600
2700
Std Mod/
Mod LU/
LU 45
Red Mod/
Fixed LU/
LU 45
Red Mod/
Mod LU/
LU 45
Std Mod/
Fixed LU/
LU 45
Std Mod/Mod
LU/LU 45/
Retarder
U, BV
CW, BL
EA,BM,ED
BT
CR,CN
Throttle
Position
Std Mod/
Mod LU/
LU 45
DE
DF
490545
620660
620660
Shift
DR1DR2
12
DR4
Closed
Red Mod
/Mod LU/
LU 45
Range
D
Full
Red Mod/Fixed
LU/LU 4th/5th
Blocked
5
or
23
490545
570610
570610
490545
570610
34
9701110
10001080
10001080
9701110
10001080
9701110
10501130
10501130
ConvLU
14901650
12901450
12901450
14901650
13351495
14901650
13701530
13701530
45
17251870
17601840
17601840
17251870
17601840
18651940
18651940
DR4
54
19402320
19402320
19402320
19402320
19052225
19402320
19402320
DR3
43
13351615
13351615
13351615
13351615
12701540
13351615
13351615
13351615
DR2
32
320425
320425
320425
320425
360415
320425
320425
320425
54*
6751295
11301475
11301475
6751295
9201365
12401575
9251345
43*
520715
625770
625770
520715
660765
625770
650795
560715
LUConv
325525
10801280
595795
13051505
590790
13051505
665865
390590
32
20245
310440
310440
20245
105405
20370
370490
280435
DR5
DR5
DR5DR1
21
** After S/N 2410096186.
Description
2800
Description

Throttle
Position
Closed
Std Mod/Mod
LU/LU 45
Std Mod/Fixed
LU/LU 45
Red Mod/Mod
LU/
LU 45
Std Mod/Mod
LU/LU 45
Retarder
CC, V
AQ
BC
CP
Std Mod/Mod
LU/LU 45
Special Low
Std Mod/Mod
LU/LU 45
Std Mod/Mod
LU/LU 45
Std Mod/
Fixed LU/
LU 45
CD, T
AR
Range
Shift
DR1DR2
12
DR4
3200
23
690750
690750
700740
700740
690750
640700
655710
655710
34
12201300
12201300
12201300
12201300
12201300
12401380
12551400
12551400
ConvLU
13951555
13951555
14151575
14201580
13951555
15751775
16251825
16251825
45
19702050
19702050
19702050
19702050
19702050
20852230
21602300
21602300
DR4
54
20952380
20952380
20952380
20252445
20952380
24102820
23352845
23352845
DR3
43
14451705
14451705
14451705
12701680
14451705
14001760
13751775
13751775
DR2
32
300460
300460
300460
300460
400460
365510
365510
365510
54*
8001340
8001340
11851585
9901400
8001340
5951035
6901115
6901115
43*
600810
600810
730870
770960
600810
525795
555795
555795
LUConv
635835
12251425
575775
605805
635835
335535
400600
13401590
32
50400
50400
270485
340525
50400
20320
20320
20320
DR5
DR5
DR5DR1
21
Full
D
R
5
or
3000
323
324
Std Mod/Mod
LU/LU 45
X, DN
Closed
D
R
5
or
3600
Red Mod/Mod
LU/LU 45
3800
Std Mod/Mod
LU/LU 45
Std Mod/Fixed
LU/LU 45
Std Mod/Mod
LU/LU 45
Red Mod/Mod
LU/LU 45
Red Mod/Mod
LU/LU 45
BX, Y
CJ
BW, AA
DS, DT
DD, DM
Range
Shift
DR1DR2
12
DR4
4000
23
685740
685740
850910
850910
880935
895950
900965
34
14201565
14201565
14451590
14451590
15301670
14851625
16101720
ConvLU
18952095
18952095
20552255
20552255
20552255
18352040
18902090
45
23002445
23002445
24452590
24452590
25902735
25752720
27202865
DR4
54
25403055
25403055
28153260
28153260
30553490
30553490
30553490
DR3
43
15251920
15251920
17102125
17102125
19602325
20102395
20102395
DR2
32
300550
300550
300550
300550
300550
300550
455565
54*
8301375
10851735
415980
415980
8701330
10851735
12451965
43*
635920
7051000
375775
375775
460895
7051000
8101050
LUConv
385585
8401040
350600
18052005
350600
11551435
11751375
32
20320
305615
20320
20320
20370
305615
315630
DR5
DR5
DR5DR1
21
Description
Throttle
Position
Full
3400
Table 38. Modulator Springs
Pressure
psi
kPa
Modulator Spring Part No.
Color Code and Modulator Valve Usage
23012948
23012948
6838077
White with Orange Stripe, 23013997 Modulator Valve

White with Orange Stripe, 23013764 Modulator Valve
Yellow, 23013764 Modulator Valve
2830
5053
2830
193207
345365
193207
Table 39. Hold Regulator Springs

Pressure
Model/Calibration
Spring Part No.*
2200
2200
2400
2400
2400
2600
2600
2600
2800
2800
2800
3000
3200
3400
3600
3800/4000
6836785
6837540
6836785
6837541
6837952
6836976
6837541
6837953
6836785
6836977
6837953
6836976
6837952
6837953
6836784
6836976
2200
2200
2400
2400
2400
2600
2600
2600
2800
3000
3200
3400
3600
3800/4000
6836784
6837541
6836785
6837952
6837953
6836976
6836977
6837953
6836785
6836976
6836976
6837953
6836785
6836976
Color Code Solid/Stripe

MT 643
White
Red
White
Yellow/Light Blue
Light Green
White/Yellow
Yellow/Light Blue
Light Blue
White
Orange
Light Blue
White/Yellow
Light Green
Light Blue
Yellow
White/Yellow
MT 653
Yellow
Yellow/Light Blue
White
Light Green
Light Blue
White/Yellow
Orange
Light Blue
White
White/Yellow
White/Yellow
Light Blue
White
White/Yellow
psi
kPa
36.040.0
35.041.0
40.044.0
40.044.0
40.044.0
42.046.0
42.046.0
42.046.0
46.050.0
46.050.0
46.050.0
42.446.4
43.747.7
46.250.2
36.040.0
42.446.4
248276
241283
276303
276303
276303
290317
290310
290317
317345
317345
317345
292320
301329
319346
248276
292320
40.044.0
40.044.0
46.050.0
46.050.0
46.050.0
42.446.4
51.055.0
51.055.0
40.044.0
42.046.0
43.747.7
46.250.2
38.842.8
42.446.4
276303
276303
317345
317345
317345
290317
352379
352379
276303
292320
301329
319346
268295
292320
* Refer to the current Parts Catalog PC1316EN for the correct hold regulator spring for each assembly.
325

Table 310. Governor Pressure Schedule
Specifications for governor output pressure at transmission shaft speeds are as follows:
Governor Output Pressure psi (kPa)
Governor
Assembly
Code No.
440 rpm
800 rpm
1500 rpm
2200 rpm
6881471
465 (formerly Code 91)
3.56.5
(2445)
17.520.5
(121141)
42.848.4
(295334)
58.664.8
(404447)
6882736
739
3.57.5
(2452)
16.020.0
(110138)
39.144.2
(270305)
59.065.0
(407448)
6882737
738
8.511.5
(5979)
27.530.5
(190210)
54.360.8
(374419)
82.691.0
(570627)
6885570
461
9.013.0
(6290)
38.042.0
(262290)
63.870.2
(440484)
103.0112.0
(710772)
6885571
462
8.511.5
(5979)
27.530.5
(190210)
54.360.8
(374419)
82.691.0
(570627)
6885572
463
3.57.5
(2452)
16.020.0
(110138)
39.144.2
(270305)
59.065.0
(407448)
23010012
012
9.013.0
(6290)
38.042.0
(262290)
63.870.2
(440484)
103.0112.0
(710772)
23018330
330
8.511.5
(5979)
27.530.5
(190210)
54.360.8
(374419)
82.691.0
(570627)
NOTES: Governor schedule testing requires main pressure to be 150 psi (1035 kPa) minimum and fluid temperature to be 100 10 F (38 5 C).
No adjustments are possible, but the internal valve may be removed and cleaned to ensure free operation. Refer to the current Parts Catalog PC1316EN
for kit part number with instructions.
314. OIL COOLER

Transmission operation at abnormally high temperatures can cause clogging of the oil cooler as well as
transmission failure. Clean the oil cooler system thoroughly after each major or minor rebuild. Failure to
clean the cooler system may cause poor performance,
overheating, and transmission damage. Recommendations for cleaning or flushing the oil cooler are in the
vehicle service manual.
2. Stall speed is the maximum engine rpm attainable when the engine is at full throttle and
when the torque converter turbine is not moving, or stalled.
3. During a stall test, compare the actual engine
speed at full throttle stall with established vehicle manufacturer's specifications.
NOTE:
315. TRANSMISSION STALL TEST
Engine stall point data can be obtained from the vehicle manufacturer or from the equipment dealer or
distributor.
a. Purpose
1. Stall testing is performed to determine whether
a power complaint is due to an engine problem
or a transmission malfunction.
326
4. Stall tests are used as troubleshooting procedures only do not perform them as general
checks or maintenance.
b. Stall Test Preparation
CAUTION:
1. Make sure the fuel control linkage goes to full

throttle and does not stick when released.
2. Check the air induction system for restrictions.
3. Perform a cold check of the transmission fluid
level and adjust as necessary.
4. Install an accurate tachometer (do not rely on
the vehicle tachometer).
5. Install a temperature gauge with the probe in
the transmission converter-out (to cooler) line.
WARNING!
While conducting a stall check, the vehicle must
be positively prevented from moving. Apply the
parking and service brake, and block the wheels
securely. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so can
cause serious injury.
For the MT 653, do not select the D1 position.

The extremely high torque produced in this
range may damage the transmission and/or the
vehicle drive line.
NOTE:
For vehicles with engines not equipped with smoke
controls, proceed to Paragraph 315c.
For vehicles with engines equipped with smoke
controls, skip Paragraph 315c and proceed to
Paragraph 315d.
c. Stall Test Procedures Vehicles Without
Smoke-Controlled Engines
1. Apply the vehicle parking and service brakes.
2. Shift to D (Drive).
3. Slowly accelerate to full throttle.
4. When the tachometer levels off, record the
maximum engine rpm attained.
6. Block the vehicle wheels.
5. Slowly release the throttle.

7. Start the engine and let the transmission sump
warm to normal operating temperature (160
200F; 7193C).
8. Perform a hot check of the transmission fluid
level and adjust as necessary.
9. Turn all engine accessories OFF.
6. Shift to N (Neutral).
7. Skip Paragraph 315d and proceed immediately with Paragraph 315e Cool-Down
Check.
d. Stall Test Procedures Vehicles With
Smoke-Controlled Engines
10. Notify everyone to stay clear of the vehicle.

CAUTION:
Never maintain the stall condition for more than
30 seconds at any one time because of the rapid

rise in fluid temperature. Do not let the converter-out fluid temperature exceed 300F
(149C). Do not rely on converter-out fluid temperature to limit stall duration. During stall conditions, internal temperatures rise much faster
than converter-out fluid temperatures. Allow
the system to cool down between stall checks by
performing the cool-down as described in Paragraph 315e. If the stall test is repeated, do not
let the engine overheat.
If the unit does not have a converter-out temperature gauge, do not stall the converter.
NOTE:
Because smoke controls and throttle-delay mechanisms inhibit engine acceleration, the stall testing may
need to be performed while the vehicle is moving.
1. Locate an isolated area to perform the driving
stall test.
2. Select a hold range that will limit road speed
(usually 2nd or 3rd range).
3. Operate the engine at full throttle, maximum
governed rpm.
4. Slowly depress the vehicle service brakes
while staying at full throttle.
5. When the vehicle comes to a stop, record the
engine rpm. This is the stall speed.
327

6. Proceed immediately with Paragraph 315e
Cool-Down Check.
e. Neutral Cool-Down Check Procedure
1. The neutral cool-down check determines if the
transmission fluid cools properly following an
engine load condition. Perform this check immediately after the engine speed has been recorded in the stall test.
2. Record the converter-out fluid temperature.
3. With the transmission remaining in N (Neutral), run the engine at 12001500 rpm for two
minutes to cool the fluid.
4. At the end of two minutes, record the converter-out fluid temperature. Converter-out
fluid temperature should return to within the
limits of normal operation.
f. Results
NOTE:
Environmental conditions, such as ambient temperature, altitude, engine accessory loss variations, etc.,
affect the power input to the converter. Under such
conditions, a stall speed deviation up to 150 rpm
from specification can be accepted as within normal
range.
1. An engine stall speed more than 150 rpm below the stall speed specified by the engine
manufacturer indicates an engine problem,
such as the need for a tune-up.
2. An engine stall speed more than 150 rpm
above specification indicates a transmission
problem, such as slipping clutches, cavitation,
or torque converter failure.
3. An extremely low stall speed, such as 33 percent of the specified engine stall rpm, during
which the engine does not smoke, could indicate a freewheeling torque converter stator.
4. If the engine stall speed conforms to specification, but the transmission fluid overheats, refer
to the cool-down check. If the fluid does not
cool during the two-minute cool-down check, a
stuck torque converter stator could be indicated.
328
5. If the engine stall speed conforms to specification and the cool-down check shows that the
transmission fluid cools properly, refer to Table
311, Paragraph 322 for troubleshooting procedures.
316. PRESERVATION AND STORAGE

a. Storage, New Transmissions (prior to installation). New transmissions are tested at the Allison factory with preservative oil and drained prior to shipment. The residual oil remaining in the transmission
provides adequate protection to safely store the transmission for up to one year (stored inside in conditions
of normal climate and with all shipping plugs installed) without further treatment.
b. Preservation Methods. When the transmission is
to be stored or remain inactive for an extended period
(one or more years), specific preservation methods are
recommended to prevent damage due to rust, corrosion, and organic growth in the oil. Preservation methods are presented for storage with and without transmission fluid.
c. Storage, One Year Without
Transmission Fluid
1. Drain the transmission fluid.
2. If the breather can be easily removed, spray
one ounce (30 milliliters) of VCI #10 (or
equivalent) into the transmission through the
breather hole. Spray one ounce (30 milliliters)
through the fill tube. If the breather cannot be
removed, spray two ounces (60 milliliters)
through the fill tube hole.
3. Seal all openings and the breather with moisture-proof tape.
4. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C11796, Class 2).
5. If additional storage time is required, repeat
Steps (2) through (4) at yearly intervals.
d. Storage, One Year With Transmission Fluid
(Normally in a Vehicle Chassis)
1. Drain the transmission fluid and replace the filter element(s) if required.
2. Fill the transmission to operating level with a
mixture of one part VCI #10 (or equivalent) to
30 parts Allison-approved transmission fluid.
Refer to Paragraph 310. Add 14 teaspoon of
Biobor JF (or equivalent) for each 3 gallons
(1 ml for every 10 liters) of fluid in the system.
NOTE:
When calculating the amount of Biobor JF required, use the total volume of the system, not just
the quantity required to fill the transmission. Include external lines, filters, and the cooler.
3. Run the engine for approximately five minutes at
1500 rpm with the transmission in N (Neutral).
4. Drive the vehicle. Make sure the transmission
shifts through all ranges. If the transmission is
equipped with a converter lockup clutch, make
sure the lockup clutch activates.
5. Continue running the engine at 1500 rpm with
the transmission in N (Neutral) until normal
operating temperature is reached.
WARNING!
Apply the parking brake, service brake, and
block the vehicle securely. Warn personnel to
keep clear of the vehicle and its travel path. Failure to do so can cause serious injury.
CAUTION:
Never maintain the stall condition for more than
30 seconds at any one time because of the rapid

rise in fluid temperature. Do not let the converter-out fluid temperature exceed 300F
(149C). Do not rely on converter-out fluid temperature to limit stall duration. During stall conditions, internal temperatures rise much faster
than converter-out fluid temperatures. Allow
the system to cool down between stall checks by
performing the cool-down as described in Paragraph 315e. If the stall test is repeated, do not
let the engine overheat.
If the unit does not have a converter-out temperature gauge, do not stall the converter.
6. If normal operating temperature is less than
225F (107C), with the vehicle wheels
blocked and the parking brake and service
brake applied, shift the transmission to D

(Drive) and stall the converter. When converter-out temperature reaches 225F (107C)
stop the engine. Do not exceed 225F (107C).
7. As soon as the transmission is cool enough to
touch, seal all openings and the breather with
moisture-proof tape.
8. Coat all exposed, unpainted surfaces with preservative grease such as petrolatum (MIL-C11796, Class 2).
9. If additional storage time is required, repeat
Steps (2) through (8) at yearly intervals. It is
not necessary to drain the transmission each
year; just add VCI #10 and Biobor JF (or
equivalents).
e. Restoring Transmission to Service
1. Remove all tape from openings and the
breather.
2. Wash off all external grease with mineral spirits.
3. If the transmission is new, drain the residual preservative oil. Refill the transmission to the proper
level as specified in Paragraphs 35 and 37.
4. If the transmission was prepared for storage
without transmission fluid, drain the residual
oil and replace the filter element(s) if required.
Refill the transmission to the proper level as
specified in Paragraphs 35 and 37.
5. If the transmission was prepared for storage
with transmission fluid, it is not necessary to
drain and refill the transmission with new
transmission fluid. Check for proper fluid level
as specified in Paragraph 35. Add or drain
fluid as required to obtain the proper level.
317. REPLACEMENT OF COMPONENTS

WHILE TRANSMISSION IS IN THE
VEHICLE CHASSIS
a. Replacement of Selector Shaft Seal
(Foldout 10,A)
1. Remove control linkage from selector shaft 60.
Place seal remover J 26401 over the end of the
selector shaft. Screw the remover into seal 61
sufficiently to cause engagement. Using a
329

wrench, tighten the screw in the remover to
draw the seal from the bore.
2. Clean the housing bore before installing a new
seal. Refer to Paragraph 46e for seal preparation. Install the seal, lip first, onto the selector
shaft. Using seal installer J 26282, install the
seal into the housing. The seal is positioned
satisfactorily when its outer surface is clear of
the lead chamber in the bore.
3. Install and adjust the control linkage as outlined in Paragraph 312a.
b. Removal of Output Flange
1. Disconnect the vehicle drive shaft from the
transmission output shaft.
2. For MT 640, 643 series transmissions, remove
the 12-20 x 112 bolt and remove the flange.
3. For MTB 643 and MT(B) 650, 653 series
transmissions, check the number of notches
that have been cut into the wrenching flats of
the output flange retaining nut. The number of
notches indicates how many times the nut has
been used. If there are five notches, hold the
flange with holding tool J 3453 and remove
and discard the nut. If there are less than five
notches, or none at all, remove all dirt and any
burrs from the exposed shaft threads. Then
hold the flange with holding tool J 3453 and
loosen the nut until there is approximately 116
inch (1.59 mm) gap between the nut and
flange. Check the running torque while removing the nut. Only reuse the nut if:
Using remover tools J 24171-1, -2 and -4, remove the

dust shield and the output oil seal from the rear cover
or retarder housing
d. Removal of Output Shaft Bearing
1. Remove the snapring that retains the output
bearing in the rear cover or retarder housing.
NOTE:
The legs of the bearing remover are designed to lock
between the inner and outer races of the bearing.
Do not force the feet of the legs into position. Forcing may damage the races.
2. To remove the output bearing, install two-leg

assembly J 24463-2 (MT 640, 643 ten ball
bearing configuration), three-leg assembly
J 38086 (MT 640, 643 nine ball bearing configuration), or J 24534 (MT 650, 653) (Figure
311), or J 33821 (MTB 600) (Figure 312)
between the balls of the rear bearing. Retain
the legs between the inner and outer races of
the bearing. Insert the legs through the slots in
bearing puller head assembly J 24420-B or
J 33821. Install one nut on each leg to secure
the assembly. Remove the rear bearing.
The running torque is at least 400 lb in. (45

REAR COVER
Nm) the first time the nut is removed (no

notches).
The running torque is at least 300 lb in. (34
Nm) each subsequent time the nut is

removed (one to four notches).
4. Remove the output flange.
J 24420-B
c. Removal of Dust Shield and Output Shaft Seal
J 24463-2
OUTPUT SHAFT
NOTE:
BEARING
The dust shield is not used on models that have an

output retarder.
330
Figure 311. Removing Output Shaft Rear

Bearing in Vehicle
H00008.01
4. Place output bearing, number side out, into the
rear cover. Using rear bearing installer J 24446
(MT 640, 643), J 24447 (MT 650, 653), or
J 33820 (MTB 643, 653) and handle
J 24202-4, drive the bearing into the rear cover
until it seats firmly.
J 33821
5. Install the beveled snapring so that the beveled

side is toward the rear of the transmission.
Make sure the snapring is fully expanded in its
groove.
OUTPUT RETARDER
6. Pack the rear oil seal with high temperature

grease that conforms to MIL-G-3545A. Place
the seal on oil seal installer J 24448-A
(MT 640, 643), J 24620-A (MT 650, 653) or
J 29618 (MTB 643, 653) with handle
J 24202-4, sealring lip away from installer.
BEARING
H00020
Figure 312. Removing Rear Bearing MTB
e. Removal of Governor and Speedometer

Drive Gear
1. For MT Series transmissions, remove spacer
11 (if used) (Foldout 12,B), speedometer gear
9 or speed sensor wheel 10, and governor gear
8 from the output shaft.
2. For MTB Series transmissions, remove spacer
26 (Foldout 18,A) and governor and speedometer drive gear 25 from the output shaft.
f. Install Governor and Speedometer Drive
Gears, Rear Bearing, Oil Seal, and Dust Shield
1. For MT Series transmissions, install governor
drive gear 8 (Foldout 12,B), slot first, onto the
output shaft. Align the slot in the gear with
spring pin 5. Install speedometer drive gear 9
or speed sensor wheel 10 and spacer 11 (if
used) onto the output shaft.
2. For MTB Series transmissions, install governor and speedometer drive gear 25 (Foldout
18,A) and spacer 26 onto the output shaft.
3. A snapring was used on the front side of the
output bearing in earlier rear covers to retain
the bearing in its proper location. Be sure the
snapring is firmly seated in its groove.
7. Apply a non-hardening sealer (Perfect Sealer

No. 4 or equivalent) onto the outer surface of
the rear oil seal. Pre-coated seals do not require
sealer on the OD.
8. Insert the seal installer and seal into the rear
cover and drive the seal into the bore. The oil
seal must be located 1.16 inch (29.5 mm) (MT
640, 643) or 1.17 inch (29.7 mm) (MT 650,
653) from the rear face of the rear cover. The
oil seal in the output retarder must be located
0.1200.150 inch (3.03.8 mm) from the inner
edge of the chamfer. The installer seats against
the hub of the rear cover or retarder housing
when the seal is properly positioned.
9. Place the dust shield, cup side toward the tool,
onto dust shield installer J 24198. Using handle J 24202-4, drive the shield into the rear
cover until it is flush with, or 0.040 inch (1.02
mm) below, the rear face of the cover assembly. The installer seats on the rear face of the
cover when the shield is properly positioned.
g. Installation of Output Flange MT 640, 643
1. Install the output flange on the output shaft.
2. Retain the output flange with a new 1220 x
112 inch Type BH bolt and washer. Do not use
the earlier style bolt. Refer to the current Parts
Catalog PC1316EN and Figure 313.
331
34 in.
Source and material grade

identification markings to
appear on top of head in
this area
1 2 in.
CONSTANT ANNULAR GROOVE

Six (6) radial slots spaced
sixty (60) degrees apart
EARLIER BOLT
P/N 23014159
STANDARD (TYPE AA PATCH) SAE GRADE 8
34 in. HEXAGON HEAD
SIX (6) GRADE ID MARKINGS*
CONSTANT UNDERHEAD FILLET**
13 16 in.
Source and material grade

identification markings to
appear on top of head in
this area
1 2 in.
VARYING ANNULAR GROOVE

Five (5) radial slots spaced
sixty (60) degrees apart
LATER BOLT
P/N 29510838
NON-STANDARD (TYPE BH PATCH) SAE GRADE 8
OFFSET, 13 16 in. HEXAGON HEAD
FIVE (5) GRADE ID MARKINGS***
VARYING UNDERHEAD FILLET**
* Radial slots spaced approximately sixty (60) degrees apart.

** Annular groove at the junction of the head bearing surface and the bolt shank.
*** Radial slots spaced approximately sixty (60) degrees apart; may be random relative to hexagon but
shall be oriented such that three (3) wide slots are symmetrically over span of large recess diameter.
V01301
Figure 313. Identification of Flange Retaining Bolts
332
CAUTION:
The use of an impact wrench requires a means to
hold the flange. Failure to hold the flange can
cause internal damage to the transmission.
Flange and yoke holding tool J 3453 or equivalent is recommended.
3. Install the flat washer and bolt into the output
shaft. Tighten the bolt to 102121 lb ft (138
164 Nm).
h. Installation of Output Flange MTB 643,
MT(B) 650, 653
1. Install the output flange on the output shaft.
2. Make sure the threads on the output shaft and
retaining nut are clean and free from damage.
3. Each time the retaining nut is reused, deeply
scribe a notch on one of the wrenching flats.
This method of marking the nut indicates how
many times the nut has been reused.

REMOVAL AND DURING
OPERATION
a. Determine Cause of Trouble
1. If the inspections in Paragraph 318 do not reveal the cause of the problem and the vehicle is
operable, further troubleshooting is necessary.
Do not remove the transmission from the vehicle until the cause of trouble listed in the troubleshooting charts (Tables 311 and 312) is
checked.
2. The engine and transmission must be regarded
as a single package during troubleshooting. A
thorough study of the description and operation of the components and hydraulic system is
helpful in determining the cause of trouble.
4. Coat the threads of the retaining nut with molybdenum disulfide grease.
b. Proper Engine Tuning. To make a thorough test

of the vehicle mounted transmission, be sure the engine is properly tuned and the fluid level in the transmission is correct. Refer to Paragraph 35 for checking fluid level.
5. Install the flange retaining nut onto the output

shaft. Restrain the output shaft by holding the
flange with holding tool J 3453. Tighten the
nut to 600800 lb ft (8141085 Nm).
320. OUTPUT RETARDER TROUBLESHOOTING BEFORE REMOVAL

REMOVAL OR OPERATION OF
TRANSMISSION
NOTE:
Oil pressure gauge set J 26417 contains all neces-
sary attachments and gauges.

Refer to Figures 314 through 317 for the location
CAUTION:
Do not operate the vehicle prior to completing
the procedures described in this Paragraph.
a. Inspect for transmission fluid leakage. Visually
inspect all splitlines, connections, valve bodies, fluid
level indicator tube, and plugs and hoses at the transmission and cooler. Fluid leakage at splitlines may be
caused by loose mounting bolts or defective gaskets.
Tighten all bolts, plugs, and connections where leakage is found.
b. Check to ensure the modulator control cable and
linkage are free. Check the shift linkage for proper operation.
of external connections and pressure taps for all

models.
a. High Speed Mode Pressure Function Test

1. Connect a high-pressure test hose, minimum
300 psi (2068 kPa), from the main pressure tap
on the transmission main case (Figure 315) to
the governor pressure tap on the retarder valve
body (Figure 317).
2. Connect a 0150 psi (01000 kPa) pressure
gauge to the retarder charging pressure tap
(Figure 317).
333

gauge to one of the two retarder clutch pressure taps on the retarder (Figure 316).
4. Shift the transmission to N (Neutral). Set the
engine speed at 1000 20 rpm.
5. Apply full retarder air pressure, 85 psi (586
kPa), at the retarder control air tap.
6. After 20 seconds, verify the following pressures:
Retarder-charging
pressure:
5565
Retarder-charging pressure: 28 psi (1455
kPa)
Retarder-clutch pressure: 2128 psi (145
193 kPa)
7. Refer to Table 312 for possible causes and
remedies.
321. TROUBLESHOOTING TRANSMISSION REMOVED FROM

VEHICLE
psi
(379448 kPa)
Retarder-clutch pressure: 5565 psi (379
448 kPa)
7. Refer to Table 312 for possible causes and
remedies. Proceed to Static Mode Pressure
Function Test.
b. Static Mode Pressure Function Test
gauge to the governor tap (Figure 315).
gauge to the retarder charging pressure tap
(Figure 317).
gauge to one of the two clutch pressure taps
(Figure 316).
4. Shift the transmission to N (Neutral). Set the
engine speed at 1000 20 rpm.
5. Apply full retarder air pressure, 85 psi (586
kPa), at the retarder control air tap.
334
6. Verify the following pressures after 20 seconds:
When the cause of a transmission malfunction is not

ascertained by tests or inspections before removal
from the vehicle, the transmission may be mounted in
a test stand (if available) and checked. Give particular
attention to proper fluid level and to proper linkage adjustment in every transmission test.
322. TROUBLESHOOTING
PROCEDURES
a. Troubleshooting Information. Tables 311 and
312 outline the possible causes of transmission or retarder trouble, and suggested remedies. Major symptoms are indicated by capital letters. Specific problems, their probable causes, and suggested remedies
are presented under the symptom headings.
b. Fluid Pressures. Various fluid pressure check
points are shown in Figures 314 through 317. Table 11, Specifications and Data, lists reference fluid
pressures.
c. Increasing Pump Volume. If after verifying and
observing minimum idle specifications, and utilizing
the troubleshooting charts, main pressure remains
low, consult SIL 5-TR-83 for additional procedures
required to increase pump volume.
NOTE
MT 650,653 external connections
and pressure taps are in identical
locations
TO OIL
COOLER
CONVERTER DRIVEN
PTO LOCATION
REVERSE SIGNAL
PRESSURE TAP
OIL DRAIN
PLUG
OIL FILLER
OPENING
LOCKUP
PRESSURE TAP
H00138
Figure 314. MT Transmission Check Points External Connections, Right-Front View
BREATHER
MANUAL SELECTOR
SHAFT
MAIN PRESSURE
TAP
NEUTRAL START
SWITCH LOCATION
GOVERNOR
PRESSURE TAP
MODULATOR
CONTROL OPENING
H00119
Figure 315. MT Transmission Check Points External Connections, Left-Rear View
335

RETARDER CLUTCH
PRESSURE
TO FILTER
FROM COOLER
TO COOLER
FROM FILTER
H00136
Figure 316. MTB Retarder Check Points External Connections, Right-Front View
RETARDER CONTROL
AIR PRESSURE
RETARDER
CHARGING
PRESSURE
GOVERNOR PRESSURE
H00009.1
Figure 317. MTB Retarder Check Points External Connections, Right-Rear View
336
Table 311. Transmission Troubleshooting Chart
Problem
Probable Causes
Suggested Remedies
A. Abnormal Automatic Shifts

Shifts occurring at too high
speed
Governor valve stuck.
Clean or replace governor. Refer to

Paragraph 622.
Shift signal valve spring adjustment too Back off spring adjusting ring.
tight.
Shifts occurring at too low

speed
Valves sticking.
Overhaul valve body assembly.
Shift points not properly adjusted.
Refer to Paragraph 313.
Governor valve stuck.
Clean or replace governor. Refer to

Paragraph 622.
Governor spring weak or missing.
Replace governor. Refer to Paragraph

622.
Shift signal valve spring adjustment too Tighten spring adjusting ring.
loose.
Rough shifting
Modulator valve stuck.
Clean or replace modulator valve.
Shift points not properly adjusted.
Shift selector linkage out of adjustment. Adjust linkage. Refer to the current
MT1357EN, MT 600 Series
Mechanics Tips.
Control valves sticking.
Replace or rebuild main control valve

body assembly. Refer to Paragraph 66.
Modulator valve sticking; spring adjust- Repair or replace valves; adjust spring.
ment.
Modulator actuator cable kinked or out
of adjustment.
Replace or adjust actuator cable.
B. Abnormal Activities or Responses

Excessive creep in first and
reverse ranges
Engine idle speed too high.
Adjust to correct idle speed. Refer to

No response to shift lever

movement
Shift selector linkage disconnected.
Connect linkage. Refer to vehicle service manual.
Shift selector linkage defective or

broken.
Repair or replace linkage. Refer to

Main pressure low.
Refer to Chart E, Low Pressure.
Shift selector not engaged at control

valve.
Install or replace parts involved (inside

pan).
Vehicle moves in neutral
Shift selector linkage out of adjustment. Adjust linkage properly.
337

Table 311. Transmission Troubleshooting Chart (contd)
Problem
Probable Causes
Suggested Remedies
C. Abnormal Stall Check Speed

High stall speed
Low stall speed
Low fluid level.
Add fluid to the proper level. Refer to

Paragraph 35.
Clutch pressure low.
Forward clutch slipping.
Rebuild forward clutch.
First clutch slipping.
Rebuild first clutch.
Engine not performing efficiently (may Refer to engine manufacturers manual

be due to plugged or restricted injectors or vehicle service manual.
or high altitude conditions).
Broken converter parts.
Replace or rebuild converter assembly.

D. Leaking Fluid
Fluid leaking into converter
housing
Fluid leaking at output shaft
Converter pump hub seal worn.
Replace seal. Refer to Paragraph 63.
Converter pump hub worn at seal area.
Replace pump hub. Refer to Paragraph

63.
Engine crankshaft rear oil seal leakage.
Refer to vehicle service manual.
Faulty or missing seal at output flange.
Install a new seal in rear of transmission housing.
Flange worn at seal surface.
Replace flange.
E. Low Pressure
Low main pressure in all
ranges
Low fluid level.

Paragraph 35.
Filter element clogged.
Replace filter or element. Refer to

Paragraph 310.
Sealring on filter tube leaking or

missing.
Install a new sealring onto the top end

of filter tube. Refer to Paragraph 310.
Main-pressure regulator valve spring weak. Replace spring. Refer to Paragraph 68.
Main control valve body leakage.

Valves sticking (trimmers, relays, regula- Overhaul valve body assembly, main
tor valve, and main pressure regulator).
pressure regulator valve.
Input charging pump worn or damaged. Replace or rebuild pump. Refer to
Paragraph 68.
Low main pressure in one
Leakage in clutch-apply circuits for speoperating range, normal pres- cific range.
sure in other ranges
Excessive leakage at clutch piston seals
for specific range.
338

Overhaul transmission and replace piston seals.
Problem
Probable Causes
Suggested Remedies
E. Low Pressure (contd)

Low lubrication pressure
Low fluid level.

Paragraph 35.
Engine idle speed too low.
Refer to vehicle service manual.
Excessive internal fluid leakage.
Check the valve body mounting bolts,

the lubrication valve seat, and valve
spring.
Cooler lines restricted or leaking.
Check for kinks or leakage. Reroute or

replace as necessary.
Lubrication valve spring weak.
Replace valve spring. Refer to Paragraph 68.
F. Slippage*
Clutch slippage in all forward Low fluid level.
ranges

Paragraph 35.
Clutch (main) pressure low.
Forward clutch slipping.
Rebuild forward clutch and replace piston sealrings. Refer to Paragraph 69.
Sealrings on front support hub worn or

broken.
Replace sealrings.
Clutch slippage in first and

reverse only
First clutch slipping.
Rebuild clutch and replace piston sealrings.
Clutch slippage in second or

third (MT 640, 643); or third
or fourth (MT 650, 653) only
Clutch for particular range slipping.
Rebuild clutch and replace piston sealrings.
Clutch slippage in fourth and

reverse only
Fourth clutch slipping.
Rebuild clutch and replace piston sealrings. Refer to Paragraph 610.
Sealrings on center support hub worn or Replace sealrings.

broken.
Clutch slippage in first only
(MT 650, 653)
Low clutch slipping.
Rebuild clutch and replace piston sealrings. Refer to Paragraph 619.
G. Overheating in All Ranges

Transmission overheating in
all ranges
Low fluid level.

Paragraph 35.
High fluid level.
Drain fluid to the proper level. Refer to

Paragraph 35.
Cooler restricted (fluid or coolant side). Remove restrictions.
* Clutch slippage may be recognized by alternate racing and loading of the engine, which is at times accompanied by a violent chatter.
339

Problem
Probable Causes
Suggested Remedies
H. Transmission Throws Fluid Out of Fill Tube and/or Breather

Fluid thrown from fill tube
Dipstick loose.
Tighten cap; replace if necessary.
Fluid level too high.
Drain fluid to proper level. Refer to

Paragraph 35.
Breather clogged.
Clean or replace breather.
Dipstick gasket worn.
Replace gasket or dipstick.
J. Dirty Transmission Fluid

Dirty fluid
Failure to change fluid at proper interval. Change fluid, install new filter. Refer
to Paragraph 310.
Heat excessive.
Refer to Chart G, Overheating.
Clutch failure.
Overhaul transmission.
Damaged oil filter.
Replace filter. Refer to Paragraph 310.
Table 312. Retarder Troubleshooting Chart

Problem
Probable Causes
Suggested Remedies
A. Abnormal Operation or Responses

No retarder operation at low
speed
No air supply.
Check and repair air supply.
Sticking regulator charging valve.
Clean or replace valve.
Sticking pressure regulator valve.
Clean valve. Refer to Paragraph 67.
Sticking charging valve.
Check valve malfunctioning, omitted, or Replace or install correctly. Refer to

installed backwards.
Paragraph 77.
No retarder operation at high

speed
Harsh retarder apply
340
Leaking clutch piston seals.
Replace seals. Refer to Paragraph 619.
Worn retarder clutch.
Replace clutch. Refer to Paragraph 618.
Low air supply.
Check air supply.
Ruptured air line to retarder control

valve.
Repair air line.
Failed air control.
Repair or replace control.
Sticking retarder control valve.
Clean or replace valve. Refer to Paragraph 67.
Plug valve installed incorrectly.
Check for correct installation (dimple

on valve must be toward springs).
Incorrect or broken pressure regulator

valve spring.
Check for correct spring and/or broken

spring. Replace as needed.
Table 312. Retarder Troubleshooting Chart (contd)
Problem
Excessive retarder response
time
Retarder does not release
Probable Causes
Suggested Remedies
Sticking priority valve.
Leaking or incorrectly sized air lines.
Fix leaks or change line size.
Leaking accumulator piston seals.
Brake pedal assembly or manual-apply

valve malfunctioning.
Repair brake pedal assembly or manual-apply valve. Refer to vehicle service manual.
Air actuator piston sealrings damaged.
Repair air actuator piston sealrings,

retarder valve body. Refer to Paragraph
67.
Repair retarder valve body. Refer to

Paragraph 67.
B. No Retarder Output
No retarder output
Failed fuel interlock/wiring.
Repair interlock/wiring. Refer to vehicle service manual.
Master switch malfunction.
Repair master switch. Refer to vehicle

service manual.
Air actuator piston sealrings damaged.
Repair air actuator piston sealrings,

retarder valve body. Refer to Paragraph
67.
Repair retarder valve body. Refer to

Paragraph 67.
C. Low Pressure
Low main and/or retarder
pressure
Leaking rotor hub seals.
Leaking accumulator piston seals.
341

NOTES
342
Section 4 GENERAL OVERHAUL INFORMATION

41.
SCOPE
Depth micrometer
This section provides general information required for

overhaul, cleaning, and inspection, and general assembly procedures for the transmission. It provides illustrations and explanations for the fabrication of improvised tooling. A listing and illustration of special tools
are included for your convenience.
42. TOOLS AND EQUIPMENT

a. Improvised Tools and Equipment
A retarder piston spring compressor, consisting
of:
Steel compressor bar (1) 1 x 112 x 18
inches (25 x 38 x 460 mm)
Threaded rods (2) 12-13 x 10 inches
Plain nuts (6) 12-13 inch
Flat washers (4) 12 inch
Compressor ring (1): 5 inches (127 mm) OD
x 4.5 inches (114 mm) ID x 1.5 inch (38
mm) wide. Make a cutout in the side to
permit access with snapring pliers (refer to
Figure 696)
Output shaft lifting fixture (Figure 41). The
materials and dimensions may be changed to
meet specified requirements.
Work table 1500 pound (700 kg) capacity
(Figure 42)
Dial indicator set

A three-leg lifting sling with 90 degree angle
attaching plates 12 ton (500 kg) capacity

Hoist 12 ton (500 kg) capacity
CAUTION:
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits.
Container of mineral spirits for cleaning parts
A 100 inch pound (15 Newton meter) torque
wrench
A 100 foot pound (150 Newton meter) torque
wrench
A 1000 foot pound (1500 Newton meter)
torque wrench
Heating equipment (for heating bearings or
other interference-fit parts to aid assembly)

A press for disassembly and assembly of
spring-loaded clutches, valves, and interference-fit parts

Clean, lint-free shop cloths (do not use waste)
Boxes, receptacles for parts
b. Special Tools. Special tools are listed in Table 4

1 and are illustrated in Figures 43, 44, 45, 46, and
47. These special tools are available from:
Supply of wood blocks
Kent-Moore Tool Division*

29784 Little Mack
Roseville, Michigan 48066
Non-hardening sealer (Permatex No. 2, or
Oil-soluble, non-fibrous grease (petrolatum)
equivalent, for plugs, seals, etc.)
Aidco, Inc.*
800 Liberty Street
Adrian, Michigan 49221
STEEL ROD
12 IN. (300 mm) LG
0.375 IN. (9.5 mm) DIA
c. Mechanics Tools, Shop Equipment. The

following tools, in addition to the common tools
ordinarily required, should be available:
OUTPUT SHAFT
NUT USED
WELD 2 PLACES
V00276
Snapring pliers
Micrometer
Figure 41. Output Shaft Lifting Fixture
* We believe these sources and their tools to be reliable. There may be additional manufacturers of such tools. General Motors does not endorse, indicate any
preference for, or assume any responsibility for the products or tools from these firms, or for any such items which may be available from other sources.
41

43. REPLACEMENT PARTS
WARNING!
Do not burn discarded Teflon seals; toxic gases
are produced by burning.
a. Ordering Information. Refer to the current Parts

Catalog PC1316EN for parts information.
44. CAREFUL HANDLING

b. Parts Normally Replaced. The following parts
are normally replaced at each transmission overhaul.
Gaskets
Lockstrips
Washers or snaprings damaged by removal
Piston sealrings, oil seals
48 in.
(120 cm)
During all rebuild procedures, handle parts and subassemblies carefully to prevent nicking, scratching, and
denting. Parts which have close operating tolerances
can bind if damaged. Parts which depend upon smooth
surfaces for sealing may leak if scratched. Control
valves, when dry, must move freely by their own
weight in their bores. Carefully handle and protect
such parts during removal, cleaning, inspection, and
installation. Keep the parts in clean containers while
awaiting installation.
78 in.
(200 cm)
TRANSMISSION FLUID DRAIN

STEEL TOP
TROUGH
16-GAUGE SHEET STEEL
112 in. (35 mm) DEEP
112 in. (35 mm) WIDE
24 in.
(60 cm)
TRANSMISSION
FLUID DRAIN
(BOTH SIDES)
4 x 4 in. LEGS
(10 x 10 cm)
2 x 6 in. BOARD
(5 x 15 cm)
FOR TOP FRAME
AND LEG BRACKETS
V02733
Figure 42. Work Table
42
GENERAL OVERHAUL INFORMATION
11
9
10
13
17
12
14
15
18
19
16
20
V00277
Figure 43. Special Tools (1 through 20)
43
21
25
22
23
26
24
27
28
29
32
31
30
34
33
35
38
36
37
V03280
44

39
41
40
45
42
46
44
43
50
51
51
49
48
47
52
53
55
54
56
57
58
59
60
V03281
45
63
64
62
61
66
65
67
70
68
69
71
73
72
74
V03282
46

75
78
76
77
80
79
81
82
85
83
84
86
90
87
88
89
V03283
47

Table 41. Special Tools
Tool No.
Figure
Item
J 1927-1
43
15
Description
Adapter housing guide pins,12-13 x 6 (2)
516-18
Ref Paragraph
73g
J 3387-2
43
11
Oil pan guide screws,
J 3289-20
46
66
Holding fixture base
53a
J 3453
43
Universal yoke and flange holder
317b, g, h
J 6125-1
45
54
Slide hammer assembly
68a
J 6438-01
44
31
Forward and fourth clutch spring compressor
69a, c, 610a, b
J 6795-01
45
46
Torque converter lifter
55a, 76e,
J 8092
43
12
Driver handle
63b, 68c, 613b,

615b, 619b
J 22912-01
47
84
Bearing and gear remover
615a
J 23549
47
86
Stator thrust bearing installer
63b
J 23642-01
46
68
Transmission holding fixture
53a
J 23717-1
45
50
Center bolt
73a
J 24171
45
56
Output shaft oil seal and dust shield remover assembly
616a, 617a, 618a
J 24171-1
45
58
Jaw attachment
317c
J 24171-2
45
57
Rod assembly
317c
J 24171-3
45
Nose adapter (part of J 24171-2)
317c
J 24171-4
45
Slide hammer (part of J 24171-2)
317c
J 24171-5
45
60
Hook
317c
J 24198
44
22
Dust shield installer
317f, 616b, 79b
J 24202-4
43
18
Driver handle
317f, 68c, 615b,

79a
J 24204-2
46
64
Clutch spring compressor base for low, first, fourth

clutches
610a, b, 616a, b,
617a, b, 620a, b
J 24218-1
44
37
Stator roller retainer
63f
J 24314
43
Valve body adjusting ring tool
313b, 64b, 65b,

66b
J 24315
43
11
Guide pin set
74c
J 24315-1
43
J 24369
43
13
Main and output shaft orifice installer
612c, 613b, 614b,

615b
J 24412-2
44
33
Valve pin remover
68a
J 24420-B
45
41
Bearing puller assembly
317d
J 24446
43
17
Rear bearing installer (MT 640, 643)
317f, 79a
J 24447
47
77
Rear bearing installer (MT 650, 653)
317f, 616b, 79a
J 24448-A
44
25
Output shaft oil seal installer (MT 640, 643)
317f, 79b
J 24449-A
44
26
Oil pump seal installer (before S/N 49490)
68c
48
x 3 (2) (part of J 24315)
76b, d
Pump body and front support guide screws, 38-16 x 6 (2) 74c
(part of J 24315)

Table 41. Special Tools (contd)
Tool No.
Figure
Item
Description
Ref Paragraph
J 24451
44
21
Output shaft bearing installer
613b, 615b
J 24452
44
29
Low and first clutch spring compressor
616a, b, 617a, b,
620a, b
J 24453
43
Lockring installer
611e
J 24454
43
20
Gear unit lifter
510b, 511a, 73k, l
J 24455
43
10
Center support lifter
59d, 73a, e, j, n
J 24457
44
28
Front support bearing installer
68c
J 24458
43
16
Valve pin installer
68c
J 24459-A
46
65
Main regulator and lockup valve spring compressor
68a, c
J 24459-5
43
19
Spring compressor adapter (used with 24459-A)
68a, c
J 24461
46
70
Oil pump body and front support centering band
68c
J 24462
46
66
Transmission holding fixture adapter set
53a
J 24463-2
45
42
Bearing puller leg assembly (MT 640, 643, for ten-ball

bearings) (2)
317d
J 24468
44
27
Sun gear shaft bushing installer
612b
J 24469
47
79
Front planetary bushing installer
624c
J 24470
47
76
Converter end play gauge assembly
63a, 63f
J 24472
47
86
Low planetary bushing installer
624c
J 24473
43
Front support lifter
58b, 74c
J 24474
47
86
Oil pump bushing installer (use with J 8092)
68c
J 24475-B
45
49
Selective snapring gauge assembly
73a
J 24475-1
45
53
Compressor base
73a
J 24475-2
45
52
Compressor bar
73a
J 24534
45
43
Bearing puller leg assembly (MT 650, 653, nine-ball

bearings) (2)
317d
J 24620-A
44
25
Output shaft oil seal installer (MT 650, 653)
317f, 616b, 79b
J 24648
44
28
Converter pump cover bushing installer
63f
J 24794
47
85
Center support bushing installer
611e
J 25000-1
46
72
Valve body test stand
313a
J 25000-226 46
73
Valve body adapter to J 25000-1
313
J 25000-338 46
74
Modulated lockup kit (used with J 25000-226)
313
J 25393-A
47
79
Output shaft front bearing outer race installer (MT 650, 616b
653) (use with J 8092)
J 25587-01* 46
71
Planetary carrier rebuild tool kit
624d
J 25587-1
46
Removing, installing and swaging fixture
63c, 624b
J 25587-2
46
Pin remover and installer adapter
624b
* Items J 25587-1 through J 25587-50 are details of Planetary Kit J 25587-01.
49

Tool No.
Figure
Item
Description
J 25587-3
46
Support block
624b
J 25587-4
46
Support block
624b
J 25587-6
46
Pin remover and installer spacer
624b
J 25587-8
46
Pin installer
624b
J 25587-11
46
Pin installer
624b
J 25587-12
46
Pin installer
624b
J 25587-13
46
Pin installer
624b
J 25587-16
46
Pin remover
624b
J 25587-17
46
Bottom swaging tool holder
624b, e
J 25587-18
46
34
inch loading pin
624b
J 25587-20
46
58
inch loading pin
624b
J 25587-22
46
12
inch loading pin
624b
J 25587-23
46
Swaging tool
624b
J 25587-25
46
Swaging tool
624b
J 25587-27
46
Swaging tool
624b
J 25587-48
46
34
inch guide pin
624b
J 25587-49
46
58
inch guide pin
624b
J 25587-50
46
12
inch guide pin
624b
J 26282
43
14
Selector shaft seal installer
317a, 621b
J 26401
47
82
Selector shaft seal remover
317a, 621a
J 26417
NI**
Oil pressure gauge set
320a
J 26857
47
83
Oil pump gear clearance gauge
68c
J 26912-A
47
88
Oil pump seal installer (after S/N 49489)
68c
J 26913
43
Forward clutch gauge (0.0790.130 in.)
69c
J 26914
43
First clutch gauge (0.0740.147 in.)
73e, j
J 26915
43
Second clutch gauge (0.0490.111 in.)
73b
J 26916
43
Third clutch gauge (0.0500.114 in.)
73o
J 26917
43
Fourth clutch gauge (0.0640.125 in.)
610b
J 28435
47
89
Converter pump hub roller bearing remover and installer 63b, f
J 28446-A
47
87
Sun gear bushing swaging tool
612b
J 28684
47
81
Governor support pin installer
616b, 617b
J 28708
47
80
Governor support pin remover
616a, 617a
J 29032
44
36
Counterbore cutter, center support
611e
J 29121
44
38
Stator rivet set
63c
J 29121-1
44
Staking tool
63c
J 29121-3
44
Rivet removing tool
63c
** NI Not illustrated.
410
Ref Paragraph

Tool No.
Figure
Item
J 29198-2
46
69
Gauge set, center and front support sealring grooves
68a, 68b, 611a
J 29355
45
55
Remover and installer set-lube valve spring guide
621a, b
J 29375
47
78
Turbine rivet tool set
63d
J 29375-1
47
Base plate (part of J 29375)
63d
J 29375-2
47
Guide plate (part of J 29375)
63d
J 29375-3
47
Staking tool (part of J 29375)
63d
J 29375-4
47
Pin remover (part of J 29375)
63d
J 29375-5
47
Drill guide bushing (part of J 29375)
63d
J 29521
44
Stator rivet set
63c
J 29521-1
44
Stator rivet base (part of J 29521)
63c
J 29521-2
44
Top plate (part of J 29521)
63c
38
44
Description
Bolt
58-11
314
(part of J 29521)
Ref Paragraph
63c
J 29612
45
39
Valve body torque wrench (pre-set 10 lb ft)
75b, c, e, f
J 29618
46
62
Output shaft seal installer
317f, 618b
J 29863
45
47
Valve body lifter
J 33163
45
48
Valve body parts tray set
66a
J 33410
44
32
Neutral start switch wrench
621a, 710b
J 33429
46
63
Accumulator cover remover (installer)
618a, b
J 33818-A
44
34
Governor and speedometer bushing remover (installer)
618a, b
J 33820
44
30
Output bearing installer, MTB
317f, 618b
J 33821
45
40
Output bearing remover, MTB
317d
J 33822
46
61
Output shaft front bearing race installer (MTB 653)
619b
J 34015
44
23
Output shaft bearing installer (0.280 in.) (MT 650, 653) 615b
J 34016
44
24
Output shaft bushing installer (MTB 643)
73d
J 34127
47
75
Center support selective snapring gauge (used with

J 24475-B)
73a
J 34814
NI**
PTO height gauge set
712a
J 36376
NI
Remover/installer, oil pump bushing
68a, c
J 38086
45
44
Bearing puller leg assembly (MT 640, 643, for nine-ball 317d
bearings)
J 39362
47
90
Front support bearing installer
68c
J 41406
44
35
Sun gear shaft bushing installer
612b
PT 8640
NI
Accumulator bore replacement sleeve
618b
PT 4555
NI
Accumulator boring tools kit
618b
250*
46
Valve body test stand
313a
72
* Available from Aidco, Inc.

** NI Not illustrated.
411

45. CLEANING AND INSPECTION
a. Dirt-Free Assembly. All parts must be clean to
permit effective inspection. It is very important that no
dirt or foreign material be allowed to enter the transmission. Even minute particles can cause the malfunction of close-fit parts, such as valves.
b. Cleaning Parts
1. Clean all metallic parts of the transmission
thoroughly with mineral spirits or by steamcleaning. Do not use caustic soda solution for
steam-cleaning.
2. Dry parts (except bearings) with compressed
air. Lubricate steam-cleaned parts with transmission fluid immediately after drying to prevent rust.
3. Clean hydraulic passages by working a piece
of soft wire back and forth through the passages and flushing with mineral spirits. Dry the
passages with compressed air.
4. After cleaning, examine parts (especially hydraulic passages) to make certain they are entirely clean. Reclean them if necessary.
5. Removing minor defects with tools such as
crocus cloth, honing stones, and scrapers produces debris and residue. Cover adjacent parts
and cavities before removing defects. Thoroughly reclean the affected areas after the repair work.
6. Use only petroleum base solvents for cleaning
oil seals. Solvents such as trichloroethylene,
benzol, acetone, and all aromatics are harmful
to seals made from polyacrylate rubber.
2. If the bearings are particularly dirty or filled

with hardened grease, soak them in mineral
spirits before trying to clean them.
3. Before inspection, lubricate the bearings with
transmission fluid.
d. Inspecting Bearings
1. Inspect bearings for roughness of rotation. Replace a bearing if its rotation is still rough after
cleaning and lubrication.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and for excessive
wear of rollers or balls. If one of these defects
is found, replace the bearing.
3. Inspect the bearing housing and shaft for
grooved, burred, or galled conditions that
would indicate that the bearing had been turning in the bore or on the shaft. If the damage
cannot be repaired with crocus cloth, replace
the defective part.
CAUTION:
Replace any bearing that has been subjected to
metal contamination (Paragraph 39b).
e. Keeping Bearings Clean. Because the presence
of dirt or grit in bearings is usually responsible for
bearing failures, it is important to keep bearings clean
during removal and installation. Observe the following
rules to ensure maximum bearing life.
1. Do not remove the wrapper from new bearings
until ready to install them.
2. Do not remove the grease in which new bearings are packed.
c. Cleaning Bearings
3. Do not lay bearings on a dirty bench; place

them on clean paper or lint-free cloth.
WARNING!
4. If assembly is not to be completed at once,

wrap or cover the exposed bearings with clean
paper or lint-free cloth to keep out dust.
Never dry bearings with compressed air. A spinning bearing can disintegrate allowing balls or
rollers to become lethal flying projectiles. Also,
spinning a bearing without lubrication can damage the bearing.
1. Wash bearings that have been in service thoroughly in mineral spirits.
412
f. Inspecting Cast Parts, Machined Surfaces

1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with crocus
cloth. Remove foreign matter. Replace parts
that have scratches or grooves that cannot be
removed with crocus cloth.

2. Inspect all hydraulic passages for obstructions.
If an obstruction is found, remove it with compressed air, or by working a soft wire back and
forth through the passage and flushing it out
with cleaning solvent.
3. Inspect mounting faces for nicks, burrs,
scratches, and foreign matter. Remove such defects with crocus cloth or a soft stone. If
scratches cannot be removed with crocus cloth,
replace the part.
4. Inspect threaded openings for damaged
threads. Chase damaged threads with the correct size used tap (a new tap can cut oversize).
A threaded insert may be used if the insert will
not be subjected to high hydraulic pressure. Inserts used in high pressure areas will leak fluid.
5. Inspect snapring grooves in the transmission
housing for nicks or shavings that would prevent the snaprings from fully seating in the
grooves. Clean up any damage with crocus
cloth.
6. Replace housings or other cast parts that are
cracked. Magnaflux and rinse planetary carriers using approximately 8000 ampere-turns (8
amperes in 1000 turn coil) to determine if fractured. Replace the carrier if cracked.
9. Inspect the hydraulic circuit tracks in the valve

body and main housing for porosity, broken
lands, cracks, dirt, and land surface imperfections. The tracks identified in Figure 48 will
assist in locating troubled areas.
g. Inspecting Bushings, Thrust Washers
1. Inspect bushings for scores, burrs, roundness,
sharp edges, and evidence of overheating. Remove scores with crocus cloth. Remove burrs
and sharp edges with a scraper or knife blade.
If the bushing is out-of-round, deeply scored,
or excessively worn, replace it using the proper
size replacer tool.
CAUTION:
Whenever it is necessary to cut out a defective
bushing, do not damage the bore into which the
bushing fits.
2. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace if defective or worn.
h. Inspecting Oil Seals, Gaskets
1. Replace all sealrings (except hook-type), oil
seals, and composition gaskets.
2. Inspect hook-type sealrings for wear, broken
hooks, and distortion.
NOTE:
Some torque converter turbines and stators have
casting irregularities near the outer edge of the turbine and stator vanes. These shut marks are not
cracks and are not detrimental to the operation of
the transmission.
7. Inspect all machined surfaces for damage that
could cause fluid leakage or other malfunction
of the part. Rework or replace the defective
parts.
8. Inspect parts for discoloration. Replace any
parts (e.g. a carrier and spindles) where discoloration indicates exposure to excessive heat.
3. Install a new hook-type sealring if the old ring

shows any wear on the OD, or if there is excessive side wear. The sides of the sealring must
be smooth within 0.005 inch (0.127 mm) maximum side wear. The sides of the shaft groove
(or the bore) into which the sealring fits should
be smooth to 50 microinches (1.27 micrometers) and square with the axis of rotation within
0.002 inch (0.05 mm). If the sides of the
grooves have to be reworked, install a new
sealring.
i. Inspecting Gears
CAUTION:
CAUTION:
Distortions and imperfections in the hydraulic
circuit tracks will cause severe fluid leakage leading to transmission failure.
Do not attempt to correct the governor driven

gear with the use of a soft stone. If the governor
driven gear is scuffed, nicked, burred, or has broken teeth, replace the governor assembly.
413

SECOND TO THIRD
THIRD TO FOURTH
CLUTCH FEED
TRIMMER
REGULATOR
REVERSE
EXHAUST
THIRD
CLUTCH
THIRD, FOURTH
FEED
FOURTH
CLUTCH
SECOND
CLUTCH
MAIN
GOVERNOR
MODULATOR
EXHAUST
EXHAUST
LOW CLUTCH
LOCKUP
SIGNAL
FIRST
CLUTCH
MAIN
FIRST CLUTCH
TRIMMER
DRIVE 3
GOVERNOR
FEED
FORWARD
CLUTCH
GOVERNOR
DRIVE 2
MAIN
CHECK VALVE
EXHAUST
DRIVE 3
DRIVE 2
FIRST CLUTCH
REVERSE
MODULATOR
SECOND TO
THIRD SIGNAL
MAIN
MAIN
GOVERNOR
FIRST TO
SECOND SIGNAL
FORWARD
DRIVE 1
L00354
Figure 48. Main Housing Valve Body Mounting Surface Tracks
1. Inspect gears for scuffed, nicked, burred, or

broken teeth. If the defect cannot be removed
with a soft honing stone, replace the gear.
2. Inspect gear teeth for wear that may have destroyed the original tooth shape. If this condition is found, replace the gear.
3. Inspect the thrust face of gears for scores,
scratches, and burrs. Remove such defects with
a soft honing stone. If the scratches and scores
cannot be removed with a soft stone, replace
the gear.
j. Inspecting Shafts
1. Inspect shafts closely for cracks. Cracks originating at the lube oil holes may appear just below the surface.
414
2. If the turbine shaft is cracked or broken (indicating the transmission was exposed to high
torsional loads), magnaflux the main shaft and
closely inspect the lube oil holes.
k. Inspecting Splined Parts. Inspect splined parts
for stripped, twisted, chipped, or burred splines.
Remove burrs with a soft stone. Replace the part if
other defects are found. Spline wear is not considered
detrimental except where it affects tightness of fit of
the splined parts.
l. Inspecting Threaded Parts. Inspect parts for
burred or damaged threads. Remove burrs with a soft
honing stone or fine file. Clean up damage on small
threads by chasing threads with a used die. Clean up
damage on large threads with a fine file. Replace the
part if damage cannot be cleaned up.

m. Inspecting Snaprings. Inspect all snaprings for
nicks, distortion, and excessive wear. Replace a
snapring if any of these defects are found. The
snapring must snap tight in its groove for proper
functioning.
n. Inspecting Springs. Inspect springs for signs of
overheating, permanent set, or wear due to rubbing
adjacent parts. Replace the spring if any one of these
defects is found. Refer to Table 82, Spring Data for
spring inspection criteria.
o. Inspecting Clutch Plates
1. Inspect friction-faced steel plates (internalsplined plates) for burrs, embedded metal particles, severely pitted faces, excessive wear,
cone, cracks, distortion, and damaged spline
teeth. Remove burrs, using a soft honing stone.
Replace plates which have other defects.
2. Inspect steel plates (external-tanged plates) for
burrs, scoring, excessive wear, cone, distortion,
embedded metal, galling, cracks, breaks, and
damaged tangs. Remove burrs and minor surface irregularities, using a soft honing stone.
Replace plates which have other defects.
q. Inspecting Balls in Clutch Housings. Inspect all

balls in rotating clutch housings for free movement.
The minimum movement is 0.040 inch (1.02 mm).
Any restriction could prevent the ball from seating
during clutch application. Inspect staking that retains
the balls.
r. Inspecting Seal Contact Surfaces
1. Inspect the surfaces that contact the sealing
area or lip of any seal. Correct any roughness,
scoring, pitting, or wear that permits transmission fluid leakage or causes damage to the seal.
Replace the affected part if defects cannot be
corrected.
2. Inspect sealring groove thrust faces for wear
and surface finish condition. There must be no
step, edge lip, or rough finish on the face. The
thrust face of the sealring groove is always the
face that is farthest from the fluid feed area between a pair of seals.
46. ASSEMBLY PROCEDURES

a. Clutches, Pistons
3. The amount of cone in a clutch plate is determined by measuring the distance between the
ID of the plate and a flat surface (Figure 49).
Discard plates having excessive cone. Refer to
Table 81, Wear Limits.
1. Establish clutch pack clearances prior to assembly. After clearances have been established, soak friction-faced clutch plates in
transmission fluid for at least two minutes and
install each plate so that any cone is in the
same direction as the cone of the adjacent
plates.
p. Inspecting Swaged, Interference-Fit Parts. If

there is evidence of looseness, replace the assembly.
2. Apply a generous amount of transmission fluid

to the piston cavity prior to final assembly.
LEVEL SURFACE
CLUTCH PLATE
b. Parts Lubrication. During final assembly,

lubricate all moving parts with transmission fluid. The
lubricant will help protect the friction surfaces and
ferrous metals until the unit is in service.
c. External Pipe Plugs, Hydraulic Fittings
Measure here for cone
V00778
Figure 49. Method of Measuring Clutch Plate Cone
CAUTION:
Inaccurate torque can cause leakage and cracked
housings. Tighten all pipe plugs to the torque
specified in the assembly step and on the exploded views.
415

1. New Precoated Plugs. New plugs that are precoated with Teflon need no preparation for
assembly.
2. Reused or Uncoated Plugs, Hydraulic Fittings. Prepare the threads with a small amount
of nonhardening sealant, such as Loctite Pipe
Sealant with Teflon, or equivalent. Do not
use Teflon tape.
d. Oil-Soluble Grease
CAUTION:
Do not use gasket-type sealing compounds, fi-
brous greases, or nonsoluble, vegetable-base

cooking compounds any place inside the transmission or where they could be flushed into the
transmission hydraulic system.
Do not use any substance as a gasket retainer.
1. Low temperature grease (petrolatum) must be
used for internal assembly. The grease must be
soluble in DEXRON-III or Allison-approved
C-4 transmission fluid. Petrolatum equivalent
to MIL-VV-P-36 or Amojell petrolatum
(Amoco Oil Co.) is recommended to temporarily retain butt-joint sealrings, hook-type
sealrings, and other parts during assembly with
mating parts. The oil-soluble grease will help
keep the sealrings centered in their grooves and
will help protect the parts from damage.
2. High temperature grease having good oxidation and water resistance should be used at the
ID of the output and input shaft fluid seals.
3. If adhesives or sealants are required for the pan
gasket, they may be applied on the pan mounting flange, but only in the area outside of the
flange bead.
the inside of the unit). Coat the inside of the

seal with high temperature grease such as
MIL-G-3545A, Mobil Grease No. 28 (Mobil
Oil Co.), Aeroshell Grease No. 22 (Shell Oil
Co.), or equivalent, to protect the seal during
shaft installation and to provide lubrication
during initial operation.
2. Allison seals are precoated with a dry sealant.
The sealant is usually colored for easy identification. The precoated seals do not require any
additional sealant before installation.
3. If the circumference of a seal is not precoated
with a dry sealant, apply a non-hardening sealant, such as Permatex #2, to the circumference of these seals before installation.
f. Butt-Joint Sealrings
CAUTION:
If humidity is allowed to penetrate and expand a
butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will leak
fluid from the clutch piston cavity and cause
clutch slippage. Do not open the airtight package
until you are ready to install the sealring.
1. Check the end clearance prior to installing the
sealring to ensure that the sealring has not expanded.
2. Remove the sealring from the airtight package
and place it in the bore.
3. Using a feeler gauge, check the end clearance
of the sealring. The end clearance must not be
less than 0.010 inch (0.25 mm).
e. Lip-Type Seals (Metal-Encased)
4. If the end clearance is less than 0.010 inch

(0.25 mm), heat the sealring in an oven at 200
300F (93149C) for 24 hours or get a new
sealring. Repeat Steps (2) and (3) to ensure
that the end clearance is correct.
CAUTION:
5. Pack the sealring groove with a liberal amount

of oil-soluble grease.
Do not use high-temperature grease on transmission internal parts.

1. When replacing metal-encased lip-type seals,
make sure the spring-loaded lip side is toward
the transmission fluid to be sealed in (toward
416
6. Roll the sealring to about half its free diameter

and hold it for about 10 seconds. Being careful
not to spread the sealring more than necessary,
slide it onto the hub. Place one end of the sealring into the groove and gradually work the
seal into the groove.

g. Interference-Fit
Parts.
Assembly
of
interference-fit parts may be accomplished by heating
and chilling the respective parts. The female part can
be heated in an oven or hot transmission fluid bath to
300F (149C), and the male part can be chilled in dry
ice. Either one or both parts may require a thermal
process. If the chill process is used for a ferrous alloy
part, coat the components with transmission fluid to
inhibit rust due to frost and moisture.
h. Sleeve-Type Bearings and Bushings. The use of
a locking compound such as Loctite Sleeve Retainer
601TM or equivalent is recommended to retain
bushings and sleeve-type bearings that have press-fit
tolerances.
3. Use expanding-type snapring pliers to spread

the snapring fully into the groove. Tapping the
snapring with a screwdriver or drift and hammer may not ensure that the snapring is fully
expanded into the groove.
47. REMOVING (OR INSTALLING)

TRANSMISSION
a. Drain Transmission Fluid. Drain the transmission fluid from the transmission before removal from
the vehicle (Paragraph 310). For better drainage, the
transmission should be warm. Since applications differ, consult the vehicle service manual for specific instructions for transmission removal and installation.
i. Bearings (Ball or Roller)

1. When installing a bearing on a shaft, heat the
bearing to 200F (93C) in an oven or in a
transmission fluid bath. Bearings must be
heated long enough for sufficient expansion.
Heating time is determined by the size of the
bearing. Forty-five minutes is sufficient for the
largest bearing in these transmissions. Use the
proper size installation sleeve and a press to
seat the bearing.
2. If a bearing must be removed or installed without a sleeve, press only on the race which is
adjacent to the mounting surface. If a press
is not available, seat the bearing with a drift
and a hammer, driving against the supported
race.
b. Check Linkages and Lines. Make sure all

linkages, controls, cooler lines, modulator actuator
cable, temperature connection, input and output
couplings, transmission fluid fill tube, parking brake
linkage, mounting bolts, etc., are disconnected before
transmission removal. Carefully place hydraulic lines
out of the way of damage and cover all openings to
keep out dirt.
NOTE:
Position jack or hoist sling to coincide with the
transmission center of gravity.
c. Retain Torque Converter
1. The torque converter is free to move forward
when the transmission is disconnected from
the engine.
j. Clutch Snaprings
CAUTION:
Snaprings that retain clutch packs must be fully
seated in the grooves in the main housing. If the
snapring is not fully seated in its groove, it can
come out of the groove and cause extensive damage.
1. Check the snapring groove in the main housing
for debris, nicks, burrs, or shavings prior to installing the snapring. A burr or shaving can be
raised when the snapring is removed.
2. Install the snapring with the ends at the twelve
oclock position to avoid scratches in the hydraulic passages at the bottom of the main
housing bore.
CAUTION:
Do not allow the torque converter to separate
from the transmission while the transmission is
being removed from the vehicle.
2. Install a retaining strap to hold the converter in
place as soon as the transmission is clear of its
mountings.
d. Clean Transmission. Clean the exterior of the
transmission. If steam cleaning is used, disassemble
and dry the transmission immediately because
condensation from the steam could cause rust in the
transmission.
417

e. Transmission Installation
1. Use a transmission jack to raise the transmission into mounting position. Mount the transmission.
2. Make all connections from the vehicle to the
transmission. Refer to the vehicles service
manual and Paragraph 312 in this manual for
control linkage adjustment procedures.
3. Verify all mechanical and electrical connections.
4. Fill the transmission with transmission fluid
(Paragraph 35 through 310) and road test after installation.
48. WEAR LIMITS

Refer to Table 81 for general and specific information
covering parts fits, clearances, and wear limits.
49. SPRING SPECIFICATIONS
charts on the foldouts are keyed by capital letters to

correspond with capital letters at the end of items in
the legend. All torque values are for dry assembly unless a lubricant is specified in the assembly procedure.
Transmission fluid on threads has little effect on
torque.
411. SELECTIVE PARTS

a. Certain parts are provided in graduated thicknesses to provide proper running clearances. These
parts are selected and matched during the manufacturing process to compensate for machining tolerances.
Selectively matched parts are assembled in the transmission and must be retained with a particular transmission until the parts are replaced. If a selective part
is replaced, related components must be selected to retain the proper running clearances.
NOTE:
Refer to Table 82 for spring identification and specifications.
410. TORQUE SPECIFICATIONS

Torque specifications are given with each assembly
procedure. The exploded view foldouts state torque
specifications for all threaded fasteners and plugs. The
To maintain the relationship of matched components, identify the related parts during assembly.
b. If any of the parts listed in Table 42 require

replacement, make appropriate measurements to
reestablish the proper running clearance within the
affected parts group.
Table 42. Selective Parts and Related Components

Foldout
Ref
19
Selective Parts
Spacer
Related Components
Affecting Clearances
Foldout
Ref
Converter cover assembly
14
Lockup clutch backplate
20
Converter turbine
24
Stator assembly
32
Stator race
39
Converter pump hub (earlier models)
42
Converter pump
48
Converter pump hub (later models)
7,A
Pump driven gear
7,A
Pump body
7,B
16
Forward clutch piston
7,B
Clutch housing assembly
418

Table 42. Selective Parts and Related Components (contd)
8,A
8,B
8,B
8,B
11,A
11,B
19,A
19,B
9, 10 Fourth clutch piston

2
5
28
23
22
28
Third clutch backplate
Center support snapring

Second clutch backplate
First clutch backplate
Low clutch piston
Retarder piston
Retarder piston
8,A
13
Clutch housing assembly
8,B
Third clutch piston
8,B
16
Center support assembly
10,A
12
Transmission housing
8,B
16
10,A
12
8,B
16
8,B
19
Second clutch piston
10,A
12
10,A
12
11,A
11
First clutch piston
11,B
Adapter housing (MT(B) 650, 653)
12,A
Rear cover (MT 640, 643)
19,A
Retarder adapter housing (MTB 640, 643)
11,B
Adapter housing (MT(B) 650, 653)
12,B
15
Rear cover (MT 650, 653)
19,B
13
18,B
6, 7
Retarder retarder plates
19,A
18,B
6, 7
Retarder clutch plates
19,B
13
419

NOTES
420
Section 5 DISASSEMBLY OF TRANSMISSION

51.
SCOPE
This section covers disassembly of transmission models MT(B) 640, 643, 650, and 653 into subassemblies.
The procedures and illustrations apply to all models
unless specific model(s) are identified. If a procedure
does not apply to the specific model being disassembled, go to the next applicable procedure. The paragraphs relating to specific models are as follows:
Model
Paragraphs
All Models
53, 55, 58, 59
MT 640, 643
56, 510, 512
MTB 643
54, 56, 511, 513
MT 650, 653
57, 511, 512, 514
MTB 653
54, 57, 511, 513, 514
2. Replace the PTO cover with J 24462-1 holding

plate and J 23642-01 holding fixture (Figure
51). Retain the plate and fixture with six 3816 x 134 inch bolts.
3. Attach a three-leg lifting sling (Figure 51)
and hoist the transmission into position for attachment to holding fixture base J 3289-20.
b. Mounting of Transmission in Overhaul Stand
The transmission may be mounted in an overhaul
stand providing the front, rear, and bottom of the transmission remain freely accessible for removal and installation of components. The stand must allow movement of the transmission into vertical and horizontal
positions. Any attachment to the transmission housing
at the PTO pad should use bolts which do not project
into the housing to obstruct removal and installation of
components.
52. GENERAL INFORMATION

Refer to Sections 4 and 8 for general information as
follows:
Title
Paragraph
42
Tools and Equipment
43
Replacement Parts
44
Careful Handling
45
Cleaning and Inspection
81
Wear Limits Data
82
Spring Data
54. PREPARATION FOR

DISASSEMBLY (MTB Series Only)
a. Relieving Trapped Hydraulic Pressure
WARNING!
Hydraulic fluid under 40 psi (280 kPa) pressure
may be trapped in the output retarder accumulators. Personal injury can occur if this pressure
is accidentally released.
53. MOUNTING TRANSMISSION

IN HOLDING FIXTURE OR
OVERHAUL STAND
J 23642-01
BOLT (6)
3/8-16 x 13/4 in.
J 24462-1
CAUTION:
The torque converter must be held into the transmission by a retaining strap as shown in Figure
12. Be sure the retainer is in place before lifting
the transmission.
a. Mounting of Transmission in Table-Mounted
Holding Fixture
1. Remove the six bolts that retain the PTO cover.
Remove the cover and gasket.
WASHER (6)
J 3289-20
H00010.01
Figure 51. Transmission Installed in Holding Fixture
51

1. Before disassembling an MTB Series transmission, relieve trapped accumulator pressure.
2. Connect a 150 psi (1000 kPa) air supply to the
air actuator port in the top of the retarder control valve.
3. Apply 60150 psi (4001000 kPa) air pressure
to the top of the retarder control valve for 23
seconds.
4. Turn off the air and disconnect the air supply.
5. Remove the drain plug and drain fluid from the
transmission.
NOTE:
For removal of the heavy-duty configuration oil
pan, go to Paragraph 55c.
b. Removal of Oil Pan and Filter (Standard
Configuration) (Foldout 10,A)
1. Remove the modulator retainer bolt (Figure 5
3). Remove the retainer. If not previously removed, remove the modulator control.
2. Remove the twenty-one washer-head screws
48 that retain the oil pan (Figure 53).
3. Remove oil pan 46 and gasket 34 or 41.
b. Removing Hose Assemblies, Fittings, and

Brackets
1. Remove flared tube connectors 7 (Foldout
17,A) and 8, and sealrings 6 and 9.
2. Remove bolt 5, washer 11, and nut 10 from
hose clamp 4 and hose clamp bracket 12.
3. Disconnect and remove converter-out hose assembly 3. Remove flared tube elbows 2 and 14,
and sealrings 1 and 13.
4. Disconnect clutch feed hose assembly 15 from
flared tube elbow 23 (Foldout 18,A) and fitting
16 (Foldout 17,A). Remove elbow 18 and connecting components from the retarder housing.
Separate fitting 16, check valve 17, and elbow
18 only if cleaning or replacement is required.
NOTE:
While the filter disassembly procedure applies to all
models, filter components vary, and are not interchangeable. Before reassembly, refer to the current
Parts Catalog PC1316EN for the correct parts for
your model.
4. Remove filter retaining screw 35 or 42.
5. Remove the filter assembly (Figure 54). For
paper element filters, separate filter 33 and filter tube 32.
J 6795-01
55. REMOVAL OF TORQUE

CONVERTER, OIL PAN,
AND FILTER
a. Removal of Torque Converter
TORQUE CONVERTER
1. Position the transmission front upward.

2. Remove the converter retaining strap used for
shipping and handling.
3. Attach lifter tool J 6795-01 and lift the complete torque converter from the transmission
(Figure 52).
4. Refer to Paragraph 63 for torque converter rebuild instructions.
52
H00120.01
Figure 52. Removing Torque Converter Assembly
DISASSEMBLY OF TRANSMISSION
6. Discard paper element filters. Discard sealring
31 or 39 from the upper end of the filter tube.
7. On deep pan models, remove the three bolts
that retain filter spacer 37.
c. Removal of Oil Pan and Filter (Heavy-Duty

Configuration) (Foldout 10,B)
1. Remove the 516-24 x 78 hex bolt 21 and nut
22. Remove the strap 20, cover 19, and spring
17 (Figure 55).
2. Remove filter retainer 16 and filter 14.
3. Remove twenty-one hex washer-head screws
24, oil pan 25, and gasket 28.
OIL PAN
SCREW (21)
GASKET
RETAINER
4. Remove hex washer-head screw 10 and 14-20

x 234 inch bolt 12 (Figure 56) that retain canister 11.
5. Remove canister 11. Discard sealring 9 from
the oil canister suction tube.
BOLT
NOTE:
For MT 650, 653 proceed to Paragraph 57.
H00121
Figure 53. Removing Modulator Retaining Bolt and

Standard Configuration Oil Pan
MODULATED LOCKUP
VALVE ASSEMBLY
OIL FILTER
OIL FILTER
SUCTION TUBE
SEALRING
56. REMOVAL OF HYDRAULIC

COMPONENTS (MT(B) 640, 643)
a. Modulated Lockup Valve Body
(Foldout 15,A)
1. Remove the bolts that retain the valve body to
the transmission housing (Figure 56).
2. Remove the valve body assembly. Refer to Paragraph 64 for rebuild of the body assembly.
FILL TUBE, DIPSTICK PROVISION
OIL DRAIN PLUG

COVER STRAP
WASHER HEAD SCREWS (21)
H03284
Figure 54. Removing Oil Filter
H00091
Figure 55. Removing Oil Pan Heavy-Duty

Configuration
53

b. Tube Adapter (Foldout 10,A)
1. Remove four bolts 21 that retain tube adapter
20 to the transmission housing (Figure 57).
2. On later models, remove the two bolts that retain the first clutch feed tube to the valve body.
3. Remove tube adapter 20 and tubes 96 and 97
(Foldout 13) as an assembly. Remove governor
screen 98 (if present) and discard.
c. Control Valve Assembly (Foldout 13)
1. Using a rubber band, or a suitable substitute,
secure the shift selector valve to a pad on the
control valve body (Figure 58). Remove the
bolt that attaches the detent spring and roller
assembly. Remove the detent spring and roller
assembly. Loosen two bolts at the top of the
control valve body to act as support bolts. Remove the remaining bolts that attach the control valve body to the transmission housing.
2. Hold the control valve body assembly firmly
and remove the two remaining bolts. Remove
the control valve using a downward and outward movement to clear the actuator pin from
the housing bore (Figure 58). Refer to Paragraph 66 for control valve body assembly rebuild instructions.
3. Remove check ball 49 if used (Figure 58). If

the check ball is light brown, white, or blue, replace it with a new dark brown ball. Later
models do not incorporate the governor check
ball.
NOTE:
57. REMOVAL OF HYDRAULIC

CONTROL COMPONENTS
(MT(B) 650, 653)
a. Modulated Lockup Valve Body (Foldout 15,A)
1. Remove the bolts that retain the valve body to
the transmission housing (Figure 56).
2. Remove the valve body assembly. Refer to
Paragraph 64 for rebuild of the assembly.
b. Low Shift Valve Assembly (Foldout 15,B)
1. Remove the six bolts that retain the external
tubes to the valve body (Figure 59). Remove
tubes 85, 86, and 87 (Foldout 14).
BOLT (16), 14-20 x 214 in.

BOLT, 1/4-20 x 2 in.
MODULATED LOCKUP
VALVE BODY ASSEMBLY
SELECTOR VALVE
FILTER
CANISTER
BOLT, 14-20 x 134
DETENT
LEVER
DETENT
SPRING
BOLT (2), 14-20 x 3

CONTROL
VALVE
ASSEMBLY
HEX WASHER
HEAD SCREW
GOVERNOR
FEED
FIRST
CLUTCH
FEED
GOVERNOR
PRESSURE
BOLT, 1/4-20 x 2 3/4 in.
PAN GASKET
TUBE
ADAPTER
H00092.01
Figure 56. Removing Oil Canister (Heavy-Duty

Configuration) and Modulated Lockup Valve
54
H03285
Figure 57. Removing Tube Adapter MT 640, 643
2. Remove the bolts that retain the low shift valve
body assembly to the transmission housing
(Figure 59). Remove valve body assembly
and separator plate. Refer to Paragraph 65 for
the low shift valve body assembly rebuild instructions.
3. Remove the two bolts that attach the low shift

oil transfer plate (Figure 510). Remove the
plate and the two governor tubes. Remove filter
screen 84 (if present) from the tube bore in the
control valve assembly (Figure 510). Discard
the filter screen (earlier models).
c. Control Valve Assembly (Foldout 14). The
procedure for removing the control valve body
assembly is the same as that described for the removal
of the MT 640, 643 control valve in Paragraph 56c.
Refer to Paragraph 66 for control valve assembly
rebuild instructions.
SHIFT
SELECTOR
VALVE
RUBBER
BAND
CHECK BALL
58. REMOVAL OF OIL PUMP

AND FRONT SUPPORT
(Foldout 7,A)
CONTROL
VALVE
ASSEMBLY
ACTUATOR PIN
H03286
Figure 58. Removing Control Valve Assembly
a. Remove twelve bolts 35 and twelve rubber-covered washers 34 that retain the oil pump and front support assembly. Discard the twelve rubber-covered
washers.
b. Install front support lifter assembly J 24473 onto
the converter ground sleeve (Figure 511). Make sure
the lifter assembly is secure before removing the
support assembly.
SHIFT
SELECTOR
VALVE
FIRST
TRIMMER
DETENT
SPRING
CONTROL
VALVE
ASSEMBLY
DRIVE 1
SCREEN
LOCATION
LOW AND
FIRST FEED
GOVERNOR
TUBES
LOW SHIFT
VALVE ASSEMBLY
H03288
H03287
Figure 59. Removing External Tubes from Valve

Bodies MT 650, 653
Figure 510. Removing Low Shift Valve Oil Transfer

Plate MT 650, 653
55

CAUTION:
J 24473
The pump and front support assembly is fitted to

the transmission housing with very little clearance. It may bind in the housing if the housing is
cold. Heat the housing slightly, if necessary. DO
NOT USE a torch to heat the housing. A sun lamp
or a current of warm air will be sufficient. If the
pump and support assembly starts upward and
then binds, tap it downward and lift again.
OIL PUMP AND

FRONT SUPPORT
ASSEMBLY
CONVERTER
GROUND
SLEEVE
TRANSMISSION
HOUSING
c. Attach a hoist to the lifter assembly and carefully

remove the oil pump and front support assembly
(Figure 511). Remove support gasket 33. Remove
thrust bearing race assembly 31 at the rear of the
support assembly. Refer to Paragraph 68 for oil pump
and front support rebuild instructions.
59. REMOVAL OF FORWARD,

FOURTH, AND THIRD CLUTCHES,
AND CENTER SUPPORT
a. Forward Clutch (Foldout 7,B). Grasp turbine
shaft 5 and lift the forward clutch, attached PTO gear,
and fourth clutch hub from the transmission housing
(Figure 512). Remove thrust bearing race assembly
26 at the rear of the clutch. Refer to Paragraph 69 for
forward clutch rebuild instructions.
b. Fourth Clutch (Foldout 8,A). Grasp fourth clutch
spring retainer 7, and lift the fourth clutch assembly
from the transmission (Figure 513). Remove thrust
bearing race assembly 15. Refer to Paragraph 610 for
fourth clutch assembly rebuild instructions.
SEALRING
GASKET
H00094.01
Figure 511. Removing Oil Pump and Front

Support Assembly
PTO GEAR
TURBINE SHAFT
FOURTH
CLUTCH HUB
FOURTH CLUTCH
HOUSING
NEEDLE ROLLER BEARING
c. Third Clutch (Foldout 8,B). Remove snapring 1

that retains third clutch backplate 2 (Figure 514).
Remove the backplate. Remove the six plates 3 and 4
of the third clutch.
H00125
Figure 512. Removing Forward Clutch Assembly
d. Center Support (Foldout 8,B)

1. Remove center support anchor bolt 54 and
washer 55 (Foldout 10,A) from the bottom of
the transmission. Retain the used bolt for selective snapring selection at assembly. A new
bolt and washer must be used at final assembly.
2. Remove snapring 5 (Foldout 8,B) that retains
the center support assembly (Figure 515).
56
CAUTION:
The center support is fitted to the transmission
case with very little clearance. It may bind in the
case if the case is cold. Heat the case slightly, if
necessary. DO NOT USE a torch to heat the case.
A sun lamp, or a current of warm air is sufficient.
If the support assembly starts upward and then
binds, tap it downward and lift again.
FOURTH CLUTCH
ASSEMBLY
CENTER
SUPPORT
ASSEMBLY
SNAPRING
THRUST BEARING
RACE ASSEMBLY
H00126.01
Figure 513. Removing Fourth Clutch Assembly
H00128
Figure 515. Removing Center Support Snapring

SNAPRING
BACKPLATE
THIRD CLUTCH
PLATES (6)
FOURTH CLUTCH
PRESSURE PORT
J 24455
RETAINER
RING TANG (4)
H00127.01
Figure 514. Removing Third Clutch Plate Snapring
3. Place center support lifter J 24455 into the recess between the sealrings on the support hub,
and remove center support assembly 13 from
the transmission (Figure 516). Remove thrust
bearing race assembly 15 (Foldout 8,A) from
the hub of the center support. Refer to Paragraph 611 for center support rebuild instructions.
NOTE:
TAPPED HOLE
CENTER
SUPPORT
ASSEMBLY
H00095.01
Figure 516. Removing Center Support Assembly
510. REMOVAL OF GOVERNOR, GEAR

UNIT, SECOND CLUTCH, AND
FIRST CLUTCH (MT 640, 643)
a. Governor. Remove the four bolts that retain the
governor cover. Remove the cover and gasket. Carefully
remove the governor assembly (Figure 517). If not
previously removed, remove the speedometer driven
57

gear assembly from the transmission rear cover. Refer
to Paragraph 622 for governor assembly inspection
and rebuild.
b. Gear Unit
1. Install gear unit lifter J 24454 behind the
splines of the main shaft (Figure 518). Attach
a hoist to the lifter tool and remove the gear
unit from the transmission housing.
2. Governor drive gear 1, speedometer drive gear
2, and sleeve spacer 4 (Foldout 12,A) may remain on output shaft 50 (Foldout 9,A) or in the
transmission housing. Remove all three items.
Refer to Paragraph 613 for gear unit rebuild
instructions.
SECOND CLUTCH, FIRST

CLUTCH, AND GOVERNOR
(MTB 643, MT(B) 650, 653)
a. Gear Unit. Install gear unit lifter tool J 24454 behind the splines of the main shaft (Figure 518). Attach a
hoist to the lifter and remove the gear unit and rear thrust
washer from the transmission housing. Refer to Paragraphs 612 and 614 for gear unit rebuild instructions.
b. Second Clutch. Remove second clutch snapring
25 (Foldout 8,B). Remove six second clutch plates 26
and 27 and second clutch backplate 28 from the
transmission housing (Figure 519).
c. Second Clutch. Remove second clutch snapring

25 (Foldout 8,B). Remove six second clutch plates 26
and 27, and the clutch backplate 28 (Figure 519).
J 24454
MAIN SHAFT
d. First Clutch. Remove snapring 1 (Foldout 11,A)

that retains first clutch backplate 2. Remove backplate
2, ten clutch plates 3 and 4, and ring gear 5 as an
assembly (Figure 520). Remove the remaining two
first clutch plates.
GEAR UNIT
H00097.01
TRANSMISSION
HOUSING
Figure 518. Removing Gear Unit Assembly
GOVERNOR ASSEMBLY
SPEEDOMETER DRIVEN
GEAR LOCATION
SECOND CLUTCH
SNAPRING
FIRST CLUTCH
SNAPRING
SECOND CLUTCH
PLATES
REAR PLANETARY
RING GEAR
REAR COVER
H00096
Figure 517. Removing Governor Assembly

H00110.01
511. REMOVAL OF GEAR UNIT,

58
Figure 519. Removing Second Clutch Snapring
c. First Clutch
1. Remove the rear planetary ring gear and hub
assembly from the transmission (Figure 521).
If parts replacement is necessary, remove
snapring 7 (Foldout 11,A) and separate ring
gear 5 from ring gear hub 6.
2. Remove snapring 1 that retains first clutch
backplate 2, and remove the backplate (Figure
521). Remove twelve first clutch plates 3 and
4. Remove thrust washer 2 (Foldout 11,B).
RING GEAR
BACKPLATE
EXTERNAL-TANGED
CLUTCH PLATES
INTERNAL-SPLINED
CLUTCH PLATES
NOTE:
MT 650 model transmissions S/N 49996 through
55402 may include a spacer between the output
flange and the output shaft rear bearing. If the letter F is not stamped after the transmission serial
number on the nameplate, spacer P/N 6883908
should be installed.This spacer should be used at reassembly, except when the output shaft is replaced.
d. Governor. Remove the four bolts that attach the

governor cover to the rear cover (Figure 522) or
retarder housing (Figure 523). Remove the governor
cover and gasket. Remove the governor from the bore
in the rear cover assembly or retarder housing (Figure
517). If not previously removed, remove the
speedometer driven gear. Refer to Paragraph 622 for
governor assembly inspection and rebuild.
H00098.01
Figure 520. Removing Backplate, First Clutch Plates,

and Rear Planetary Ring Gear MT 640, 643
RING GEAR AND

HUB ASSEMBLY
BACKPLATE
SNAPRING
FIRST CLUTCH PLATES (12)
THRUST WASHER
512. REMOVAL OF REAR COVER

(MT 640, 643, 650, 653)
H00111.01
a. Positioning. Invert the transmission. If not previously removed, remove the speedometer driven gear
and governor.
b. MT 640, 643 Rear Cover. Remove fourteen
flanged bolts 19 or bolts 18, and washers 17 (Foldout
12,A) that retain the rear cover to the transmission
housing. Carefully remove the rear cover assembly
and the attached parts (Figure 524). Remove rear
cover gasket 5. Refer to Paragraph 617 for rear cover
rebuild instructions and Paragraph 621 for
transmission housing rebuild instructions.
Figure 521. Removing Rear Ring Gear

and Hub Assembly
c. MT 650, 653 Rear Cover

1. Attach a lifting tool to the output shaft (Figure
525). Remove fourteen flanged bolts 27 or
bolts 26, and washers 25 from the rear cover
(Foldout 12,B). Using a hoist, carefully separate the rear cover assembly from the adapter
housing. Remove the rear cover gasket 12.
2. Remove the output shaft and attached parts
from the rear cover assembly (Figure 526).
59

On later models which have a roller bearing
next to the governor drive gear, the roller bearing outer race stays in the rear cover. On earlier
MT 650 models, remove the spacer, speedometer drive gear, and governor drive gear from the
output shaft. On later MT 650 and all MT 653
models, remove only the spacer (if present)
and speedometer drive gear. Refer to Paragraph
615 for rebuild of the output shaft assembly.
Refer to Paragraph 616 for rebuild of the rear
cover assembly.
b. Retarder Housing
1. Place transmission rear upward. Remove three
bolts 32 (Foldout 18,A) and three washers 31.
2. On MTB 643 models, remove eleven bolts 2
(Foldout 19,A) and washers 3, and six bolts 5
and washers 6.
GASKET
COVER
513. REMOVAL OF OUTPUT

RETARDER (MTB 643, 653)
a. Retarder Control Valve Assembly
1. Remove two bolts 4 (Foldout 17,B) and two
washers 3 from retarder control valve assembly 7.
2. Remove ten bolts 6 and ten washers 5 from retarder control valve assembly 7.
3. Remove retarder control valve assembly 7,
separator plate 2, and two gaskets 1.
BOLT (4), M8 x 1.25 x 25 mm
4. Refer to Paragraph 67 for rebuild of the retarder control valve assembly.
LOCKWASHER, M8 (4)
H00099.01
Figure 523. Removing Governor Cover MTB 643,

653
REAR
COVER
GOVERNOR
COVER
BOLT (4)
5/16-18 x 11/16 in.
REAR COVER
GASKET
ADAPTER
HOUSING
TRANSMISSION
HOUSING
H00112
H00134.01
Figure 522. Removing Governor Cover MT 650, 653
510
Figure 524. Removing Rear Cover MT 640, 643
SPEEDOMETER
DRIVE GEAR
LIFTING TOOL
GOVERNOR
DRIVE GEAR
OUTPUT SHAFT
REAR COVER
ASSEMBLY
OUTPUT SHAFT
PIN
REAR COVER
ASSEMBLY
H00114.01
GASKET
Figure 526. Removing Output Shaft MT 650, 653
H00113.01
Figure 525. Removing Rear Cover Assembly and

Output Shaft MT 650, 653
OUTPUT
SHAFT
RETARDER
HOUSING
3. On MTB 653 models, remove twelve bolts 8

and washers 9 (Foldout 19,B), and five bolts 11
and washers 12.
GASKET
4. Install a three-leg sling onto the retarder housing (Figure 527). Adjust the length of the
sling legs so that the retarder housing is level
for easier removal. Attach a hoist to the sling.
5. On MTB 643 models, tap on the output shaft
during separation from the adapter housing so
that the shaft remains with the transmission.
ADAPTER
HOUSING
H00115.01
Figure 527. Removing Retarder Housing
6. On MTB 653 models, separate the retarder

housing from the adapter housing.
7. Place the retarder housing on a work bench,
rear side downward.
8. Refer to Paragraph 618 for rebuild of the retarder housing.
9. On MTB 643 models, remove output shaft assembly 8 (Foldout 18,B) from the adapter
housing. Remove bushing 9 and orifice plug 10
from shaft 11 only if replacement is necessary.
If bearing 4 (Foldout 19,A) remained on the
output shaft assembly, remove the bearing only
if necessary. If bearing 4 remained in the
adapter housing, refer to Paragraph 619.
511

c. Retarder Adapter Housing
WARNING!
1. For MTB 643 models, remove fourteen bolts

20, washers 19, and sealrings 18 (Foldout
19,A) that retain the adapter housing to the
transmission (Figure 528). For MTB 653
models, remove fourteen bolts 26, washers 25,
and sealrings 24 (Foldout 19,B).
2. For MTB 643, remove adapter housing 7 and
gasket 1 (Foldout 19,A). For MTB 653, remove adapter housing 13 and gasket 7 (Foldout 19,B).
3. Refer to Paragraph 619 for rebuild of the
adapter housing.
4. On MTB 653 models, remove output shaft assembly 2 (Foldout 19,B) from the transmission. Remove spacer 10 from shaft assembly 2.
Remove bushing 3 and orifice plug 4 only if replacement is necessary. If bearing inner race
and rollers 6 are removed for replacement, also
remove bearing outer race 14 from adapter
housing assembly 13.
BOLT (14), 1/2-13 x 5 1/2 in.
Do not position the transmission so that its rear

end is lower than its front end. The components
in the rear of the transmission are not secured.
These components could fall out and cause personal injury and/or damage to the parts.
514. REMOVAL OF LOW CLUTCH,

LOW PLANETARY, AND LOW
GEAR ADAPTER HOUSING
(MT(B) 650, 653) (Foldout 11,B)
a. Low Clutch. Remove low planetary ring gear 19
(Figure 529). Remove thrust washer 16 from the ring
gear hub.
b. Low Planetary Carrier. Remove low planetary
carrier assembly 8 and remove thrust washer 7 from
the carrier (Figure 530). Refer to Paragraph 624 for
rebuild of the low planetary carrier assembly. Remove
sun gear 6 and thrust washer 5. Remove eleven low
clutch plates 17 and 18.
c. Low Clutch Adapter Housing. Remove adapter
housing 3 and attached first clutch piston components
(Figure 531). Remove gasket 1. Refer to Paragraph
620 for adapter housing rebuild instructions, and to
Paragraph 621 for transmission housing rebuild
instructions.
PLAIN WASHER (14), 1/2 in.

SEALRING (14)
ADAPTER
HOUSING
THRUST
WASHER
LOW PLANETARY
CARRIER
ASSEMBLY
LOW PLANETARY
RING GEAR
H00168.01
H00080.01
Figure 528. Removing Adapter Housing
512
Figure 529. Removing Low Planetary Ring

Gear MT 650, 653
ADAPTER
HOUSING
THRUST
WASHER
LOW PLANETARY
CARRIER
ASSEMBLY
LOW CLUTCH
PLATES (11)
LOW
PLANETARY
SUN GEAR
THRUST
WASHER
ADAPTER HOUSING
GASKET
TRANSMISSION
HOUSING
H00116.01
Figure 530. Removing Low Planetary Carrier

Assembly MT 650, 653
H00081
Figure 531. Removing Adapter

Housing MT 650, 653
513

NOTES
514
Section 6 REBUILD OF SUBASSEMBLIES

61. SCOPE
a. Check the End Play
a. Section. This section describes the rebuild procedures for the subassemblies which were removed in
Section 5.
1. Support the converter assembly on the converter cover, pump hub upward. Place converter
end play gauge J 24470 into the converter pump
hub (Figure 61).
b. Procedures. During rebuild procedures, refer to

the exploded views (Foldouts 6 through 19) in the
back of this manual. Refer to the following specific
paragraphs for the different models:
2. Hold the center screw of the gauge and tighten

the nut until the gauge is securely retained in
the converter turbine hub. Do not overtighten.
Model
All Models
Paragraphs
62, 63, 64, 66, 68, 69,
610, 611, 621, 622, 623,
624
MT 640, 643
613, 617
MTB 643
67, 614, 618, 619
MT 650, 653
65, 612, 615, 616, 620
MTB 653
65, 67, 612, 618, 619, 620

REBUILD OF SUBASSEMBLIES
Refer to Sections 4 and 8 for general overhaul information as follows:
Paragraph
Title
42
Tools and Equipment
43
Replacement Parts
44
Careful Handling
45
Cleaning and Inspection
46
Removing (or Installing) Transmission
410
411
Selective Parts
81
Wear Limits Data
82
Spring Data
3. Install the dial indicator as shown in Figure 62.

Adjust the indicator bracket so the stem of the
indicator is in firm contact with the top of the
center screw. Set the dial to read zero.
4. Using both hands, lift the center screw as far
as possible (Figure 62). Record the dial indicator reading. Proper end play is any reading between 0.001 and 0.025 inch (0.03 and
0.64 mm).
5. End play greater than 0.025 inch (0.64 mm) indicates excessive wear of converter components. Replace worn components and select a
new spacer following the instructions in Paragraph 63f(23).
6. If end play does not exceed 0.025 inch (0.64
mm), disassemble the converter for inspection
and cleaning. Reassemble with the same
spacer, unless major parts must be replaced.
J 24470
TORQUE
CONVERTER
ASSEMBLY
63. TORQUE CONVERTER ASSEMBLY

NOTE:
Before disassembling the converter assembly, check
the amount of converter end play.
H00082.01
Figure 61. Installing Torque Converter End Play Gauge
61

b. Disassembly (Foldout 6)
1. Remove six rubber spacers 4 (earlier models
use both retainers 3 and spacers 4) from converter cover assembly 6.
NOTE:
If snapring 15 has a bevel on the ID, replace the
snapring at assembly. Inspect sealring 9 and replace
if necessary.
2. Remove twenty-four nuts 5 from cover 6.

3. Remove as a unit, the converter cover, lockup
clutch piston, and related parts (Figure 63).
4. Place the cover assembly on the work table
with the lockup clutch piston up. Remove bearing race 16. Compress the center of piston 10
and remove piston retaining snapring 15.
DIAL INDICATOR
J 24470
TORQUE
CONVERTER
ASSEMBLY
5. Turn the cover assembly over (piston down)

and bump the cover sharply on a wood surface
to remove the piston. Remove sealring retainer
8 and sealring 9 from cover 6. Remove sealring
11 from piston 10.
6. Remove bushing 7 only if replacement is necessary. Refer to Paragraph 45g.
7. Remove lockup clutch plate 12.
8. Remove lockup clutch backplate 14 from
torque converter pump 42. Remove sealring 13
from plate 14.
9. Remove roller bearing assembly 17, bearing
race 18, and spacer 19 (if used) from the hub of
turbine 20.
10. Remove the torque converter turbine assembly
(Figure 64).
H00083.01
Figure 62. Measuring Torque Converter End Play
BEARING
RACE
TORQUE
CONVERTER
COVER
11. Grasp the stator and the roller race as shown in

Figure 65 and remove as a unit.
CONVERTER
TURBINE ASSEMBLY
LOCKUP
CLUTCH
PISTON
SEALRING
BEARING
CONVERTER
STATOR
ASSEMBLY
LOCKUP
CLUTCH
PLATE
LOCKUP
CLUTCH
BACKPLATE
SEALRING
BALANCE
MARKS
H00117.01
Figure 63. Removing (or Installing) Torque

Converter Cover Assembly
62
CONVERTER
PUMP ASSEMBLY
H00347
Figure 64. Removing (or Installing) Torque

Converter Turbine Assembly
12. Position stator assembly 24 on the work table
so that freewheel roller race 32 is upward. Remove the roller race by rotating it clockwise
while lifting it out of the converter stator.
13. Remove ten rollers 34 and ten springs 33 from
stator assembly 24.
14. Check needle bearing assembly 31. Wash and
flush the needle bearing assembly thoroughly
with mineral spirits. Dry and lubricate the assembly with transmission fluid. Replace freewheel race 32 only and rotate the bearing while
pressing upon the freewheel race. If there is no
roughness or binding, the needle bearing assembly may be left in the stator and cam assembly and reused. Do not mistake dirt or grit
for a damaged needle bearing. Reclean and lubricate the needle bearing if dirt is suspected.
Check the needle bearing end of freewheel race
32 for smooth finish. Replace the freewheel
race if the bearing end is scratched or contains
chatter marks.
15. If needle bearing assembly 31 needs replacement, follow Steps (16) through (18). If replacement is not necessary, proceed to Step
(19).
CAUTION:
Do not scratch or nick any stator bores. Do not
attempt to disassemble the stator and cam assembly, unless parts replacement is required. Refer to the rebuild procedure in Paragraph 63c.
16. If the needle bearing must be replaced, remove

it carefully to avoid nicking the aluminum bore
in which it is held.
17. Place a new bearing assembly, thrust race first,
into the aluminum bore of the stator. Use bearing installer J 23549 and handle J 8092 to install the thrust bearing (Figure 66).
CAUTION:
NOTE:
If it is necessary to rebuild stator assembly 24, remove needle bearing assembly 31 before starting
the rebuild procedure.
Apply the load only to the outer shell of the bearing during installation (Figure 67).
STATOR
ASSEMBLY
SEALRING
J 8092
BEARING
J 23549
ROLLER
RACE
LOCKSTRIP
BEARING
ASSEMBLY
BOLT (8), 1/4-20 x 5/8 in.
H00118.01
STATOR
Figure 65. Removing (or Installing) Torque Converter

Stator and Race Assembly
H00349.01
Figure 66. Installing Stator Thrust Bearing
63

18. Drive bearing assembly 31 into stator 24 until
the top of the outer shell is 0.0250.035 inch
(0.640.89 mm) above the shoulder in the side
plate (Figure 67). When the bearing is properly installed, bearing installer J 23549 seats
on the stator area surrounding the bearing.
19. For transmissions prior to S/N 49490, remove
bearing 35 and bearing race 36 from converter
pump hub 39. For transmissions S/N 49490
and later, remove needle bearing 35 and bearing race 44. Remove roller bearing 45 from
converter pump hub 48 using tool J 28435. Remove sealring 49.
20. Flatten the corners of lockstrips 38 or 47. Remove eight bolts 37 or 46 and four lockstrips
from converter pump hub 39 or 48.
21. Remove hub 39 or 48 and gasket 40 from

pump 42. Remove sealring 41.
c. Rebuilding Stator Assembly (Foldout 6)
NOTE:
Do not disassemble the stator assembly unless replacement of stator thrust washer 25, rivets 30, or
washer 29 is necessary. If stator 27 or cam 28 is
cracked or damaged, replace the complete stator
assembly.
A hydraulic press having a minimum capacity of
five tons (4536 kg), an adjustable table, and a pressure gauge (for determining the rivet staking load)
are required to rebuild the stator assembly.
1. Place the stator assembly in a drill press,
formed rivet side up (Figure 68).
BEARING
B
A
A
B
0.035 in. (0.89 mm)

0.025 in. (0.64 mm)
CAM
STATOR
Assembly load to be
applied in this area
on outer shell only
B -B
DEEP POCKET
Assemble with
cam pockets in
position shown
DIRECTION OF
FREEWHEEL
ROTATION
ENLARGED VIEW
OF CROSS-SECTION
ENLARGED VIEW
SECTION A-A
Figure 67. Stator Thrust Bearing Installation
64
VIEW AT
L00294.01
2. Using a 38 inch drill, align and drill the rivet,
removing the formed head.
STATOR ASSEMBLY
3. Place base plate J 29521-1 under the stator assembly (Figure 69). Make sure the holes in the
base plate are under the rivet heads. Place top
plate J 29521-2 on top of the stator assembly.
STATOR
RIVET (6)
4. Install the 58-11 x 314 inch bolt to hold the

two plates together. Tighten the bolt to 60 lb ft
(81 Nm).
5. Place fixture stand J 25587-1 on a hydraulic
press (Figure 69). Install rivet remover pin
J 29121-3 into the fixture head. Tighten the
tool retainer thumb screw.
6. Place the stator assembly, with base and top
plates, onto the fixture stand, drilled rivet
side up.
7. Align the rivet remover pin with the drilled
rivet and press the rivet from the stator assembly. Repeat the process for each rivet.
8. Remove the retaining bolt and top plate (Figure
69). Separate thrust washer 25, sideplate
washer 29, two cam washers 26, and cam 28
from stator 27.
9. Inspect the stator and cam for cracks, and the
rivet holes for burrs or swelling. Deburr as required. If cam or stator is cracked or distorted,
replace the stator assembly.
H00350
Figure 68. Drilling Stator Rivets
J 25587-1
RIVET REMOVING
PIN J 29121-3
BOLT, 58-11 x 314 in.
J 29521-2
TOP PLATE
10. Clean the stator assembly components. Assemble cam 28 and stator 27 with the roller pocket
positioned as shown in Figure 67. Install cam
washer 26, one on each side of the stator. Install sideplate washer 29 and thrust washer 25.
11.
Align the six rivet holes and insert six new 14 x

1.94 inch rivets into the stator assembly from
the rear to the front of the stator (Figure 610).
12. Place the stator assembly on base plate

J 29521-1 (Figure 610). Make sure the rivet
heads rest on the base plate, between the clearance holes. Install top plate J 29521-2 and the
58-11 x 314 retaining bolt. Strike the top plate
with a rubber mallet to seat the components.
Tighten the retaining bolt to 60 lb ft (81 Nm).
J 29521-1
BASE PLATE
H00351.01
Figure 69. Removing Stator Rivets
13. Place the stator assembly on fixture J 25587-1

(Figure 610). Install staking tool J 29121-1
into the fixture head and tighten the thumb
screw finger tight.
14. Apply approximately 8000 pounds (3629 kg)
load to swage each rivet head. The amount of
force to apply will vary, depending on the condition of the swaging tool and the press equipment being used.
65
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1 2-13
J 25587-1
RIVET PUNCH
J 29121-1
BOLT, 5 8-11 x 314 in.
THUMB
SCREW
J 29521-2
TOP PLATE
BOLT,
x 31 2 in.
GUIDE PLATE
J 29375-2
CONVERTER
TURBINE
LOCKUP CLUTCH
DRIVE HUB
BASE PLATE
J 29375-1
V03278
STATOR
ASSEMBLY
Figure 611. Rivet Removing Fixture
3. Place converter turbine assembly 20, front side

upward (turbine vanes down), on top of the
base plate. Align the eight rivets in the hub to
the holes in the base plate.
J 29521-1
BASE PLATE
H00352.01
Figure 610. Staking Stator Rivets
15. Swage the first rivet. Rotate 180 degrees from

the first rivet and swage the second rivet. Rotate 60 degrees and swage the third rivet. Rotate 180 degrees and swage the fourth rivet.
Rotate 60 degrees and swage the fifth rivet.
Swage the remaining rivet.
16. Remove the retaining bolt, top plate, base
plate, and staking tool. Install new needle bearing 31. Refer to Paragraph 63b(17) and (18).
d. Rebuilding Torque Converter Turbine
Assembly (Foldout 6)
4. Place guide plate J 29375-2 on top of converter

turbine assembly 20. Centrally locate each
rivet in the guide plate holes.
5. Install the 12-13 x 312 inch clamping bolt to
retain the guide plate, turbine, and base plate
together. Tighten the bolt to 50 lb ft (68 Nm).
6. Place the turbine assembly and fixture in the
drill press.
7. Place drill bushing J 29375-5 into guide plate
J 29375-2 (Figure 612). Using a 14 inch drill,
drill approximately 316 inch deep into the
rivet.
8. Place the drill guide into the next hole. Rotate
the converter turbine assembly to the next hole
and drill the rivet head. Continue until all the
rivet heads have been drilled.
NOTE:
Do not disassemble the turbine assembly unless the
turbine hub must be replaced. If the converter turbine is damaged, replace the assembly.
CAUTION:
Do not use a hammer to remove the rivets.
A hydraulic press having a minimum capacity of
ten tons (9070 kg), an adjustable press bed with a

25 inch (635 mm) opening, and a pressure gauge
(for determining the rivet swaging load), are required to rebuild the turbine assembly.
1. Punch alignment marks on the turbine and turbine hub to show their relationship.
2. Using Figure 611 as a guide, place base plate
J 29375-1 on a work table, rivet hole side up.
66
9. Place the turbine and fixture in a hydraulic

press. Install rivet remover tool J 29375-4 into
the guide plate (Figure 613). Press out each
rivet.
10. Remove the 12-13 x 312 inch bolt, guide plate,
and base plate.
11. Inspect the turbine for cracks, distortion, and
abrasions. If defects are noted, the turbine assembly must be replaced.
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CONVERTER
TURBINE
LOCKUP CLUTCH
DRIVE HUB
BOLT, 1 2-13 x 31 2 in.

GUIDE PLATE
J 29375-2
RIVET (8),
516 x 1116 in.
DRILL GUIDE
J 29375-5
GUIDE PLATE
J 29375-2
BASE PLATE
J 29375-1
V03290
Figure 614. Rivet Installation Fixture
V03279
Figure 612. Drilling Rivet Heads From

Torque Converter Turbine
HYDRAULIC
PRESS
CONVERTER
TURBINE
LOCKUP CLUTCH
DRIVE HUB
GUIDE PLATE
J 29375-2
HYDRAULIC
PRESS
RIVET (8),
x 1116 in.
516
STAKING TOOL
J 29375-3
CONVERTER
TURBINE
PIN REMOVER
J 29375-4
V03291
Figure 615. Staking Converter Turbine Rivets
BASE PLATE
J 29375-1
V03289
Figure 613. Removing Rivets From Torque

Converter Turbine
12. Inspect the rivet holes for burrs. Deburr as necessary.

13. Assemble the new and reusable turbine parts.
Align the punch marks on the turbine and hub.
Use eight new rivets to ensure proper indexing.
14. Install the eight new rivets through the turbine

and turbine hub (Figure 614).
15. Assemble base plate J 29375-1 with the solid
side of the plate against the rivet heads (Figure
614).
16. Place guide plate J 29375-2 on top of the assembled components. Centrally locate the rivets in the holes of the guide plate.
17. Retain the turbine assembly, base plate, and

guide plate with one 12-13 x 312 inch bolt (Figure 614). Tighten the bolt to 50 lb ft (68 Nm).
18. Place the assembled turbine and fixture in the
hydraulic press. Insert staking tool J 29375-3
into one of the holes in guide plate J 29375-2
(Figure 615).
19. Swage the first rivet. Rotate 180 degrees from

the first rivet and swage the second rivet. Rotate 90 degrees and swage the third rivet. Continue in an alternating pattern until all eight
rivets have been swaged.
20. Remove staking tool, retaining bolt, guide
plate, and base plate.
21. Using a rotating type static balance, balance
each rebuilt turbine assembly to within 0.50
oz. in. (360 Nmm), with respect to the turbine
shaft spline diameter, by welding weights to
the shroud.
67

e. Rework of Converter Pump Hub (Foldout 6). If
converter ground sleeve 27 (Foldout 7,A) or roller
bearing 45 (Foldout 6) are to be replaced, rework
converter pump hub 48 on units prior to S/N 2410204975
that do not incorporate the wide bearing configuration.
Refer to Figure 616 for machining instructions.
f. Assembly (Foldout 6)
1. Install a new gasket 40 onto converter pump
42. Install the gasket dry and with the silicone
bead against the converter pump hub. Install
hub 39 or 48 into pump 42, aligning the holes
in the hub and gasket with the holes in the
pump.
2. Install four new lockstrips 38 or 47 and eight
14-20 x 58 inch bolts 37 or 46 through hub 39
or 48 into pump 42. Tighten the bolts to 911
lb ft (1215 Nm). Bend the corners of the
lockstrips against the bolt heads.
3. Replace all damaged or missing flange bolts
43. Make sure all the balance weights are in
their original positions.
4. Install sealring 41 into the groove in the outer
circumference of converter pump 42. Position
the color identified edge of the seal outward,
toward the converter pump studs.
5. For transmissions prior to S/N 49490, install bearing race 36 and needle bearing 35 into converter
pump hub 39. For transmissions S/N 49490 and
later, install roller bearing 45 with tool J 28435,
bearing race 44 (lugged side first), and needle
bearing 35 into converter pump hub 48. Install
sealring 49 into the groove of hub 48.
;;
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0.813 in. (20.65 mm)

0.803 in. (20.39 mm)
0.04 in. (1.01 mm)
0.01 in. (0.25 mm)
R
2.8336 in. (71.973 mm)

2.8326 in. (71.948 mm)
DIA
0.08 in.
(2.03 mm)
25 50
ENLARGED VIEW
(4 x SIZE)
NOTE:
If replacing any stator springs, do not mix current
and former springs in the same stator assembly. Refer to Figure 618.
7. Install ten freewheel rollers 34 and ten springs
33. Install the rollers in the small ends of the
cam pockets. Position the springs and rollers as
shown in Figure 618. The ends of the springs
must be against the rollers.
8. Install freewheel roller race 32, shoulder side
first (Figure 617), until the race engages the
rollers. Rotate the race in a clockwise direction
while pressing downward until the race
touches the collapsible retainer. Lift up on the
stator assembly and pull on the cord to remove
the retainer. Continue rotating the race while
pressing downward. When the race is fully
seated, rotate it firmly in the opposite direction
to lock the stator and cam assembly.
9. Grasp the stator and cam assembly as shown in
Figure 65. Hold the roller race firmly to retain
it in position. Install the stator assembly.
10. Install the torque converter turbine assembly
(Figure 64).
ROLLER
SPRING
ROLLER RACE
J 24218-1
2.247 in. (57.07 mm)

2.246 in. (57.04 mm)
DIA
0.04 in. (1.01 mm) R

MAX
0.03 in.
(0.76 mm)
V03292
Figure 616. Rework of Converter Pump Hub for

Wide Bearing Configuration
68
6. Place stator and cam assembly 24 on the work

table, bearing side down (Figure 617). Cover
the bottoms of the stator cam pockets with oilsoluble grease. Install stator roller retainer
J 24218-1 (Figure 617).
STATOR AND
CAM ASSEMBLY
BEARING
AND RACE
H00348.01
Figure 617. Installing Freewheel Roller Race
THRUST WASHER
NOTE:
Install the same spacer 19 removed in Paragraph 6
3b(9) only if the end play reading taken before disassembly was satisfactory, and if no parts affecting
end play are being replaced (refer to Paragraph 4
11). Install the spacer (when used) into the hub of
converter turbine 20 before Step (11).
RIVET
CURRENT SPRING
STATOR CAM
Roller to be installed in
small end of cam pocket
11. Install bearing race 18, outer lip upward, into

the hub of turbine assembly 20. Grease and install bearing 17 onto the bearing race.
CURRENT CONFIGURATION
THRUST WASHER
RIVET
12. Install sealring 13 onto lockup clutch backplate

14. Position the color identified edge of the
seal outward, toward the converter pump stud
holes. Install the backplate onto torque converter pump 42. Align the balance mark on the
backplate with the balance mark on the converter pump.
STATOR CAM
ROLLER
SPRING
13. Install lockup clutch plate 12 to backplate 14.

14. If converter cover bushing 7 in the converter
hub was removed, use installer J 24648 to install a new bushing (Figure 619). After installation, the bushing ID should be 0.9990
1.0010 inch (25.37525.425 mm).
15. Install sealring retainer 8, smaller end first,
onto the hub of converter cover 6. Install sealring 9 into the retainer. Install sealring 11 onto
piston 10.
This flap may point up

(as shown) or down
FORMER CONFIGURATION
V03293
16.
Figure 618. Spring and Roller in Stator Cam

J 24648
BUSHING
CAUTION:
The lockup clutch will not release if the piston is
not engaged with the piston guide pins.
H00100.01
NOTE:
For easier lockup clutch piston installation, align
the balance marks (Figure 620) and place a pencil
mark in line with the pin nearest the orifice in the
piston. When installing the piston, use the pencil
mark as a guide for the location of the pin beneath
the orifice (one recessed hole is concentric with the
orifice). If necessary, rotate the piston slightly during installation to ensure that the piston engages the
pins. When the piston is properly seated, the distance from the pump cover mounting surface to the
piston should measure approximately 112 inches
(38 mm).
Figure 619. Installing Converter Cover Bushing
16. Install lockup clutch piston 10 (Figure 620)

into converter cover 6, with the balance marks
aligned so that the piston guide pins enter the
nearest recessed holes in the piston.
17. Using a punch and hammer, tap snapring 15
until it seats in its groove. Install bearing race
16, inner lip first, into the hub of converter
cover 6. Use oil-soluble grease to retain it.
18. Install as a unit the converter cover, lockup
clutch piston, and related parts (Figure 63).
Align the balance marks on the cover with the
69

balance marks on the lockup clutch backplate
and the converter pump. Secure the converter
cover with twenty-four nuts 5. Tighten the nuts
evenly to 1923 lb ft (2631 Nm).
22. Install the dial indicator (Figure 62). Adjust

the indicator bracket so the stem of the indicator is in firm contact with the top of the center
screw. Set the dial to read zero.
19. Install six rubber spacers 4 (earlier models use

retainers 3 and spacers 4) onto each of the six
drive studs on converter cover 6.
23. Using both hands as shown in Figure 62, lift

the center screw as far as possible. Record the
dial indicator reading (Dimension B). Proper
end play is any reading between 0.001 and
0.025 inch (0.03 and 0.64 mm). Select the
proper size spacer 19 from the following chart.
NOTE:
The end play check in Steps (20) through (23) verifies that proper end play remains after rebuild. The
check is necessary if spacer 19 was not installed at
buildup, and is recommended even if spacer 19 was
installed. Omit Steps (24) through (26) if the end
play reading is satisfactory.
20. Support the converter assembly on the converter cover, pump hub upward. Place converter end play gauge J 24470 into the
converter pump hub (Figure 61).
21. Hold the center screw of the gauge and tighten
the nut until the gauge is securely retained in
the converter turbine hub. Do not overtighten.
PIN
PENCIL MARK
Dimension B
Inch / (mm)
Use
Part No.
Color
Less than 0.014 (0.36)
Use no spacer
0.0140.016 (0.360.41)
6837429
Gold
0.0290.031 (0.740.79)
6837430
Silver
0.0410.043 (1.041.09)
6837431
Plain
0.0590.061 (1.501.55)
6837432
Black
0.0740.076 (1.881.93)
6837433
Copper
24. Remove only those items necessary to install

the spacer by following Paragraph 63b(2),
(3), and (9).
25. Install selected spacer 19 into the turbine hub.
26. Assemble the converter by following Paragraph
63f(11) through (18). The end play may be rechecked as in Steps (20) through (23).
ORIFICE
64. MODULATED LOCKUP VALVE

BODY ASSEMBLY
a. Disassembly (Foldout 15,A)
1. Mark adjusting ring 7 to indicate its position in
relation to retainer pin 3.
PISTON
2. Compress ring 7 (Figure 621) and remove retainer pin 3.
SEALRING
3. Remove adjusting ring 7, valve stop 6, valve

spring 5, and valve 4 from valve body 2.
b. Assembly (Foldout 15,A)
L
FORMER
CURRENT
BALANCE MARK STYLES
H00101.01
Figure 620. Installing Lockup Clutch Piston
610
1. Install valve 4, smaller diameter first, into

valve body 2.
2. Install valve spring 5. Install valve stop 6, undrilled end first, into spring 5.
3. Install adjusting ring 7, flat side first, over
valve stop 6. Compress ring 7 and install pin 3
through the holes in valve body 2, valve stop 6,
and into the slot of adjusting ring 7.
4. Using adjusting ring tool J 24314 (Figure 621),
align adjusting ring 7 with the pin as it was before disassembly.
NOTE:
For MT(B) 640, 643 proceed to Paragraph 66.
65. LOW SHIFT VALVE ASSEMBLY

(MT(B) 650, 653)
2. Install low shift signal valve 10, stem end first,

into the remaining valve bore. Install valve
spring 11, valve stop 12, and washer 13. Install
adjusting ring 14, flat side first, into the valve
bore. Align the hole in valve stop 12 and the
slot in ring 14 with the hole in valve body 4.
3. Compress ring 14 and install retainer pin 6
through the holes in valve body 4, valve stop
12, and into the slot of adjusting ring 14.
4. Using adjusting ring tool J 24314, align adjusting ring 14 with the pin as it was before disassembly.
66. CONTROL VALVE ASSEMBLY
a. Disassembly (Foldout 15,B)

1. Mark adjusting ring 14 to indicate its position
in relation to retainer pin 6.
2. Compress ring 14 and valve stop 9, and remove
retainer pins 5 and 6 from low shift valve body
4.
3. Remove adjusting ring 14, washer 13, valve
stop 12, valve spring 11, and low shift signal
valve 10 from body 4.
4. Remove valve stop 9, valve spring 8, and low
shift relay valve 7.
b. Assembly (Foldout 15,B)
NOTE:
Valve body assemblies for all models are similar.
The following instructions cover all items in all
valve body assemblies. Specific assemblies may differ in quantities of springs and in other minor details. Refer to Foldout 13 (MT(B) 640, 643) or 14
(MT(B) 650, 653) for specific differences.
a. Disassembly (Foldouts 13 and 14)
CAUTION:
Before removing retainer pins 12, 18, 24, 30, and
1. Install low shift relay valve 7 into the longer

bore of valve body 4. Install valve spring 8 and
valve stop 9 into the same bore. Compress valve
stop 9 and install retainer pin 5 into body 4.
SEPARATOR
PLATE
J 24314
MODULATOR
BODY
CONTROL VALVE
ASSEMBLY
48, record the positions of adjusting rings 10, 17,

23, 29, and 46 in relation to their retainer pins
(Figure 622). To retain the original calibration
of the valve assembly, the adjusting rings must
be reinstalled in the same positions as when removed. Adjusting rings are spring-loaded.
The valve body assembly contains springs and
other parts, some of which are similar and can
be mistakenly interchanged. Also, springs vary
in valve bodies used on different models. If parts
are not reinstalled in the same locations from
which they were removed, the calibration of
valve body functions will be lost. Tag each part
at removal with the item number in Foldout 13
or 14 and use valve body parts tray set J 33163
to simplify correct reassembly of the valve body
components.
H00102.01
Figure 621. Compressing Modulator Valve Adjusting

Ring (Earlier Models)
1. Place valve assembly 1 on the work table,

modulator valve body 47 upward.
611

7
8. Remove eight (earlier models) or nine (later

models) bolts 75 from trimmer valve cover 74.
6
3
4
NOTE:
5
5
4
For earlier smooth shift models with external accumulator valve (Foldout 13), remove four 12-20 x 34
bolts 90 and four 14-20 x 212 bolts 95 from accumulator valve body 94. Remove accumulator valve 91,
spring 92, and stop 93 from valve body 94.
9. Remove trimmer valve cover 74 or 89. Remove

valve stops 55, 60, 65, and 73.
3
7
1
2
V02930
Figure 622. Step Numbers for Recording the

Positions of Adjusting Rings
2. Remove three bolts 40 from the modulator

body and remove the modulator body.
3. Compress adjusting ring 46 and remove retainer pin 48 from modulator body 47.
4. For earlier models, remove ring 46, valve stop
45, washer 44, spring 43, valve 42, and actuator pin 41. For later models, remove ring 46,
spring 43, valve 42, and actuator pin 41.
5. Slide separator plate 39 lengthwise to disengage the slot in the plate from the flared end of
retainer pin 34. Remove the plate.
6. Remove priority valve 4, spring 3, and stop 2.
Remove 14 inch (6.35 mm) check ball 49 (if
used). Note the location of the ball in the valve
body before removal.
NOTE:
Refer to the current Parts Catalog PC1316EN for
servicing of check ball 49.
7. Place control valve body 50 on the work table,
flat side down.
10. Remove springs 53, 54, 58, 59, 63, 64, 71, and
72. Inner springs 54, 59, 64, and 72 are used
after S/N 13800. Remove trimmer plugs 52,
57, 62, and 70. Remove trimmer valves 51, 56,
61, and 69.
11. For all later models, remove accumulator valve
68, spring 67, and stop 66.
WARNING!
Valve stop 79 and spacer 82 are spring-loaded
and must be restrained while pins 76 are removed.
12. Remove two retainer pins 76 from the control
valve.
13. Remove valve stop 79 and machined spacer 82.
14. Remove relay valve springs 78 and 81. Remove relay valves 77 and 80.
15. Mark adjusting ring 10 (models after S/N
66939) to indicate its position in relation to retainer pin 12.
16. Compress adjusting ring 10 or spacer 8 (models prior to and including S/N 66939). Remove
pin 12, ring 10 or spacer 8, washer 9 (models
after S/N 66939), valve stop 7, spring 6, and
valve 5.
17. Remove selector valve 11.
WARNING!
Trimmer valve cover 74 or 89 is spring-loaded
and must be restrained while the bolts are removed.
612
18. On models equipped with second range start

(Foldout 13), remove retainer pin 18, washer
88, valve stop 87, spring 86, valve 85, valve 84,
and spring 83.
19. On models not equipped with second range
start, compress adjusting rings 17, 23, and 29,
and remove retainer pins 18, 24, and 30. Remove the adjusting rings.
20. Remove valve stops 16, 22, and 28. Remove
springs 15, 21, and 27. Remove shift modulator valves 14, 20, and 26. Remove shift valves
13, 19, and 25.
21. Compress relay valve stop 33 and remove retainer pin 34.
22. Remove valve stop 33, valve spring 32, and relay valve 31.
23. Compress trimmer regulator valve stop 37 and
remove retainer pin 38.
24. Remove valve stop 37, spring 36, and valve 35.
b. Assembly (Foldouts 13 and 14)
NOTE:
Check the configuration and position of all components (Figure 623). Check the identification of all
springs (Paragraph 82). All valves, when dry, must
move freely by their own weight in their bores.
1. Install valve 5 into Bore A (Figure 623) in
valve body 50. For earlier models, install
spring 6, valve stop 7, and spacer 8 into Bore
A. For later models, install spring 6, valve stop
7 (drilled end last), washer 9, and adjusting
ring 10 into Bore A. Compress adjusting ring
10 or spacer 8 against spring pressure and install pin 12 through the holes in valve body 50
and valve stop 7.
2. For models equipped with second range start
(Foldout 13), install spring 83, 12 shift valve
84 (open end first), 12 modulator valve 85
(longer land first), spring 86, valve stop 87, and
washer 88 into Bore B (Figure 623). Insert
pin 18 through the holes in valve body 50 and
valve stop 87.
3. For models not equipped with second range
start, install valve 13 (shorter land first) into
Bore B in valve body 50. Into the same bore,
install valve 14 (smaller end first). Install
spring 15, valve stop 16, and adjusting ring 17.
Compress ring 17 against spring pressure and
install pin 18 so that it passes through valve
stop 16 and retains ring 17.
4. Install valve 19 (smaller end first) into Bore C

(Figure 623) in valve body 50. Into the same
bore, install valve 20 (smaller end first). Install
spring 21, valve stop 22, and adjusting ring 23.
Compress ring 23 against spring pressure and
install pin 24 so that it passes through valve
stop 22 and retains ring 23.
5. Install valve 25 (smaller end first) into Bore D
bore, install valve 26 (smaller end first), spring
27, valve stop 28, and adjusting ring 29. Compress adjusting ring 29 against spring pressure
and install pin 30 so that it passes through
valve stop 28 and retains ring 29.
6. Install valve 31 into Bore E (Figure 623) in
valve body 50. Into the same bore, install spring
32 and valve stop 33. Compress valve stop 33
against spring pressure and install pin 34.
7. Install valve 35 (smaller end first) into Bore F
bore, install spring 36 and valve stop 37. Compress valve stop 37 and install pin 38.
8. Install third clutch trimmer valve 51 (open end
first) into Bore G (Figure 623) in valve body
50. Into the same bore, install plug 52, springs
53 and 54, and valve stop 55.
9. Install first clutch trimmer valve 56 (open end
first) into Bore H (Figure 623) in valve body
50. Into the same bore, install plug 57, springs
58 and 59, and valve stop 60.
10. Install second clutch trimmer valve 61 (open
end first) into Bore J (Figure 623) in valve
body 50. Into the same bore, install plug 62,
springs 63 and 64, and valve stop 65.
11. Install fourth clutch trimmer valve 69 (open
end first) into Bore K (Figure 623) in valve
body 50. Into the same bore, install plug 70,
springs 71 and 72, and valve stop 73.
12. For later models incorporating the internal
trimmer accumulator, install stop 66, spring
67, and valve 68 into Bore I (Figure 623).
13. Install cover 74 over the trimmer springs and
accumulator valve (if used). Compress the
cover against spring pressure and install eight
(earlier models) or nine (later models) 14-20 x
34 inch bolts 75. Tighten the bolts to 812 lb ft
(1116 Nm).
613
A
D
D
SECTION E-E
L
K
SECTION B-B
I
F
A
SECTION D-D
SECTION F-F
SECTION A-A
L03318
Figure 623. Control Valve Assembly Cross-Section View
614
NOTE:
For early smooth shift models with external trimmer accumulator valve (Foldout 13), install spring
92, and valve 91 (open end over spring) into stop 93,
body 94. Compress the accumulator valve assembly
on cover 89 against trimmer spring pressure and retain with four 14-20 x 212 inch bolts 95. Insert remaining 14-20 x 34 inch bolts 90 into cover 89.
Tighten the bolts to 812 lb ft (1116 Nm).
14. Install valve 77 (either end first) into Bore L

bore, install spring 78 and valve stop 79. Compress stop 79 against spring pressure, and install pin 76.
15. Install valve 80 (larger end first and open end
up) into Bore M (Figure 623) in valve body
50. Into the same bore, install spring 81 and
machined spacer 82. Compress spacer 82
against spring pressure, and install pin 76.
16. Install actuator rod 41 (smaller end first) into
Bore N of modulator valve body 47 (Figure
623). Install valve 42, longer land first. For
earlier models, install spring 43, washer 44,
valve stop 45, and adjusting ring 46. For later
models, install spring 43 and adjusting ring
46. Compress adjusting ring 46 against spring
pressure, and install pin 48 so that it passes
through valve stop 45 (if used) and retains
ring 46.
21. Install three 14-20 x 134 inch bolts 40 through

valve body 47 and plate 39, and into valve
body 50.
22. After making sure that the plate and valve body
are properly aligned so that all valve body
mounting bolts will pass through them, tighten
bolts 40 to 812 lb ft (1116 Nm).
23. Install selector valve 11 (drilled end first) into
Bore P (Figure 623) in valve body 50. Secure
the valve against dropping out during assembly
by using a rubber band, tape, or soft wire.
24. If not already done, use adjusting tool J 24314
to position adjusting rings 10, 17, 23, 29, and
46 as they were before disassembly.
25. Put the assembled valve body into a plastic bag
or other dirt-proof, lint-free wrapping until
ready to install it.
NOTE:
Refer to Paragraph 313 for adjustment of shift
points. For MT 640, 643, 650, and 653, proceed to
Paragraph 68.
67. RETARDER CONTROL VALVE

ASSEMBLY (MTB Series Only)
1. Place retarder control valve assembly 7 on a
clean work surface.
17. If ball 49 was removed from body 50 during

disassembly, replace with a new ball. Refer to
Section B-B, Figure 623, and the current
Parts Catalog PC1316EN for check ball location and servicing. Retain the ball with oil-soluble grease.
2. Remove bolts 46 and 48, and washers 45 and

47, that retain regulating valve assembly 24 to
the bottom of retarder valve body 17.
18. Install valve stop 2, spring 3, and priority valve

4 (open end first for later models), into Bore O
(Figure 623) in valve body 50.
4. Remove bolts 42 and 44, and washers 41 and

43. Separate regulating valve body 27, gasket
26, and oil transfer plate 25.
19. Place separator plate 39 onto body 50 and align

the bolt holes. The slot in the separator plate
must engage the flared end of pin 34.
5. Remove two bolts 40 and washers 39 that retain cover 38 to valve body 27. Remove cover
38 and gasket 37. Do not remove orifice plug
32 unless part replacement is necessary.
20. Install the assembled modulator valve onto

separator plate 39. Align the bolt holes.
6. Remove valve plug 36, springs 34 and 35, and

regulator valve 33.
3. Separate the two valve bodies and remove gasket 23, spring 22, and valve 21.
615

7. Remove plug 31, sealring 30, charging valve
29, and spring 28.
8. Remove four bolts 8 and washers 9 that retain
cover 10 to valve body 17. Remove cover 10
and gasket 11.
9. Remove piston 14, retarder valve 15, and
spring 16. Remove sealrings 12 and 13 from
piston 14.
10. Plugs 18, 19, and 20 may be removed if they
obstruct proper cleaning or if they are damaged.
1. If removed, apply sealant to plugs 18, 19, and
20, and install the plugs into valve body 17.
Tighten plug 18 to 1620 lb ft (2227 Nm),
plug 19 to 810 lb ft (1114 Nm), and plug 20
to 3648 lb inch (4.06 Nm).
2. Place valve body 17 on a clean work surface,
top side up. Install spring 16 and retarder valve
15 into the valve bore in valve body 17.
3. Install sealring 13, followed by sealring 12
(one on top of the other), into the sealring
groove in piston 14. Install the piston, sealring
end first, into cover 10.
4. Install four bolts 8 and washers 9 into cover 10.
Place gasket 11 onto cover 10.
5. Align and install the cover, gasket, and four
bolts and washers onto valve body 17. Tighten
the bolts to 4884 lb inch (69 Nm).
11. Install two M8 x 1.25 x 50 bolts 42 and two 8

mm washers 41. Install four M8 x 1.25 x 60
bolts 44 and four 8 mm washers 43. Tighten all
six bolts to 1316 lb ft (1822 Nm).
12. Position retarder valve body 17 on a clean
work surface so the retarder valve bore is accessible.
13. Insert regulator valve spring 22 into the open
end of regulator valve 21. Install the regulator
valve (closed end first) and valve spring into
the retarder valve bore in valve body 17.
14. Align and install gasket 23 and valve body assembly 24 onto retarder valve body 17.
15. Install two M8 x 1.25 x 80 bolts 46 and two 8
mm washers 45. Install two M8 x 1.25 x 90
bolts 48 and two 8 mm washers 47. Tighten the
bolts to 1316 lb ft (1822 Nm).
68. OIL PUMP AND FRONT

SUPPORT ASSEMBLY
1. Place the oil pump and front support assembly
on a work table, support side upward.
2. Remove two butt-joint sealrings 32 from the
hub of front support 28 (Figure 624).
6. Install spring 28, charging valve 29 (smaller

end first), sealring 30, and plug 31 into their
bore in regulating valve body 27. Tighten the
plug to 5070 lb ft (6895 Nm).
3. Remove oil pump sealring 2.
7. If governor orifice plug 32 was removed, install a new plug. Install the plug flush with or
below the surface of the valve body.
5. Remove twelve bolts 21 and two bolts 20 that

hold the oil pump and the front support together.
8. Install pressure regulator valve 33 (grooved

end first), springs 34 and 35, and valve plug 36
into their bore in regulating valve body 27.
6. Separate front support assembly 22 from oil

pump body and gear assembly 4.
9. Align the slot in valve body cover 38 with the

holes in the end of valve body 27. Install gasket 37, cover 38, two 10 mm washers 39, and
two M10 x 1.5 x 35 bolts 40. Tighten the bolts
to 3035 lb ft (3948 Nm).
616
10. Place regulating valve body 27, bottom side

down, on a clean work surface. Align and install gasket 26 and oil transfer plate 25 on top
of body 27.
4. Remove roller bearing assembly 30 from the

bore of converter ground sleeve 27 only if replacement is necessary.
7. If parts replacement is necessary, install valve

pin remover J 24412-2 onto the head of the
converter pressure regulator valve guide pin
(Figure 625). Attach slide hammer J 6125-1
to the valve pin remover tool and remove guide
pin 23, valve spring 24, and regulator valve 25.
CONVERTER
GROUND SLEEVE
BOLT (2), 3/8-16 x 11/2 in.
Remove the snaprings. For later models (Figure 627), tighten the compressor screws to remove all force from cross pins 18 and 19.
Remove the cross pins.
ROLLER BEARING
SEALRING (2)
BOLT (12),
5/16-18
13/4
in.
FRONT
SUPPORT
ASSEMBLY
LOCKUP VALVE
CONVERTER PRESSURE
REGULATOR VALVE
MAIN PRESSURE
REGULATOR VALVE
SEALRING
OIL PUMP
ASSEMBLY
H00103.01
Figure 624. Oil Pump and Front Support Assembly
WARNING!
The main-pressure regulator valve spring is under approximately 65 lbs (290 kN) compression.
8. Attach the main-pressure regulator and lockup
spring compressor J 24459-A, and (for later
models) adapters J 24459-5, to front support
28 (Figures 626 and 627). For earlier models
(Figure 626), tighten the compressor screws
to remove all force from snaprings 10 and 14.
9. Carefully loosen the screws on spring compressor J 24459-A until it can be removed from
the front support. Remove valve stops 11 and
15, valve springs 12 and 16, main-pressure regulator valve 13, and lockup valve 17.
10. For earlier models, if the orifice plug in main
regulator valve assembly 13 is loose, damaged,
or distorted, replace regulator valve assembly
13. The regulator valve assembly used in later
models does not contain an orifice plug.
11. If ground sleeve 27 is damaged and support 28
is serviceable, press the sleeve out of the support. Mark the position of the lube passage in
the ground sleeve on the front support before
removal for correct installation of the new
sleeve. If movement is detected, the parts must
be replaced as an assembly.
12. If replacement of plug 29 is necessary, remove
the plug from the circumference of the support.
13. Remove oil pump gears 8 and 9 from oil pump
body 7.
SPRING
J 6125-1
J 24412-2
GUIDE
OIL PUMP AND FRONT
SUPPORT ASSEMBLY
H00084.01
Figure 625. Removing Converter-Pressure Regulator Valve Guide Pin
617

b. Rework of Front Support Sealring Grooves
(Foldout 7,A)
MAIN REGULATOR VALVE

SNAPRING
CAUTION:
Do not attempt this rework procedure unless adequate machining facilities are available.
J 24459-A
LOCKUP VALVE
H00086.01
Figure 626. Removing (Installing) Main-Pressure

Regulator Valve Spring Snapring Earlier Models
J 24459-5
J 24459-A
FRONT
SUPPORT
CROSS
PIN
c. Assembly (Foldout 7,A)

1. If bushing 6 was removed, install a new bushing. The bushing joint (splitline) must be
within the 10 to 12 oclock position, as viewed
from the front of the oil pump body (Figure 6
29). If pump body 7 has a 0.68 inch (17.3 mm)
deep gear pocket, use installer J 24474 and
handle J 8092 to install the bushing flush to
0.010 inch (0.25 mm) below the surface. If
pump body 7 has a 0.82 inch (20.8 mm) deep
gear pocket, use installer J 36376 and handle
J 8092 to install the bushing 0.0350.045 inch
(0.891.14 mm) below the surface.
H00085.01
Figure 627. Removing (Installing) Main-Pressure

Regulator Valve and Lockup Valve Retainer
Cross Pins Later Models
14. If oil pump body 7 is damaged, replace oil

pump assembly 4.
15. Remove oil seal 3 from oil pump body 7.
16. If oil pump body 7 has bushing 6 installed and
the bushing is worn or damaged, remove the
bushing. For earlier models, remove the split
ring bushing by collapsing the ends of the
bushing inward. For later models, use remover
J 36376 to remove the solid ring bushing.
Models that have bearing 45 (Foldout 6) do not
require bushing 6 (Foldout 7,A).
17. Determine the serviceability of the sealring
grooves on the front support hub. Insert (do not
force) gauge J 29198-2 into the groove on the
front support hub. Rotate the gauge 360 degrees around the hub. If the gauge does not rotate freely, the support is damaged and should
be repaired or replaced.
618
If the front support sealring grooves are determined to

be unserviceable in Paragraph 68a(17), rework the
sealring hub. Refer to Figure 628 for sleeve material
information, machining instructions, and installation
directions.
NOTE:
If an oil seal installer is not available, install the seal
(spring loaded lip first) into the seal bore of the oil
pump. On models with bushing 6, press the seal to
0.0100.020 inch (0.250.51 mm) below the front
surface of the pump body. On models without bushing 6, press the seal to 0.0300.050 inch (0.761.27
mm) below the front surface of the pump body.
2. If oil seal 3 was removed from oil pump body
7, install a new seal. Place the oil pump body
on the work table, flat side down. Seat the oil
seal, with the spring-loaded lip facing away
from the tool, on installer J 24449-A (for
charging pumps with bushing 6) or J 26912-A
(for charging pumps without bushing 6). Attach driver handle J 24202-4 to the oil seal installer. Drive the seal into the pump housing
(Figure 630). Remove the seal installer and
apply a high temperature seal lubricant such as
MILG3545A to the ID of the oil seal.
NOTE: When mounted on DIA AS and
SURFACE AZ features shall be within
the total runout specified by BA. Must
be clean and free from burrs.
NOTE: When mounted on DIA A features shall

be within the total runout specified by B.
0.030" (0.76 mm)
50
25
0.03" (0.76 mm)

R
0.01" (0.25 mm)
0.080"
(2.03 mm)
OPTIONAL
ENLARGED
VIEW
(2 x SIZE)
BA 0.005" (0.127 mm)

DIA A
0.07" (1.77 mm) R MAX
0.090" (2.28 mm) X 45
80
DIA A
AS
0.925" (23.49 mm)

0.915" (23.24 mm)
B 0.002 in.
Break edges
0.01 in. (0.25 mm) MAX
2 PLACES
B 0.005 in.
(0.127 mm)
0.060" (1.52 mm)

R
10
2
PLACES
0.04"
(1.01 mm)
2 PLACES
2.740" (69.59 mm)
DIA
To be machined so as to
result in a 0.002-0.003 in.
(0.05-0.07 mm) interference
fit with sleeve
2.677" (67.99 mm)

2.667" (67.74 mm)
DIA
2.617" (66.47 mm)
2.613" (66.37 mm)
80
0.260"
(6.60 mm)
Max out-of-round to be
0.006 in. (0.152 mm) TIR
average of highest and
lowest readings must
be within these limits
AZ REF
Z
BZ
0.020" (0.50 mm) R MAX

2 GROOVES
0.0980" (2.48 mm)

0.0965" (2.45 mm)
2 PLACES
0.105" (2.66 mm)

0.095" (2.41 mm)
0.040" (1.01 mm) x 45

2 PLACES
SURFACE Z
35 POLISH
NOTE: SURFACE Z must be perpendicular with
AXIS BZ-BZ on respective assembly drawing
within 0.0005 in. (0.0127 mm) total for
effective depth of groove and total
runout not to exceed 0.002 in. (0.127 mm).
DIA AS
REF
2.913" (73.99 mm)

2.907" (73.83 mm)
DIA
DIA A
0.01" (0.25 mm) R

MAX
0.325" (8.25 mm)
0.315" (8.00 mm)
1.235"
(31.36 mm)
SURFACE
B 0.002 in. (0.05 mm)
(0.05 mm)
AZ
13.999" (355.57 mm)

13.996" (355.49 mm)
DIA
NOTE: Sleeve material specification: SAE 4100

series alloy tube, or 1141 and 1144, cold draw or
heat treated, RC20 min.
Z
Installation: Heat the sleeve, press
with installation tool to minimize risk
of damage
BZ
Semi circular ring gauge J 29198-2 must
rotate freely in grooves after assembly
0.785" (19.93 mm)

2 HOLES
NOTE: Must be clean and free from burrs.
Axis BZ-BZ established by DIA AS (ref)
perpendicular to Surface AZ (ref) Surface Z
must be perpendicular with AXIS BZ-BZ
within 0.0005 in. (0.0127 mm) total for
effective depth of groove and total runout not
to exceed 0.005 in. (0.127 mm).
3
SECTION A-A
0.410"
(10.41 mm)
0.312" (7.92 mm) DIA THRU

SLEEVE AND ONE WALL OF SUPPORT
2 HOLES
L00303.01
Figure 628. Rework of Front Support Sealring Grooves
619

3. Invert the oil pump body so that the flat side is
up. Install drive gear 9 and driven gear 8 into
the oil pump body. Place a straight edge across
the surface of the oil pump (Figure 631). Insert a thickness gauge between the straight edge
and the driven gear. Measurement can also be
made with slide gauge tool J 26857. If the
clearance is not 0.0010.003 inch (0.0250.076
mm), selective driven gears are available. Repeat the above procedure (Figure 632) for
drive gear 9. If clearance is not 0.00120.0020
inch (0.0300.051 mm), selective drive gears
are available. Refer to Table 61.
J 24202-4
J 24449-A
(WITH BUSHING)
J 26912-A
(WITHOUT BUSHING)
PUMP BODY
H00087
Bushing joint
to be within
this angle
60
Figure 630. Installing Oil Seal Into Oil Pump Body

STRAIGHT EDGE
OIL PUMP BODY
Bushing must
withstand
600 lbs in
direction
shown
DIA A
Y REF
Press flush
to 0.010 in.
below surface
NOTE: When mounted on DIA B and SURFACE Y
the total runout of DIA A to be within 0.002 in.
DIA B
REF
L00304.01
Figure 629. Installing Bushing Into Oil Pump
THICKNESS
GAUGE
DRIVE GEAR
DRIVEN GEAR
Figure 631. Checking Oil Pump Driven

Gear Side Clearance
Table 61. Selective Oil Pump Gears

0.6850 Inch Pump Gears
Part No.
Gear Thickness
Drive Gear
23015391
0.68350.6840 inch (17.3617.37 mm)
23015392
0.68400.6845 inch (17.3717.39 mm)
23015393
0.68450.6850 inch (17.3917.40 mm)
23015394
0.68500.6855 inch (17.4017.41 mm)
23015402
0.68350.6840 inch (17.3617.37 mm)
23015404
0.68450.6850 inch (17.3917.40 mm)
Driven Gear
620
H00088
Table 61. Selective Oil Pump Gears (contd)
0.8200 Inch Pump Gears
Part No.
Gear Thickness
Drive Gear
23015397
0.81850.8190 inch (20.79020.803 mm)
23015398
0.81900.8195 inch (20.80320.815 mm)
23015399
0.81950.8200 inch (20.81520.828 mm)
23015400
0.82000.8205 inch (20.82820.841 mm)
23016106
0.8180.819 inch (20.77720.803 mm)
23016107
0.8190.820 inch (20.80320.828 mm)
Driven Gear
OIL PUMP BODY

STRAIGHT EDGE
PLUG
Press flush
to 0.010 in. (0.25 mm)
below counterbore
support assembly
CONVERTER
GROUND SLEEVE
TIR 0.006"
(0.152 mm)
2.010"
(51.0 mm)
THIS DISTANCE
THIS DIAMETER
1.6255"1.6245"
(41.29 mm41.26 mm)
TIR 0.002"
(0.05 mm)
1.260" (32.00 mm)

1.240" (31.50 mm)
60-100
DRIVEN GEAR
DRIVE GEAR
THICKNESS GAUGE
Bearing cage
must withstand
200 lb (91 Kg) load
in the direction
indicated
BEARING
6.005" (152.53 mm)
5.995" (152.27 mm)
THRUST BEARING
SURFACE A
L00305.01
H00278
Figure 632. Checking Oil Pump Drive

Gear Side Clearance
4. If plug 29 was removed from support 28, replace it. Press the plug into the bore to the dimension shown in Figure 633.
NOTE:
If ground sleeve 27 was removed, measure the
sleeve and check the runout (Figure 633). If unable
to check runout, replace the ground sleeve with a
new assembly.
5. Support front support 28 in a press (8 ton
(7257 kg) minimum) with the pump face of the
front support facing up. Place ground sleeve 27
in the center bore and align the sleeve lube hole
with the mark on the support. Refer to Paragraph 68a(11).
Figure 633. Ground Sleeve Bearing and

Sleeve Installation
6. Press the sleeve into the front support. The dimension from thrust bearing surface A to the
end of the sleeve (Figure 633) should measure
5.9956.005 inch (152.27152.53 mm).
7. Measure the runout of the sleeve at an area below the splines. Runout should not exceed
0.006 inch (0.152 mm).
8. Machine the bearing bore of the sleeve (Figure
633) to a diameter of 1.62451.6255 inch
(41.2641.29 mm) and a depth of 2.010 inch
(51.0 mm). Remove any metal chips and dirt
from the assembly.
621

NOTE:
When ground sleeve 27 is replaced, the converter
bearing assembly should also be replaced. For units
prior to S/N 2410204975, refer to Paragraph 63e
and the current Parts Catalog PC1316EN for rework of the converter pump hub to the wide bearing configuration.
NOTE:
When replacing the main-pressure regulator valve
or the front support assembly, refer to the current
Parts Catalog PC1316EN for correct part selection.
The current main-pressure regulator valves cannot
be used with earlier front support assemblies, and
earlier valves cannot be used with current front
support assemblies.
CAUTION:
Do not use a full complement needle bearing in
transmissions which use calibrations of 3000 rpm
and higher.
9. Place roller bearing 30 into ground sleeve 27,
with the numbered end of the bearing cup (the
outer bearing race) facing up. Using installer
J 24457 and driver handle J 8092 for the caged
needle bearing, or installer J 39362 and driver
handle J 8092 for the full complement needle
bearing, drive the bearing into the ground
sleeve (Figure 634). If the special tools are
not available, drive the bearing (numbered end
of bearing cage up) into the ground sleeve until
the bearing is 1.2401.260 inch (31.5032.00
mm) from the face of the hub (Figure 633).
When installed, the bearing must withstand a
200 lb (91 kg) load without moving.
J 8092
OIL PUMP AND

FRONT SUPPORT
ASSEMBLY
J 24457
OR J 39362
H00071
Figure 634. Installing Needle Bearing

Into Ground Sleeve
622
10. Install main regulator valve 13 (smaller diameter first) and lockup valve 17 (longer land first)
into their proper bores in support assembly 22.
11. For earlier models (Figure 626), install compressor tool J 24459-A. Place snaprings 10 and
14, plate side up, onto the compressor tool
screws before compressing the springs. Compress springs 12 and 16 and install the
snaprings in their grooves. Remove the spring
compressor. Check that the plate sides of the
snaprings are facing upward in the grooves as
installed. For later models, install springs 12
and 16, and valve stops 11 and 15, into their
proper bores. Install main-pressure regulator
and lockup valve spring compressor J 24459-A
and adapters J 24459-5 on the front support
(Figure 627). Compress the springs and stops
to allow installation of cross pins 18 and 19.
12. If valve guide pin 23 was removed, replace it
with a new pin. Place the pin into valve guide
pin installer J 24458. Place spring 24 and converter-pressure regulator valve 25 onto valve
guide pin 23. Install the valve guide pin and
components into the front support (Figure 6
35). If valve pin installer J 24458 is not available, install the guide pin and components to
extend 1.161.20 inches (29.530.5 mm)
above the finished surface (Figure 636).
13. Place oil pump body and gear assembly 4 on
the work table, front side down. Align the bolt
holes in front support assembly 22 with those
in assembly 4. Install two 516-18 x 134 inch
bolts 21 approximately 180 degrees apart.
Tighten the bolts one or two threads.
14. Install centering band J 24461 around the oil
pump body and front support assembly (Figure
637). Install the remaining ten 516-18 x 134
inch bolts 21, and two 38-16 x 112 inch bolts 20.
15. Check the centering band to ensure a secure fit.
The splitline between the pump and the support must be perfectly smooth after bolt installation. Tighten the twelve 516-18 bolts to 17
20 lb ft (2327 Nm). Tighten the 38-16 bolts
to 3643 lb ft (4958 Nm). Remove centering
band J 24461 from oil pump and front support
assembly 1.
16. Lubricate sealring 2 with oil-soluble grease
and install it into the groove on the outer circumference of the oil pump body. Make sure
the sealring does not twist in its groove.
69. FORWARD CLUTCH AND

TURBINE SHAFT
1. Remove sealring 1 from the end of shaft 5. Remove sealrings 4 from housing and shaft assembly 3.
2. Remove snapring 25 that retains fourth clutch
driving hub 24 in forward clutch housing 6
(Figure 638). Remove the fourth clutch hub
and forward clutch hub 21 from the housing.
J 24458
REGULATOR VALVE
;
;
;
;;;;
;;;;
NOTE:
Do not install front support sealrings 32 onto the
support hub until final assembly of the transmission. Refer to Paragraph 46f and 74b.
3. Remove thrust bearing race assembly 20 (the assembly may adhere to either forward clutch hub
21 or forward clutch housing 6). Remove five internal-splined plates 23 and five external-tanged
plates 22 from the forward clutch housing.
OIL PUMP AND FRONT

SUPPORT ASSEMBLY
H00072.01
;
;
;; ;;
;
;; ;
Figure 635. Converter-Pressure Regulator

Valve Installation
4. Place the housing and shaft assembly in a press

(Figure 639). Using compressor J 6438-01,
compress spring retainer 18 and remove retainer snapring 19. Remove retainer 18, piston
return spring 17, and piston 16. Remove sealring 15 from the piston and sealring 14 from
the housing. For transmissions modified with a
spring apply piston, remove the twenty-four
springs from the piston bores.
SUPPORT ASSEMBLY
VALVE GUIDE
SPRING
J 24461
VALVE
1.20 in. (30.5 mm)

1.16 in. (29.5 mm)
V03294
Figure 636. Installing Converter-Pressure

Regulator Valve Components
BOLT (12), 5/16-18 x 13/4 in.

OIL PUMP ASSEMBLY
BOLT (2), 3/8-16 x 11/2 in.

H00167.01
Figure 637. Installing Oil Pump and Front

Support Assembly Bolts
623

7. If the transmission is equipped with PTO gear
13, remove the gear by compressing snapring
12 (located within the gear) and pressing the
gear from the housing.
SNAPRING
FORWARD CLUTCH
HOUSING
FOURTH CLUTCH HUB

FORWARD CLUTCH HUB
H00105.01
Figure 638. Removing Fourth Clutch

Driving Hub Snapring
8. To compress the snapring, locate the opening

(missing spline) nearest the snapring gap. Insert a small screwdriver into the opening and
press the snapring into its groove in the housing. Slip a piece of 332 x 0.020 x 3 inch (2.38 x
0.508 x 76 mm) shim stock between the
snapring and the inner ends of the gear splines.
Repeat the procedure at the other side of the
snapring gap. Working at each missing spline
opening, insert strips of shim stock at approximately 3 inch (72 mm) increments. With all
shims in place, position the assembly, shaft
downward, in a press. Support the PTO gear
and press the housing from the gear. Remove
the snapring.
9. Press turbine shaft 5 from housing 6 only if
replacement is necessary. Refer to Paragraph
45j for shaft inspection. To press the shaft
from the housing, place the assembly, shaft
downward, in a press. Support the assembly at
the front hub of the housing.
b. Rework of Rotating Sealring Bore,
Forward Clutch (Foldout 7,B)
J 6438-01
PISTON
CAUTION:
SPRING
SNAPRING
FORWARD
CLUTCH
HOUSING
SPRING
RETAINER
adequate machining facilities are available.

Do not attempt to salvage the fourth clutch
housing using this rework procedure.
H00106.01
Figure 639. Removing (or Installing) Forward

Clutch Spring Retainer
5. Do not remove balls 7 from housing and shaft

assembly 3 unless replacement is necessary. If
necessary, clear the bores of staked metal and
remove the balls.
6. On models after S/N 49489 remove retainer
pin 8, valve plug 9, valve spring 10, and valve
11 from the outer circumference of forward
clutch housing assembly 3.
624
Do not attempt this rework procedure unless
1. Acceptable wear in the rotating sealring bore

of the forward clutch housing consists of normal polishing of the sealing surfaces by the
seals, and step wear no greater than 0.0005
inch (0.0127 mm).
2. If wear exceeds acceptable limits, rework the
forward clutch rotating sealring bore. Refer to
Figure 640 for sleeve material information,
machining instructions, and installation directions.
;;;
;;;
;;;
;; ;;;
;;;
;;;
;;
;;;
;;
;;;
SURFACE
NOTE: When mounted on

DIA C or DIA D, runout
of A must not exceed
0.005 in. (0.127 mm). Runout
of SURFACE E must not
exceed 0.004 in. (0.101 mm).
3.167" (80.44 mm)

3.166" (80.42 mm)
(DIA A)
Sleeve material specification:

SAE 4100 series alloy steel
tube, or 1141 and 1144, cold
drawn or heat treated, RC20 Min.
0.030" (0.76 mm)

R
1.0625"
(26.987 mm)
3.059" (77.70 mm)

3.049" (77.44 mm)
REF.
DIA DIA
C D
0.005" (0.127 mm)
0.150"
(3.81 mm)
0.651"
(16.54 mm)
15
0.187" (4.75 mm) DIA
30
2 HOLES
DIAMETRICALLY
OPPOSITE
SLEEVE 3x SCALE
SURFACE
Freeze sleeve in dry ice

approximately ten minutes
prior to installation
60120
100
30
NOTE: No sleeve ID or OD dimension is

called out. Sleeve OD should be machined
so as to result in a 0.003 in. (0.076 mm)
press fit in housing bore A. Sleeve ID
must be machined after sleeve is installed
to dimension (DIA B).
2.9395" (74.663 mm)

2.9375" (74.613 mm)
(DIA B)
DIA DIA
C D
0.16" (4.06 mm)

0.12" (3.05 mm)
Align the two 0.187 in. (4.75 mm) angled

holes with the angled feed passages
in housing. Press sleeve into bore
until bottoming on bore shoulder.
NOTE: When mounted on DIA C or DIA D:

Runout of SURFACE E must not exceed
0.004 in. (0.101 mm). Runout of SURFACE B
must not exceed 0.005 in. (0.127 mm).
V03295
Figure 640. Rework of Forward Clutch Rotating Sealring Bore
625

c. Assembly (Foldout 7,B)
1. If turbine shaft 5 was removed, press a new
shaft to a firm seat against housing 6. A minimum of 250 lb (11.12 kN) press-out force is
required to ensure a satisfactory fit. The total
runout must be within 0.005 inch (0.127 mm).
2. On all models with the centrifugal valve provision, inspect centrifugal valve parts 8, 9, 10,
and 11 for damage. If damaged, replace with
new parts. The color code of any new part must
be the same as the color code of the part replaced. Parts 9, 10, and 11 must be identically
coded.
3. Install centrifugal valve 11 (conical end first)
into its bore in forward clutch housing 6. Place
spring 10 inside the valve. Compress the spring
with valve plug 9 and retain the spring and
plug with retainer pin 8.
4. If check balls 7 were removed, replace them.
Place each ball in its bore. Stake each bore at
three equally spaced places. Each bore is properly staked when the ball has at least 0.040
inch (1.02 mm) axial movement, and when the
ball is retained by the stakes when a 30 lb
(133 N) load is applied against the ball.
5. Before completing the assembly, establish the
clutch clearance. To check clearance by direct
measurement follow Steps (6) through (10).
Direct measurement must be used on transmissions modified with a spring apply forward
clutch piston. For other models, an alternate
method is the stack dimension computation
outlined in Paragraph 623b.
6. Position clutch housing and shaft assembly 3
(shaft downward) on a work table. Lubricate
and install piston sealrings 14 and 15 into their
grooves in the hub of housing 6 and piston 16.
Make sure the sealring lips face toward the
fluid pressure side of the piston (Figure 641).
If the transmission has been modified to include a spring apply forward clutch piston, install a spring into each of the twenty-four
machined bores of the piston. Install the piston
into the housing.
7. Alternately install five external-tanged plates
22 and five internal-splined plates 23, starting
with an external-tanged plate. Install fourth
clutch driving hub 24 and retain it with
snapring 25.
626
8. Hold the fourth clutch driving hub firmly

against the snapring and, using forward clutch
clearance gauge J 26913, check the clearance
between the fourth clutch driving hub and the
internal-splined clutch plate. The correct forward clutch clearance is 0.0790.130 inch
(2.013.30 mm) for standard piston units (Figure 641), and 0.0050.096 inch (0.1272.44
mm) for spring apply piston units. When the
clearance is correct, the first step of the gauge
fits between the hub and plate, and the second
step does not.
9. If the clearance is excessive (the second step of
the gauge fits), replace the thinner clutch plates
with new plates. If the clearance is still excessive after all ten plates and fourth clutch drive
hub have been replaced, a thicker piston is required. Refer to the current Parts Catalog
PC1316EN for selection of a thicker piston.
10. If the clearance is insufficient (the first step of
the gauge does not fit), a thinner piston is required. Refer to the current Parts Catalog
PC1316EN for selection of a thinner piston.
FOURTH CLUTCH
HUB
CLUTCH
PLATES
Check clearance here

0.079 in. 0.130 in. (10 PLATE)
(2.01 mm 3.30 mm)
HOUSING
PISTON
SEALRINGS
30 LB LOAD
(133 N)
L00308
Figure 641. Measuring Forward Clutch Clearance
11. Remove snapring 25, fourth clutch driving hub
24, and the forward clutch plates.
CAUTION:
If either piston sealring 14 or 15 is installed incorrectly, the forward clutch will not operate
properly.
12. Lubricate and install piston sealrings 14 and 15
into their grooves in the hub of housing 6 and
piston 16. Make sure the sealring lips face toward the fluid pressure side of the piston (Figure 641). If the transmission has been
modified to include a spring apply forward
clutch piston, install a spring into each of the
twenty-four machined bores of the piston. Install the piston into the housing.
13. Place clutch housing and shaft assembly 3 and
the assembled forward clutch piston on a press
bed (Figure 639). Install piston return spring
17 and spring retainer 18, and position
snapring 19 on the housing hub. Using compressor J 6438-01, compress the spring retainer
sufficiently to install the snapring into its
groove in the housing hub.
CAUTION:
For earlier models, the use of oil-soluble grease to
retain bearing races and bearing assemblies is
very important. Failure to center bearing races
or assemblies before the forward clutch assembly
is installed (Paragraph 73q), can prevent proper
assembly. Extensive damage could result from
improper assembly.
install five external-tanged plates 22 and five

internal-splined plates 23 (selected in Step (9)
or removed in Step (11)), starting with an external-tanged plate.
NOTE:
Excessive taper may cause snapring 25 to become
dislodged from the snapring groove. The difference
of thickness between the outside of the snapring and
the inside must not exceed 0.0015 inch (0.038 mm).
16. Install fourth clutch driving hub 24 and retain
it with snapring 25 (Figure 643). Install PTO
gear snapring 12 onto forward clutch housing
6. Install the PTO gear (chamfered ID first)
from the rear of the clutch housing. Slide the
gear onto the housing until the snapring engages its mating groove in the gear.
17. Install thrust bearing race assembly 26 onto the
forward clutch hub, lube scallops up. For earlier models, install one bearing race (flat side
first) and bearing onto the forward clutch hub
(Figure 643). Retain all bearing components
with oil-soluble grease.
18. Invert the assembly and install two sealrings 4
at the base of shaft 5 and one sealring 1 near
the end of the shaft (Figure 644). Retain the
sealrings with oil-soluble grease.
19. For earlier models, install the bearing race
(outer lip first) for thrust bearing 31 (Foldout
7,A) onto the hub of the forward clutch housing. Retain the race with oil-soluble grease.
BEARING
RACE
14. Return the assembly to the work table and install thrust bearing race assembly 20 onto the
inside of forward clutch housing 6, lube relief
scallops down. For earlier models, install one
bearing race (outer lip first) onto the hub of the
forward clutch housing (Figure 642). Install
the other bearing race (flat side first) onto the
inner hub of forward clutch hub 21, and install
the bearing onto the race. Retain all bearing
components with oil-soluble grease.
15. Position clutch housing and shaft assembly 3
(shaft downward) on a work table. Place forward clutch hub 21 (outer splines first) onto the
hub of forward clutch housing 6. Alternately
FORWARD CLUTCH
HOUSING
FORWARD
CLUTCH
HUB
BEARING
BEARING
RACE
H00107.01
Figure 642. Installing Bearing Into Forward Clutch

Hub (Earlier Models)
627

PTO GEAR
J 24204-2
SNAPRING
FOURTH CLUTCH
DRIVE HUB
FOURTH CLUTCH
HOUSING ASSEMBLY
FORWARD CLUTCH
HUB
J 6438-01
BACKPLATE
BEARING
RACE
SPRING RETAINER
BEARING
H00108.01
Figure 643. Installing Bearing Onto Forward

Clutch Hub (Earlier Models)
SEALRING
BEARING
RACE
SEALRING (2)
FORWARD CLUTCH
HOUSING AND
SHAFT ASSEMBLY
H00109.01
Figure 644. Installing Bearing Race Onto Forward

Clutch Housing (Earlier Models)
610. FOURTH CLUTCH
H00157.01
Figure 645. Removing (or Installing) Fourth Clutch

Spring Retainer Snapring
2. Using compressor J 6438-01 and compressor base

J 24204-2, compress spring retainer 7 sufficiently
to allow removal of snapring 6 (Figure 645). Remove the snapring. Remove the spring retainer
and piston return spring 8, which is directly beneath the retainer. Remove snapring 2 that retains
backplate 3, and remove the backplate.
3. Remove four internal-splined plates 4 and four
external-tanged plates 5, and fourth clutch piston 9 or 10. Remove sealring 11 from the piston
and sealring 12 from fourth clutch housing 13.
4. Remove check balls 14 from fourth clutch
housing 13 only if replacement is necessary. If
necessary, clear the bores of staked metal and
remove the balls.
5. Inspect the clutch housing inner sealring
groove to determine if a step is present in the
top side of the groove (refer to SIL 33-TR-96).
If a step is detected, replace the housing assembly. Refer to the current Parts Catalog
PC1316EN for the correct housing part number for your transmission.

1. If not previously removed, remove thrust bearing race assembly 26 (Foldout 7,B) from the
front hub of fourth clutch housing 13 (Foldout
8,A). Remove bearing race 15 from the rear hub
of the clutch housing if not previously removed.
628
SNAPRING
1. If check balls 14 were removed, replace them.

Place each ball in its bore. Stake each bore at
three equally spaced places. Each bore is properly staked when the ball has at least 0.040 inch
(1.02 mm) axial movement, and when the ball
is retained by the stakes when a 30 lb (133 N)
load is applied against the ball (Figure 646).
2. Before completing the assembly, establish the
clutch clearance. To check clearance by direct
measurement follow Steps (3) through (7). Alternately, use the stack dimension computation
outlined in Paragraph 623c.
CAUTION:
If either piston sealring 11 or 12 is installed incorrectly, the fourth clutch will not operate
properly.
3. Position the fourth clutch housing, rear hub
downward, on a work table. Lubricate and install piston sealrings 11 and 12 into their
grooves in the housing hub and piston. Make
sure the sealring lips face toward the fluid pressure side of the piston (Figure 646).
9. For earlier models, install one bearing race

7,B) onto the front hub of the fourth clutch
housing (Figure 647). Install one bearing race
8,A) onto the rear hub of the clutch housing
(Figure 648). Retain all bearing components
with oil-soluble grease.
FOURTH CLUTCH
HOUSING
Check clearance here

0.064 in. 0.125 in. (8 PLATES)
(1.63 mm 3.18 mm)
BACKPLATE
SNAPRING
PLATES (8)
PISTON
4. Install piston 9 or 10 into the fourth clutch

housing (Figure 646). Alternately install four
external-tanged plates 5 and four internalsplined plates 4, starting with an externaltanged plate. Install backplate 3 and retain it
with snapring 2.
SEALRINGS
5. Using fourth clutch clearance gauge J 26917,

check the clearance between the backplate and
the first internal-splined plate. Correct fourth
clutch clearance is 0.0640.125 inch (1.625
3.175 mm). When clutch clearance is correct,
the first step of the gauge fits between the
backplate and the clutch plate, and the second
step does not.
6. If the clearance is excessive (the second step of
the gauge fits), replace the thinner clutch plates
with new plates. If the clearance is still excessive after all eight plates and the backplate
have been replaced, a thicker piston is required. Refer to the current Parts Catalog
PC1316EN for selection of a thicker piston.
30 LB LOAD
(133 N)
L00309
Figure 646. Measuring Fourth Clutch Clearance
BEARING RACE
FOURTH CLUTCH
HOUSING ASSEMBLY
7. If the clearance is insufficient (the first step of

the gauge does not fit), a thinner piston is required. Refer to the current Parts Catalog
PC1316EN for selection of a thinner piston.
8. Install piston return spring 8 and spring retainer 7. Using compressor J 6438-01 and
compressor base J 24204-2, compress the
spring retainer (Figure 645). Install snapring
6 to retain the spring retainer.
H00158.01
Figure 647. Installing Bearing Race at Front of Fourth

Clutch (Earlier Models)
629
FOURTH CLUTCH
HOUSING ASSEMBLY
BEARING RACE
SPRING RETAINER
EJECTOR
BOSS
SPRING (20)
CLUTCH PISTON
H00160.01
H00159.01
Figure 648. Installing Bearing Race at Rear of Fourth

Clutch (Earlier Models)
611. CENTER SUPPORT ASSEMBLY

1. Place center support assembly 13 upright on
the work table.
Figure 649. Removing Push-On Nuts

and Spring Retainer
9. Determine the serviceability of the sealring

grooves on the center support hub. Insert (do
not force) gauge J 29198-2 into the groove on
the center support hub. Rotate the gauge 360
degrees around the hub. If the gauge does not
rotate freely, the support is damaged and
should be repaired or replaced.
2. For later models, remove oil filter 24 and sealring 23 from center support 16.
b. Rework Center Support Anchor Bolt Hole

(Foldout 8,B)
3. Remove third clutch piston 9 and second clutch

piston 19, with attached parts.
CAUTION:
4. Remove inner sealrings 10 and 18 and outer

sealrings 11 and 17 from pistons 9 and 19.
5. If parts replacement is necessary, disassemble
the two piston assemblies. Cut the push-on
nuts to prevent damaging the piston projections
(Figure 649). Remove four push-on nuts 6 or
22, spring retainer ring 7 or 21, and twenty
springs 8 or 20 from each piston.
Do not attempt this rework procedure unless adequate machining facilities are available.
1. Starting with S/N 2410260655, a longer (38-16
x 3 inch) patch lock anchor bolt 54 (Foldout
10,A) and a chamfered washer 55 are used.
2. Using a drill press, locate the center support
against a square, flat surface.
6. Remove two sealrings 12 from the hub of center support assembly 13.
3. Turn a 38-16 tap into the existing hole by hand.

Use a level and the shank of the tap to ensure
that the center support is square and level.
7. If bushing 14 in center support 16 is worn or

damaged, collapse the bushing inward at the
bushing splitline and remove.
4. Refer to Figure 650 for machining instructions.
8. Remove check ball 15 (freed by removing the

bushing) from the hub of the support.
630
PUSH-ON NUT
5. Remove any burr from the top of the bore before checking depth reading (Figure 650).
Clean all chips out of the center support.
;;;;
;;;;
;;;;
;;;;
;;;;
;;;;
1.380" MIN
(35.0 mm)
TAP DRILL 1.610 in. (40.89 mm) MAX DEEP

COUNTERDRILL 0.469 in. DIA (11.91 mm) x
0.660.70 in. (16.7617.78 mm) DEEP 0.37616
UNC 2B MIN FULL THREAD DEPTH TO DIMENSION
SHOWN
V03296
Figure 650. Rework of Center Support

Anchor Bolt Hole
30
0.090 in.
(2.29 mm)
0.250 in.
(6.35 mm)
NOM.
0.090 in.
(2.29 mm)
CENTER SUPPORT
0.156 in. (3.96 mm) DIA

LUBE HOLE
c. Rework of Center Support for One Piece

Thrust Bearing Race Assembly (Foldout 8,B)
1. Later models incorporate a one piece thrust
bearing race assembly 15 (Foldout 8,A). Center supports prior to S/N 2410226363 require a
rework to ensure correct fluid flow and proper
positioning of the bearing.
2. Secure the center support with the 0.156 inch
(3.96 mm) diameter lube hole on the sealring
side facing up (Figure 651).
3. Using a number 15 (14 x 1 inch) or number 91
(14 x 34 inch) woodruff key cutter wheel or
equivalent, undercut the area to the front of the
lube hole 0.090 inch (2.29 mm) deep and 0.250
inch (6.35 mm) wide (Figure 651). Do not cut
a groove around the entire circumference of the
hub. Cut only the area the length of the hole diameter. Clean all chips out of the center support.
4. With the black oxide race facing upward, make
sure there is clearance around the widest lip of
the race for fluid flow to bearing 15 and the
third clutch.
d. Rework of Non-Eccentric Center Support to
Eccentric Support (Foldout 8,B)
NOTE:
Transmissions S/N 2410260655 and later have an
eccentric center support in which the bushing bore
is slightly offset from center. This provides improved shaft alignment at normal transmission operating temperature. The center support in
transmissions prior to S/N 2410260655 may be reworked to provide the offset by machining the center support OD and installing shim 29 under the
support.
CAUTION:
NOTE: Do not cut groove around the entire circumference of

the hub, cut only the area the length of the hole diameter.
This rework applies for non-eccentric center

V03297
Figure 651. Rework of Center Support for One Piece

Thrust Bearing Race Assembly
support assemblies only. Do not rework an eccentric center support assembly.

Do not attempt this rework unless adequate machining facilities are available.
631

1. Determine if the center support assembly is eccentric or non-eccentric (Figure 652).
2. Rework the center support anchor bolt hole if it
has not previously been reworked. Refer to
Paragraph 611b.
3. Collapse center support bushing 14 inward at
the bushing splitline and remove. Remove
ball 15.
CAUTION:
4. Mount the center support in a lathe, using a

four-jaw chuck on the center support bushing
bore. Use a dial indicator to center the support
so that runout is no more than 0.002 inch
(0.05 mm).
5. Machine the OD of the support to 11.1145
11.1175 inch (282.30282.40 mm) (Figure
653).
6. Machine a 10 degree chamfer on the front and
back edges of the OD (Figure 653).
7. Machine two grooves on the center support
OD. These grooves indicate that the support
has been reworked for shim installation.
;;
;
8. Clean and remove all machining burrs and

debris.
MEASUREMENT INSTRUCTIONS:
DIM. B Measured at bottom of
support (anchor bolt hole location)
2. Install the ball and bushing as illustrated in

Figure 654. Use installer J 24794 to press the
bushing into the center support. The bushing is
pre-bored and requires no reaming.
NOTE:
If the pistons are not installed to the bottom of their
cavities during installation of push-on nuts 6 and 22,
proper clutch clearance cannot be established.
;;
;;
;;
SEE VIEW A
0.0300.060"
(0.801.52 mm)
10
VIEW A
BOTH SIDES
DIM. A Measured directly

opposite DIM. B location
NON-ECCENTRIC SUPPORT:
DIM. B = DIM. A 0.002 in. (0.05 mm)
ECCENTRIC SUPPORT:
DIM. B DIM. A = 0.015 0.002 in.
(0.38 0.05 mm)
0.75" (19.0 mm)

BOTH SIDES
V03298
Figure 652. Identification of Center

Support Eccentric vs. Non-Eccentric
632
1. If bushing 14 and check ball 15 were removed

from the center support, replace with new
parts.
11.114511.1175"
(282.30282.40 mm)
DIM.
10. The reworked support requires the installation

of shim 29 (P/N 23046695) during transmission reassembly. Refer to Paragraph 73n.
e. Assembly (Foldout 8,B)
Do not damage the center support bushing bore

with the chuck jaws.
DIM.
9. Apply Dykem orange paint #DXX323 or

equivalent to the reworked center support bolt
counterbore. The color will be visible from the
valve body mounting face, allowing identification of a reworked support without complete
transmission disassembly.
0.030"
0.030"
(0.80 mm)
(0.080 mm)
VIEW B
2 IDENT. GROOVES
SEE VIEW B
Figure 653. Rework of Center Support to

Eccentric Configuration
V03299
3. Temporarily place third clutch piston 9 in the
front piston cavity of center support assembly
13. Install springs 8 into the pockets of the piston. Align spring retainer 7 on the four ejectorpin bosses of the piston. Compress the springs
by forcing the retainer into the recess at the
outer edge of the center support. Install four
new push-on nuts 6 (Figure 655) on the ejector pins of the piston, using lock ring installer
J 24453. Remove the piston from the center
support.
4. Repeat the procedure in Step (3) to assemble
second clutch piston components 19 through
22 into the rear cavity of center support assembly 13.
NOTE:
The lips of both the inner and outer sealrings must
face the piston cavities of the center support.
5. Install inner sealrings 10 and 18, and outer
sealrings 11 and 17, onto pistons 9 and 19. Retain the sealrings with oil-soluble grease.
6. Inspect the piston cavities in center support assembly 16 for any obstruction or foreign material. Install piston 19 into the rear of the center
support, engaging the lug on the piston with
the recess in the support. Leave the assembled
third clutch piston out of the center support until final installation of the center support assembly in Paragraph 73n.
7. If oil filter 24 and sealring 23 were removed,
install the new filter, closed end of the cone
first, and sealring into the center support. The
sealring on the filter must seat against the
shoulder in the support. Center supports without a fourth clutch filter can be reworked to include the filter with counterbore cutter
J 29032.
NOTE:
Do not install center support sealrings 12 (Foldout
8,B) onto the support hub until final assembly of the
transmission. Refer to Paragraph 46f and 73n.
NOTE:
Notch must be
within this area

20
10
BALL
For MTB 643, proceed to Paragraph 614.

SECTION
D-D
CENTER
SUPPORT
RETAINER
RING
THIRD CLUTCH
PISTON
J 24453
NOTCH
16
X-
BUSHING
SECTION
A-A
Press bushing flush

with, to 0.010 in. (0.25 mm)
below this surface
NOTE: After assembly, bushing must withstand
500 lb (2224 N) end load in direction of arrow X.
EJECTOR BOSS
Figure 654. Center Support Bushing Installation
CENTER SUPPORT
H00073.01
L00319
Figure 655. Installing Retainer Ring and Push-On Nuts
633

612. GEAR UNIT AND MAIN SHAFT
ASSEMBLY (MT(B) 650, 653)
1. Remove thrust washers 1 and 47 at each end of
the gear unit assembly (Figure 656).
2. Remove front sun gear 2 (Figure 657). Remove thrust washer 3 from the gear (or from
center sun gear shaft assembly 23).
THRUST WASHER
(FRONT)
THRUST WASHER
(REAR)
CENTER SUN GEAR

SHAFT ASSEMBLY
GEAR UNIT AND
MAIN SHAFT ASSEMBLY
H00161.01
Figure 656. Removing (or Installing) Gear Unit Rear

Thrust Washer MT 650, 653
FRONT SUN GEAR
3. Lift off front planetary carrier assembly 4 (Figure 658). Remove thrust washer 12 from the
assembly (or from center planetary carrier assembly 15). Refer to Paragraph 624 for rebuild of the front planetary assembly.
NOTE:
Bearing assembly 28 and bearing race 29 may come
out when center sun gear shaft assembly 23 is removed.
4. Remove center sun gear shaft assembly 23 (Figure 659). If parts replacement is necessary, remove bushings 26 and spring pins 24 from shaft
assembly 23. Using a small punch inserted
through the swaging hole, collapse front bushing 26 and remove. Collapse rear bushing 26 using a small chisel inserted between the shaft and
the bushing OD. Be careful not to damage the
shaft ID during bushing removal.
5. Remove bearing assembly 28 and bearing race
29, if not previously removed.
6. Remove snapring 13 that retains front planetary ring gear 14 (Figure 660). Remove the
ring gear from planetary connecting drum 30.
THRUST WASHER
THRUST WASHER
SUN GEAR
SHAFT ASSEMBLY
FRONT PLANETARY
CARRIER ASSEMBLY
BUSHING
CENTER PLANETARY
CARRIER ASSEMBLY
H00162
Figure 657. Removing (or Installing) Front

Planetary Sun Gear
634
H00163
Figure 658. Removing (or Installing) Front Planetary

Carrier Assembly
7. Lift out center planetary carrier assembly 15
(Figure 660). Refer to Paragraph 624 for rebuild of the center planetary carrier assembly.
8. Remove main shaft 35, and its attached parts
from planetary connecting drum 30 (Figure
661).
SUN GEAR
SHAFT ASSEMBLY
9. Remove spiral snapring 37 that retains rear

planetary sun gear 36 on main shaft 35 (Figure
662). Remove the main shaft. Remove orifice
plug 34 from the main shaft only if replacement is necessary. Refer to Paragraph 45j for
shaft inspection.
SPRING PIN
H00164
Figure 659. Removing (or Installing) Center

Sun Gear Shaft Assembly
10. Remove snapring 31. Remove rear planetary

sun gear 36 from center planetary ring gear 32.
11. Remove snapring 46 that retains rear planetary
carrier assembly 38 or 48 in planetary connecting drum 30 (Figure 663). Lift the carrier assembly out of the drum. Remove needle
bearing assembly 39 or 49. Refer to Paragraph
624 for rebuild of the rear planetary carrier
assembly.
NOTE:
Needle bearing assembly 39 or 49 may not easily
come out of the rear planetary carrier assembly. In
most cases, it can be removed by careful manipulation after rotating the planetary pinions to allow the
bearing race to tilt.
FRONT
PLANETARY
RING GEAR
SNAPRING
REAR PLANETARY CARRIER ASSEMBLY
MAIN SHAFT
PLANETARY
CONNECTING DRUM
CENTER PLANETARY
CARRIER ASSEMBLY
H00165
PLANETARY
CONNECTING DRUM
CENTER PLANETARY
RING GEAR
H00166
Figure 660. Removing (or Installing) Front Planetary

Ring Gear Snapring
Figure 661. Removing (or Installing) Main Shaft
635

27. Index the bushing so that the split is 45 degrees from the swaging hole in the shaft (Figure 664).
SNAPRING
NOTE:
Use a minimum of 600 lb (2.669 kN) assembly force
on bushing installer.
Be careful not to damage the bushing ID coating
MAIN SHAFT
during installation.
REAR SUN GEAR
CENTER RING GEAR

H00149
Figure 662. Removing (or Installing) Main Shaft

Spiral Snapring
3. Using the short end of bushing installer tool

J 41406 (Figure 665), press new front bushing
26 into the small OD end of shaft 27 until it is
0.410 inch (10.41 mm) below the end surface
(Figure 664).
4. Using the long end of tool J 41406 (Figure 6
66), press new rear bushing 26 into the large
OD end of shaft 27 until it is 0.660 inch (16.76
mm) below the end surface (Figure 664).
REAR PLANETARY
CARRIER ASSEMBLY
SNAPRING
PLANETARY
CONNECTING
DRUM
H00150
Figure 663. Removing (or Installing) Rear

Planetary Snapring
b. Installing Replacement Sun Gear Shaft

Bushings (Foldout 9,B)
5. Using swaging tool J 28446-A, swage both

bushings into holes in the sun gear shaft (Figure 667). Make sure to use the collar when
swaging the forward bushing to prevent damage to the shaft.
6. Check the ID of bushings for runout. TIR must
not exceed 0.002 inch (0.05 mm). Surface finish
should be 30 microinches (0.762 micrometer).
7. If spring pins 24 (Foldout 9,B) were removed
from shaft 27, install new pins. For each pin,
align the split so that it is approximately 90 degrees to the axis of the shaft. Press the pin into
the shaft until it is flush to 0.010 inch (0.25
mm) below the top of the gear tooth.
c. Assembly (Foldout 9,B)
NOTE:
Use pre-bored sun gear shaft bushings when replacing bushings 26 at overhaul. Do not use the former
installation tool J 24468 for this procedure.
1. If bushings 26 were removed, install new bushings after inspecting center sun gear shaft 27.
Identify the rear swaging hole with a marker on
the end of the shaft prior to bushing installation.
2. For each bushing 26, apply Loctite Sleeve
Retainer 601 (or equivalent) to the bushing
OD. Position the bushing at the bore of shaft
636
NOTE:
Visually and manually inspect all carrier assemblies. Refer to Paragraph 624a.
1. If lubrication orifice plug 34 was removed
from main shaft 35, install a new plug. Using
installer J 24369, install the plug, small-orificed end first, into the front of the main shaft.
Press the plug into the shaft until the front of
the plug is recessed 0.1400.180 inch (3.56
4.57 mm) below the front end of the shaft.
TWO BUSHINGS Press to
dimension shown
using tool J 41406
DIA A
600 LBS
(2669 N)
600 LBS
(2669 N)
1.5640*
1.5677
1.5640*
1.5677
B.006
B.006
0.410 in. (10.41 mm)
0.660 in. (16.76 mm)
mounted on DIA A features shall

be within the total runout specified by
B prior to bushing installation
When
Swage bushings into holes

using tool J 28446-A
Bushing
split must be more than 45

from the swaging hole (2 places)
Each
bushing must withstand the

specified load in the indicated
direction
*Bushing is pre-sized to give

1.5640-1.5677 in. DIA after assembly
V03300
Figure 664. Sun Gear Shaft Bushing Replacement Diagram
LONG
STEP
SHORT
STEP
J 41406
J 41406
SUN GEAR SHAFT
SUN GEAR SHAFT
H00075.01
H00074.01
Figure 665. Installing Sun Gear Shaft Front Bushing
Figure 666. Installing Sun Gear Shaft

Rear Bushing
637

2. Install needle bearing assembly 39 or 49. If the
assembly does not install easily on rear planetary carrier assembly 38 or 48, rotate the planetary pinions to allow the bearing race to tilt and
carefully manipulate the assembly.
3. Position planetary connecting drum 30, front
(long internal-splines) downward (Figure 6
63). Install rear planetary carrier assembly 38
or 48. Install snapring 46 that retains the carrier assembly in the drum.
4. Install rear planetary sun gear 36 into the rear
of center planetary ring gear 32. Retain the sun
gear with snapring 31.
5. Install main shaft 35 into the front of rear planetary sun gear 36 (Figure 662). Retain the
main shaft in the sun gear by installing spiral
snapring 37 into the groove in the main shaft.
6. Install the main shaft, and its attached parts,
into the planetary connecting drum (Figure 6
61). The rear sun gear must seat against the
needle bearing in the rear planetary carrier.
SWAGING TOOL
J 28446-1
COLLAR
J 28446-2
7. Position the assembled components so that the

hub of the rear planetary carrier assembly is
downward (Figure 668). Install needle bearing race 29, inner lip upward, onto the front of
rear planetary sun gear 36. Retain the race with
oil-soluble grease. Install needle bearing assembly 28, coated with oil-soluble grease, onto
the bearing race.
8. Install center planetary carrier assembly 15
(pinions first) into center planetary ring gear
32 and planetary connecting drum 30 (Figure
660). Install front planetary ring gear 14,
outer splines first. Retain the ring gear with
snapring 13.
9. Install center sun gear shaft assembly 23,
larger diameter first (Figure 659). The shaft
must seat on needle bearing assembly 28 and
race 29.
10. Coat thrust washer 12 with oil-soluble grease
and install it onto the rear hub of front planetary carrier assembly 4 (Figure 658). Install
the carrier assembly.
and install it onto the rear hub of front planetary sun gear 2 (Figure 657). Install the sun
gear onto center sun gear shaft assembly 23,
external splines up, so that the missing internal-spline locations of the sun gear index with
the spring pins in the center sun gear shaft assembly.
REAR PLANETARY
SUN GEAR
SUN GEAR
SHAFT ASSEMBLY
BEARING RACE
NEEDLE
BEARING ASSEMBLY
H00151
L00773
Figure 667. Sun Gear Shaft and Swaging Tool
638
Figure 668. Installing Center Sun Gear Rear

Bearing Assembly
12. Coat both front and rear thrust washers 1 and
47 with oil-soluble grease, and install them
onto the assembled gear unit (Figure 656).
NOTE:

ASSEMBLY (MT 640, 643)
NOTE:
Because of the similarity of the MT 640, 643 and
MT 650, 653 gear units, the majority of the rebuild
procedures are identical. When applicable, procedures in Paragraph 612 will be referenced.
1. Remove thrust washer 1 from the front of the
gear unit (Figure 656).
assembly (or from center planetary carrier assembly 15). Refer to Paragraph 624 for rebuild of the front planetary carrier assembly.
NOTE:
out when sun gear shaft assembly 23 is removed.
4. Remove center sun gear shaft assembly 23
(Figure 659). If parts replacement is necessary, remove spring pins 24 from shaft assembly 23. Using a small punch inserted through
the swaging hole, collapse forward bushing 26
and remove. Collapse rear bushing 26 using a
small chisel inserted between the shaft and the
bushing OD. Be careful not to damage the
shaft ID during bushing removal. Refer to
Paragraph 612b for rebuild instructions.

6. Remove snapring 13 that retains front planetary
ring gear 14 (Figure 660). Remove the ring
gear from the planetary connecting drum 30.
(Figure 660). Refer to Paragraph 624 for rebuilding the center planetary carrier assembly.
8. Remove main shaft 35, and its attached parts,
661).
9. Remove thrust washer 36 from main shaft 35
(or from the front of shaft 54).
planetary sun gear 37 on main shaft 35 (Figure 662). Remove the main shaft. Remove
orifice plug 34 from shaft 35 only if replacement is necessary. Refer to Paragraph 45j for
shaft inspection.
11. Remove snapring 31 from rear planetary sun
gear 37. Remove gear 37 from center planetary
ring gear 32.
12. Position the remaining components so that
planetary connecting drum 30 is downward.
Remove snapring 48 that retains rear planetary
carrier assembly 40 (Figure 663). Lift the carrier assembly and output shaft assembly 50 out
of the drum.
13. Tap output shaft assembly 50 forward (toward
carrier assembly 40) until ball bearing 49 is
lightly pinched between spring pin 53 and carrier assembly 40.
14. Working through the front of carrier assembly
40, remove snapring 39. Tap the shaft assembly rearward and remove it from the carrier assembly. Refer to Paragraph 624 for rebuild of
the rear planetary carrier assembly.
15. Press shaft assembly 50 from ball bearing 49.
16. Remove spring pin 53, needle roller bearing or
bushing 51, and cup plug 52 from shaft 54 only
if parts replacement is necessary.
1. If cup plug 52 was removed from shaft 54, install a new plug. Place the plug on the end of
639

installer J 24369. Install the plug into the output shaft just below the chamfer. Refer to Figure 669.
NOTE:
Output shaft bushing 51 replaces the needle bearing
used on earlier models.
2. If bearing or bushing 51 was removed from

shaft 54, install a new bushing using installer
J 24451 and drive handle J 8092. Install the
bushing into the output shaft 0.370 inch
(9.40 mm) below the face of the shaft (Figure 670).
3. If spring pin 53 was removed from shaft 54, install a new pin. Press the pin into the shaft until
it protrudes 0.0660.076 inch (1.681.93 mm)
above the shaft surface.
J 24369

from main shaft 35, install a new plug. Use installer J 24369 and install the new orifice plug
into the main shaft. If the installer is not
available, press the plug into the shaft until it
is recessed 0.1400.180 inch (3.564.57 mm)
below the front end of the shaft.
5. Install ball bearing 49 onto the front of output
shaft assembly 50. Position the bearing against
spring pin 53.
6. Install shaft assembly 50 and bearing 49 (front
end first) into the rear of rear planetary carrier
assembly 40. Tap the shaft until bearing 49
contacts the rear hub of the carrier.
7. Install snapring 39 to retain the shaft. Press the
shaft rearward until the snapring is seated
firmly in the counterbore of the carrier.
8. Position planetary connecting drum 30, long
internal splines downward, and install rear
planetary carrier assembly 40 and output shaft
50. Install snapring 48 that retains the rear
planetary carrier assembly (Figure 663).
CUP PLUG
J 8092
J 24451
OUTPUT SHAFT
OUTPUT SHAFT
H00076.01
H00077.01
Figure 669. Installing Orifice Plug Into

Output Shaft MT 650, 653
640
Figure 670. Installing Bushing Into Output

Shaft MT 640, 643
10. Install main shaft assembly 33 (rear first) into
the front of rear planetary sun gear 37. Retain
the shaft assembly by installing spiral snapring
38 (Figure 662).
and install it onto the rear of main shaft 35.
12. Install main shaft 35, and its attached parts,
into planetary connecting drum 30 (Figure 6
61). The main shaft must seat against the thrust
washer that seats against the output shaft.
13. Coat bearing race 29 and needle bearing assembly 28 with oil-soluble grease (Figure 6
68). Install the race, inner lip upward. Install
the needle bearing assembly onto the race.
14. Install center planetary carrier assembly 15
(pinions first) into center planetary ring gear
32 and planetary connecting drum 30 (Figure
660). Install front planetary ring gear 14,
snapring 13.
must seat on the needle bearing assembly installed in Step (13).
and install it onto the rear of front sun gear 2
(Figure 657). Install the front sun gear, indexing the cutout splines with the spring pins in
the center sun gear shaft assembly.
18. Coat front thrust washer 1 with oil-soluble
grease and install it onto center sun gear shaft
27 (Figure 656).
NOTE:

ASSEMBLY (MTB 643)
NOTE:
Because of the similarity of the MTB 643 and
MT(B) 650, 653 gear units, the majority of the rebuild procedures are identical. When applicable,
procedures in Paragraph 612 will be referenced.
1. Remove thrust washer 1 from the front of the
gear unit (Figure 656).
assembly (or from center planetary carrier assembly 15). Refer to Paragraph 624 for rebuild of the front planetary carrier assembly.
NOTE:
out when center sun gear shaft assembly 23 is removed.
4. Remove center sun gear shaft assembly 23
(Figure 659). If parts replacement is necessary, remove bushings 26 and spring pins 24
from shaft 23. Refer to Paragraph 612b for rebuild instructions.
6. Remove snapring 13 that retains front planetary ring gear 14 (Figure 660). Remove the
ring gear from planetary connecting drum 30.
(Figure 660). Refer to Paragraph 624 for rebuilding the center planetary carrier assembly.
8. Remove main shaft 35, and its attached parts,
661).
9. Remove thrust washer 36 from main shaft 35
(or from the front of shaft 54).
641

planetary sun gear 37 on main shaft 35 (Figure 662). Remove the main shaft. Remove
orifice plug 34 from shaft 35 only if replacement is necessary. Refer to Paragraph 45j for
shaft inspection.
7. Install main shaft 35, and its attached parts,

into planetary connecting drum 30. (Figure 6
61). Rear planetary sun gear 37 must seat
against needle roller bearing 49 installed on the
hub of rear planetary carrier assembly 40.
11. Remove snapring 31 from rear planetary sun

gear 37. Remove gear 37 from center planetary
ring gear 32.
8. Coat bearing race 29 and needle bearing assembly 28 with oil-soluble grease (Figure 6
68). Install the race, inner lip upward. Install
the needle bearing assembly onto the race.
12. Position the remaining components so that

planetary connecting drum 30 is downward.
Remove snapring 48 that retains rear planetary
carrier assembly 40 (Figure 663). Lift the carrier assembly and output shaft assembly 50 out
of the drum.
9. Install center planetary carrier assembly 15,

pinions first, into center planetary ring gear 32
and planetary connecting drum 30 (Figure 6
60). Install the front planetary ring gear 14,
snapring 13.
13. Remove needle roller bearing assembly 47

from the front of rear planetary carrier assembly 40.

must seat on the needle bearing assembly installed in Step (8).

from main shaft 35, install a new one. Use installer J 24369 and install the new orifice plug
into the main shaft. If the installer is not available, press the plug into the shaft until it is recessed 0.1400.180 inch (3.564.57 mm) below the front end of the shaft.
2. Position planetary connecting drum 30, long
internal splines downward, and install rear
planetary carrier assembly 40. Install snapring
48 that retains the rear planetary carrier assembly (Figure 663).
3. Rotate the assembly so that the connecting
drum is up. Coat needle roller bearing assembly 47 with oil-soluble grease. Install the bearing assembly (inner lip downward) onto the
hub of rear planetary carrier assembly 40.
5. Install main shaft assembly 33 (rear first) into
the front of rear planetary sun gear 37. Retain
the shaft assembly by installing spiral snapring
38 (Figure 662).
and install it onto the rear of main shaft 35.
642

and install it onto the rear of front sun gear 2
(Figure 657). Install the front sun gear, indexing the cutout splines with the spring pins in
the center sun gear shaft assembly.
13. Coat front thrust washer 1 with oil-soluble
grease and install it onto center sun gear shaft
27 (Figure 656).
NOTE:
615. OUTPUT SHAFT (MT 650, 653)

NOTE:
For models with a press-fit governor drive gear, use
Steps (1) through (4) and Step (6).
For earlier models with a loose-fit governor drive
gear use Steps (5) and (6).
1. If output shaft assembly 1 has a press-fit governor drive gear 8, place the assembly on a press,
small end of shaft upward.
2. Install remover J 22912-01 so the flat sides of
the puller plates make contact with the forward
edge of the teeth of governor drive gear 8.
J 8092
J 34015 (CURRENT)
J 24451 (EARLIER)
3. Force the shaft down with the press until spring

pin 5 clears the slot of gear 8. Remove gear 8,
speedometer drive gear 9 or 10, and spacer 11
(used with gear 9).
BUSHING
OUTPUT SHAFT
4. Remove spring pin 5 and roller bearing 7 (earlier models, ball bearing 6) from output shaft 4,
using remover J 22912-01 if necessary.
5. If output shaft assembly 1 does not have a
press-fit governor drive gear 8, remove spring
pin 5 from output shaft 4. Press roller bearing 7
(earlier models, ball bearing 6) from the shaft,
using remover J 22912-01 if necessary.
6. For all models, remove output shaft bushing 2
(earlier models, needle bearing 2) and cup plug
3 only if replacement is necessary.
H00078.01
Figure 671. Installing Bushing Into Output

Shaft MT 650, 653

1. If cup plug 3 was removed from shaft 4, install
a new plug. Place the plug on the end of installer J 24369. Install the plug into the output
shaft (Figure 669). The plug is installed correctly when it is below the chamfer on the
bore.
2. If bushing 2 (earlier models, needle bearing 2)
was removed from shaft 4, install a new bushing using installer J 34015 or J 24451 and
driver handle J 8092. Install the bushing into
the output shaft to a depth of 0.370 inch (9.40
mm) (Figure 671).
3. Place output shaft 4 on a press, small end
downward.
4. Place roller bearing 7 (earlier models, ball
bearing 6), chamfered end first, onto shaft 4.
Place a steel sleeve 2.375 inches (60.33 mm)
ID x 2.875 inches (73.03 mm) OD x 1.750 inch
(44.45 mm) long next to the bearing. Install
tools J 24447 and J 24202-4 onto the output
shaft and press roller bearing 7 against the
shoulder on the shaft.
5. Remove the tools and the sleeve from the output shaft. Press spring pin 5 into its hole in
shaft 4 until it protrudes 0.0660.076 inch
(1.681.93 mm) above the shaft surface adjacent to the pin.
6. Place governor drive gear 8, slot first, onto
shaft 4. Precisely align the slot in the gear with
spring pin 5 on the shaft.
7. For models using a press-fit governor drive
gear, place installer J 24447 and then driver
handle J 24202-4 onto shaft 4 and press gear 8
into place.
616. REAR COVER ASSEMBLY

(MT 650, 653)
1. Place rear cover assembly 13 on the work table, front side down.
2. Using remover J 24171, remove dust shield 32
(Figure 672).
643
J 24171
J 24171
OIL SEAL
DUST SHIELD
REAR COVER
REAR COVER
H00153.01
H00152.01
Figure 672. Removing Dust Shield from Rear Cover
Figure 673. Removing Oil Seal from

Rear Cover
3. Using remover J 24171, remove oil seal 31

from the rear cover (Figure 673).
4. Remove beveled snapring 30 that retains rear
output shaft bearing 29. Remove the bearing
using a soft drift to drive against the bearing
outer race.
J 24204-2
SNAPRING
J 24452
5. Place the cover front side up. Place spring compressor J 24452 on piston spring retainer 21
(Foldout 11,B). Install spring compressor base
J 24204-2. Compress the spring retainer and remove snapring 20 (Figure 674). Carefully release the spring compressor and remove it.
SPRING
RETAINER
REAR COVER
6. Remove spring retainer 21 and twenty-six piston return springs 22 (Figure 675).
7. Remove low clutch piston 23 (Figure 676).
Remove inner and outer sealrings 25 and 24
from the piston.
644
H00154.01
Figure 674. Removing (or Installing) First

Clutch (or Low Clutch) Spring
Retainer Snapring
8. Remove plugs 17, 18, 22, sealring 21, and governor filter 20 from cover 15 (Foldout 12,B).
For earlier models remove the conical metal
filter screen retained in the housing by plug 18.
Do not use the conical screen when filter 20 is
used.
9. Remove roller bearing outer race 14 only if replacement is necessary.
10. Inspect governor support pin 16. If wear is

noted on the end or OD of the pin, replacement
is necessary. Remove the governor support pin
with tool J 28708.
11. Remove plug 24, drain tube 23, and snapring
28 (if used) from the rear cover, if replacement
is necessary.
1. For earlier models, install snapring 28 into rear
cover 15 to retain the output bearing in the
housing (Figure 677).
2. If removed, install governor support pin 16 to
the dimension shown in Figure 679 (earlier
models) or Figure 680 (later models). Use
special tool J 28684 to install the governor support pin. Accuracy of location and concentricity with the governor bore are of the utmost
importance.
SPRING
RETAINER
SPRING (26)
PISTON
REAR COVER
H00155
Figure 675. Removing (or Installing) First Clutch (or

Low Clutch) Spring Retainer
OUTER
SEALRING
3. Install drain tube 23 into rear cover 15. For earlier models, press metal tube 23 into the rear
cover until it is 0.0500.100 inch (1.272.54
mm) below the chamfer in the cover (Figure 6
77). For later models, press rubber tube 23 into
rear cover 15 until it is 0.0200.150 inch
(0.513.81 mm) below the surface in the cover
(Figure 678).
4. Lubricate sealrings 24 and 25 (Foldout 11,B)
with transmission fluid and install them into
the grooves of low clutch piston 23. The lip of
each sealring must face the rear of the piston
(toward the piston cavity in the rear cover).
PISTON
;;;
;;
;;;
;;
OIL SHIELD
1.05"
(26.7 mm)
DUST SHIELD
SNAPRING
BEVEL SNAPRING
INNER
SEALRING
REAR COVER
0.050" (1.27 mm)

0.100" (2.54 mm)
H00156
DRAIN TUBE
Figure 676. Removing (or Installing) First Clutch (or

Low Clutch) Piston
V03302
Figure 677. Oil Seal and Drain Tube

Location Earlier Models
645
;;
;;;
;;;;;
1.05"
(26.67 mm)
0.020" (0.51 mm)

0.150" (3.81 mm)
BELOW SURFACE
OIL SEAL
DUST
SHIELD
BEVEL
SNAPRING
TUBE
FLUSH TO
0.040" (1.02 mm)
BELOW SURFACE
V03301
Figure 678. Oil Seal and Drain Tube

Location Later Models
REAR COVER
5.896" (149.76 mm)

5.886" (149.50 mm)
6. Install one spring 22 into each of the twentysix pockets of low clutch piston 23. Install
spring retainer 21 (cupped side first) onto the
springs (Figure 675).
7. Install spring compressor base J 24204-2 and
compressor J 24452. Compress the twenty-six
springs until snapring 20 can be installed (Figure 674).
8. Place ball bearing 29 (Foldout 12,B) into the
rear cover. Using rear bearing installer
J 24447, install the bearing until it seats firmly
in the rear cover. For earlier models, the bearing seats against snapring 28 (Figure 677).
9. Install bearing snapring 30, beveled side toward the rear of the transmission. Make sure
the snapring is fully expanded into its groove.
PIN
L00333
Figure 679. Governor Support Pin

Location Earlier Models
12. For earlier models, install the conical metal

screen (open end first) before installing plug
18. For later models, install governor filter 20
and sealring 21 into cover 15. Install plugs 17,
18, 22, and 24. Tighten plugs 17 and 18 to 48
lb ft (511 Nm). Tighten plug 24 to 1822 lb ft
(2430 Nm). Tighten filter plug 22 to 5070
lb ft (6895 Nm).
PIN
L00332
Figure 680. Governor Support Pin

Location Later Models
10. Place oil seal 31 onto installer J 24620-A, the

spring-loaded side facing away from the installer. Drive the seal into the bore of cover 15
until its rearward surface is 1.0301.070 inch
(26.227.2 mm) below the rear face of the rear
cover assembly.
11. Place dust shield 32 onto dust shield installer
J 24198, concave side first. Coat the outer circumference of the shield with a non-hardening
sealer. Drive the shield into the rear cover until
it is 0.0000.040 inch (0.001.02 mm) below
the rear face of the rear cover assembly (Figure
678).
5.896" (149.76 mm)

5.886" (149.50 mm)
646
5. Align the lug on the piston with the recess in

the housing and carefully install the piston into
the rear cover (Figure 676). Use extreme care
to prevent the lip of either seal from folding
back over itself. If installation is difficult, remove the piston and check the seal and the
cover bore before again attempting installation.
13. If roller bearing outer race 14 was removed (or

if replacing ball bearing 6 with roller bearing
7), install race 14 (inner lip first) into the front
of cover 15. The race is positioned correctly
when it is 0.1800.190 inch (4.574.83 mm)
below the surface adjacent to the bore in the
hub. Installer J 25393-A can be used to position race 14 in cover 15.
10. Remove plug 16, drain tube 15, and snapring

20 (if used) from the rear cover, if replacement
is necessary.
1. For earlier models, install snapring 20 into the
rear cover to retain the output bearing.
NOTE:
617. REAR COVER ASSEMBLY

(MT 640, 643)
1. Place rear cover assembly 6 on the work table,
front side down.
2. Using remover J 24171, remove dust shield 24
(Figure 672).
from the rear cover (Figure 673).
4. Remove beveled snapring 22 that retains rear
output shaft bearing 21. Remove the bearing
using a soft drift to drive against the bearing
outer race.
5. Place spring compressor J 24452 on piston
spring retainer 9 (Foldout 11,A). Install spring
compressor base J 24204-2. Compress the
spring retainer and remove snapring 8 (Figure
674). Carefully release the spring compressor
and remove it.
6. Remove spring retainer 9 and twenty-six
springs 10 (Figure 675).
7. Remove first clutch piston 11 (Figure 676).
Remove the inner and outer sealrings 13 and
12 from the piston.
8. For earlier models, remove the filter screen retained by plug 10 (Foldout 12,A) and the plug
from the cover. For later models remove plugs
9, 10, 14, sealring 13, and oil filter 12 from the
cover.
9. Inspect governor support pin 8. If wear is noted
on the end or OD of the pin, replacement is
necessary. Remove the governor support pin
with tool J 28708.
2. If removed, install governor support pin 8 to

the dimension shown in Figure 679 (earlier
models) or Figure 680 (later models). Use
special tool J 28684 to install the governor support pin. Accuracy of location and concentricity with the governor bore are of the utmost
importance.
3. Install drain tube 15 into rear cover 7. For earlier models, press metal tube 15 into the cover
until it is 0.0500.100 inch (1.272.54 mm)
below the chamfer in the cover (Figure 677).
For later models, press rubber tube 15 into
cover 7 until it is 0.0200.150 inch (0.513.81
mm) below the cover surface (Figure 678).
4. Lubricate sealrings 12 and 13 (Foldout 11,A)
with transmission fluid and install them into
the grooves of first clutch piston 11. The lips of
both sealrings must face the rear of the piston.
5. Carefully install the piston into the rear cover
(Figure 676). Use extreme care to prevent the
lip of either seal from folding back over itself.
If installation is difficult, remove the piston
and check the seal and the cover bore before
again attempting installation.
6. Install one spring 10 into each of the twentysix pockets of first clutch piston 11. Install
spring retainer 9 (cupped side first) onto the
springs (Figure 675).
7. Install spring compressor base J 24204-2 and
compressor J 24452. Compress the springs until snapring 8 can be installed (Figure 674).
8. For earlier models, install the conical metal
screen (open end first) before installing plug 10
(Foldout 12,A). For later models, install filter
12 and sealring 13 into cover 7. Install plugs 9,
10, 14, and 16. Tighten plugs 9 and 10 to 48
lb ft (511 Nm). Tighten plug 16 to 1822 lb ft
(2430 Nm). Tighten filter plug 14 to 5070 lb
ft (6895 Nm).
647

NOTE:
WARNING!
For MT 640, 643, proceed to Paragraph 621.
Accumulator piston springs are highly compressed. Use extreme caution during removal of
accumulator cover 27 (Foldout 17,A). Personal
injury can occur if the bolts are removed without
properly relieving the spring force.
618. OUTPUT RETARDER HOUSING

(MTB 643, 653)
a. Disassembly (Foldouts 17,A, 18,A, and 18,B)
13. Using Figure 681 as a guide, remove four

bolts 32 (Foldout 17,A) and washers 31 that
permit installation of compressor J 33429.
1. Remove six (some models, 7) bolts 2 (Foldout

18,B) and washers 3 that retain stator 4 to the
retarder housing. Remove the stator.
14. Install the four compressor bolts into the four

empty bolt holes. Tighten the four bolts finger
tight.
2. Remove sealring 5 from the groove in the OD

of stator 4.
15. Position the base of the compressor center

screw on the accumulator cover (Figure 681).
Tighten the center screw.
3. Remove clutch plate retaining snapring 1 from

stator 4.
4. Remove four internal-splined plates 7 and four
external-splined plates 6.
5. Remove retarder rotor hub 13 from the retarder
housing. Remove one sealring 12 from each
end of the rotor hub.
6. Remove rotor assembly 14.
7. Remove the three remaining clutch plates (two
internal-splined plates 7 and one externalsplined plate 6).
8. Remove backplate 15.
16. Remove the remaining nine bolts 32 and washers 31 from the accumulator cover.
17. Unscrew the center screw until piston spring
force is completely relieved (Figure 682). Remove the spring compressor and accumulator
cover 27.
18. Plugs 28 and 29 may be removed from cover
27 if they obstruct proper cleaning, or if they
are damaged and require replacement.
19. Remove three pistons 24, three inner springs 21,
three outer springs 22, and three spring retainers
20. Remove two sealrings 23 and 25 from each
piston. Do not remove spring retainer snaprings
19 unless they have been damaged.
9. Remove governor and speedometer drive gear

25 (Foldout 18,A).
10. Place the retarder housing on a work surface,
front side down.
J 33429
ACCUMULATOR
COVER
BOLT (13),
M10 x 1.5 x 50 mm
NOTE:
Perform Steps (11) and (12) only if replacement of
seal 29 (Foldout 18,A), snapring 28, or bearing 27 is
necessary.
from the rear of the retarder housing.
12. Remove snapring 28. Using a suitable drift, remove bearing 27. Remove spacer 26.
648
H00079.01
Figure 681. Installing Accumulator

Remover (Installer) Tool
20. If axial scoring or excessive wear has occurred
in the accumulator piston bores, the bores must
be reworked. Replacement sleeve PT-8640 and
boring tool kit PT-4555 are available from
Kent-Moore.
21. Remove plug 15 (Foldout 18,A), sealring 14,
and governor filter 13.
3. Install oil seal 29 with installer J 29618 into

retarder housing 2, the lip of the seal pointing
inward. Press the seal 0.050.06 inch (1.3
1.5 mm) below the chamfer in the housing.
RETARDER
HOUSING
SPACER
22. Remove plug 20, valve stop pin 22, valve stop
19, spring 18, and retarder priority valve 17.
23. Do not remove retainer and ball assembly 9,
flared tube elbow 23, and plugs 11, 16, 21, and
24 unless replacement is required.
24. Do not remove retarder housing sleeve 8 or
pin 7.
25. Remove plug 33. Inspect governor bushing 4
and speedometer bushing 10 for signs of wear.
If wear is noted, remove using remover tool
J 33818-A.
1. Place governor drive gear spacer 26 into its
cavity in the retarder housing (Figure 683).
2. Install ball bearing 27 (Figure 684). Drive the
bearing to the bottom of its bore with installer
J 33820. Retain the bearing with snapring 28.
Make sure the snapring is properly seated in its
groove.
H00062
Figure 683. Installing Governor Drive Gear Spacer
CENTER
SCREW
ACCUMULATOR
COVER
BASE
BALL BEARING
J 33429
COMPRESSOR
SNAPRING
ACCUMULATOR
PISTON (3)
PISTON
SPRING (6)
H00061
Figure 682. Removing (Installing) Accumulator Cover
H00063
Figure 684. Installing Snapring
649

4. Apply sealant, if necessary, and install plugs 11,
16, 21, and 24, and flared tube elbow 23 into
their respective bores in the retarder housing.
Tighten plugs 11 and 24 to 45 lb ft (57 Nm).
Tighten plug 16 to 810 lb ft (1114 Nm).
Tighten plug 21 to 1620 lb ft (2227 Nm).
Tighten fitting 23 to 8 lb ft (11 Nm).
5. Install governor bushing 4 and speedometer
bushing 10 into their respective bores in the retarder housing with installer J 33818-A. Install
plug 33 and tighten to 2030 lb ft (2740 Nm).
6. Install retainer and ball assembly 9 into its
bore. Press the assembly into the housing until
it bottoms against the shoulder. Stake the housing to retain the assembly.
7. Install new governor filter 13, new sealring 14,
and plug 15 into their bore. Tighten 78-14 hex
socket plug 15 to 5070 lb ft (6895 Nm).
8. Install retarder priority valve 17, spring 18, and
valve stop 19 into their bore. Press the valve
stop into the bore and insert valve stop retainer
pin 22. Install plug 20 and tighten to 1620 lb
ft (2227 Nm).
SPRING RETAINER
H00064
Figure 685. Installing Accumulator Spring Retainer

ACCUMULATOR PISTON
INNER SPRING
ACCUMULATOR PISTON
OUTER SPRING
9. If snaprings 19 (Foldout 17,A) were removed,

place the retarder housing (front side upward)
on the work surface. Install the snaprings.
10. Turn the retarder housing over. Install one
spring retainer 20 (cup side upward) into each
piston bore (Figure 685).
11. Install one outer spring 22 into each bore (Figure 686). Install one inner spring 21 inside
each outer spring.
12. Install two lip-type sealrings 23 and 25 onto
each piston 24 (Figure 687). Be sure the lips
of the sealrings point toward the tops of the
pistons. Install the pistons onto the piston
springs.
13. If accumulator cover plugs 28 and 29 were removed during disassembly, install new plugs.
Tighten each plug to 45 lb ft (57 Nm).
14. Check the retarder housing to determine if the
accumulator bores have been sleeved. If the
bores have been sleeved, special flanged-head
bolts 34 and sealring washers 33 are required
at two locations when cover assembly 27 is installed.
650
H00065
Figure 686. Installing Inner Accumulator Spring
15. Align and install a new gasket 26 and accumulator cover assembly 27 on top of the three accumulator pistons 24. Using Figure 682 as a
guide, screw in the four bolts of spring compressor J 33429. Make sure the base of the center screw is not in contact with the cover. Then
tighten the four bolts finger tight.
16. Make sure the gasket, cover, and pistons are in
proper alignment with the retarder housing.
17. Tighten the center screw, forcing the cover
downward. Using Foldout 17,A for bolt location, install nine M10 x 1.5 x 50 mm bolts 32
and nine 10 mm flat washers 31 to retain cover
assembly 27. If the accumulator bores have
been sleeved, substitute one flanged-head bolt
34 and sealring washer 33 for one plain bolt 32
and washer 31. Remove the spring compressor.
Install the remaining four bolts and washers.
Make sure that the two flanged-head bolts 34
and sealring washers 33 are in the correct locations (Foldout 17,A) if the accumulator bores
have been sleeved. Tighten the thirteen cover
ACCUMULATOR PISTON
SEALRING
INNER
SPRING
OUTER
SPRING
18. Turn the retarder housing front side upward

(Figure 688). Install governor and speedometer drive gear 25 (Foldout 18,A).
19. Install backplate 15 (Foldout 18,B), bevel
downward, into the retarder housing. Alternately install two internal-splined plates 7 and
one external-splined plate 6 into the retarder
housing, starting with an internal-splined plate
(Figure 689).
20. Install rotor assembly 14, rivet heads upward,
into the retarder housing (Figure 690).
21. Install two new sealrings 12 (Foldout 18,B)
onto rotor hub 13. Align the splines of the rotor
hub with the splines of rotor assembly 14 and
install the hub into the housing, long hub end
up (Figure 691). Make sure the hub splines
engage the two internalsplined clutch plates.
22. Alternately install four internal-splined plates
7 and four external-splined plates 6 into the retarder housing, starting with an internalsplined clutch plate.
NOTE:
RETARDER
HOUSING
Steps (23), (25), and (27) describe the three measurements that must be made during assembly to
ensure satisfactory running clearance.
H00066
Figure 687. Accumulator Pistons

EXTERNAL-SPLINED
PLATE
INTERNAL-SPLINED
PLATE
DRIVE GEAR
H00067
H00068
Figure 688. Installing Governor and

Speedometer Drive Gear
Figure 689. Installing Clutch Plates
651

26. Dimension C is the distance from the bottom
of the piston bore to the clutch pack. To obtain
Dimension C, add Dimensions A and B (A + B
= C). Using Dimension C, select the appropriate piston from the table in Figure 692. Install
the selected piston into the adapter housing.
ROTOR ASSEMBLY
27. Measure the vertical distance from the piston

face to the splitline of the housing with the gasket installed at three places (Figure 692). Calculate the average dimension and record the
value as Dimension D.
H00069
Figure 690. Installing Rotor Assembly

ROTOR ASSEMBLY
29. When the running clearance is satisfactory, remove the gasket and selected piston from the
adapter housing. Remove the top eight clutch
plates from the retarder housing.
ROTOR HUB
H00070
Figure 691. Installing Rotor Hub
23. Apply a 5080 lb (222356 N) load to the

clutch plates. Measure the vertical distance
from the retarder housing splitline (without
gasket) to the top clutch plate at three places
(Figure 692). Calculate the average dimension and record the value as Dimension B. Remove the eight clutch plates 6 and 7.
24. Disassemble the retarder adapter housing. Refer to Paragraph 619.
25. Place the retarder adapter housing (front side
down) on the work surface. Measure the vertical distance from the adapter splitline with
gasket installed to the bottom of the piston
bore at three places (Figure 692). Calculate
the average dimension and record the value as
Dimension A.
652
28. To find Dimension E (clutch running clearance) subtract Dimension D from Dimension
B. If Dimension E is between 0.064 inch (1.63
mm) and 0.097 inch (2.46 mm), the running
clearance is satisfactory. If dimension E is not
within the limits specified, recheck the affected
parts against the wear limits chart and repeat
Steps (18) through (28).
30. Install sealring 5 into the groove in the OD of

retarder stator 4 (Figure 693). Install the stator into the retarder housing. Align the bolt
holes in the stator with those in the retarder
housing. Install six M10 x 1.5 x 35 mm bolts 2
and six 10 mm flat washers 3 to retain the stator. Earlier models have a threaded hole at the
four oclock position. Do not install a bolt and
washer at this location. Tighten the bolts to 29
35 lb ft (3948 Nm).
31. Install the eight clutch plates that were removed in Step (29) (Figure 694). Install
snapring 1 to retain the retarder components in
the housing (Figure 695).
619. RETARDER ADAPTER HOUSING

(MTB 643, 653)
a. Disassembly (Foldout 19,A or 19,B)
1. Place the adapter housing, rear side upward, on
the work surface.
WARNING!
The retarder piston return spring 25 (Foldout
19,A) or 31 (Foldout 19,B) is highly compressed.
Use extreme caution during removal of the
spring. Personal injury can occur if proper removal procedures are not followed.
DIM D
DIM A
GASKET
DIM B
DIM E
DIM C
SELECTIVE PISTON TABLE

DIMENSION C
INCHES
MILLIMETERS
USE PISTON
PART NO.
PISTON
IDENT NO.
FROM
TO
FROM
TO
0.805
0.834
20.44
20.20
23015365
0.835
0.864
21.21
21.97
23015366
0.865
0.895
21.98
22.74
23015367
7
V03303
Figure 692. Establishing Clutch Running Clearance
2. Fabricate a spring removal tool similar to that

shown in Figure 696. This tool consists of a
spring compressor, a 1 x 112 x 18 inch steel
compressor bar, and two 12-13 x 10 inch
threaded rods. Each threaded rod has two jam
nuts and a flat washer on one end, and a freerunning nut and a flat washer on the other end.
3. From the front side of the housing, install the
two threaded rods through two holes 180 degrees apart in the adapter housing (Figure 6
96). Place the spring compressor on top of the
spring retainer. Place the compressor bar
across the compressor and engage the two
threaded rods. Install a flat washer and freerunning nut on each threaded rod. Tighten the
nuts finger tight.
NOTE:
For MTB 643, follow Steps (4) through (13).
4. For the MTB 643, tighten the two nuts evenly

until spring retainer 26 (Foldout 19,A) is clear
of snapring 27 (Figure 696).
5. Using snapring pliers, release snapring 27 from
its groove in the hub.
6. Carefully unscrew the two free-running nuts
evenly until the spring force is fully released.
Remove the removal tool. Remove the loose
snapring.
653

7. Remove spring retainer 26, spring 25, and retarder piston 22 from the adapter housing (Figure 697). Remove both inner and outer
sealrings 24 and 23 from the piston.
RETARDER
STATOR
8. Turn the adapter housing over, front side upward.

9. Compress spring retainer 9 (Foldout 11,A) and
remove snapring 8 (Figure 698). Remove the
retainer and twenty-six springs 10.
SEALRING
10. Remove first clutch piston 11. Remove inner

and outer sealrings 13 and 12 from the piston
(Figure 699).
H00051
11. If sleeve 11 (Foldout 19,A) is damaged, replace the entire adapter housing assembly.
Figure 693. Installing Retarder Stator

INTERNAL-SPLINED
PLATE
GUIDE BOLT (2),

NUT (6), 1/2-13 in.
1/2-13 x 10 in.
PLAIN WASHER (4), 1/2 in.
EXTERNAL-SPLINED
PLATE
COMPRESSOR
BAR
COMPRESSOR
SPRING RETAINER
PISTON
SNAPRING
PLAIN WASHER (6),
BOLT (6),
M10
M10 x 1.5 x 35 mm
H00052.01
Figure 694. Installing Clutch Plates
H00054.01
Figure 696. Removing (Installing) Piston

Retaining Snapring
SNAPRING
SPRING RETAINER
SPRING
PISTON
ADAPTER HOUSING
H00055
H00053
Figure 695. Installing Snapring
654
Figure 697. Removing (Installing) Clutch

Spring and Retainer
12. If necessary, remove plugs 8, 9, 15, 16, 17, and
retainer and ball assembly 14 for cleaning or
replacement.
22. If necessary, remove plugs 15, 16, 22, 23, retainer and ball assembly 18, and bearing race
14 for cleaning or replacement.
13. Remove roller bearing assembly 4 from the

adapter housing assembly if it did not remain
with output shaft assembly 8 (Foldout 18,B).
23. If bearing outer race 14 requires replacement,

also remove bearing race and rollers 6 from
output shaft 5.
14. For the MTB 653, tighten the two nuts evenly
until spring retainer 32 (Foldout 19,B) is clear
of snapring 33 (Figure 696).
15. Using snapring pliers, release snapring 33 from
its groove in the hub.
16. Carefully unscrew the two free-running nuts
evenly until the spring force is fully released.
Remove the removal tool. Remove the loose
snapring.
17. Remove spring retainer 32, spring 31, and retarder piston 28 from the adapter housing (Figure 697). Remove both inner and outer
sealrings 30 and 29 from the piston.
18. Turn the adapter housing over, front side upward.
19. Compress spring retainer 21 (Foldout 11,B)
and remove snapring 20 (Figure 698). Remove the retainer and twenty-six springs 22.
b. Assembly (Foldout 19,A or 19,B)

NOTE:
For MTB 643, follow Steps (1) through (9) and proceed to Step 20.
1. For the MTB 643, install plugs 8 (Foldout
19,A), 9, 15, and 16 and tighten the plugs to
810 lb ft (1114 Nm).
2. Install plug 17 and tighten to 45 lb ft (57
Nm).
3. Install retainer and ball assembly 14. Press the
new assembly into the housing until it bottoms
against its shoulder. Stake the housing for positive retention.
20. Remove the low clutch piston 23. Remove inner and outer sealrings 25 and 24 from the piston (Figure 699).
4. Lubricate and install new inner and outer liptype sealrings 13 and 12 (Foldout 11,A) into the
grooves in first clutch piston 11 (Figure 699).
Make sure the lips of the sealrings point toward
the bottom of the piston bore when the piston is
installed.
21. If sleeve 20 (Foldout 19,B) is damaged, replace

the entire adapter housing.
5. Install first clutch piston 11 into its piston

cavity (Figure 699).
FIRST CLUTCH PISTON
SNAPRING
SPRING RETAINER
SPRING (26)
OUTER SEALRING
INNER SEALRING
ADAPTER
HOUSING
H00056
Figure 698. Removing (Installing) Snapring, Spring

Retainer, and Springs
H00057.01
Figure 699. Removing (Installing) Low or

First Clutch Piston
655

6. Install twenty-six piston return springs 10 into
the pockets in the piston (Figure 698). Place
spring retainer 9 on top of the springs. Compress the retainer and install snapring 8.
7. Place the adapter housing on a work surface,
rear side upward.
8. For retarder piston 22 (Foldout 19,A) selected
in Paragraph 618b(28), lubricate and install
new lip-type sealrings 24 and 23 into the inner
and outer sealring grooves. The lips of the sealrings must point toward the bottom of the piston bore when the piston is installed.
9. Install the selected piston into the adapter
housing (Figure 697). Place piston return
spring 25, spring retainer 26, and snapring 27
on the piston.
10. For the MTB 653, install plugs 15 (Foldout
19,B), 16, and 22, and tighten the plugs to 8
10 lb ft (1114 Nm).
11. Install plug 23 and tighten to 45 lb ft (57
Nm).
12. Install retainer and ball assembly 18. Press the
new assembly into the housing until it bottoms
against its shoulder. Stake the housing for positive retention.
13. Install bearing outer race 14, inner lip first, into
its bore in the front of the adapter housing. The
outer edge of the race must be 0.2000.207
inch (5.085.26 mm) below the surface. Use
installer J 33822 and handle J 8092 to install
the race.
14. Lubricate and install new inner and outer liptype sealrings 25 and 24 (Foldout 11,B) into
the grooves in low clutch piston 23 (Figure 6
99). Make sure the lips of the sealrings point
toward the bottom of the piston bore when the
piston is installed.
15. Install low clutch piston 23 into its piston cavity (Figure 699).
the pockets in the piston (Figure 698). Place
spring retainer 21 on top of the springs. Compress the retainer and install snapring 20.
17. Place the adapter housing on a work surface,
rear side upward.
656
18. For retarder piston 28 (Foldout 19,B) selected

in Paragraph 618b(28), lubricate and install
new lip-type sealrings 30 and 29 into the inner
and outer sealring grooves. The lips of the sealrings must point toward the bottom of the piston bore when the piston is installed.
19. Install the selected piston into the adapter
housing (Figure 697). Place piston return
spring 31, spring retainer 32, and snapring 33
on the piston.
20. For both the MTB 643 and 653, install the two
threaded rods through two holes 180 degrees
apart in the adapter housing (Figure 696). The
rods must be installed from the front side.
Place the spring compressor on top of the
spring retainer. Place the compressor bar
across the spring compressor and engage the
two threaded rods. Install a flat washer and
free-running nut on each threaded rod. Tighten
the nuts finger tight.
21. Tighten the two nuts evenly until the spring retainer is compressed below the snapring
groove in the adapter housing hub. Install the
snapring.
22. Loosen the two free-running nuts evenly until
the spring retainer is against the snapring. The
snapring should be recessed into the ID of the
retainer. If the snapring rides up on the surface
of the retainer, it is not properly seated in the
snapring groove. Repeat Steps (21) and (22)
until the snapring properly seats its groove.
23. Remove the compressor tool and components.
NOTE:
620. LOW CLUTCH ADAPTER

HOUSING AND FIRST CLUTCH
PISTON (MT(B) 650, 653)
a. Disassembly (Foldouts 11,A and 11,B)
1. Place the adapter housing and attached piston
(piston upward) on the work table. Install compressor J 24452 (Figure 6100) onto first
clutch spring retainer 9 (Foldout 11,A). Attach
compressor base J 24204-2, and tighten the
base screw, compressing the retainer springs.
Remove snapring 8, retainer 9, and twenty-six
piston return springs 10.
2. Remove first clutch piston 11 from the adapter
housing, and remove inner and outer sealrings
13 and 12 from the piston (Figure 6101).
3. Remove plug 4 (Foldout 11,B) only if necessary for cleaning the internal passages in the
housing.
1. If the 14-18 plug 4 (Foldout 11,B) was removed, replace it. Tighten the plug to 810 lb
ft (1114 Nm).
2. Lubricate and install inner and outer piston
sealrings 13 and 12 (Foldout 11,A) into their
grooves in piston 11 (Figure 6101). The sealring lips must face toward the fluid pressure
side (the cavity in the adapter housing) of the
piston. Align the lug on the piston with the recess in the housing and install the piston.
the pockets of first clutch piston 11. Place
spring retainer 9, cupped side first, on top of
the twenty-six springs.
J 24204-2
J 24452
FIRST CLUTCH
PISTON
ADAPTER
HOUSING
PLUG
b. Assembly (Foldouts 11,A and 11,B)
4. Place compressor J 24452 onto spring retainer

9 (Figure 6100). Install compressor base
J 24204-2. Tighten the compressor-base center
screw handle to allow sufficient clearance for
installation of spring retainer snapring 8. Install the snapring and remove the compressor
tool.

H00058.01
Figure 6100. Removing (or Installing) First Clutch

Spring Retainer Snapring MT 650, 653
FIRST CLUTCH
PISTON
SEALRING
ADAPTER
HOUSING

1. Remove oil seal 61 from the bore in the housing, using remover J 26401. Screw the remover
into the seal. Hold the remover housing and
tighten the remover screw against the shaft,
drawing the seal out.
2. To remove manual detent lever 49, remove
shaft retainer pin 56 and nut 50. File the burred
detent lever side of the shaft. Hold the detent
lever in one hand and remove the shaft, carefully pulling it through the oil seal in the housing. Remove the detent lever.
3. If replacement of breather 2 is necessary, use
an open end wrench and rotate the breather
counterclockwise (Figure 6102). Remove the
breather.
H00059.01
Figure 6101. Removing First Clutch

Piston MT 650, 653
4. Remove 34-16 plug 62 and washer 63 (or neutral switch) and two 18 inch plugs 57 only if
necessary for cleaning internal passages.
657

5. Remove two bolts 8 (and washers, if used) that
retain lubrication valve adapter 9 (Figure 6
103). Remove the adapter and discard gasket
10 or sealring 11.
6. For earlier models, remove lubrication valve
13 and spring 14 (Figure 6103). Later transmission assemblies have lubrication regulator
valve 13, spring 14, and valve guide tube 15
pressed into housing 16 as an assembly. Do not
remove this assembly unless parts replacement
is necessary. If necessary, remove the tube with
remover J 29355. The spring and valve will
also come out.
7. Remove 18 inch plug 17 (two plugs on units

with modulated lockup) from the right side of
the transmission housing.
8. Remove drive screw 18 and nameplate 19 only
if the nameplate has been damaged.
9. If not previously removed, remove the neutral
start switch with special socket tool J 33410.
1. For earlier models, if valve guide tube 15 was
removed, install a new tube. Press the tube into
its bore until it is 0.5600.600 inch (14.215.2
mm) below the external surface of the adapter
mounting boss.
2. If 18 inch plugs 17 were removed, replace
them. Tighten the plugs to 48 lb ft (511 Nm)
(Figure 6103).
BREATHER
NOTE:
For accurate ordering of replacement parts, the information on a new nameplate must be identical to
the information that was stamped on the damaged
nameplate.
PLUG (2), 1/8 in.

PLUG, 3/4-16 in.
SELECTOR SHAFT
H00043.01
Figure 6102. Transmission Housing Left Side View
PLUG, 1/8 in.

LUBRICATION VALVE
DRIVE SCREW
NAMEPLATE
LUBRICATION
VALVE ADAPTER
GASKET
H03312
Figure 6103. Removing Lubrication Valve Adapter
658
3. If a new nameplate 19 is required, all information on the old plate must be metal stamped
into the new plate. Install the new plate and retain it with drive screw 18.
4. For earlier models, install lubrication valve 13
and spring 14. For later models, if lubrication
valve 13, spring 14, and tube 15 were removed,
install new parts. Assemble valve 13 and spring
14 onto tube 15, respectively. Install the assembly into its bore in housing 16. Press the valve
tube into its bore until it is 0.580 inch (14.7
mm) below the external surface of the adapter
mounting boss. Special tool J 29355 simplifies
the installation of the lube valve assembly.
5. Install a new gasket 10 onto valve adapter 9.
Install the adapter into the bore. Retain the
adapter with two new 14-20 x 78 inch sockethead bolts 8. The bolts and lockwashers formerly used can be replaced with socket-head
bolts when interference with hose end-fittings
occurs. Use bolts only one time. Tighten the
6. If plug 62 and washer 63 (or the neutral start
switch) or two 18 inch plugs 57 were removed, replace them. Tighten 34-16 plug 62
(or neutral start switch) to 5060 lb ft (6881
Nm). Tighten two 18 inch plugs 57 to 48 lb
ft (511 Nm).
7. Place selector shaft oil seal 61 (sealing lip
away from tool) onto installer J 26282-1. Install the seal into the housing bore (Figure
6104). Lubricate the inner bore of the seal.
Installer J 26282-1 permits installation of the
oil seal with or without the selector shaft installed.
8. Remove burrs from shaft 60 to protect oil seal
61. Guide the grooved end of the shaft through
the seal. Position detent lever 49 so that the selector valve pin extends toward the inside of
the housing, and engage the slot in the detent
lever with the flats on the selector shaft. Install
nut 50 and retainer pin 56 to retain the shaft
and lever. Tighten the nut to 1520 lb ft (2027
Nm). Refer to Paragraph 312 for installation
of the external selector lever.
9. If breather 2 was removed, install a new
breather (Figure 6102). Tighten the breather
sufficiently, using care not to distort or crush
the breather stem.
622. GOVERNOR
a. Disassembly
1. The governor may be disassembled for cleaning and inspection. Inspect the governor driven
gear for scuffed, nicked, burred, or broken
teeth. Any damage or wear requires governor
assembly replacement. Do not disassemble the
governor unless the kit consisting of two governor weight pins and the cover gasket is available.
2. Follow the directions furnished with the kit to
disassemble the governor.
b. Assembly
1. Assemble the governor as outlined in the directions furnished with the governor service kit.
2. Check the governor port openings as outlined
in the kit instructions. Refer to Figure 6105.
623. CLUTCH STACK MEASUREMENT

a. Methods. When assembly line overhaul practices
are used, stack dimension computation may be more
convenient than direct measurement. To obtain accurate dimensions, the stack to be measured must have
new clutch plates, and the applied load must be evenly
distributed over the entire clutch pack.
OIL SEAL
J 26282
GOVERNOR FEED
(Must open 0.020 in.
(0.51 mm) min)
EXHAUST PORTS
(Must open 0.020 in.
(0.51 mm) min)
GOVERNOR
PRESSURE
PORTS
H00060.01
Figure 6104. Installing Selector Shaft Oil Seal
V02308
Figure 6105. Governor Port Check
659

b. Forward Clutch
d. Low Clutch MT 650, 653
1. Stack the forward clutch plates and fourth

clutch hub (Figure 6106).
2. Apply the specified load, and measure Dimension X.
3. From the table in Figure 6106, select the forward clutch piston. Use the parts measured,
and the selected piston, in the forward clutch
assembly.
c. Fourth Clutch
1. Stack the low clutch plates into the rear of the

adapter housing (Figure 6108).
3. From the table in Figure 6108, select the low
clutch piston. Use the parts measured, and the
selected piston, when the transmission is assembled.
e. First Clutch
1. Stack the fourth clutch plates and backplate

(Figure 6107).
1. Stack the first clutch plates and piston (Figure

6109).
;;
;;
;;
;;
;;
3. From the table in Figure 6107, select the

fourth clutch piston. Use the parts measured,
and the selected piston, in the fourth clutch assembly.

3. From the table in Figure 6109, select the first
clutch backplate. Use the parts measured, and
the selected backplate, when the transmission
is assembled.
9801020 LB
(4359 4537 N)
LOAD
9801020 LB
(4359 4537 N)
LOAD
EIGHT-PLATE CLUTCH
DIMENSION X
USE PISTON MARKED PISTON THICKNESS
1.01401.0450 in.
(25.75626.543 mm)
6834668
1.0201.030 in.
(25.9126.16 mm)
1.04501.0760 in.
(26.54327.330 mm)
6834669
0.9951.005 in.
(25.2725.53 mm)
TEN-PLATE CLUTCH
DIMENSION X
DIMENSION X
1.20451.2305 in.
(30.5931.25 mm)
6834219
1.0451.055 in.
(26.5426.80 mm)
1.20451.2299 in.
(30.59431.239 mm)
23017262
1.0201.030 in.
(25.9126.16 mm)
1.23051.2565 in.
(31.2531.91 mm)
6834668
1.0201.030 in.
(25.9126.16 mm)
1.23001.2552 in.
(31.24231.882 mm)
23017261
0.9951.005 in.
(25.2725.53 mm)
1.25651.2820 in.
(31.9232.56 mm)
6834669
0.9951.005 in.
(25.2725.53 mm)
1.25521.2804 in.
(31.88232.522 mm)
23017260
0.9700.980 in.
(24.6424.89 mm)
V03304
Figure 6106. Forward Clutch Stack Dimensions
660
V03305
Figure 6107. Fourth Clutch Stack Dimensions
;;
;;
;;
;;;
;;;
9801020 LB
(4359 4537 N)
LOAD
DIMENSION X
0.40350.4325 in.
(10.24910.986 mm)
23040806
0.8000.810 in.
(20.3220.57 mm)
0.43250.4615 in.
(10.98611.722 mm)
23040807
0.8290.839 in.
(21.0621.31 mm)
0.46150.4905 in.
(11.72212.459 mm)
23040808
0.8580.868 in.
(21.7922.05 mm)
V03306
Figure 6108. Low Clutch Stack

Dimensions MT 650, 653
9801020 LB
(4359 4537 N)
LOAD
DIMENSION X
USE PLATE
MARKED
PLATE THICKNESS
2.2862.317 in.
(58.0658.85 mm)
0.7020.712 in.
(17.8318.08 mm)
2.3172.348 in.
(58.8559.64 mm)
0.6710.681 in.
(17.0417.30 mm)
2.3482.380 in.
(59.6460.45 mm)
0.6400.650 in.
(16.2616.51 mm)
f. Second and Third Clutches

1. Stack the second clutch plates and piston (Figure 6110).
NOTE:
If the measurement of Dimension X corresponds to
more than one backplate in Figure 6110, use either
plate to obtain acceptable running clearance.
3. From the table in Figure 6110, select the second clutch backplate. Use the parts measured,
and the selected backplate, when the transmission is assembled.
4. Repeat Steps (1), (2), and (3), stacking the
third clutch plates and piston. Select the third
clutch backplate. Use the parts measured, and
the selected backplate, when the transmission
is assembled.
624. PLANETARY CARRIER

ASSEMBLIES
NOTE:
The disassembly and assembly procedures for all
the planetary carrier assemblies in the MT 600 Series transmissions differ only in the proper tool selection for the specific carrier assembly. Refer to
the tool chart and Figure 6111 for specific use and
the identity of the carrier (front, center, rear, low)
and tools involved. If the tool is common to all of
the planetary carrier assemblies, its number is
listed in the text. If the tool is not common, the text
refers to the chart. For planetary carrier detailed
information, refer to the exploded views at the
back of this manual.
The hydraulic press used with J 25587-01 planetary rebuilding set (Figure 6111) should have a
ten-ton (9072 kg) capacity, an adjustable press bed
of 25 inches (64 cm) minimum opening, and a pressure gauge to assist in determining proper installation and staking of the pinion pins.
a. Assembly Inspection
V03307
Figure 6109. First Clutch Stack Dimensions
1. Visually inspect the planetary carrier assembly for

evidence of excessive wear, indications of overheating, damage, or heavy metal contamination.
661
;;
;;

will be drilled. Drill the front ends of the center
carrier assembly pins.
9801020 LB
(4359 4537 N)
LOAD
2. Place press fixture J 25587-01 in a hydraulic

press. Select the proper spacer and adapter, if
required, from the tool chart. Position these
parts (if used) to support the carrier assembly
solidly on the press fixture. The drilled ends of
the pinion pins should face upward.
DIMENSION X
USE PLATE
MARKED
PLATE THICKNESS
1.69841.7244 in.
(43.13943.799 mm)
0.4760.486 in.
(12.0912.34 mm)
1.72441.7504 in.
(43.79944.460 mm)
0.4500.460 in.
(11.4311.68 mm)
1.71141.7374 in.
(43.47044.130 mm)
0.4630.473 in.
(11.7612.01 mm)
3. Install pin remover J 25587-16 into the ram of

the press fixture. Press the pinion pins from the
carrier assembly.
4. Remove the pinion groups consisting of pinions, bearings, and thrust washers.
c. Replacing Bushing in Front and Low
Planetary Carrier Assemblies
V03308
Figure 6110. Second and Third Clutch

Stack Dimension
2. Check the end play of the planetary carrier pinions. With the thrust washer (either rotating or
non-rotating type) held flat against the pinion,
insert a feeler gauge between the carrier and
thrust washer. End play with rotating thrust
washers must be within 0.0080.031 inch
(0.200.79 mm). End play with non-rotating
thrust washers must be within 0.0040.031
inch (0.100.79 mm).
NOTE:
Do not disassemble the carrier assembly unless
parts replacement is necessary. Failure of one pinion requires replacement of the entire matched pinion gear set, pinion pins, and bearings.
Depending on the amount of labor (machining the
bushing), time, parts replacement, and extent of rework, complete replacement of the assembly may
be more practical.
b. Removal of Pinion Components
1. Using a drill that is slightly smaller than the
pinion pin diameter, drill into the swaged (rear)
end on the pins (only one end required). Do not
drill into the carrier. The rear ends of all pinion
pins except those in the center carrier assembly
662
1. Fabricate six dummy pinion pins to the dimensions shown in Figure 6112 or 6113.
2. Place the carrier on a work table, rear downward.
3. Press the bushing from the carrier. Do not
scratch or score the bushing bore. Refer to
Paragraph 45g(1).
4. Place the carrier in a press, rear downward.
5. Apply Loctite Sleeve Retainer No. 601 (or
equivalent) to the OD of the new bushings. Using bushing installer tool J 24469, install the
new bushing into the bore of the front planetary carrier. Press the bushing 0.2650.275
inch (6.736.99 mm) below its adjacent surface (Figure 6112). Using bushing installer
tool J 24472, install the new bushing into the
bore of the low planetary carrier. Press the
bushing flush to 0.010 inch (0.25 mm) below
its adjacent surface (Figure 6113). Remove
excess Loctite from the carriers.
6. Using a lathe with a four jaw chuck, mount the
carrier with Surface A facing the chuck. Insert
the six fabricated dummy pins (Figure 6112
or 6113) into the pinion pin holes. Adjust the
chuck, centering the carrier based on Surface B
and the runout of the dummy pins.
7. The total runout of the bushing after boring
must not exceed 0.002 inch (0.05 mm).
-48
-49
-50
-01
-18
-20
-16
-22
-03
-04
-12
-25
-11
-23
-13
-06
-27
-17
-08
-02
H00045
Figure 6111. Planetary Rebuild Special Tools
Planetary Carrier Assembly Rebuild Tool Chart

Note All tools in this chart have a basic number (J 25587) and a suffix. Only the suffix is shown below.
The figures in parentheses are quantities required.
Planetary Carrier
Assembly
Pin
Pin
Remover Remover
and
and
Support
Pin
Installer Installer
Block Remover Adapter Spacer
Loading
Pin
Guide
Pin
Installer
Swaging
Tool
Holder
Swaging
Tool
MT 640, 643 Front
-4
-16
-22 (6)
-50 (6)
-13
-17
-27 (2)
MT 640, 643 Center
-4
-16
-18 (4)
-48 (4)
-11
-17
-23 (2)
MT 640, 643 Rear
-3
-16
-18 (4)
-48 (4)
-12
-17
-23 (2)
MT 650, 653 Front
-4
-16
-22 (6)
-50 (6)
-13
-17
-27 (2)
MT 650, 653 Center
-4
-16
-18 (4)
-48 (4)
-11
-17
-23 (2)
MT 650, 653 Rear
-3
-16
-18 (4)
-48 (4)
-12
-17
-23 (2)
MT 650, 653 Low
-3
-16
-20 (6)
-49 (6)
-8
-17
-25 (2)
-2
-2
-6
-6
Tools in the chart above are components of Planetary Rebuilding Kit J 25587-01. Refer to Paragraph 42.
663
;;
;
;;
;;;;
;;

DUMMY PINS (6)
Bushing to be 0.265 in. (6.73 mm) to

0.275 in. (6.99 mm) below this surface
C 0.002 in. (0.05 mm) TIR
Bushing installation load must be
525 LB (2335 N) in direction shown
BUSHING
0.275 in. (6.99 mm)
0.265 in. (6.73 mm)
SURFACE A
Adjust chuck jaws to achieve

0 TIR (this locates true
position of dummy pins)
SURFACE B
2.5034 in. (63.586 mm)

DIA A
2.5019 in. (63.548 mm)
Diameter A must be perpendicular with surface B within 0.001 in. (0.02 mm) TIR.
With respect to surface B and the true position of the six (6) dummy pins,
diameter A shall be within the total runout specified by C.
2.50 in. (63.5 mm)
2.45 in. (62.2 mm)

0.025 in. (0.63 mm)
30
0.5117 in. (12.997 mm)

0.5114 in. (12.990 mm)
DUMMY PIN
V03309
Figure 6112. Front Carrier Bushing Installation Requirements
SURFACE A
0.002 in.
(0.05 mm) E
Adjust chuck jaws to achieve "O" TIR

(This locates true position of dummy pins)
DUMMY PINS (6)
0.6384 in./0.6379 in. x 2.50 in.
(16.215 mm/16.203 mm x 63.55 mm)
Bushing to be flush to
0.010 in. below this surface
3.2534 in. (82.636 mm)

3.2512 in. (82.580 mm) DIA B
Bushing installation load must be a minimum

of 525 LBS (2335 N) in direction shown
NOTE: DIAMETER B must be perpendicular with SURFACE A within 0.001 in. (0.02 mm) TIR.
With respect to SURFACE A and the true position of the six (6) dummy pins, DIAMETER B shall
be within the total runout specified by E.
Figure 6113. Low Carrier Bushing Installation Requirements
664
V03310
d. Rework Center Carrier for Non-Rotating
Thrust Washers
NOTE:
Non-rotating thrust washers may be used in any
four-pinion center carrier assembly, if the center
carrier is machined at two locations to provide
clearance for the non-rotating thrust washers to lay
flat on the carrier thrust surface.
Do not attempt this rework unless adequate machining facilities are available.
1. Disassemble the center carrier assembly. Refer
to Paragraph 624b.
2. Machine the two points of interference (Figure
6114) flush to 0.020 inch (0.51 mm) below
the existing thrust surface. Maintain a 0.050
inch (1.27 mm) radius in the corners. Do not
machine radially more than necessary to provide clearance for the thrust washers.
3. Thoroughly clean the carrier to remove machining debris.
4. Reassemble the carrier assembly. Refer to
Paragraph 624e.
CENTER
CARRIER
NON-ROTATING
THRUST WASHERS
; ;
INTERFERENCE
POINTS
NOTE: Remove interference points flush to 0.020 in. (0.51 mm)

below the existing thrust surface, with a 0.05 in. (1.27 mm)
radius in the corners.
V03311
Figure 6114. Rework of Center Carrier for

Non-Rotating Thrust Washers
e. Installation of Pinion Components
NOTE:
Lubricate needle rollers and thrust washers before
assembling the pinion groups.
1. For MT 650, 653 rear carriers, if needle bearing assembly 39 or 49 (Foldout 9,B) was not
removed in Paragraph 612a(11), remove it
now. Make sure to install a new bearing assembly (inner lip of race first) into the carrier before installing the pinions.
2. Assemble all the pinion groups for the carrier
assembly. Assemble each group by inserting
the proper loading pin into the pinion bore, installing the needle roller bearings around the
loading pin, installing a steel thrust washer at
each end of the pinion, and installing a bronze
thrust washer onto each steel thrust washer. If
using non-rotating thrust washers, the bronze
surface must be next to the steel thrust washer.
3. Position the carrier assembly, rear upward
(center carrier, front upward). Install all the
pinion groups into the planetary carrier, aligning the loading pins with the pin bores in the
carrier.
4. Install the proper pinion guide pins (refer to the
tool chart and Figure 6111), larger diameters
first, into the pinion pin bores. Push the guide
pins through the carrier until the loading pins
drop out.
5. Position the carrier assembly on the press fixture, using the proper pin remover and installer
adapter (if required).
NOTE:
Pin installers are shaped to avoid interference with
bosses on the carrier assemblies. They must be installed in the ram so the cutaway portion of the installer will clear the bosses when the pinion pin is
pressed in.
665

6. Select the proper pin installer, and install it into
the press fixture ram.
CAUTION:
Do not put pressure on the carrier. Distortion of
the carrier will damage it.
7. Place a pinion pin on the pilot end of the pin

guide located below the press fixture ram.
Press the pinion pin into the carrier until the installer contacts the carrier.
8. Proceed with the installation of the remaining
pinion pins.
9. Remove the carrier assembly from the press
fixture. Install swaging tool holder J 25587-17
into the opening of the press fixture bed. Install
a swaging tool into the holder. Install another
swaging tool into the press fixture ram. Lubricate both ends of the pinion pins with oil-soluble grease.
10. Position the carrier assembly, rear upward
(center carrier, front upward) on the press fixture. Use the proper support block to level the
carrier while the lower swaging tool is supporting the lower end of one pinion pin.
NOTE:
Swaging pressure is approximately two tons (1814
kg) for front carrier pinion pins and three tons
(2722 kg) for center, rear, and low carrier pinion
pins. While applying pressure, rotate the pinions
and feel for reduction of end play. The pinions must
rotate freely. Pinions with rotating bronze thrust
washers must have 0.0080.031 inch (0.200.79
mm) minimum end play after swaging the pins. Pinions with non-rotating bronze thrust washers must
have 0.0040.031 inch (0.100.79 mm) minimum
end play after swaging the pins.
11. Apply sufficient pressure to the press fixture
ram to firmly swage the end of the pinion pin
against the metal of the carrier. Figure 6115
illustrates a typical swage pattern. Repeat the
procedure to swage the remaining pinion pin
ends.
0.120 in. (3.048 mm) TYPICAL
90
Swage both ends of six

pins securely, as shown.
Gears must turn freely.
V02967
Figure 6115. Typical Swaging Pattern on Pinion Pin
666
Section 7 ASSEMBLY OF TRANSMISSION

71.
SCOPE
a. Selecting Center Support Snapring
This section covers assembly of models MT(B) 640,

643, 650, and 653. Procedures common to all models
have no model identification. Where procedures apply
to specific models, the model(s) will be identified. If
the procedure does not apply to the model being assembled, continue with the next applicable procedure.
Assembly procedures for the various models are organized as follows:
Model
Paragraphs
All Models
73, 74, 75, 76, 78,

710, 711, 712
MT 640, 643
79
MTB 643
77
MT 650, 653
79
MTB 653
77
1. Position the transmission housing, converter

end up. Install second clutch backplate 28
(Foldout 8,B).
2. Beginning with an internal-splined clutch
plate, alternately install three internal-splined
clutch plates 27 and three external-tanged
clutch plates 26 into the transmission housing.
Retain the plates with snapring 25. Install the
snapring with the snapring gap at the 12
oclock position and be sure the snapring is
fully seated in its groove.
3. Remove third clutch piston 9 from center support assembly 13. Attach center support lifter
J 24455 into the recess between the sealring
grooves on the support hub (Figure 71).

FINAL ASSEMBLY
Refer to Sections 4 and 8 for general information as
follows:
Paragraph
Description
42
Tools and Equipment
43
Replacement Parts
44
Careful Handling
46
Assembly Procedures
410
411
Selective Parts
81
Wear Limits Data
82
Spring Data
4. Align the tapped hole in the support (Figure

71) with the anchor bolt hole in the transmission housing (Figure 72). Carefully lower the
support into the housing, seating it firmly
against second clutch retaining snapring 25.
Remove the lifting bracket from the support.
Retain the support by installing the original
38-16 x 3 inch (earlier models, 38-16 x 214
inch) self-locking anchor bolt 54 and washer
55 (Foldout 10,A) removed in Paragraph 59d.
Tighten the bolt finger tight.
FOURTH CLUTCH
PRESSURE PORT
J 24455
73. INSTALLATION OF CLUTCHES,

CENTER SUPPORT, PLANETARY
GEARING, AND REAR COVER OR
RETARDER
NOTE:
The clearances for low, first, second, and third
clutches are established by direct measurement in
this section (Paragraphs 73b, e, f, j, and o). Refer to
Paragraph 623 for stack dimension computation
of clutch clearances.
RETAINER
RING TANG (4)
TAPPED HOLE
CENTER
SUPPORT
ASSEMBLY
H00095.01
Figure 71. Installing Center Support Assembly
71
J 23717-1
CENTER SUPPORT
BOLT HOLE
J 24475-2
H03313
Figure 72. Center Support Anchor Bolt Hole
5. Install compressor base J 24475-1 over the hub

of the center support (Figure 73). Install compressor bar J 24475-2 and screw J 23717-1, retaining the bar to the transmission with two 3816 x 114 inch bolts. Compress the support by
applying a torque of 5 lb ft (7 Nm) to screw
J 23717-1.
6. Using gauge J 34127, measure the clearance
between the top edge of the center support and
the top of the snapring groove in the housing
(Figure 74). Select the proper snapring 5
(Foldout 8,B), using the following table.
Measured
Clearance
in. (mm)
Snapring
Thickness
in. (mm)
0.1500.154
(3.813.91)
0.1480.150
(3.763.81)
White
0.1540.157
(3.913.99)
0.1520.154
(3.863.91)
Yellow
0.1570.160
(3.994.06)
01550.157
(3.943.99)
Green
0.1600.164
(4.064.17)
0.1580.160
(4.014.06)
Red
BOLT (2), 3/8-16 x 11/4 in.
J 24475-1
H00139.01
CENTER SUPPORT
Figure 73. Compressing Center Support
Snapring
Color
J 24475-2
J 34127
7. Install the selected snapring and remove the

center support compressor from the transmission.
CENTER SUPPORT
b. Second Clutch Clearance
H00140.01
1. Invert the transmission housing, output end upward.

72
Figure 74. Measuring for Selection of Center

Support Snapring
ASSEMBLY OF TRANSMISSION
2. Using gauge J 26915, check the second clutch
plate clearance. Insert the gauge between the
backplate and the transmission housing (Figure
75). The prescribed clearance is 0.0490.111
inch (1.242.82 mm). When the clearance is
correct, the first step of the gauge fits between
the backplate and the transmission housing,
and the second step does not.
3. If the clearance is not satisfactory, measure the
total plate thickness and replace all plates necessary to satisfy the prescribed clearance. If required, the backplate may be replaced by a
thicker or thinner plate.
NOTE:
For MTB 643, proceed to Paragraph 73d.
For MT(B) 650, 653 proceed to Paragraph 73f.
c. Rear Cover MT 640, 643 (Foldout 12,A)
1. Place rear cover gasket 5 on the transmission
housing, aligning the holes in the gasket with
those in the housing (Figure 76).
2. Install rear cover assembly 6 (as assembled in
Paragraph 617) onto the transmission housing
(Figure 76).
J 26915
BACKPLATE
NOTE:
Do not mix zinc plated and non-zinc plated rear
cover bolts in the same transmission. Do not use
washers with zinc plated flanged hex head bolts.
3. Install fourteen 12-13 x 112 inch bolts 18 or 19
and fourteen washers 17 (used with nonflanged bolts 18) to retain the rear cover assembly. Tighten two bolts that are 180 degrees
apart to 33 lb ft (45 Nm). Move approximately
90 degrees around the bolt circle and repeat the
operation. Tighten the remaining bolts at 180
degrees increments to 33 lb ft (45 Nm). Repeat the entire process tightening each of the
fourteen bolts to 6780 lb ft (91108 Nm) for
non-plated bolts or 6173 lb ft (8399 Nm)
for zinc plated bolts.
NOTE:
For MT 640, 643, proceed to Paragraph 73e.
d. Output Retarder MTB 643
1. If bearing 4 (Foldout 19,A) was removed from
output shaft 11 (Foldout 18,B), install a new
bearing. Press the new bearing to a firm seat
against the shaft shoulder. If bearing 9 and orifice plug 10 were removed, install new ones. Install bearing 9 to 0.1800.200 inch (4.575.08
mm) below end of shaft with installer J 34016.
Install orifice plug 10 (orifice end first) to just
below the chamfer of its bore in the shaft.
REAR COVER
GASKET
CENTER SUPPORT
TRANSMISSION
HOUSING
H00141.01
Figure 75. Checking Second Clutch Clearance
H00112
Figure 76. Installing Rear Cover MT 640, 643
73

2. Install two 12-13 guide bolts into the adapterto-transmission housing bolt circle. Install one
bolt at 3 oclock and one at 9 oclock.
3. Align and install gasket 1 (Foldout 19,A) onto
the guide bolts.
4. Install sealring 21 onto the adapter housing.
5. Install the adapter housing assembly onto the
guide bolts (Figure 77). Remove the guide
bolts.
6. Install fourteen 12-13 x 2 inch bolts 20, fourteen 12 inch flat washers 19, and fourteen sealrings 18 to retain the adapter housing to the
transmission housing. Tighten two bolts 180
degrees apart to 45 lb ft (61 Nm). Move approximately 90 degrees around the bolt circle
and repeat the operation. Tighten the remaining
bolts at 180 degrees increments to 45 lb ft (61
Nm). Repeat the entire procedure tightening
each of the fourteen bolts to 8197 lb ft (110
132 Nm).
7. Install gasket 1 (Foldout 18,A) onto the adapter
housing.
8. Install the output shaft (splined-end first) into
the adapter housing. Lightly tap the output
shaft until the bearing seats against the hub of
the rear planetary carrier.
9. Attach a three-leg sling to the rear of the retarder housing (Figure 78). Adjust the length
of the sling legs so that the retarder housing is
level for easier installation.
10. Using a hoist, lower the retarder housing onto

the adapter housing. Guide governor and
speedometer drive gear 25 (Foldout 18,A) and
spacer 26 onto the output shaft as the retarder
housing is lowered onto the transmission. Recheck the gasket alignment and tap the retarder
housing to a firm seat on the adapter housing.
NOTE:
Hose clamp bracket 12 (Foldout 17,A) is retained to
the adapter housing by one of the retarder housing
bolts at the ten-thirty oclock position.
11. From the front side of the adapter housing, install eleven M12 x 1.75 x 60 mm bolts 2 (Foldout 19,A) and eleven 12 mm flat washers 3,
and six M12 x 1.75 x 45 mm bolts 5 and six 12
mm flat washers 6. Remove the sling. Install
three M12 x 1.75 x 130 mm bolts 32 (Foldout
18,A) and three 12 mm flat washers 31 from
the rear side of the retarder housing.
12. Tighten two bolts 180 degrees apart to 30 lb ft
(40 Nm). Move approximately 90 degrees
around the splitline and repeat the operation.
Tighten the remaining bolts at 180 degree increments to 30 lb ft (40 Nm). Repeat the entire
procedure, tightening each of the twenty bolts
to 5363 lb ft (7285 Nm).
OUTPUT
SHAFT
RETARDER
HOUSING
OUTPUT
SHAFT
SEALRING
GASKET
REAR
ADAPTER
HOUSING
GASKET
H00047
Figure 77. Installing Retarder Adapter Housing

Assembly MTB 653
74
ADAPTER
HOUSING
H00115.01
Figure 78. Installing Retarder Housing Assembly
e. First Clutch Clearance MT(B) 640, 643
(Foldout 11,A)
RING GEAR
1. Invert the transmission, front side up.

2. Remove the selected snapring that retains the
center support. Remove the center support anchor bolt and washer. Attach center support
lifter J 24455 to the hub of the support (Figure
71). Remove the center support from the
transmission. Remove the lifting bracket from
the center support.
BACKPLATE
EXTERNAL-TANGED
CLUTCH PLATES
INTERNAL-SPLINED
CLUTCH PLATES
3. Remove the second clutch retaining snapring.

Remove the six second clutch plates and the
backplate from the transmission housing. Retain the second clutch plates in a pack. Do not
intermix with other plates.
H00098.01
4. Alternately, install two external-tanged clutch

plates 4 and one internal-splined clutch plate 3,
starting with an external-tanged plate.
Figure 79. Installing Rear Planetary Ring Gear,

First Clutch Plates, and Backplate
5. Place rear planetary ring gear 14 (extended

tooth side down) on the work table. Beginning
with an internal-splined clutch plate, install
five internal-splined clutch plates 3 and four
external-tanged clutch plates 4 and backplate 2
(flat side first) onto the ring gear. Install the
ring gear and plates as an assembly into the
transmission housing (Figure 79).
SNAPRING
BACKPLATE
RING GEAR
6. Retain the first clutch pack with snapring 1

(Figure 710). Install the snapring with the
snapring gap at the 12 oclock position and be
sure the snapring is fully seated in its groove.
7. Using first clutch clearance gauge J 26914,
check the clearance between the snapring and
backplate (Figure 711). Correct first clutch
clearance is 0.0740.147 inch (1.883.73 mm).
When the clearance is correct, the first step of
the gauge fits between the snapring and backplate, and the second step does not.
total plate thickness and replace all plates necessary to achieve the correct clearance. If required, the backplate may be replaced by a
H00142.01
Figure 710. Installing First Clutch

Snapring MT 640, 643
NOTE:
For MT(B) 640, 643 proceed to Paragraph 73k.
75

f. Low Clutch Clearance MT(B) 650, 653
(Foldout 11,B)
1. Position adapter housing 3 and the first clutch
piston (as assembled in Paragraph 620) on a
clean work surface, piston downward (Figure 7
12). Install the low clutch plates (six externaltanged plates 17 and five internal-splined plates
18) into the adapter housing (Figure 712).
2. Position the rear cover (as assembled in Paragraph 616) or retarder adapter housing (as assembled in Paragraph 619) on a clean work
surface, piston upward, and install the rear
cover gasket (Figure 712). Using a depth micrometer as shown in Figure 712, measure
and record Dimension A (distance from top of
housing to top clutch plate). Use firm hand
pressure against the plates at the point of measurement.
3. Using a depth micrometer as shown in Figure
712, measure and record Dimension B (distance from top of piston to gasket on mounting
flange).
5. If the low clutch adapter housing, rear cover, or

retarder adapter housing was replaced, it may
be necessary to select a piston with a different
thickness to obtain the desired clearance.
6. After the desired clearance is established, remove and identify the low clutch pack.
g. Low Clutch Planetary MT(B) 650, 653
(Foldout 11,B)
1. Install low clutch adapter housing gasket 1
onto the rear of the transmission housing (Figure 713). Install the adapter housing 3 and the
first clutch piston (as assembled in Paragraph
620). Use 12-13 x 6 inch guide bolts J 1927-1
to maintain gasket alignment during assembly.
2. Install tanged thrust washer 5 and low planetary sun gear 6 (Figure 714).
3. Install thrust washer 7 into low planetary
assembly 8 and retain it with oil-soluble
grease (Figure 715). Install the planetary
assembly (as assembled in Paragraph 624)
onto the planetary sun gear (Figure 715).
4. Subtract Dimension B from Dimension A to obtain low clutch clearance. The clearance is acceptable if it is within 0.0810.139 inch (2.06
3.53 mm). Replace worn plates with new plates
to obtain the desired running clearance.
ADAPTER
HOUSING
DEPTH MICROMETER
A
CLUTCH PLATES
DEPTH MICROMETER
PISTON
SNAPRING
BACKPLATE
GASKET
SECOND CLUTCH
PLATES
J 26914
REAR
COVER
A B = CLEARANCE
H00048.01
Figure 711. Checking First Clutch Clearance
76
Figure 712. Establishing Low Clutch

Clearance MT(B) 650, 653
L00342
J 1927-1
LOW PLANETARY
ASSEMBLY
J 1927-1
ADAPTER
HOUSING
GASKET
THRUST WASHER
LOW SUN GEAR
H00143.01
H00050.01
Figure 713. Installing Adapter

Housing MT(B) 650, 653
Figure 715. Installing Low Planetary Carrier

Assembly MT(B) 650, 653
LOW RING
GEAR
LOW PLANETARY
SUN GEAR
ADAPTER
HOUSING
THRUST
WASHER
LOW
PLANETARY
ASSEMBLY
THRUST
WASHER
H00031.01
H00049
Figure 714. Installing Low Planetary Sun

Gear MT(B) 650, 653
4. Install thrust washer 16 onto the hub of low

ring gear 19 and retain it with oil-soluble
grease (Figure 716). Center the thrust washer
within the planetary assembly and install the
ring gear (Figure 716).
5. Beginning with an external-tanged plate, install the low clutch pack (removed in Paragraph 73f) into the adapter housing. Particular
attention must be given to the positioning of
the three sets of double tangs on the plates. If
the tangs are not positioned as shown in Figure
717, movement of the stationary plates will
occur.
Figure 716. Installing Low Planetary Ring

Gear MT(B) 650, 653
6. Install the output shaft assembly (as assembled

in Paragraph 615) into the low ring gear (Figure 718).
7. For MT 650, 653, if the governor drive gear was
not previously installed, install it onto the output
shaft and engage the spring pin with the slot in
the drive gear (Figure 719). Install speedometer drive gear 9 or speed sensor wheel 10 (Foldout 12,B), and spacer 11 (if used) onto the
output shaft.
NOTE:
For MTB 653, proceed to Paragraph 73i.
77
EXTERNALTANGED
PLATE
h. Rear Cover, Governor MT 650, 653

(Foldout 12,B)
DOUBLE
TANG
DOUBLE
TANG
INTERNALSPLINED
PLATE
DOUBLE
TANG
1. Install rear cover gasket 12 onto the adapter

housing (Figure 719). Install rear cover assembly 13 (as assembled in Paragraph 616)
onto the adapter housing (Figure 719).
NOTE:
Do not mix zinc plated and non-zinc plated rear
cover bolts in the same transmission. Do not use
washers with zinc plated flanged hex head bolts.
H00032
.
Figure 717. Installing Low Clutch

Plates MT(B) 650, 653
2. Install twelve 12-13 x 514 inch bolts 26 or 27

and twelve washers 25 (used with non-flanged
bolts 26) through the rear cover and adapter
housing, and into the transmission housing
(Figure 720). Replace the two guide bolts with
the two remaining cover bolts and washers.
Tighten two bolts that are 180 degrees apart to
33 lb ft (45 Nm). Move approximately 90 degrees around the bolt circle and repeat the operation. Tighten the remaining opposite pairs of
bolts to 33 lb ft (45 Nm). Repeat the entire process, tightening all fourteen bolts to 6780 lb ft
(91108 Nm) for non-plated bolts or 6173 lb
ft (8399 Nm) for zinc plated bolts.
OUTPUT
SHAFT
ASSEMBLY
REAR
COVER
ASSEMBLY
BEARING
LOW RING
GEAR
SPEEDOMETER
DRIVE GEAR
GOVERNOR
DRIVE GEAR
J 1927-1
J 1927-1
H00033.01
Figure 718. Installing Output

Shaft MT(B) 650, 653
GASKET
H00034.01
Figure 719. Installing Rear Cover MT 650, 653
78
3. Install the governor into the rear cover assembly (Figure 721). Install governor cover gasket 38 and governor cover 39 onto the rear
cover assembly. Retain the governor cover
with four 516-18 x 1116 inch bolts 40. Tighten
the bolts to 1520 lb ft (2027 Nm).
3. Install two 12-13 guide bolts into the adapterto-transmission housing bolt circle. Install one
bolt at 3 oclock and one at 9 oclock.
4. Align and install gasket 7 onto the guide bolts.
4. If an output flange spacer is required, refer to

the note in Paragraph 511c(2). Refer to Paragraph 317h for installation of the output
flange retaining nut.
OUTPUT SHAFT
REAR COVER
GOVERNOR
NOTE:
For MT 650, 653, proceed to Paragraph 73j.
i. Output Retarder MTB 653 (Foldout 19,B)
1. If bearing race and rollers 6 were removed
from output shaft 5, install new bearing and
race 6. Press the new bearing and race to a firm
seat against the shaft shoulder. If bushing 3 and
orifice plug 4 were removed, install new ones.
Install bushing 3 to 0.3600.380 inch (9.14
9.65 mm) below end of shaft. Install orifice
plug 4 (orifice end first) to just below the
chamfer of its bore in the shaft.
2. Slip spacer 10 onto the output shaft assembly
(Figure 722). Install the shaft assembly into
the transmission.
ADAPTER
HOUSING
TRANSMISSION
HOUSING
H00145
Figure 721. Installing Governor

Assembly MT 650, 653
OUTPUT SHAFT
REAR COVER
SPACER
BEARING RACE
AND ROLLERS
OUTPUT SHAFT
BOLT (14), 1/2-13 x 51/4 in.
WASHER (14)
ADAPTER
HOUSING
H00035
H00144.01
Figure 720. Tightening Rear Cover Bolts MT 650,

653
Figure 722. Installing Output Shaft

Assembly MTB 653
79

5. Install sealring 27 onto retarder adapter housing 13.
NOTE:
6. Install the adapter housing assembly onto the

guide bolts (Figure 723). Remove the guide
bolts.
Hose clamp bracket 12 (Foldout 17,A) is retained to

the adapter housing by one of the retarder housing
bolts at the ten-thirty oclock position.
7. Install fourteen 12-13 x 512 inch bolts 26,

fourteen 12 inch flat washers 25, and fourteen
sealrings 24 to retain the retarder adapter housing and low clutch adapter housing to the
transmission housing. Tighten two bolts 180
degrees apart to 45 lb ft (61 Nm). Move approximately 90 degrees around the bolt circle
and repeat the operation. Tighten the remaining
bolts at 180 degree increments to 45 lb ft (61
Nm). Repeat the entire procedure, tightening
each of the fourteen bolts to 8197 lb ft (110
132 Nm).
8. Install gasket 1 (Foldout 18,A) onto the retarder adapter housing.
9. Attach a three-leg sling to the rear of the retarder housing (Figure 724). Adjust the length
of the sling legs so that the retarder housing is
level for easier installation.
10. Using a hoist, lower the retarder housing onto
the adapter housing. Guide governor and
speedometer drive gear 25 (Foldout 18,A) and
spacer 26 onto the output shaft as the retarder
housing is lowered onto the transmission. Recheck the gasket alignment and tap the retarder
housing to a firm seat on the adapter housing.
11. From the front side of the adapter housing, install twelve M12 x 1.75 x 90 mm bolts 8
(Foldout 19,B) and twelve 12 mm flat washers
9, and five M12 x 1.75 x 45 mm bolts 11 and
five 12 mm flat washers 12. Remove the sling.
Install three M12 x 1.75 x 130 mm bolts 32
(Foldout 18,A) and three 12 mm flat washers
31 from the rear side of the retarder housing.
12. Tighten two bolts 180 degrees apart to 30 lb ft
(40 Nm). Move approximately 90 degrees
around the splitline and repeat the operation.
Tighten the remaining bolts at 180 degree increments to 30 lb ft (40 Nm). Repeat the entire
procedure, tightening each of the twenty bolts
to 5363 lb ft (7285 Nm).
j. First Clutch Clearance MT(B) 650, 653

(Foldout 11,A)
1. Invert the transmission, front side upward.
OUTPUT
SHAFT
RETARDER
HOUSING
OUTPUT
SHAFT
SEALRING
GASKET
REAR
ADAPTER
HOUSING
GASKET
H00047
Figure 723. Installing Retarder Adapter Housing

Assembly MTB 653
710
ADAPTER
HOUSING
H00115.01
Figure 724. Installing Retarder Housing Assembly
2. Remove the center support anchor bolt and
washer. Remove the snapring that retains the
center support. It may be necessary to compress the center support in order to remove the
snapring. Attach center support lifting bracket
J 24455 to the hub of the support. Remove the
center support.
3. Remove the second clutch plate retaining
snapring. Remove the six second clutch plates
and backplate from the transmission housing.
Retain the second clutch plates in a pack. Do
not intermix with other plates.
4. Install ring gear hub 6 into ring gear 5 and retain it with snapring 7.
5. Install tanged thrust washer 2 (Foldout 11,B)
into the hub of the adapter housing (Figure 7
25). Install the rear planetary ring gear and hub
assembly.
6. Starting with an external-tanged plate, alternately install six external-tanged clutch plates
4 (Foldout 11,A) and six internal-splined
clutch plates 3. Install backplate 2 (flat side
first) and retain it with snapring 1 (Figure 7
26). Install the snapring with the snapring gap
at the 12 oclock position and be sure the
snapring is fully seated in its groove.
7. Using first clutch gauge J 26914, check the

clearance between the snapring and the backplate as shown in Figure 711. Correct first
clutch clearance is 0.0740.147 inch (1.88
3.73 mm). When the clearance is correct, the
first step of the gauge fits between the snapring
and the backplate, and the second step does not.
NOTE:
For MT(B) 650, 653 proceed to Paragraph 73l.
k. Gear Unit Assembly MT(B) 640, 643
(Foldout 9,A)
1. Attach gear unit lifter J 24454 behind the
splines of the main shaft (Figure 727).
2. Using a hoist, carefully lower the gear unit (as
assembled in Paragraph 613) into the transmission housing. Engage the pinions of the
rear planetary carrier assembly with the teeth
of the rear planetary ring gear. For the MTB
643, also engage the splines of the rear planetary carrier with the splines of the output shaft.
NOTE:
For MT(B) 640, 643 proceed to Paragraph 73m.
RING GEAR
AND HUB
ASSEMBLY
SNAPRING
BACKPLATE
FIRST
CLUTCH
PISTON
FIRST CLUTCH
PLATES (12)
THRUST WASHER
H00036.01
Figure 725. Installing Rear Planetary Ring Gear and

Hub Assembly MT 650, 653
H00037.01
Figure 726. Installing First Clutch

Snapring MT 650, 653
711

l. Gear Unit Assembly MT(B) 650, 653
(Foldout 9,B)
1. Attach gear unit lifter J 24454 behind the
splines of the main shaft (Figure 727). Be
sure that thrust washer 47 is retained by oilsoluble grease to rear carrier assembly 38.
2. Using a hoist, carefully lower the gear unit (as
assembled in Paragraph 612) into the transmission housing. Engage the internal-splines
of the rear planetary carrier assembly hub with
the splines of the output shaft, and the pinions
of the rear carrier assembly with the teeth of
the rear planetary ring gear.
2. Install snapring 25 to retain the second clutch

(Figure 729). Place the ends of the snapring at
the top of the main case. Be sure the thrust
washer is in place on the front sun gear.
n. Center Support (Foldout 8,B)
1. Install the third clutch piston (as assembled in
Paragraph 611e) into the center support. Be
sure that the piston sealrings are not pinched or
distorted when the piston is installed.
SECOND CLUTCH
BACKPLATE
INTERNAL-SPLINED
PLATE
m. Second Clutch (Foldout 8,B)

NOTE:
Before installing the second clutch, be sure the
clutch pack meets the required clearance. Refer to
Paragraph 73b.
1. Install the second clutch pack into the transmission (Figure 728). Install second clutch
backplate 28. Beginning with an internalsplined plate 27, alternately install three internal-splined plates 27 and three external-tanged
plates 26.
GEAR UNIT
H00038.01
Figure 728. Installing Second Clutch Plates

SECOND CLUTCH
PLATES
SNAPRING
J 24454
MAIN SHAFT
GEAR UNIT
THRUST
WASHER
H00097.01
Figure 727. Installing Gear Unit
712
H00039
Figure 729. Installing Second Clutch Snapring
2. Attach center support lifter J 24455 into the recess between the sealring grooves on the support hub (Figure 730).
3. If the center support has two grooves machined
in the OD of the support, shim 29 is required.
Bend the shim to conform to the center support
OD. Apply oil-soluble grease to the shim and
position it over the fluid supply holes in the
center support. Index the boss on the shim into
the corresponding fluid passage for retention.
When correctly installed, the holes in the support and shim align and the shim lies flush on
the support.
4. Apply a light film of fluid on the transmission
housing center support bore to aid assembly.
5. Align the tapped hole in the center support
(Figure 730) with the anchor bolt hole in the
transmission housing (Figure 731). Install the
center support (as assembled in Paragraph 6
11) and shim 29 (if required). Seat the support
firmly against the second clutch snapring.
FOURTH CLUTCH
PRESSURE PORT
J 24455
RETAINER
RING TANG (4)
TAPPED HOLE
CENTER
SUPPORT
ASSEMBLY
H00095.01
Figure 730. Installing Center Support Assembly
6. Check the support and shim alignment by

viewing from the valve body mounting surface.
The support and shim should align with all
fluid passages in the transmission housing.
7. Remove the lifter from the center support. Start
a new 38-16 x 3 inch special self-locking bolt
54 (Foldout 10,A) and chamfered washer 55
into the center support assembly. Earlier models use a 38-16 x 214 inch bolt and plain
washer. Refer to Paragraph 611b for rework
to the later configuration.
CENTER SUPPORT
BOLT
H03314
8. Install snapring 5 (Foldout 8,B) selected in

Paragraph 73a, to retain the center support.
Place the ends of the snapring at the top of the
main case. Tighten the center support anchor
bolt to 3946 lb ft (5362 Nm) (Figure 731).
CAUTION:
Improper installation of butt-joint sealrings may
cause transmission failure. Refer to Paragraph
46f for proper installation procedure.
9. Install needle roller thrust bearing race assembly 15 (Foldout 8,A), lube relief scallops and
black oxide race up, onto the center support
hub. Install two butt-joint sealrings 12 (Foldout
8,B) onto the hub.
Figure 731. Tightening Center Support Bolt
NOTE:
For earlier models, install the needle roller bearing
assembly (rollers upward) onto the center support
hub.
o. Third Clutch Clearance (Foldout 8,B)
1. Starting with external-tanged plate, as shown
in Figure 732, alternately install three external-tanged plates 4 and three internal-splined
plates 3. Note the location of the three sets of
double tangs. If the tangs are not positioned as
shown, movement of the stationary plates will
occur.
713

2. Install backplate 2 and retain it with snapring 1
(Figure 733). Using third clutch clearance
gauge J 26916, check the clearance between the
snapring and backplate. Correct third clutch
clearance is 0.0500.114 inch (1.272.90 mm).
When the clearance is correct, the first step of
the gauge fits between the snapring and the
backplate, and the second step does not.
INTERNALSPLINED
PLATE
DOUBLE
TANGS
DOUBLE
TANGS

p. Fourth Clutch (Foldout 8,A). On earlier models,
be sure the needle bearing race is in place on the rear
of the fourth clutch housing hub. Align the internal
splines of the third clutch plates to the external splines
on the fourth clutch housing. Grasp the fourth clutch
assembly (as assembled in Paragraph 610) by the
spring retainer and install it onto the center support
hub (Figure 734).
q. Forward Clutch and Turbine Shaft (Foldout 7,B)
1. Align the internal-splined plates of the fourth
clutch, and direct air into the fourth clutch apply port (Figure 735). The air applies the
fourth clutch and prevents movement of the
clutch plates during installation of the forward
clutch assembly.
EXTERNALTANGED
PLATE
DOUBLE
TANGS
H00021
Figure 732. Installing Third Clutch Plates
2. Be sure thrust bearing race assembly 26 is in

place (black oxide race and lube scallops facing down) on the fourth clutch housing hub.
For earlier models, the needle bearing and race
should be securely in place on the forward
clutch hub, and the mating race on the hub of
fourth clutch housing (Figure 735).
FOURTH
CLUTCH
ASSEMBLY
SNAPRING
GAP
J 26916
SNAPRING
BACKPLATE
H00146.01
Figure 733. Checking Third Clutch Clearance
714
THIRD
CLUTCH
PISTON
RETAINER RING
TANG
H00022
Figure 734. Installing Fourth Clutch Assembly
FORWARD CLUTCH
ASSEMBLY
FOURTH
CLUTCH
HUB
FOURTH
CLUTCH
BEARING
RACE
TURBINE
SHAFT
GASKET
FORWARD
CLUTCH
HOUSING
INTERNALSPLINED
PLATES (4)
BEARING
RACE
H00024
Figure 736. Installing Front Support Gasket
CAUTION:
Improper installation of butt-joint sealrings may
cause transmission failure. Refer to Paragraph
46f for proper installation procedure.
AIR SUPPLY
H00023.01
Figure 735. Installing Forward Clutch Assembly
3. Install the forward clutch assembly (as assembled in Paragraph 69) while engaging the
fourth clutch hub within the internal-splined
plates of the fourth clutch (Figure 735).
When the forward clutch assembly seats
properly, the front surface of the forward
clutch housing is approximately 12 inch (12.7
mm) behind the forward edge of the PTO
opening. Another check is to apply air in short
bursts to the fourth clutch and watch the forward clutch assembly for an up and down
movement. If the assembly does not move, it
is properly seated.
74. INSTALLATION OF OIL PUMP AND

FRONT SUPPORT (Foldout 7,A)
a. Install front support gasket 33 onto the forward
clutch housing (Figure 736). Be sure the two hooktype sealrings at the base of the turbine shaft are held
in place with oil-soluble grease.
b. Install thrust bearing race assembly 31 onto the

hub of support assembly 22, black oxide race and lube
scallops up. Install two butt-joint sealrings 32 onto the
hub. Retain the bearing and sealrings with oil-soluble
grease.
NOTE:
For earlier models, install the bearing and race assembly (race first) onto the hub of support assembly
22. Check for the race on the front of the forward
clutch housing.
c. Lubricate sealring 2 with oil-soluble grease and
install it onto support assembly 22. Install two 38-16 x
6 inch headless guide screws J 24315-1 into the
transmission housing (Figure 737). Attach front
support lifter J 24473 to the converter ground sleeve.
Align all the holes in the front support with the
corresponding holes in the transmission housing.
Index two of these holes to corresponding holes
containing the two guide bolts and install the front
support.
715

d. Install ten of the twelve 38-16 x 338 inch bolts 35
and rubber-covered washers 34 (Figure 738).
Remove the two guide bolts and install the two
remaining bolts 35 and washers 34. Do not tighten the
bolts in sequence. Maintain an even pull on the outer
perimeter of the support by tightening the first two
bolts 180 degrees apart to 15 lb ft (20 Nm). Move
approximately 90 degrees around the bolt circle and
repeat the operation. Tighten the remaining opposite
pairs of bolts. Repeat the entire procedure, tightening
all twelve bolts to 2432 lb ft (3343 Nm).
75. INSTALLATION OF HYDRAULIC

CONTROL COMPONENTS
NOTE:
For MT(B) 650, 653 proceed to Paragraph 75c.
J 24473
FRONT SUPPORT
CONVERTER GROUND SLEEVE
a. Control Valve Assembly MT(B) 640, 643

(Foldout 13)
1. Install governor check ball 49 (if used) into the
deep pocket end of the governor pressure recess (Figure 739).
NOTE:
Later model transmissions do not utilize governor
check ball 49.
2. With the shift selector valve suitably secured,
position the control valve assembly (as assembled in Paragraph 66) so the actuator pin enters the housing bore (Figure 739). Install the
control valve body and retain it with two 14-20
x 3 inch bolts 24 (Foldout 10,A), and sixteen
14-20 x 214 inch bolts 28 (Figure 740). Earlier models require one 14-20 x 234 inch bolt
25 and seventeen 14-20 x 214 inch bolts 28
(Figure 741). On later models, do not install
the two first clutch feed tube retainer bolts.
Leave all bolts sufficiently loose to move the
valve body for engagement of the selector
valve with the shift pin.
3. Later models discontinued the use of the governor oil screen (Figure 741). If the screen
was not discarded during disassembly, discard
it now.
J 24315-1
SHIFT
SELECTOR
VALVE
H00147.01
Figure 737. Installing Oil Pump and Front

Support Assembly
RUBBER
BAND
OIL PUMP AND FRONT

SUPPORT ASSEMBLY
CHECK BALL
BOLT (12), 3/8-16 x 33/8 in.
RUBBER-COVERED
WASHER (12)
H00025.01
CONTROL
VALVE
ASSEMBLY
ACTUATOR PIN
H03286
Figure 738. Tightening Oil Pump and

Front Support Bolts
716
Figure 739. Installing Control Valve Assembly
b. Tube Adapter MT(B) 640, 643
(Foldout 10,A)
DETENT LEVER
1. On later models, insert the two governor feed

and pressure tubes into tube adapter 20 (Figure
740). Place the tube adapter in position on the
transmission housing and insert the two tubes
into their respective bores in the valve body.
Simultaneously insert the first clutch feed tube
into its bore in the tube adapter and valve body.
2. On earlier models, insert the first clutch feed
tube and the two governor feed and pressure
tubes into tube adapter 20 (Figure 741). Place
the tube adapter in position on the transmission
housing and insert the three tubes into their respective bores in the valve body.
3. Install four 14-20 x 114 inch bolts 21 to retain
the tube adapter. Tighten the bolts to 812 lb ft
(1116 Nm). Use preset torque wrench
J 29612 for this operation.
4. Engage the notch in the shift selector valve
with the pin on the detent lever (Figure 740 or
741). Position the detent spring to engage a
notch in the detent lever and install one 14-20 x
134 inch bolt 26 to retain it. Tighten the bolt to
812 lb ft (1116 Nm).
5. On later models, install the 14-20 x 3 inch bolts
24 that retain the first clutch feed tube. Working
from the center outward, tighten two 14-20 x 3
inch bolts, and sixteen 14-20 x 214 inch bolts
28 (Figure 740) to 812 lb ft (1116 Nm).
Earlier models use one 14-20 x 234 inch bolt 25
and seventeen 14-20 x 214 inch bolts 28. Use
preset torque wrench J 29612 for this operation.
NOTE:
For MT 640, 643 proceed to Paragraph 75f.
c. Control Valve Assembly MT(B) 650, 653
(Foldout 14)
1. Install governor check ball 49 (if used) into the
deep pocket end of the governor pressure recess (Figure 739).
NOTE:
Later model transmissions do not utilize governor
check ball 49.
DETENT SPRING
BOLT, 1/4-20 x 13/4 in.
BOLT (2), 1/4-20 x 3 in.
BOLT (16), 1/4-20 x 21/4 in.
FIRST CLUTCH
FEED
GOVERNOR PRESSURE
GOVERNOR FEED
TUBE ADAPTER
H00026.01
Figure 740. Installing Tube Adapter MT 643

(Later Models)
DETENT LEVER
SELECTOR VALVE
DETENT SPRING
BOLT, 1/4-20
23/4 in.
BOLT, 1/4-20 x 13/4 in.
BOLT (17), 1/4-20 x 21/4 in.

CONTROL VALVE
ASSEMBLY
FIRST CLUTCH FEED
GOVERNOR SCREEN
GOVERNOR FEED
GOVERNOR
PRESSURE
TUBE ADAPTER
H00093.01
Figure 741. Installing Tube Adapter MT 640, 643

(Earlier Models)
2. With the shift selector valve suitably secured,

position the control valve assembly (as assembled in Paragraph 66) so the actuator pin
enters the housing bore (Figure 739). Install
the control valve body and retain it with two
14-20 x 3 inch bolts 24 (Foldout 10,A), and
sixteen 14-20 x 214 inch bolts 28. Earlier
717

models require one 14-20 x 234 inch bolt 25
and seventeen 14-20 x 214 inch bolts 28. Leave
the bolts sufficiently loose to move the valve
body for engagement of the selector valve, and
installation of the bracketed external tubes
used on later models.
d. Low Shift Valve Body MT(B) 650, 653.

Install the separator plate and low shift valve (as
assembled in Paragraph 65) onto the oil transfer plate
(Figure 746). Install seven 14-20 x 234 inch bolts 22
(Foldout 10,A) to retain the low shift valve. Do not
tighten the bolts at this time.
3. Later models discontinued the use of the governor oil screen (Figure 742). If the screen
was not discarded during disassembly, discard
it now.
4. Retain the oil transfer plate with two 14-20 x
78 inch bolts 23 (Figure 743). Temporarily install seven 14-20 x 234 inch bolts 22 to align
the transfer plate. Tighten the two 14-20 x 78
inch bolts to 812 lb ft (1116 Nm), and remove the seven temporarily installed bolts 22.
5. Engage the groove in the shift selector valve
with the pin on the detent lever (Figure 743).
Position the detent spring to engage a notch in
the detent lever and install one 14-20 x 134
inch bolt 26. Tighten the bolt to 812 lb ft
(1116 Nm).
6. If the external tubes illustrated in Figure 744
are used, tighten the eighteen control valve
bolts, working from the center outward, to 8
12 lb ft (1116 Nm). Use preset torque wrench
J 29612 for this operation. Then proceed to
Paragraph 75d. If the external tubes illustrated in Figure 745 are used, do not tighten
the bolts and proceed with Paragraph 75d.
SHIFT SELECTOR
VALVE
DETENT
LEVER
DETENT
SPRING
BOLT,
1/4-20 x 13/4 in.
BOLT (16),
x 21/4 in.
1/4-20
BOLT (2),
x 3 in.
1/4-20
OIL TRANSFER
PLATE
BOLT (2), 1/4-20 x 7/8 in.

H03315
Figure 743. Tightening Control Valve Bolts
FORWARD REGULATOR TUBE
CONTROL
VALVE
ASSEMBLY
GOVERNOR
OIL SCREEN
TUBES
DRIVE 1
OIL
TRANSFER
PLATE
LOW SHIFT
VALVE ASSEMBLY
FIRST TRIMMER
LOW AND FIRST FEED
H00029
H00027
Figure 742. Installing Oil Transfer Plate MT 650, 653
718
Figure 744. Installing External Tubes into Valve

Bodies MT 650, 653 (Earlier Models)
e. Valve Tubing MT(B) 650, 653 (Foldout 14)
NOTE:
The external tubes shown in Figure 744 and described in Step (1) were used on earlier models. Later models use external tubes with bolted brackets
permanently attached (Figure 745) and are described in Steps (2) and (3).
1. Install the valve external tubes in this order:

drive-1 tube 87, forward regulator tube 88, first
trimmer tube 85, and low and first feed tube 86
(Figure 744). The forward-regulator tube is
required on some transmissions before S/N
47285. Be sure each tube is seated in its bore.
Failure to seat the tubes properly will cause
leakage and interference at final torquing.
2. Place each of the bracketed external tubes in
their proper positions, inserting the tubes into
their respective bores. Locate the brackets on
the tubes for their particular valve body retaining bolts. Mark the bolts. Remove the tubes
and their corresponding bolts.
3. Install the tubes in this order: drive-1 tube 87,

low and first feed tube 86, and first trimmer
tube 85. Be sure the tubes are properly seated
into their respective bores. Install the bracket
retaining bolts, but do not tighten (Figure 7
45).
4. Working from the center outward, tighten the
eighteen control valve body bolts (Figure 7
45) to 812 lb ft (1116 Nm). Tighten the
seven low shift valve body bolts to 812 lb ft
(1116 Nm) (Figure 746). Use preset torque
wrench J 29612 for this operation.
f. Modulated Lockup Valve Assembly
(Foldout 15,A)
1. Install the modulated lockup valve body assembly (as assembled in Paragraph 64). Install three 14-20 x 2 inch bolts to retain the
valve body (Figure 747). If four 14-20 x 134
inch bolts (earlier models) were removed during disassembly, use only three bolts for valve
body installation. Do not install the fourth bolt.
2. Tighten the bolts to 812 lb ft (1116 Nm) using preset torque wrench J 29612.
LOW SHIFT
VALVE ASSEMBLY
BOLT (7),
x 2 34 in.
14-20
FIRST
TRIMMER
CONTROL VALVE
BODY
SEPARATOR
PLATE
OIL TRANSFER
PLATE
DRIVE 1
LOW AND
FIRST FEED
LOW SHIFT
VALVE ASSEMBLY
H03316
H03287
Figure 745. Installing External Tubes into Valve

Bodies MT 650, 653 (Later Models)
Figure 746. Tightening Low Shift Valve

Bolts MT 650, 653
719

76. INSTALLATION OF OIL FILTER,
PAN, TORQUE CONVERTER
MODULATED LOCKUP
VALVE ASSEMBLY
OIL FILTER
OIL FILTER
SUCTION TUBE
SEALRING
CAUTION:
When installing the oil filter, filter tube, and sealring, avoid twisting the tube or filter in any way
that might pinch, cut, or deform the sealring. An
airtight seal must be maintained to enable the oil
pump to draw fluid from the sump free of entrained air.
a. Oil Filter (Standard Configuration)
(Foldout 10,A).
1. If using a paper element filter, install filter tube
32 into filter 33 (Figure 748). Install sealring
31 or 39 onto the upper end of the tube. Apply
oil-soluble grease to both the sealring and its
bore in the housing.
2. Install filter assembly 30 or 38 and retain it
with a 516-18 x 58 inch bolt 35 or 42. Tighten
the bolt to 1015 lb ft (1420 Nm).
H03284
Figure 748. Installing Oil Filter Standard

Configuration
b. Oil Pan (Foldout 10,A)

1. Install two 516-18 x 3 inch headless guide
screws J 3387-2 into the transmission housing
(Figure 749). Install the oil pan gasket.
J 3387-2
2. Install the oil pan and retain it with twenty-one

washer-head screws 48. Remove the two guide
bolts for installation of last two screws.
Tighten the screws to 1520 lb ft (2027 Nm).
Pan bolts must retain a minimum of 5 lb ft (7
Nm) after gasket set to prevent leakage.
GASKET
BOLT (3)
No bolt required
OIL PAN
MODULATED
LOCKUP VALVE
ASSEMBLY
H00011.01
H03317
Figure 747. Tightening Modulated Lockup Valve Bolts
720
Figure 749. Installing Oil Pan Standard

Configuration
c. Oil Filter Canister (Heavy-Duty
1. Install a new sealring 9 on filter canister 11
neck. Apply a liberal amount of oil-soluble
grease to the sealring.
2. Install the canister assembly, secure with hex
washer-head screw 10 and 14-20 x 234 inch
bolt 12 into the low shift valve body. Tighten
the screw to 1015 lb ft (1420 Nm). Tighten
d. Oil Pan and Filter (Heavy-Duty
1. Install two 516-18 x 3 inch headless guide bolts
J 3387-2 into the transmission housing. Install
gasket 28 (Figure 750). Install oil pan 25 and
retain it with twenty-one washer-head screws
24. Tighten the screws to 1520 lb ft (2027
Nm).
2. Attach torque converter lifter J 6795-01 to the

torque converter assembly (as assembled in
Paragraph 63).
3. Suspend the torque converter assembly on a
hoist (Figure 751). Install the assembly onto
the transmission while rotating it to engage the
flats on the pump hub with the flats in the
transmission oil pump. The splines of the turbine hub (within the converter) must also engage the splines of the turbine shaft.
4. When the converter assembly is seated, measure the distance from the transmission mounting flange to the converter cover (Figure 752).
This distance should be approximately 916
inch (14.3 mm). If the measurement is significantly greater than 916 inch (14.3 mm), raise
the converter assembly slightly, rotate it to
align the pump hub flats, and reseat it.
J 6795-01
2. Install sealrings on filter retainer 16 and filter

access lip of pan. Install filter 14 and retainer 16.
3. Install spring 17 in cover 19 and place over the
filter retainer. Install 516-24 x 78 inch bolt 21
and nut 22 to attach strap 20 to pan. Tighten
ASSEMBLED
TORQUE
CONVERTER
FLAT AREA
4. Refer to Paragraph 34 for dipstick calibration

specifications.
e. Torque Converter (Foldout 6)
H00012.01
1. For transmissions after S/N 49489, check that

sealring 49 is lubricated with oil-soluble grease
and installed into its groove in pump hub 48 before installing the torque converter assembly.
HEX HEAD SCREWS (23)
Figure 751. Installing Torque Converter Assembly

SCALE
J 6795-01
BAR STOCK
SEALRING
FILTER
RETAINER
NUT (24), 5/16-24 in.
GASKET
H00013.01
H00130
Figure 750. Installing Oil Pan

and Filter Heavy-Duty Configuration
Figure 752. Measuring Installed

Height of Torque Converter
721

5. Remove lifter J 6795-01. Install a retaining
strap (Figure 753) to prevent the torque converter assembly from moving. Keep this strap
in place until ready to install the transmission
into the vehicle.
NOTE:
For MT 640, 643, 650, 653, proceed to Paragraph 79.
b. Hose Assemblies, Fittings, and Brackets

(Foldout 17,A)
1. Install sealrings 1 and 13 onto elbows 2 and 14.
Screw elbow 2 into the transmission housing.
Screw elbow 14 into the retarder valve port located at the rear of the retarder valve (Figure
756). Tighten the elbows until the sealrings
start to compress against the housing. Do not
tighten the jam nut.
77. INSTALLING RETARDER

EXTERNAL COMPONENTS
(MTB 643, 653)
GUIDE BOLT (2)
a. Retarder Valve Body (Foldout 17,B)

1. Install two M10 x 1.5 guide bolts (Figure 754).
2. Install a new gasket 1, separator plate 2, and a
new gasket 1 onto the guide bolts (Figure 754).
SEPARATOR PLATE
3. Using the two guide bolts to support the valve,

install retarder valve assembly 7 onto the retarder housing (Figure 755).
GASKET (2)
RETARDER HOUSING
H00131
4. Retain the valve body to the retarder housing

with nine M10 x 1.5 x 100 mm bolts 6, one
M10 x 1.5 x 45 mm bolt 4, and ten 10 mm
lockwashers 3 and 5.
Figure 754. Installing Retarder Valve

Gasket and Separator Plate
5. Remove the two guide bolts and install the two

remaining bolts and lockwashers. Tighten the
twelve bolts to 3035 lb ft (3948 Nm).
GUIDE BOLT (2)
RETARDER
VALVE BODY
RETAINING STRAP
H00014
Figure 753. Converter Retaining Strap
722
H00132
Figure 755. Installing Retarder Valve Body
2. If converter-out hose assembly 3 does not
have hose clamp 4 attached, install a new
clamp. Connect the ends of the hose assembly
to elbows 2 and 14. Tighten hose coupling
nuts to 5565 lb ft (7588 Nm). Tighten the
jam nuts on elbows 2 and 14 to 2535 lb ft
(3447 Nm).
NOTE:
Hose clamp bracket 12 is retained to the adapter
housing by one of the retarder housing bolts (Figure
756). If bracket 12 was not previously installed, install it now.
3. Install one 516-18 x 12 inch bolt 5 through
hose clamp 4 and hose clamp bracket 12. Retain the bolt, clamp, and bracket together with
one 516 inch lockwasher 11 and one 516-18
hex nut 10. Tighten the nut to 120144 lb in.
(1416 Nm).
4. Install sealrings 6 and 9 onto flared tube connectors 7 and 8.
5. Install connector 8 into the center port in the
front of the retarder valve (Figure 756). Tighten
the connector to 2535 lb ft (3447 Nm).
TO RETARDER
CLUTCH
RETARDER
CONTROL
VALVE
6. Install connector 7 into the side of the transmission housing (Figure 756). Tighten the
connector to 2535 lb ft (3447 Nm).
7. Install elbow 18 into the retarder valve body
(Figure 756). Tighten the elbow between 12
16 lb ft (1622 Nm) and at an angle to accept
the check valve and feed line.
NOTE:
Check valve 17 must be installed with the flow arrow (on side of valve) pointing upward.
Do not mix current clutch feed hose 15 and fitting
16 with the earlier hose and fitting. Refer to the
current Parts Catalog PC1316EN.
8. Attach check valve 17 onto elbow 18 and
tighten the valve to 1215 lb ft (1621 Nm).
Install fitting 16 into check valve 17 and
tighten the fitting to 1215 lb ft (1621 Nm).
Attach clutch feed hose assembly 15 to fitting
16 and elbow 23 (Foldout 18,A). Tighten the
hose coupling nuts to 1620 lb ft (2227 Nm).
78. INSTALLING GOVERNOR AND

GOVERNOR COVER
a. Install the governor assembly by pushing it inward with a slight rotation, counter-clockwise (Figure
757 or 758).
HOSE CLAMP
AND BRACKET
CONVERTER-OUT
HOSE ASSEMBLY
OUTPUT SHAFT
REAR COVER
GOVERNOR
ADAPTER
HOUSING
CHECK
VALVE
COOLER OIL TO
LUBE CONNECTORS
Figure 756. External Hose Connections

(Earlier Models)
TRANSMISSION
HOUSING
H00136.2
H00145

Assembly MT 640, 643, 650, 653
723

REAR
COVER
GOVERNOR
COVER
BOLT (4)
5/16-18 x 11/16 in.
ADAPTER
HOUSING
GOVERNOR
ASSEMBLY
H00133
I

Assembly MTB 643, 653
b. For MT 640, 643, 650, and 653, install the

governor cover gasket and cover (Figure 759). Retain
the cover with four 516-18 x 1116 inch bolts. Tighten
the bolts to 1520 lb ft (2027 Nm).
H00134.01

Cover MT 640, 643, 650, 653
.
GASKET
c. For MTB 643 and 653, install the governor cover

gasket and cover (Figure 760). Retain the cover with
four M8 x 1.25 x 25 bolts and M8 lockwashers.
Tighten the bolts to 1316 lb ft (1822 Nm).
COVER
NOTE:
For MTB 643, 653, proceed to Paragraph 710.
79. INSTALLATION OF
OUTPUT COMPONENTS
(MT 640, 643, 650, 653)
a. Governor and Speedometer Drive Gears,
Rear Bearing
BOLT (4), M8 x 1.25 x 25 mm
1. For MT 640, 643, install governor drive gear 1

(Foldout 12,A), slot first, onto the output shaft
assembly (Figure 761). Engage the slot in the
drive gear with the protruding pin on the output shaft. Install speedometer drive gear 2 or
speed sensor wheel 3, and sleeve spacer 4 (if
used) onto the output shaft. Place ball bearing
21 (Foldout 12,A) into the rear cover. Using
installer J 24446, install the bearing into the
cover (Figures 762). Seat the bearing at the
bottom of its bore against snapring 28 (earlier
models) or the cast surface of the rear cover.
724
LOCKWASHER, M8 (4)
H00099.01
Figure 760. Installing Governor Cover MTB 643, 653
2. For MT 650, 653, install governor drive gear 8

(Foldout 12,B), slot first, onto the output shaft
assembly (Figure 761). Engage the slot in the
drive gear with the protruding pin on the output
shaft. Install speedometer drive gear 9 or speed
sensor wheel 10, and sleeve spacer 11 (if used)
onto the output shaft. Place ball bearing 29
(Foldout 12,B) into the rear cover. Using installer J 24447 with J 24202-4, install the
bearing into the cover (Figures 763). Seat the
bearing at the bottom of its bore against
snapring 28 (earlier models) or the cast surface
of the rear cover.
3. Secure the rear bearing with beveled snapring
22 (Foldout 12,A) or 30 (Foldout 12,B) (Figure
764). Be sure the beveled side of the snapring
faces the rear of the transmission, and the
snapring is fully expanded into the groove of
the housing.
J 24446
b. Oil Seal, Dust Shield

REAR COVER
1. Lubricate and pack oil seal 23 (Foldout 12,A)

or 31 (Foldout 12,B) with a high-temperature
grease that conforms to MIL-G-3545A. Place
the seal on oil seal installer J 24448 (MT 640,
643) or J 24620-A (MT 650, 653), sealing lip
away from installer. Insert the seal installer and
the seal into the rear cover and drive the seal
into the bore until its rearward surface is 1.03
1.07 inch (26.227.2 mm) below the rear face
of the cover assembly (Figure 765). The installer seats against the rear cover hub when
the seal is properly positioned.
H00135.01
Figure 762. Installing Output Shaft Rear

Bearing MT 640, 643
J 24447
J 24202-4
REAR COVER
ASSEMBLY
OUTPUT SHAFT
GEAR
PIN SLOT
H00016.01
H00015
Figure 761. Installing Governor Drive Gear
Figure 763. Installing Output Shaft Rear

Bearing MT 650, 653
725

2. Place dust shield 24 (Foldout 12,A) or 32
(Foldout 12,B) onto dust shield installer
J 24198, concave side first (Figure 766).
Drive the seal into the rear cover until it is flush
with, to 0.040 inch (1.02 mm) below the rear
face of the rear cover assembly (the installer
will seat on the rear face).
3. For MT 640 and 643, refer to Paragraph 317g
for installation of the output flange retaining bolt.
710. REMOVAL OF TRANSMISSION

FROM OVERHAUL STAND AND
INSTALLATION OF NEUTRAL
START SWITCH
a. Supporting Transmission
1. Attach a sling to the transmission (Figure 7
67). Support the transmission and remove it
from the holding fixture.
2. Remove the bolts, adapter, and adapter plate.
Lower the transmission to a supporting surface, and remove the sling.
BEARING
SNAPRING
b. Installing PTO Cover (Foldout 10,A)
REAR COVER
ASSEMBLY
1. Install gasket 5 and cover 6.

2. Retain the cover with six 38-16 x 34 inch bolts
7. Tighten the bolts to 1520 lb ft (2027 Nm).
3. If not previously installed, install the neutral
start switch with socket wrench J 33410 using
partial turns of the wrench. Torque the switch
to 5060 lb ft (6881 Nm). Make sure the tool
is not contacting the transmission housing
when verifying the final torque reading.
H00018.01
Figure 764. Installing Rear Bearing Snapring

J 24202-4
J 24202-4
J 24448 (MT 640, 643)

J 24620-A (MT 650, 653)
J 24198
DUST SHIELD
OIL SEAL
REAR COVER
ASSEMBLY
REAR COVER
ASSEMBLY
H00019.01
H00017.01
Figure 765. Installing Output Shaft Oil Seal
726
Figure 766. Installing Dust Shield
BOLT (6)
3/8-16 x 13/4 in.
J 23642-01
ing pad. Place the required shims (or gaskets)

on the guide bolts.
CAUTION:
J 24462-1
The transmission and PTO can be damaged if the

PTO is installed with its drive gear to the front of
the PTO drive gear.
5. If the PTO has a manual disconnect, be sure
that the disconnect lever is in the disconnect
position. When the PTO is installed on the
mounting pad, the PTO driven gear must be to
the rear of the PTO drive gear in the transmission.
WASHER (6)
J 3289-20
H00010.01
Figure 767. Removing Transmission

from Overhaul Stand
711. CHECKING SHIFT POINTS

Refer to Paragraph 313 for shift point checks and adjustments.
712. POWER TAKEOFF COMPONENTS

CAUTION:
Cork or other soft gasket material cannot be
used to mount the PTO. Use only the shims or
gaskets recommended by the PTO manufacturer.
a. Establishing PTO Backlash
1. Be sure the mounting pad is clean and free of
burrs, debris, and shims. Position tool J 34814
(Figure 768) onto the pad so that the gauge
pin is between two drive-gear teeth.
2. Tighten the two hold-down bolts.
3. Measure the height between the gauge pin and
base plate (Figure 768) with a feeler gauge.
Refer to the chart for the quantity of shims or
gaskets required to establish gear backlash of
0.0060.029 inch (0.150.73 mm).
4. Place the shim(s) onto the mounting pad and
install two headless guide bolts, one into the
top and one into the bottom of the PTO mount-
6. Install the PTO on the mounting pad and

tighten the six mounting bolts to 2632 lb ft
(3543 Nm).
7. Connect the lubrication line (if used).
b. New Installation
1. Contact Allison Transmission Division of General Motors for approval of planned installation, or for recommendations.
2. Speeds, type of duty, power requirements, and
other factors must be considered when adding
a PTO to a transmission. If the job requirements of the PTO cannot be fully met by the
transmission, the installation will not be satisfactory. Also, the transmission could be damaged.
3. Install the PTO as described in Paragraph
712a.
4. If a lubrication source is required, the return
line from cooler-to-transmission may be
tapped. Provide a 0.032 inch (0.81 mm) restriction in the lubrication circuit (usually already
provided in the PTO assembly).
CAUTION:
Do not remove lubrication regulator valve
adapter 9 (Foldout 10,A). Remove only the fluid
line or fitting that connects to the adapter. Drill
and tap the fitting or hose end to provide PTO lubrication.
727
;;

TRANSMISSION
MAIN CASE
BASE PLATE
GAUGE PIN
MEASUREMENT
PTO PAD
HOLD-DOWN
BOLT
J 34814
MEASUREMENT
PTO DRIVE
GEAR
CORRECTION
0.0110.046 inch
(0.271.16 mm)
Correct Height
One 0.030 inch Gasket

(One 0.76 mm Gasket)
0.0470.070 inch
(1.191.78 mm)
Correct Height
Two 0.030 inch Gaskets

(Two 0.76 mm Gaskets)
Figure 768. Measuring Converter-Driven PTO Backlash

.
728
V02394
Section 8 WEAR LIMITS AND SPRING DATA

81.
WEAR LIMITS DATA
a. Maximum Variations. Wear limit information in

this section shows the maximum wear at which components are expected to perform satisfactorily. Table 81
lists the wear limits data and is referenced to the exploded
views (Foldouts 6 through 19) in the back of this manual.
b. Cleaning and Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Paragraph 45.
82. SPRING DATA

a. Springs must be clean to permit effective inspection. Replace springs if there are signs of overheating,
wear due to rubbing adjacent parts, or permanent set.

Discard springs which do not meet the load-height
specifications in the spring chart.
b. Spring inspection criteria (load vs height) and
identification characteristics are presented in Table 82.
The spring data is referenced to the exploded views
(Foldouts 6 through 19) in the back of this manual.
NOTE:
Where more than one spring part number is listed
for the same location, refer to the current Parts Catalog PC1316EN to determine which spring is used
in your specific assembly number.
Table 81. Wear Limits

Wear Limit
Illustration
Foldout 6
Description
inch
(mm)
TORQUE CONVERTER, LOCKUP CLUTCH
Bushing, maximum clearance on turbine shaft 5 (Foldout 7,B)
0.0045
10
Piston, face wear
No scoring permitted
12
Clutch plate, minimum thickness
0.175
14
Backplate, face wear
26
Side plates, maximum ID
2.857
72.57
Stator thrust washer in stator, minimum thickness (measure across

thrust face and needle bearing with bearing installed)
0.435
11.05
Roller race, diameter
24, 25
32
0.114
4.45
Foldout 7,A OIL PUMP, FRONT SUPPORT ASSEMBLY

6
Bushing, maximum clearance on pump hub 39 or 48 (Foldout 6)

0.68 inch wide pump
0.005
0.127
0.82 inch wide pump
0.012
0.305
Maximum end clearance
0.003
0.076
Maximum diametral clearance
0.0084
0.213
Drive gear, maximum end clearance
0.002
0.051
Minimum thickness
0.0955
2.426
Maximum cone
0.010
0.25
Driven gear
Foldout 7,B FORWARD CLUTCH, TURBINE SHAFT

22
External-tanged clutch plate
81

Table 81. Wear Limits (contd)
Wear Limit
Illustration
23
24
Description
inch
(mm)
Internal-splined clutch plate

Minimum thickness
0.090
2.29
Maximum cone
0.010
0.25
Minimum depth of oil grooves
0.008
0.20
0.248
6.30
0.252
6.40
Minimum thickness
0.090
2.29
Maximum cone
0.010
0.25
0.008
0.20
Minimum thickness
0.0955
2.426
Maximum cone
0.010
0.25
Minimum thickness
0.476
12.09
Maximum step wear
0.010
0.25
Minimum thickness
0.450
11.43
Maximum step wear
0.010
0.25
Minimum thickness
0.463
11.76
Maximum step wear
0.010
0.25
Minimum thickness
0.117
2.97
Maximum cone
0.010
0.25
0.008
0.20
Minimum thickness
0.0955
2.426
Maximum cone
0.010
0.25
0.006
0.152
Fourth clutch driving hub

Minimum thickness at clutch plate contact area
Foldout 8,A FOURTH CLUTCH

3
Clutch backplate
Minimum thickness at clutch plate contact area
Internal-splined plate
External-tanged plate
Foldout 8,B THIRD CLUTCH, CENTER SUPPORT, SECOND CLUTCH

2
3, 27
4, 26
14
82
Backplate (No. 7)
Backplate (No. 8)
Backplate (No. 9)
Bushing, maximum clearance on sun gear shaft 23 (Foldout 9,B) or

23 (Foldout 9,A)
WEAR LIMITS AND SPRING DATA

Wear Limit
Illustration
Description
inch
(mm)
Foldout 9,A GEAR UNIT, MAIN SHAFT MT 640, 643

1
Thrust washer, minimum thickness
0.092
2.34
0.091
2.31
Front carrier bushing, maximum clearance on front sun gear 2
0.0049
0.124
0.091
2.31
Sun gear shaft bushing, maximum clearance on main shaft 35
0.006
0.152
0.091
2.31
Output shaft bushing, maximum clearance on main shaft 35
0.0065
0.165
2, 11
12
26, 35
36
51, 35
Foldout 9,B GEAR UNIT, MAIN SHAFT MT 650, 653

1
0.092
2.34
3, 47
0.091
2.31
2, 11
Front carrier bushing, maximum clearance on front sun gear 2
0.0049
0.124
0.091
2.31
Sun gear shaft bushing, maximum clearance on main shaft 35
0.006
0.152
12
26, 35
Foldout 11,A FIRST CLUTCH, REAR PLANETARY RING GEARS

2
Backplate (No. 4), minimum thickness
0.702
17.83
0.671
17.04
0.640
16.26
Minimum thickness
0.090
2.29
Maximum cone
0.010
0.25
0.008
0.20
Minimum thickness
0.0955
2.426
Maximum cone
0.010
0.25
Foldout 11,B LOW CLUTCH PLANETARY, ADAPTER HOUSING

MT 650, 653
2, 5
0.091
2.31
7, 16
0.123
3.12
15, 19
Carrier bushing, maximum clearance on hub of ring gear 19
0.0049
0.124
17
External-tanged plate, minimum thickness
0.0955
2.426
18
Internal-splined plate, minimum thickness
0.117
2.97
83

Wear Limit
Illustration
Description
inch
(mm)
Foldout 12,A REAR COVER COMPONENTS MT 640, 643

27, 6
Governor, maximum clearance in rear cover bore
0.0035
0.089
0.0065
0.165
0.0035
0.089
0.0035
0.089
3.270
83.06
Minimum thickness
0.117
2.97
Maximum cone
0.010
0.25
Minimum thickness
0.156
3.96
Maximum cone
None permitted
Foldout 12,B OUTPUT SHAFT, REAR COVER COMPONENTS

MT 650, 653
2
Output shaft bushing

Maximum clearance on main shaft 35 (Foldout 9,B)
35, 13
Governor, maximum clearance in rear cover bore
Foldout 17,A RETARDER ACCUMULATORS AND GOVERNOR

MTB 643, 653
35
Governor, maximum clearance in retarder housing bore
Foldout 18,A RETARDER HOUSING MTB 643, 653

6
Accumulator piston bores, maximum diameter
Foldout 18,B RETARDER CLUTCH MTB 643, 653

6
15
84
External-splined clutch plate
Internal-splined clutch plate
Backplate, minimum thickness at clutch plate contact area
0.312
7.92
Table 82. Spring Data

Length Under Load
33
Stator freewheel roller
6774966
(Not a coil-type spring)
7,A
12
Main-pressure
regulator valve
6834531
Solid yellow
16
6880552
Solid white
15
6836277
Solid yellow
15
6836278
Solid orange
15
6773551
10
6882639
Solid red,
white stripe
Solid white
6883236
Solid red
9.5
16
7,A
24
7,B
10
Lockup valve
Converter pressure
regulator valve
Centrifugal valve
Part No.
Color Code
11
23013747 Solid light green
10
7,B
17
Forward clutch piston
6836773
No color code
3.1
8,A
Fourth clutch piston
6836773
No color code
3.1
8,B
Third clutch piston
6831656
Solid green
11.5
23011242 No color code
85
* Mean dimension shown.
12.5
Wire Dia.*
in. (mm)
0.112
(2.85)
0.121
(3.05)
0.080
(2.03)
0.080
(2.03)
0.080
(2.03)
0.041
(1.04)
0.048
(1.21)
0.041
(1.04)
0.281
(7.14)
0.281
(7.14)
0.041
(1.04)
0.047
(1.19)
Free
Length
in. (mm)
in.
(mm)
lb
(N)
0.812
(20.62)
0.830
(21.08)
0.690
(17.53)
0.690
(17.53)
0.468
(11.89)
0.330
(8.38)
0.371
(9.42)
0.270
(6.86)
4.072
(103.43)
4.072
(103.43)
0.385
(9.78)
0.359
(9.13)
0.64
(16.3)
3.32
(84.3)
3.16
(80.3)
2.84
(72.1)
3.05
(77.5)
1.21
(30.7)
0.87
(22.1)
0.96
(24.4)
0.760
(19.3)
3.30
(83.8)
3.30
(83.8)
1.29
(32.8)
1.31
(33.2)
0.30
(7.6)
2.01
(51.1)
1.93
(49.0)
1.46
(37.1)
1.46
(37.1)
1.00
(25.4)
0.60
(15.2)
0.60
(15.2)
0.61
(15.4)
1.28
(32.5)
1.28
(32.5)
0.81
(20.6)
0.80
(20.3)
0.150.33
(0.71.5)
58.5064.50
(260.2286.9)
76.4084.40
(339.8375.4)
26.1028.90
(116.1128.6)
30.3033.50
(134.8149.0)
23.4028.60
(104.1127.2)
4.755.25
(21.123.4)
9.5010.50
(42.346.7)
5.76.3
(25.428.0)
157.5192.5
(700856)
157.5192.5
(700856)
4.305.70
(19.125.4)
10.8411.44
(48.250.9)
Ref
7,A
Spring
No.
Coils
Foldout
Spring
OD
in. (mm)
86
Table 82. Spring Data (contd)

Length Under Load
Ref
8,B
20
10,A
14
11,A
10
Spring
Second clutch piston
Lubrication regulator
valve
First clutch piston
Part No.
6831656
22
Low clutch piston
15
12 shift valve
(MT 640, 643)
11.5
0.41
(1.04)
0.047
(1.19)
0.065
(1.65)
0.044
(1.12)
0.063
(1.60)
0.044
(1.12)
0.063
(1.60)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.059
(1.50)
0.054
(1.37)
0.054
(1.37)
0.385
(9.78)
0.359
(9.13)
0.680
(17.27)
0.461
(11.71)
0.450
(11.54)
0.461
(11.71)
0.450
(11.54)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
6830180
Solid white
17.5
6835391
Solid blue,
yellow stripe
Solid orange,
yellow stripe
Solid blue,
yellow stripe
Solid orange,
yellow stripe
Solid blue
11.5
Solid blue, white

stripe
Solid white
13.5
6835391
6833935
6833941
6833942
6834576
6834902
6834903
6835309
Wire Dia.*
in. (mm)
12.5
6880251
13
Solid green
No.
Coils
6880251
11,B
Color Code
10
11.5
10
9
12
Solid orange,
yellow stripe
Solid orange
12
Solid white,
yellow stripe
Solid yellow,
blue stripe
12
13
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.29
(32.8)
1.31
(33.2)
3.09
(78.5)
1.50
(38.1)
1.28
(32.5)
1.50
(38.1)
1.28
(32.5)
2.17
(55.1)
2.15
(54.6)
2.50
(63.5)
2.39
(60.7)
2.41
(61.2)
2.22
(56.4)
2.32
(58.9)
0.81
(20.6)
0.80
(20.3)
1.30
(33.0)
0.84
(21.3)
0.95
(24.1)
0.84
(21.3)
0.95
(24.1)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
4.305.70
(19.125.4)
10.8411.44
(48.250.9)
11.2513.75
(50.061.2)
4.955.49
(22.024.4)
13.616.4
(6173)
4.955.49
(22.024.4)
13.616.4
(6173)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
7.858.35
(34.937.1)
7.187.68
(31.934.2)
9.9510.45
(44.346.5)
6.106.70
(27.129.8)
6.757.25
(30.032.3)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
13
(contd)
15
Spring
12 shift valve
(MT 640, 643)
Part No.
Color Code
0.672
(17.07)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
10.8
6884934
No color,
yellow stripe
No color,
red stripe
Solid white,
orange stripe
Solid blue
12
6885065
23011980 Solid red,

white stripe
23012946 Solid orange,
yellow stripe
23012950 Solid white, blue
stripe
red stripe
23012955 Solid green, blue
stripe
23013276 Solid blue,
red stripe
black stripe
23017043 Solid light green,
black stripe
23017044 Solid red,
black stripe
12
12
12
12
12
12
9
13.5
12
12
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.98
(50.3)
2.23
(56.6)
2.40
(61.0)
2.07
(52.6)
1.82
(46.2)
2.11
(53.6)
2.39
(60.7)
2.90
(73.7)
2.17
(55.1)
2.15
(54.6)
2.36
(59.9)
2.36
(59.9)
2.23
(56.6)
2.28
(57.9)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
8.228.72
(36.638.8)
6.206.80
(27.530.2)
7.207.80
(32.034.7)
5.205.80
(23.125.8)
3.754.25
(16.718.9)
5.506.00
(24.526.7)
7.187.68
(32.034.2)
10.1510.85
(45.248.3)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
6.957.55
(30.933.6)
6.957.55
(30.933.6)
6.26.8
(2830)
6.457.05
(28.731.4)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
Solid yellow
6885007
Wire Dia.*
in. (mm)
6837454
6884937
87
No.
Coils
Spring
OD
in. (mm)
88

Length Under Load
Ref
13
(contd)
15
13
21
Spring
12 shift valve
(MT 640, 643)
23 shift valve
(MT 640, 643)
Part No.
23017045 Solid light blue,

purple stripe
23017046 Solid yellow,
purple stripe
purple stripe
6833935 Solid blue
6833941
No.
Coils
Wire Dia.*
in. (mm)
12
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.059
(1.50)
0.062
(1.57)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.062
(1.57)
0.062
(1.57)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.672
(17.07)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
12
12
9
13.5
6834902
Solid blue, white

stripe
Solid orange,
yellow stripe
Solid orange
6837454
Solid yellow
10.8
6838356
Solid blue,
yellow stripe
Solid white,
green stripe
No color code
14
No color, orange
stripe
No color,
white stripe
No color,
green stripe
14
6834576
6883665
6884947
6884951
6884952
6884953
Color Code
12
13
12
12
14
14
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.40
(61.0)
2.44
(62.0)
2.48
(63.0)
2.17
(55.1)
2.15
(54.6)
2.39
(60.7)
2.41
(61.2)
1.99
(50.4)
2.43
(61.7)
2.82
(71.6)
2.86
(72.6)
2.40
(61.0)
2.43
(61.7)
2.45
(62.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
7.27.8
(3235)
7.458.05
(33.235.8)
7.78.3
(3437)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
7.187.68
(31.934.2)
9.9510.45
(44.346.5)
8.228.72
(36.638.8)
11.4511.95
(50.953.2)
9.6510.35
(42.946.0)
9.9010.60
(44.047.2)
11.2511.75
(50.052.3)
11.5012.00
(51.253.4)
11.7512.25
(52.354.5)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
13
(contd)
21
Spring
23 shift valve
(MT 640, 643)
27
34 shift valve
(MT 640, 643)
23012949 Solid blue, green

stripe
23012950 Solid white, blue
stripe
red stripe
stripe
23012956 Solid red,
blue stripe
23013267 Solid yellow
No.
Coils
Wire Dia.*
in. (mm)
12
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.059
(1.50)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.056
(1.42)
0.054
(1.37)
0.062
(1.57)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
12
9
13.5
13
12
23013269 Solid orange
12

yellow stripe
23013272 Solid white
12

black stripe
purple stripe
end color red
6833935 Solid blue
12
6833941
89
Color Code
Solid blue, white

stripe
12
14
13.7
9
13.5
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.94
(74.7)
2.90
(73.7)
2.17
(55.1)
2.15
(54.6)
2.41
(61.2)
2.57
(65.3)
2.69
(68.3)
2.73
(69.3)
2.78
(70.6)
2.65
(67.3)
2.37
(60.2)
2.92
(74.2)
2.17
(55.1)
2.15
(54.6)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
10.3511.15
(46.149.6)
10.1510.85
(45.248.3)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
9.9510.45
(44.346.5)
8.208.80
(36.539.1)
8.909.60
(39.642.7)
9.159.85
(40.743.8)
9.4010.10
(41.844.9)
8.659.35
(38.541.6)
1111.5
(4951.2)
10.3511.15
(46.049.6)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
13
Part No.
Spring
OD
in. (mm)
810

Length Under Load
Ref
13
(contd)
27
Spring
34 shift valve
(MT 640, 643)
Part No.
Color Code
Wire Dia.*
in. (mm)
0.054
(1.37)
0.059
(1.50)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.059
(1.50)
0.062
(1.57)
0.059
(1.50)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.640
(16.26)
0.640
(16.26)
0.672
(17.07)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
6833942
Solid white
12
6834902
Solid orange
13
6837454
Solid yellow
10.8
6884947
No color code

green stripe
red stripe
green stripe
stripe
23012956 Solid red,
blue stripe
No.
Coils
12
12
9
13
13.5
13
12
12

yellow stripe
12

purple stripe
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.50
(63.5)
2.41
(61.2)
1.99
(50.4)
2.86
(72.6)
2.98
(75.7)
2.17
(55.1)
2.51
(63.8)
2.15
(54.6)
2.41
(61.2)
2.57
(68.3)
2.69
(68.3)
2.73
(69.3)
2.78
(70.6)
2.48
(63.0)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
7.858.35
(34.937.1)
9.9510.45
(44.346.5)
8.228.72
(36.638.8)
9.9010.60
(44.047.2)
10.6011.40
(47.250.7)
8.609.10
(38.340.5)
10.7511.25
(47.850.0)
9.359.85
(41.643.8)
9.9510.45
(44.346.5)
8.208.80
(36.539.1)
8.909.60
(39.642.7)
9.159.85
(40.743.8)
9.4010.10
(41.844.9)
7.78.3
(3437)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
13
(contd)
27
32
34 shift valve
(MT 640, 643)
34 relay valve
(MT 640, 643)
Part No.
Color Code
23017048 Solid white,

purple stripe
purple stripe
end color white
6832462 Solid red
6834528
811
Wire Dia.*
in. (mm)
12
0.054
(1.37)
0.062
(1.57)
0.056
(1.42)
0.072
(1.83)
0.073
(1.85)
0.062
(1.57)
0.072
(1.83)
0.073
(1.85)
0.20
(0.51)
0.054
(1.37)
0.720
(18.29)
0.054
(1.37)
0.041
(1.04)
0.041
(1.04)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.690
(17.53)
0.680
(17.27)
0.672
(17.07)
0.690
(17.53)
0.680
(17.27)
0.330
(8.38)
0.733
(18.62)
0.660
(16.76)
0.384
(9.75)
0.400
(10.16)
0.400
(10.16)
14
13.8
11
6837454
Solid blue,
yellow stripe
Solid yellow
6832462
Solid red
11
6834528
11
6837882
Solid blue,
yellow stripe
Solid yellow,
end color white
No color code
8.5
6839555
No color code
11
11
14
13
78
13
81
13
83
13
86
13
92
23 relay valve
(MT 640, 643)
12 relay valve
(MT 640, 643)
12 shift valve return
(2nd range start)
12 shift valve
(2nd range start)
Accumulator valve
13, 14
Priority valve
6835729
13, 14
Hold regulator valve
6836784
Solid white,
yellow stripe
Solid yellow
6836785
Solid white
No.
Coils
6834536
11
10.8
15
13
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.61
(66.3)
2.37
(60.2)
2.98
(75.7)
2.18
(55.4)
1.52
(38.6)
1.99
(50.4)
2.18
(55.4)
1.52
(38.6)
1.25
(31.8)
1.74
(44.2)
1.84
(46.7)
1.16
(29.5)
1.90
(48.3)
2.00
(50.8)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.20
(30.5)
1.10
(27.9)
1.15
(29.2)
1.20
(30.5)
1.10
(27.9)
0.94
(23.9)
0.81
(20.5)
1.15
(29.2)
0.94
(23.8)
1.15
(29.2)
1.15
(29.2)
8.459.05
(37.640.3)
11.011.5
(4951)
10.6011.40
(47.150.7)
16.2019.80
(72.188.1)
7.208.80
(32.039.1)
8.228.72
(36.638.8)
16.2019.80
(72.188.1)
7.208.80
(32.039.1)
0.170.21
(0.80.9)
5.026.14
(22.327.3)
14.3114.81
(63.665.9)
8.159.15
(36.340.7)
5.936.17
(26.427.5)
6.226.48
(27.728.8)
13
Spring
Spring
OD
in. (mm)
812

Length Under Load
Ref
13, 14
(contd)
13, 14
13, 14
36
43
13, 14
53
13, 14
54
Spring
Trimmer regulator
Modulator valve
Third clutch trimmer

valve outer
valve inner
No.
Coils
Wire Dia.*
in. (mm)
14
6836977
Solid white,
yellow stripe
Solid orange
6837540
Solid red
11
6837541
14
6837952
Solid yellow,
blue stripe
Solid light green
6837953
Solid blue
14
0.044
(1.12)
0.047
(1.19)
0.041
(1.04)
0.044
(1.12)
0.044
(1.12)
0.044
(1.12)
0.047
(1.19)
0.041
(1.04)
0.041
(1.04)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.099
(2.51)
0.091
(2.31)
0.400
(10.16)
0.400
(10.16)
0.400
(10.16)
0.400
(10.16)
0.400
(10.16)
0.400
(10.16)
0.500
(12.70)
0.464
(11.79)
0.464
(11.79)
0.490
(12.45)
0.490
(12.45)
0.490
(12.45)
0.940
(23.88)
0.690
(17.53)
Part No.
6836976
Color Code
6834527
Solid light blue,

red stripe
blue stripe
end color green
orange stripe
16
14
14
12
12.5
10
10

orange stripe
10
6880118
8.5
Solid blue, white

stripe
10
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.85
(47.0)
1.85
(47.0)
1.74
(44.2)
1.83
(46.4)
1.88
(47.6)
1.91
(48.5)
1.87
(47.5)
1.37
(34.8)
1.33
(33.8)
1.47
(37.3)
1.15
(29.2)
1.47
(37.3)
2.18
(55.4)
1.45
(36.8)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.14
(29.0)
0.89
(22.6)
0.86
(21.8)
0.80
(20.3)
0.80
(20.3)
0.80
(20.3)
1.94
(49.3)
1.10
(27.9)
6.917.19
(30.732.0)
7.798.11
(34.736.1)
5.735.97
(25.526.6)
6.616.89
(29.430.7)
7.107.40
(31.632.9)
7.467.76
(33.234.5)
4.254.75
(18.921.1)
2.432.69
(10.812.0)
2.302.54
(10.211.3)
11.9013.10
(52.958.3)
6.017.15
(26.731.8)
11.9013.10
(52.958.3)
6.207.40
(27.632.9)
20.7025.30
(92.1112.5)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
13, 14
(contd)
13, 14
54
58
Spring
6885166
6833940
6880045
Color Code
Solid orange,
white stripe
Solid orange,
yellow stripe
Solid orange

13, 14
59
First clutch trimmer

valve inner
6880118
63
Second clutch trimmer

valve outer

valve inner
813
0.690
(17.53)
0.950
(24.13)
0.940
(23.88)
0.949
(24.11)
0.690
(17.53)
0.690
(17.53)
0.950
(24.13)
0.940
(23.88)
0.940
(23.88)
0.940
(23.88)
0.940
(23.88)
0.940
(23.88)
0.690
(17.53)
0.690
(17.53)
8.5
10
9
10
6880045
6885047
Solid light green
10
9.6
8.5
9.5
10
23014200 Solid red
12
6880118
8.5
6885166
0.092
(2.34)
0.121
(3.07)
0.099
(2.51)
0.098
(2.49)
0.091
(2.31)
0.092
(2.34)
0.121
(3.07)
0.102
(2.59)
0.102
(2.59)
0.099
(2.51)
0.099
(2.51)
0.080
(2.03)
0.091
(2.31)
0.092
(2.34)
Solid white,
yellow stripe
Solid orange
6833940
6839271
64
9.6
8.5
6837692
13, 14
Wire Dia.*
in. (mm)
Solid blue, white

stripe
Solid orange,
white stripe
Solid orange,
yellow stripe
Solid yellow
6885166
13, 14
No.
Coils
Solid blue, white

stripe
Solid orange,
white stripe
9.6
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.69
(42.9)
2.38
(60.5)
2.18
(55.4)
2.27
(57.7)
1.45
(36.8)
1.69
(42.9)
2.38
(60.5)
2.33
(59.2)
2.56
(65.0)
2.18
(55.4)
2.57
(65.3)
2.68
(68.1)
1.45
(36.8)
1.69
(42.9)
1.10
(27.9)
1.94
(49.3)
1.94
(49.3)
1.94
(49.3)
1.10
(27.9)
1.10
(27.9)
1.94
(49.3)
1.20
(30.5)
1.94
(49.3)
1.94
(49.3)
1.94
(49.3)
1.10
(27.9)
1.10
(27.9)
1.10
(27.9)
32.6039.80
(145.0177.0)
29.0035.00
(129.0155.7)
6.207.40
(27.632.9)
9.4011.40
(41.850.7)
20.7025.30
(92.1112.5)
32.6039.80
(145.0177.0)
29.0035.00
(129.0155.7)
37.8041.80
(168.1185.9)
20.022.0
(8998)
6.207.40
(27.632.9)
16.119.7
(71.687.6)
13.216.2
(5972)
20.7025.30
(92.1112.5)
32.6039.80
(145.0177.0)

valve inner
First clutch trimmer
valve outer
Part No.
Spring
OD
in. (mm)
814

Length Under Load
Ref
13, 14
(contd)
13, 14
64
71
Spring

valve inner
Fourth clutch trimmer
valve outer
No.
Coils
Wire Dia.*
in. (mm)
10
6833945
Solid light blue
7.4
6833938
Solid yellow
12.5
6880045
Solid orange
10
0.080
(2.03)
0.092
(2.34)
0.080
(2.03)
0.099
(2.51)
0.080
(2.03)
0.078
(1.98)
0.091
(2.31)
0.092
(2.34)
0.073
(1.85)
0.072
(1.83)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.690
(17.53)
0.930
(23.62)
0.940
(23.88)
0.940
(23.88)
0.940
(23.88)
0.940
(23.88)
0.690
(17.53)
0.690
(17.53)
0.680
(17.27)
0.690
(17.53)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
Part No.
Color Code
23014200 Solid red
13, 14
14
72
15
Fourth clutch trimmer

valve inner
23 shift valve
(MT 650, 653)
23018733 End color orange
11.3
6880118
8.5
Solid blue, white

stripe
white stripe
23011987 Solid red,
orange stripe
blue stripe
6833935 Solid blue
6833941
6833942
6834576
12
Solid blue, white

stripe
Solid white
Solid orange,
yellow stripe
9.6
11
10.5
9
13.5
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.80
(45.7)
2.27
(57.7)
2.96
(75.2)
2.18
(55.4)
2.68
(68.1)
2.98
(75.7)
1.45
(36.8)
1.69
(42.9)
1.52
(38.6)
1.70
(43.2)
2.17
(55.1)
2.15
(54.6)
2.50
(63.5)
2.39
(60.7)
1.10
(27.9)
1.94
(49.3)
1.10
(27.9)
1.94
(49.3)
1.10
(27.9)
1.94
(49.3)
1.10
(27.9)
1.10
(27.9)
1.10
(27.9)
1.10
(27.9)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
20.3024.90
(90.3110.8)
9.4011.40
(41.850.7)
15.9517.65
(70.978.5)
6.207.40
(27.632.9)
13.216.2
(5972)
8.3010.30
(36.945.8)
20.7025.30
(92.1112.5)
32.6039.80
(145.0177.0)
7.208.80
(32.039.1)
10.412.8
(46.357.0)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
7.858.35
(34.937.1)
7.187.68
(31.934.2)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
14
(contd)
15
Spring
23 shift valve
(MT 650, 653)
Part No.
0.640
(16.26)
0.640
(16.26)
0.672
(17.07)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
6835309
Solid yellow,
blue stripe
Solid yellow
12
6884937
23011980
23012952
23012955
23012956
Solid white,
yellow stripe
No color,
red stripe
Solid red,
white stripe
Solid orange,
red stripe
Solid green, blue
stripe
Solid red,
blue stripe
Solid yellow
10.8
12
12
12
9
13.5
13
12
12

yellow stripe
black stripe
black stripe
12
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.41
(61.2)
2.32
(58.9)
1.99
(50.4)
2.22
(56.4)
2.40
(61.0)
2.11
(53.6)
2.17
(55.1)
2.15
(54.6)
2.41
(61.2)
2.57
(65.3)
2.69
(68.3)
2.65
(67.3)
2.65
(67.3)
2.23
(56.6)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
9.9510.45
(44.346.5)
6.757.25
(30.032.3)
8.228.72
(36.638.8)
6.106.70
(27.129.8)
7.27.8
(32.034.7)
5.506.00
(24.526.7)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
9.9510.45
(44.346.5)
8.208.80
(36.539.1)
8.909.60
(39.642.7)
8.659.35
(38.541.6)
8.659.35
(38.541.6)
6.26.8
(2830)
0.059
(1.50)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.059
(1.50)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
13
23013267
815
Wire Dia.*
in. (mm)
Solid orange
6834903
No.
Coils
6834902
6837454
Color Code
Spring
OD
in. (mm)
816

Length Under Load
Ref
14
(contd)
15
14
21
Spring
23 shift valve
(MT 650, 653)
34 shift valve
(MT 650, 653)
No.
Coils
Wire Dia.*
in. (mm)
23017044 Solid red,

black stripe
purple stripe
purple stripe
purple stripe
end color red
12
6884952
No color,
white stripe
23012949 Solid blue, green
stripe
green stripe
14

yellow stripe
12

black stripe
purple stripe
12
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
Part No.
Color Code
12
12
12
12
12
12
12
12
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.28
(57.9)
2.40
(61.0)
2.44
(62.0)
2.48
(63.0)
2.53
(64.3)
2.86
(72.6)
2.43
(61.7)
2.94
(74.7)
2.98
(75.7)
2.57
(65.3)
2.73
(69.3)
2.78
(70.6)
2.65
(67.3)
2.61
(66.3)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
6.457.05
(28.731.4)
7.27.8
(3235)
7.458.05
(33.235.8)
7.78.3
(3437)
7.958.55
(35.438.0)
9.9010.60
(44.047.2)
11.5012.00
(51.253.4)
10.3511.15
(46.149.6)
10.6011.40
(47.250.7)
8.208.80
(36.539.1)
9.159.85
(40.743.8)
9.4010.10
(41.844.9)
8.659.35
(38.541.6)
8.459.05
(37.640.3)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
14
(contd)
21
27
34 shift valve
(MT 650, 653)
45 shift valve
(MT 650, 653)

817
No.
Coils
Wire Dia.*
in. (mm)

end color red
end color white
6833935 Solid blue
13.7
6833941
13.5
0.056
(1.42)
0.056
(1.42)
0.054
(1.37)
0.062
(1.57)
0.054
(1.37)
0.059
(1.50)
0.059
(1.50)
0.062
(1.57)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.672
(17.07)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
Part No.
Color Code
13.8
9
6833942
Solid blue, white

stripe
Solid white
6834902
Solid orange
13
6835310
Solid green
13
6837454
Solid yellow
10.8
6884947
No color code
12
12

green stripe
12
12

yellow stripe
12
12
12
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.92
(74.2)
2.98
(75.7)
2.17
(55.1)
2.15
(54.6)
2.50
(63.5)
2.41
(61.2)
2.51
(63.8)
1.99
(50.4)
2.86
(72.6)
2.98
(75.7)
2.57
(65.3)
2.69
(68.3)
2.73
(69.3)
2.78
(70.6)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
10.3511.15
(46.149.6)
10.6011.40
(47.150.7)
8.609.10
(38.340.5)
9.359.85
(41.643.8)
7.858.35
(34.937.1)
9.9510.45
(44.346.5)
10.7511.25
(47.850.0)
8.228.72
(36.638.8)
9.9010.60
(44.047.2)
10.6011.40
(47.250.7)
8.208.80
(36.539.1)
8.909.60
(39.642.7)
9.159.85
(40.743.8)
9.4010.10
(41.844.9)
14
Spring
Spring
OD
in. (mm)
818

Length Under Load
Ref
14
(contd)
27
14
32
Spring
45 shift valve
(MT 650, 653)
45 relay valve
(MT 650, 653)
Part No.

black stripe
purple stripe
end color red
end color white
6832462 Solid red
6834528
14
78
14
81
15,A
Color Code
Wire Dia.*
in. (mm)
12
0.054
(1.37)
0.054
(1.37)
0.054
(1.37)
0.056
(1.42)
0.072
(1.83)
0.073
(1.85)
0.072
(1.83)
0.073
(1.85)
0.063
(1.59)
0.072
(1.83)
0.059
(1.50)
0.060
(1.52)
0.063
(1.60)
0.063
(1.60)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.690
(17.53)
0.680
(17.27)
0.690
(17.53)
0.680
(17.27)
0.640
(16.26)
0.657
(16.69)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
12
12
13.8
11
Solid blue,
yellow stripe
Solid red
11
Solid blue,
yellow stripe
Solid red
11
Solid white,
green stripe
green stripe
23016355 Solid red
11
23016359 Solid red,

yellow stripe
23016360 Solid purple,
yellow stripe
15
34 relay valve
6832462
(MT 650, 653)
23 relay valve
6834528
(MT 650, 653)
Modulated lockup valve 6838357
6880773
No.
Coils
11
14
13
17
15
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.65
(67.3)
2.61
(66.3)
2.53
(64.3)
2.98
(75.7)
2.18
(55.4)
1.52
(38.6)
2.18
(55.4)
1.52
(38.6)
2.53
(64.3)
2.09
(53.1)
2.51
(63.8)
2.93
(74.4)
2.64
(67.1)
2.67
(67.8)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.15
(29.2)
1.20
(30.5)
1.10
(27.9)
1.20
(30.5)
1.10
(27.9)
1.15
(29.2)
1.39
(35.3)
1.15
(29.2)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
8.659.35
(38.541.6)
8.459.05
(37.640.3)
7.958.55
(35.438.9)
10.6011.40
(47.150.7)
16.2019.80
(72.188.1)
7.208.80
(32.039.1)
16.2019.80
(72.188.1)
7.208.80
(32.039.1)
12.2512.75
(54.556.7)
13.7716.83
(61.374.9)
10.7511.25
(47.850.0)
9.7510.25
(43.445.6)
10.6211.38
(47.250.7)
10.8711.63
(48.451.7)
Foldout
Spring
OD
in. (mm)

Length Under Load
Foldout
Ref
15,A
(contd)
15,B
11
Part No.
Color Code
819
Modulated lockup valve 23016363 Solid purple,

orange stripe
23016364 Solid red,
white stripe
white stripe
23016366 No color,
yellow stripe
23016370 No color, end
color yellow
23016383 No color, end
color light blue
red stripe
end color red
end color yellow
end color orange
12 relay valve
orange stripe
green stripe
12 shift valve
(MT 650, 653)
orange stripe
orange stripe
No.
Coils
Wire Dia.*
in. (mm)
16.5
0.066
(1.66)
0.066
(1.66)
0.066
(1.66)
0.066
(1.66)
0.067
(1.70)
0.072
(1.83)
0.072
(1.83)
0.066
(1.66)
0.064
(1.63)
0.067
(1.70)
0.054
(1.37)
0.054
(1.37)
0.041
(1.04)
0.044
(1.12)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.640
(16.26)
0.560
(14.22)
0.594
(15.09)
0.501
(12.73)
0.501
(12.73)
16.5
16.5
16.5
15
14.5
14.5
16.5
16.5
15
14
14
8
9
Free
Length
in. (mm)
in.
(mm)
lb
(N)
2.64
(67.1)
2.67
(67.8)
2.69
(68.3)
2.72
(69.1)
2.54
(64.5)
2.40
(61.0)
2.45
(62.2)
2.61
(66.3)
2.74
(69.6)
2.52
(64.0)
1.99
(50.5)
1.92
(48.8)
1.10
(27.9)
1.12
(28.5)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
1.39
(35.3)
0.84
(21.3)
0.84
(21.3)
0.69
(17.5)
0.69
(17.5)
11.6212.38
(51.755.0)
11.8712.63
(52.856.1)
12.1212.88
(53.957.3)
12.3713.13
(55.058.4)
13.2514.25
(59.063.4)
16.2917.71
(72.578.8)
17.2918.71
(76.983.3)
11.3712.13
(50.654.0)
12.6213.38
(56.259.5)
13.014.0
(5862)
8.109.90
(36.044.0)
6.307.70
(28.034.3)
2.573.13
(11.413.9)
2.833.47
(12.615.4)
15,B
Spring
Spring
OD
in. (mm)
820

Length Under Load
Ref
15,B
(contd)
11
Spring
12 shift valve
(MT 650, 653)
Part No.
Color Code
21
Accumulator inner
17,A
22
Accumulator outer
17,B
16
Retarder valve
17,B
22
17,B
28
Retarder charging
cutoff valve
Charging valve
17,B
34
17,B
35
18,A
18
Retarder pressure
regulator valve inner
Retarder pressure
regulator valve outer
Retarder priority valve
19,A
25
19,B
31
Wire Dia.*
in. (mm)
0.044
(1.12)
0.041
(1.04)
0.044
(1.12)
0.176
(4.47)
0.207
(5.26)
0.091
(2.31)
0.041
(1.04)
0.054
(1.37)
0.054
(1.37)
0.72
(18.3)
0.072
(1.83)
0.331
(8.41)
0.331
(8.41)
0.501
(12.73)
0.501
(12.73)
0.501
(12.73)
1.96
(50.5)
2.46
(62.5)
1.28
(32.5)
0.45
(11.4)
0.594
(15.09)
0.417
(10.59)
0.69
(17.5)
0.59
(15.0)
4.82
(122.4)
4.82
(122.4)
6839014
Solid orange
6880997
Solid yellow
6881036
17,A
No.
Coils
Solid orange,
blue stripe
23018716 No color,
end color yellow
23018600 No color,
end color orange
6880154
Solid white,
green stripe
23016040 No color,
end color purple
end color orange
23013909 Solid green
9
13.4
12
5.9
11
10.6
15
11
11
Piston return
2.5
Piston return
2.5
Free
Length
in. (mm)
in.
(mm)
lb
(N)
1.32
(33.5)
1.03
(26.2)
1.16
(29.5)
7.92
(201.2)
9.90
(251.5)
2.57
(65.3)
1.88
(47.8)
1.10
(27.9)
1.520
(38.6)
1.80
(45.7)
1.67
(42.4)
3.00
(76.2)
3.00
(76.2)
0.69
(17.5)
0.69
(17.5)
0.69
(17.5)
6.07
(154.2)
6.07
(154.2)
1.00
(25.4)
1.09
(27.7)
0.96
(24.4)
1.09
(27.9)
1.10
(27.9)
1.15
(29.2)
0.90
(22.9)
0.90
(22.9)
4.185.12
(18.622.8)
2.162.64
(9.611.7)
3.374.13
(15.018.4)
38.8942.9
(173.0191.0)
86.5595.54
(385.0425.0)
21.6026.42
(96.1117.5)
4.554.95
(20.222.0)
8.012.0
(3653)
8.339.20
(37.140.9)
11.414.0
(5162)
14.4817.72
(64.478.8)
361.22441.48
(1606.71963.7)
361.22441.48
(1606.71963.7)
Foldout
Spring
OD
in. (mm)
Section 9 CUSTOMER SERVICE

91.
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison

transmissions are of primary concern to Allison Transmission Division (ATD), its distributors, and their
dealers.
Step Two If your problem cannot be readily resolved at the distributor level without additional assistance, contact the Allison Transmission Regional
Office responsible for your local distributor (see
maps in Warranty Manual). You will be assisted by a
member of the Regional Service Managers staff.
As an owner of an Allison transmission, you have service locations throughout the world eager to meet your
parts and service needs with:
For prompt assistance, please have the following information available.
Expert service by trained personnel

Emergency service 24 hours a day in many
areas
Name and location of authorized distributor
or dealer
Type and make of equipment
Complete parts support
Transmission model number, serial number,
Sales teams to help determine your trans-
mission requirements
Product information and literature
Refer to a current North American Parts and Service

Directory SA2229EN or the International Parts and
Service Directory SA2338EN for a listing of Allison
Transmission authorized distributors and service
dealers.
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will
be handled by the distributor or dealer in your area.
(Check the telephone directory for the Allison Transmission service outlet nearest you.)
We recognize, however, that despite the best intentions
of all concerned, misunderstandings may occur. To
further assure your complete satisfaction, we have developed the following three-step procedure in the
event you have a problem that has not been handled
satisfactorily.
Step One Discuss your problem with a member
of management from the distributorship or dealership. Complaints are frequently the result of a breakdown in communication and can be quickly resolved
by a member of management. If you have already discussed the problem with the Sales or Service Manager,
contact the General Manager. All ATD dealers are associated with an ATD distributor. If your problems
originate with a dealer, explain the matter to a distributorship member of management with whom the dealer
has his service agreement. The dealer will provide his
ATD distributors name, address, and telephone number on request.
and assembly number if equipped with

electronic controls, also provide the ECU
assembly number
Transmission delivery date and accumu-
lated miles and/or hours of operation

Nature of problem
Chronological summary of units history
Step Three If you contacted a regional office and

you are still not satisfied, present the entire matter in
writing or by phone to the Home Office:
Manager Warranty Administration PF9
P. O. Box 894
Indianapolis, Indiana 46206-0894
Phone: (317) 2423538
The inclusion of all pertinent information will assist
the Home Office in expediting the matter. If an additional review by the Home Office of all the facts involved indicates that some further action can be taken,
the Regional Office will be advised.
When contacting the Regional or Home Office, please
keep in mind that ultimately your problem will likely
be resolved at the distributorship or dealership using their facilities, equipment, and personnel. Therefore, we suggest you follow the above steps, in sequence, when experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to assure complete satisfaction.
91

92. SERVICE LITERATURE
Table 91. Service Literature
Additional service literature is available. This service

literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. To ensure that you get
maximum performance and service life from your
transmission, see your dealer or distributor for the following publications. (Check the telephone directory
for the Allison Transmission service outlet nearest
you.)
92
Literature Title
MT(B) 640, 643,

650, 653
Operators Manual
OM1334EN
Mechanics Tips
MT1357EN
Parts Catalog
PC1316EN
Troubleshooting Manual
TS1838EN
Automatic Transmission Fluids

Technicians Guide
GN2055EN
Preventive Maintenance Manual
PM2572EN
Output Retarder Technicians

Guide
GN2009EN

Legend For Foldout 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Torque converter cover

Lockup clutch
Torque converter turbine
Torque converter pump
Oil pump
Forward support and valve assembly
Centrifugal valve
Power takeoff gear
Forward clutch
Fourth clutch
Third clutch
Center support
Second clutch
Planetary connecting drum
Transmission main shaft
First clutch
Transmission rear cover
Governor drive gear
Speedometer drive gear
Output shaft
Rear planetary gear set
Center planetary gear set
Sun gear shaft
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Front planetary gear set

Control valve assembly
Oil filter
Oil pan
Modulated lockup valve
Converter stator
Turbine shaft
First clutch piston
Retarder adapter housing
Retarder stator
Retarder rotor assembly
Retarder housing
Retarder clutch pack
Governor and speedometer drive gear
Output shaft
Output flange nut
Retarder rotor hub
Accumulator cover
Accumulator piston
Accumulator springs
Retarder piston
Piston return spring
Foldout 1
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21
Foldout 1. Model MT(B) 640, 643 Automatic Transmission Cross Section View
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Torque converter cover

Lockup clutch
Torque converter pump
Oil pump
Forward support and valve assembly
Centrifugal valve
Power takeoff gear
Forward clutch
Fourth clutch
Third clutch
Center support
Second clutch
Transmission main shaft
First clutch
Adapter housing
Low clutch
Rear cover
Governor drive gear
Output shaft
Output flange nut
Low planetary gear set
Rear planetary gear set
Low shift valve
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Center planetary gear set

Oil filter
Front planetary gear set
Sun gear shaft
Oil pan
Converter stator
Turbine shaft
Low clutch piston
Retarder adapter housing
Retarder stator
Retarder rotor assembly
Retarder housing
Output shaft
Output flange nut
Retarder rotor hub
Accumulator cover
Accumulator piston
Accumulator springs
Retarder clutch pack
Retarder piston
Foldout 2
F OLDOUT 2
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Foldout 2. Model MT(B) 650, 653 Automatic Transmission Cross Section View
39
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V00280.01
V00272.17
F OLDOUT 3
THIRD CLUTCH PRESSURE
SECOND CLUTCH PRESSURE
LUBRICATION
LOCKUP CLUTCH PRESSURE
CONVERTERIN
Forward
Clutch
Fourth
Clutch
Third
Clutch
Second
Clutch
FIRST CLUTCH PRESSURE
First
Clutch
OIL
COOLER
Converter
Pressure
Regulator
Open
Throttle
(Optional)
Lubrication
Pressure
Regulator
ORIFICE
Oil Pump
ORIFICE
Main
Pressure
Tap
ORIFICE
FILTER
Lockup
Relay
Valve
MAIN PRESSURE
SUMP
CONVERTEROUT
CONVERTERIN
Modulator
Valve
MAIN PRESSURE
Main Pressure
Regulator
FORWARD CLUTCH PRESSURE

FOURTH CLUTCH PRESSURE
Mechanical
Control
OIL SCREEN
GOVERNOR PRESSURE
MODULATOR PRESSURE
Trimmer
Regulator Valve
2 3 Shift
Signal Valve
3 4 Shift
Signal Valve
34
Relay Valve
1 2 Shift
Signal Valve
DRIVE 3
PRESSURE
DRIVE 2 PRESSURE
DRIVE 1 PRESSURE
CONVERTERIN
ORIFICE
MAIN PRESSURE
13
14
Vacuum Control
Neutral Start
Switch
SWITCH
GROUNDED
WHEN IN
NEUTRAL
N
R
D2
FORWARD
CLUTCH
REVERSE
TRIMMER
REGULATOR
PRESSURE
ORIFICE
12
D3
D3
ORIFICE
Oil Pump
D2
D1
ORIFICE
ORIFICE
LOCKUP
SIGNAL
DRIVE 1
PRESSURE
DRIVE 2
PRESSURE
Converter
Pressure
Regulator
D1
HOLD FEED
Reverse
Signal Switch
1 2 SIGNAL
REDUCED MODULATION
Priority
Valve
ORIFICE
FILTER
Lockup
Relay
Valve
LOCKUP
SUMP
Hold Regulator
Valve
Manual
Selector Valve
ORIFICE
MAIN
ORIFICE
ORIFICE
Main Pressure
Regulator
ORIFICE
ORIFICE
ORIFICE
Governor Pressure
Tap
ORIFICE
Lockup Signal
Pressure Tap
Earlier Models
REVERSE
MAIN PRESSURE
MODULATOR
GOVERNOR PRESSURE
ORIFICE
Trimmer
Regulator Valve
1st Clutch
Trimmer Valve
3rd Clutch
Trimmer Valve
2nd Clutch
Trimmer Valve
4th Clutch
Trimmer Valve
12
Relay Valve
23
Relay Valve
0.250 in.
(6.35 mm)
BALL
Reverse Bypass
Priority Check Ball
(Earlier Models)
Trim Boost
Accumulator
FILTER
FIRST TRIMMER
ORIFICE
FIRST TRIMMER
Governor Valve
FORWARD REGULATOR PRESSURE

GOVERNOR PRESSURE
Modulated
Lockup Valve
0.090 in.
(2.29 mm)
ORIFICE
GOVERNOR FEED
MAIN PRESSURE
GOVERNOR PRESSURE
ORIFICE
Trimmer
Regulator Valve
1 2 Shift
Signal Valve
FORWARD
REGULATOR
GOVERNOR
PRESSURE
ORIFICE
ORIFICE
ORIFICE
ORIFICE
MODULATED LOCKUP
REVERSE
SIGNAL
PRESSURE
ORIFICE
FORWARD
REGULATOR
DRIVE 1
MAIN
Modulated
Lockup Valve
1st Clutch
Trimmer Valve
ORIFICE
3rd Clutch
Trimmer Valve
2nd Clutch
Trimmer Valve
4th Clutch
Trimmer Valve
12
SIGNAL
GOVERNOR
ADJUSTABLE LOCKUP
Trim Boost
Accumulator
STANDARD MODULATION
Foldout 3. Model MT(B) 640, 643 Transmission Hydraulic Schematic
SECOND GEAR START
MAIN PRESSURE
CONVERTERIN
CONVERTEROUT
LUBRICATION
EXHAUST OR SUMP
GOVERNOR PRESSURE
MODULATOR PRESSURE
FORWARD REGULATOR
TRIMMER REGULATOR PRESSURE
V03319
F OLDOUT 4
LUBRICATION
Oil Cooler
Converter
Pressure
Regulator
MAIN PRESSURE
CONVERTERIN
CONVERTEROUT
LUBRICATION
EXHAUST OR SUMP
GOVERNOR PRESSURE
MODULATOR PRESSURE
FORWARD REGULATOR
LOW AND FIRST CLUTCH FEED
TRIMMER REGULATOR PRESSURE

THIRD CLUTCH PRESSURE
;;
Lube Press.
Regulator
ORIFICE
Forward
Clutch
Fourth
Clutch
Third
Clutch
Second
Clutch
First
Clutch
Low
Clutch
LOW CLUTCH PRESSURE
Main
Pressure
Tap
Oil
Pump
FILTER
SUMP
ORIFICE
ORIFICE
CONVERTER OUT
Lockup
Relay
Valve
ORIFICE
DRIVE3 PRESSURE
CONVERTER Main Pressure
Regulator Valve
IN
LOCKUP
SIGNAL Lockup Signal
FOURTH CLUTCH
PRESSURE
FORWARD REGULATOR PRESSURE

FORWARD CLUTCH PRESSURE
4th CL. OIL SCREEN
Modulator
Valve
MAIN PRESSURE
MAIN PRESSURE
Pressure Tap
MODULATOR PRESSURE
DRIVE2 PRESSURE
Neutral
Start
Switch
1
23
24
25
N
R
D1
D2
D3
D
ORIFICE
HOLD FEED
FORWARD
CLUTCH
Modulated
Lockup Valve
12
Shift Valve
45
Relay Valve
Trimmer
Regulator
Valve
4 5 Shift
Signal Valve
REVERSE
3 4 Shift
Signal Valve
Manual
Selector
Valve
2 3 Shift
Signal Valve
Hold
Regulator
Valve
ORIFICE
REVERSE
Reverse
Signal Switch
DRIVE1 PRESSURE
Priority
Valve
MAIN PRESSURE
ORIFICE
REVERSE
23
Relay Valve
ORIFICE
ORIFICE
34
Relay Valve
ORIFICE
ORIFICE
12 FEED
0.090 in.
(2.29 mm)
ORIFICE
0.250 in.
(6.35 mm)
BALL
1st Clutch
Trimmer Valve
Trim Boost
Accumulator
3rd Clutch
Trimmer Valve
STANDARD MODULATION
FIRST TRIMMER
2nd Clutch
Trimmer Valve
REDUCED MODULATION
(SHOWN BY
)
4th Clutch
Trimmer Valve
21
Inhibitor Valve
Governor
Pressure Tap
ORIFICE
ORIFICE
FILTER
Reverse Bypass
Priority Check Ball
(Earlier Models)
PIPE PLUG
FIRST TRIMMER
GOVERNOR PRESSURE
GOVERNOR PRESSURE
Foldout 4. Model MT(B) 650, 653 Transmission Hydraulic Schematic
Governor
Valve
Earlier Models
V03320
F OLDOUT 5
Air
Supply
Retarder
Control
CONVERTER OUT
Retarder
Priority Valve
Retarder
Valve
Priority
Valve
MAIN PRESSURE
ORIFICE
FROM OIL COOLER

LOCKUP FEED
TO RETARDER
LUBE ORIFICE
TO TRANSMISSION LUBE
CONVERTER
OUT
Check Valve
CLUTCH APPLY PRESSURE
External
Oil Filter
Oil Cooler
FROM
RETARDER
Converter
Pressure
Regulator
LUBRICATION
Pressure
Regulator
Plug Valve
Lube Pressure
Regulator Valve
REGULATED
PRESSURE
Cutoff
Valve
ORIFICE
ORIFICE
CONVERTER IN
RETARDER IN
Pressure
Regulator
Valve
Oil
Pump
MAIN PRESSURE
ORIFICE
ORIFICE
FORWARD
REGULATOR
ORIFICE
SUMP
RETARDER
CHARGING
PRESSURE
FROM RETARDER IN PRESSURE
Charging
Valve
ORIFICE
TO PRESSURE
REGULATOR
VALVE
TO RETARDER
Lockup
Relay
Valve
LOCKUP
ACCUMULATOR
Main Pressure
Regulator Valve
MAIN PRESSURE
LOCKUP SIGNAL
MAIN PRESSURE
CONVERTERIN
CONVERTEROUT
LUBRICATION
LUBRICATION FEED
GOVERNOR PRESSURE
SUMP
RETARDER CLUTCH
AIR SUPPLY
ACCUMULATOR PISTON
ACCUMULATOR PISTON SPRINGS
FROM RETARDER
Governor
Valve
V00283
Foldout 5. Model MTB 643, 653 Output Retarder Hydraulic Schematic (Retarder Off)
F OLDOUT 6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Flanged nut, 38-24 (6) A

Torque converter assembly
Spacer retainer (6)*
Spacer (6)
Self-locking nut, 516-24 (24) B
Torque converter cover assembly
Bushing
Sealring retainer
Lockup clutch piston inner sealring
Lockup clutch piston
Lockup clutch piston outer sealring
Lockup clutch plate
Sealring
Lockup clutch backplate
Snapring
Bearing race
Thrust bearing assembly
Bearing race
Turbine thrust bearing spacer (selective):
0.0140.016 inch (0.360.41 mm) (Gold)
0.0290.031 inch (0.740.79 mm) (Silver)
0.0410.043 inch (1.041.09 mm) (Plain)
0.0590.061 inch (1.501.55 mm) (Black)
0.0740.076 inch (1.881.93 mm) (Copper)
Torque converter turbine assembly
Turbine hub
Rivet, 516 x 1116 (8)
Torque converter stator assembly
Stator thrust washer
Stator cam washer (2)
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Stator
Cam
Sideplate washer
Rivet (6)
Needle roller bearing assembly
Stator freewheel roller race
Stator freewheel roller spring (10)
Stator freewheel roller (10)
Bearing race (before S/N 49490)
Bolt, 14-20 x 58 (8) C
Lockstrip (4)
Converter pump hub (before S/N 49490)
Gasket
Sealring
Converter pump assembly
Bolt, 516-24 x 1.36 (24)
Bearing race (after S/N 49489)
Roller bearing (after S/N 49489)
Bolt, 14-20 x 58 (8) C
Lockstrip (4)
Converter pump hub (after S/N 49489)
Sealring (after S/N 49489)
Torque
A
B
C
Nm
4554
2631
1215
lb ft
3340
1923
911
* Not used with spacers having bonded rubber insert.
Foldout 6. Torque Converter and Lockup Clutch

7,A
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Oil pump and front support assembly

Sealring
Oil seal
Oil pump assembly
Pump body and bushing assembly
(after S/N 49489)
Bushing (after S/N 49489)
Pump body
Pump driven gear (selective):
0.68350.6840 inch (17.3717.39 mm)
0.68450.6850 inch (17.3917.40 mm)
0.8180.819 inch (20.7820.80 mm)
0.8190.820 inch (20.8020.83 mm)
Pump drive gear (selective):
0.68350.6840 inch (17.3617.37 mm)
0.68400.6845 inch (17.3717.39 mm)
0.68450.6850 inch (17.3917.40 mm)
0.68500.6855 inch (17.4017.41 mm)
0.81850.8190 inch (20.7920.80 mm)
0.81900.8195 inch (20.8020.82 mm)
0.81950.8200 inch (20.8220.83 mm)
0.82000.8205 inch (20.8320.84 mm)
Snapring (before S/N 2410219363)
Valve stop
Main-pressure regulator valve spring
Main-pressure regulator valve
Snapring (before S/N 2410219363)
Valve stop
Lockup valve spring
Lockup valve
Pin (after S/N 2410219363)
Pin (after S/N 2410219363)
Self-locking bolt, 38-16 x 112 (2) A
Self-locking bolt, 516-18 x 134 (12) B
Valve and front support assembly
Valve guide pin
Converter-pressure regulator valve spring
Converter-pressure regulator valve
Front support assembly
Converter ground sleeve
Front support
Plug
31
32
33
34
35
Thrust bearing race assembly

Butt-joint sealring (2)
Gasket
Washer (12)
Bolt, 38-16 x 338 (12) C
Torque
A
B
C
lb ft
36 43
17 20
24 32
Nm
49 58
23 27
33 43
7,B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Sealring
Forward clutch and turbine shaft assembly
Turbine shaft and clutch housing assembly
Sealring (2)
Turbine shaft
Forward clutch housing
Check ball (2)
Retainer pin (after S/N 49489)
Valve plug (after S/N 49489)
Valve spring (after S/N 49489)
Centrifugal valve (after S/N 49489)
Snapring
PTO drive gear
Clutch housing sealring
Clutch piston sealring
Forward clutch piston (selective)
Piston A 0.9951.005 inch (25.2725.53 mm)
Piston B 1.0201.030 inch (25.9126.16 mm)
Piston C 1.0451.055 inch (26.5426.80 mm)
Forward clutch piston return spring
Spring retainer
Snapring
Forward clutch hub
External-tanged plate (5) (some models, 6)
Internal-splined plate (5) (some models, 6)
Fourth clutch driving hub
Snapring
Foldout 7
F OLDOUT 7
A
Foldout 7,A. Oil Pump and Front Support Assembly
Foldout 7,B. Forward Clutch and Turbine Shaft Assembly

8,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Fourth clutch assembly

Snapring
Clutch backplate
Internal-splined plate (4) (some models, 5)
External-tanged plate (4) (some models, 5)
Snapring
Piston spring retainer
Fourth clutch piston (selective)*
Piston A 0.9951.005 inch (25.2725.53 mm)
Piston B 1.0201.030 inch (25.9126.26 mm)
Fourth clutch piston (selective)**
Piston J 0.9700.980 inch (24.6424.89 mm)
Piston K 0.9951.005 inch (25.2725.53 mm)
Piston L 1.0201.030 inch (25.9126.16 mm)
Piston outer sealring
Piston inner sealring
Fourth clutch housing assembly
Check ball (4)
* Use with four-plate clutch.

** Use with five-plate clutch.
8,B
1 Snapring
2 Third clutch backplate (selective):
ID No. 7: 0.4760.486 inch (12.0912.34 mm)
ID No. 8: 0.4500.460 inch (11.4311.68 mm)
ID No. 9: 0.4630.473 inch (11.7612.01 mm)
3 Internal-splined clutch plate (3)
4 External-tanged clutch plate (3)
5 Snapring (selective):
Color code: White 0.148 0.150 inch
(3.76 3.81 mm)
Color code: Yellow 0.152 0.154 inch
(3.86 3.91 mm)
Color code: Green 0.155 0.157 inch
(3.94 3.99 mm)
Color code: Red 0.158 0.160 inch
(4.01 4.06 mm)
6 Push-on nut (4)
7 Spring retainer ring
8 Piston return spring (20)
9 Third clutch piston
10 Piston inner sealring
11 Piston outer sealring
12 Butt-joint sealring (2)
13 Center support housing assembly
14 Bushing
15 Check ball
16 Center support
19 Second clutch piston
21 Spring retainer ring
22 Push-on nut (4)
23 Sealring (after S/N 100431)
24 Oil filter (after S/N 100431)
25 Snapring
26 External-tanged plate (3)
27 Internal-splined plate (3)
28 Second clutch backplate (selective):
ID No. 7: 0.476 0.486 inch (12.0912.34 mm)
ID No. 8: 0.450 0.460 inch (11.4311.68 mm)
ID No. 9: 0.4630.473 inch (11.7612.01 mm)
29 Shim (use with grooved center support only)
Foldout 8
F OLDOUT 8
A
Foldout 8,A. Fourth Clutch Assembly
Foldout 8,B. Third Clutch, Center Support, and Second Clutch

9,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Thrust washer
Front sun gear
Thrust washer
Front planetary carrier assembly
Pinion pin (6)
Bronze thrust washer (12)
Steel thrust washer (12)
Front planetary pinion (6)
Roller (120)
Bushing
Thrust washer
Snapring
Front planetary ring gear
Center planetary carrier assembly
Pinion pin (4)
Center planetary carrier
Center planetary pinion (4)
Roller (72)
Bronze thrust washer, two-pinion (4)
Sun gear shaft assembly
Spring pin (2)
Shaft and bushing assembly
Bushing (2)
Sun gear shaft
Needle roller bearing
Bearing race
Snapring
Center planetary ring gear
Main shaft assembly
Lubrication orifice plug
Main shaft
Thrust washer
Rear planetary sun gear
Snapring
Snapring
Rear planetary carrier assembly
Pinion pin (4)
Roller (72)
Pinion (4)
Rear planetary carrier
Needle roller bearing assembly*
Snapring
Ball bearing**
Output shaft assembly**
Bushing**
Cup plug**
Spring pin**
Output shaft**
* Used on MTB Series only.

** Used on MT Series only.
9,B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Thrust washer
Front sun gear
Thrust washer
Pinion pin (6)
Front planetary pinion (6)
Roller (120)
Flange and carrier assembly
Bushing
Thrust washer
Snapring
Front planetary ring gear
Center planetary carrier assembly
Pinion pin (4)
Center planetary carrier
Center planetary pinion (4)
Roller (72)
Center sun gear shaft assembly
Spring pin (2)
Shaft and bushing assembly
Bushing (2)
Center sun gear shaft
Roller bearing race
Snapring
Center planetary ring gear
Main shaft assembly
Lubrication orifice plug
Main shaft
Rear planetary sun gear
Snapring
Rear planetary carrier assembly, four-pinion
Pinion pin (4)
Roller (72)
Rear planetary pinion (4)
Snapring
Thrust washer
Rear planetary carrier assembly, five-pinion
Pinion pin (5)
Roller (90)
Pinion (5)
Bronze thrust washer, three-pinion (2)
Foldout 9
F OLDOUT 9
A
B
16
17
16
5
1
10
8
4
10
18
9
7
11
18
22
12
11
22
13
15
14
22
21
19
23
15
14
21
19
18
20
20
13
19
12
18
19
7
17
24
22
31
23
25
26
32
27
24
31
26
32
33
34
25
26
27
28
29
35
33
34
26
28
30
36
29
30
35
37
36
37
46
49
38
39
50
47
48
47
48
38
41
49
40
42
46
50
51
51
52
55
53
53
54
56
54
45
40
52
43
44
39
52
51
45
43
56
42
41
42
43
44
E01331.01
Foldout 9,A. Gear Unit Assembly MT(B) 640, 643
42
Foldout 9,B. Gear Unit Assembly MT(B) 650, 653
41
E01330.01

10,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Shroud (used with small vent cap)

Breather
Modulated lockup check plug A
Fill tube plug
PTO cover gasket
PTO access cover
Bolt, 38-16 x 34 (6) B
Bolt, 14-20 x 78 (2) D
Lube regulator valve adapter
Gasket
Sealring (if used)
Transmission housing assembly
Lube regulator valve
Valve spring
Valve guide tube
Plug, 18 A
Drive screw
Nameplate
Tube adapter (MT(B) 640, 643)
Bolt, 14-20 x 114 (4) (MT(B) 640, 643) C
Bolt, 14-20 x 234 (7) (MT(B) 650, 653) C
Bolt, 14-20 x 78 (2) (MT(B) 650, 653) C
Bolt, 14-20 x 3 (2) (later models) C
Bolt, 14-20 x 234 (1) (earlier models) C
Bolt, 14-20 x 134 (1) C
Detent roller and spring assembly
Bolt, 14-20 x 214 (16) (earlier models,17) C
Bolt, 14-20 x 2 (3) C
Filter kit
Sealring
Filter tube
Filter (paper element)
Gasket
Washer-head screw, 516-18 x 58
(516-18 x 114 used with 5.10 inch pan) G
Flat washer (if used)
Filter spacer (used with 5.10 inch pan)
Filter kit
Sealring
Filter (stainless sump screen) and filter tube
assembly
Gasket
Washer-head screw, 516-18 x 58 G
Drain plug
Gasket
Magnet
Pan assembly, standard
Flared tube plug
Washer-head screw, 516-18 x 58 (21) B
Detent lever
Nut, 38-24 B
Bolt, 516-18 x 58
Modulator retainer
Governor pressure check ball
54 Bolt, 38-16 x 3
(38-16 x 214, earlier models) F
55 Chamfered washer, 38
(Plain washer, 38, earlier models)
56 Shaft retainer pin
57 Plug, 18 A
58 Selector shaft and nut assembly
59 Nut (metric thread)
60 Manual selector shaft
61 Selector shaft oil seal
62 Plug, 34-16 E
63 Washer
64 Pan filler flange plug
Torque
A
B
C
D
E
F
G
lb ft
48
1520
812
1215
5060
3946
1015
Nm
511
2027
1116
1620
6881
5362
1420
10,B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Bolt, 14-20 x 214 (16) (earlier models,17) A

Bolt, 14-20 x 2 (3) A
Detent roller and spring assembly
Bolt, 14-20 x 134 (1) A
Bolt, 14-20 x 3 (2) (later models) A
Bolt, 14-20 x 78 (2) (MT(B) 650, 653) A
Tube adapter (MT(B) 640, 643)
Bolt, 14-20 x 114 (4) (MT(B) 640, 643) A
Sealring
Hex washer screw, 516-18 x 58 B
Filter canister
Bolt, 14-20 x 234 (1) (MT(B) 650, 653) A
Drain plug
Oil filter
Sealring
Filter retainer
Spring
Sealring
Filter cover
Cover strap
Bolt, 516-24 x 78 B
Nut, 516-24
Flared tube plug (if used)
Washer-head screw, 516-18 x 58 (21) C
Pan assembly, heavy-duty
Magnet
Pan filler flange plug
Pan gasket
Torque
A
B
C
lb ft
812
1215
1520
Nm
1116
1620
2027
Foldout 10
F OLDOUT 10
A
Foldout 10,A. Transmission Housing, Standard Oil Filter and Oil Pan Configuration
Foldout 10,B. Heavy-Duty Oil Filter and Oil Pan Configuration

11,A
11,B
1 Snapring
2 First clutch backplate (selective):
ID No. 4: 0.7020.712 inch (17.8318.08 mm)
ID No. 5: 0.6710.681 inch (17.0417.30 mm)
ID No. 6: 0.6400.650 inch (16.2616.51 mm)
3 Internal-splined plate (6)
4 External-tanged plate (6)
5 Rear planetary ring gear (MT(B) 650, 653)
6 Rear planetary ring gear hub
(MT(B) 650, 653)
7 Snapring (MT(B) 650, 653)
8 Snapring
9 Spring retainer
11 First clutch piston
14 Rear planetary ring gear (MT(B) 640, 643)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Adapter housing gasket

Thrust washer
Adapter housing
Hex head pipe plug, 14 inch A
Thrust washer
Low sun gear
Thrust washer
Low planetary carrier assembly
Pinion pin (6)
Pinion (6)
Roller (114)
Carrier and bushing assembly
Bushing
Thrust washer
External-tanged plate (6)
Internal-splined plate (5)
Low planetary ring gear
Snapring
Piston spring retainer
Piston return spring (26)
Low clutch piston (selective)
Piston C 0.8580.868 inch (21.7922.05 mm)
Piston B 0.8290.839 inch (21.0621.31 mm)
Piston A 0.8000.810 inch (20.3220.57 mm)
Torque
A
lb ft
810
Nm
1114
Foldout 11
F OLDOUT 11
B
A
1
7
3
8
9
10
11
12
14
13
V03323
Foldout 11,A. First Clutch and Rear Planetary Ring Gears
Foldout 11,B. Low Clutch, Planetary, and Adapter Housing MT(B) 650, 653

12,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
12,B
Governor drive gear

Speed sensor wheel
Sleeve spacer
Rear cover gasket
Rear cover assembly
Rear cover
Governor support pin
Plug, 18 C
Plug, 18 C
Governor filter kit
Governor filter
Sealring
Filter plug,78-14 E
Drain tube
Plug, 38 D
Flat washer, 12 (14) (used with non-flanged
bolt)
Bolt, 12-13 x 112 (14) A* or F**
Flanged bolt, 12-13 x 112 (14) F
Snapring (earlier models)
Ball bearing
Beveled snapring
Oil seal
Dust shield
Output flange washer
Bolt, 12-20 x 112
Governor assembly
Governor service kit
Governor weight pin (2)
Governor cover gasket
Governor cover
Bolt, 516-18 x 1116 (4) B
Torque
A
B
C
D
E
F
* Non-plated bolts
** Zinc plated bolts
lb ft
6780
1520
48
1822
5070
6173
Nm
91108
2027
511
2430
6895
8399
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Shaft and plug assembly

Output shaft bushing
Cup plug
Output shaft
Spring pin
Ball bearing assembly (earlier models)
Roller bearing (later models)
Governor drive gear
Speedometer drive gear (used with sleeve
spacer 11, earlier models)
Speed sensor wheel
Sleeve spacer (earlier models)
Rear cover gasket
Rear cover assembly
Roller bearing outer race (later models)
Rear cover
Governor support pin
Plug, 18 D
Plug, 18 D
Governor filter kit
Governor filter
Sealring
Filter plug, 78-14 F
Drain tube
Plug, 38 E
Flat washer, 12 (14) (used with non-flanged
bolt)
Bolt, 12-13 x 514 (14) A* or G**
Flanged bolt, 12-13 x 514 (14) G
Snapring (earlier models)
Ball bearing
Beveled snapring
Oil seal
Dust shield
Spacer (if used)
Self-locking nut B
Governor assembly
Governor cover
Bolt, 516-18 x 1116 (4) C
Torque
A
B
C
D
E
F
G
lb ft
6780
600800
1520
48
1822
5070
6173
Nm
91108
8141085
2027
511
2430
6895
8399
* Non-plated bolts
** Zinc plated bolts
Foldout 12
F OLDOUT 12
B
A
1
2
4
5
3
17
18
19
16
20
8
21
9
28
22
15
12
23
13
11
29
27
10
14
24
30
31
32
25
26
E03335.01
Foldout 12,A. Rear Cover Components MT 640, 643
Foldout 12,B. Output Shaft and Rear Cover Components MT 650, 653

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53

Valve stop pin
Priority valve spring
Priority valve
Hold regulator valve spring
Valve stop pin
Valve plug (before S/N 66152)
Washer (after S/N 66151)
Adjusting ring (after S/N 66151)
Selector valve
Retainer pin
12 shift valve
12 shift modulator valve
12 shift valve spring
Valve stop
Adjusting ring
Retainer pin
23 shift valve
Valve stop
Adjusting ring
Retainer pin
34 shift valve
Valve stop
Adjusting ring
Retainer pin
34 relay valve
34 relay valve spring
Valve stop (later models)
Retainer pin
Trimmer regulator valve
Trimmer regulator valve spring
Trimmer regulator valve stop
Separator plate
Bolt, 14-20 x 134 (3) A
Modulator valve actuator pin
Modulator valve
Modulator valve spring
Washer (earlier models)
Valve stop (earlier models)
Adjusting ring
Modulator valve body
Retainer pin
Reverse priority bypass check ball
(after S/N 47284, MT(B) 650, 653 only)
Control valve body
Third clutch trimmer valve
Trimmer plug
Valve outer spring
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
Valve inner spring (after S/N 13800)

Valve stop
First clutch trimmer valve
Trimmer plug
Valve outer spring
Valve inner spring
Valve stop
Second clutch trimmer valve
Trimmer plug
Valve outer spring
Valve inner spring
Valve stop
Accumulator valve spring (later models)
Accumulator valve (later models)
Fourth clutch trimmer valve
Trimmer plug
Valve outer spring
Valve inner spring (after S/N 13800)
Valve stop
Trimmer valve cover
Bolt, 14-20 x 34 (9) (8, earlier models) A
Retainer pin (2)
23 relay valve
12 relay valve
Spacer
12 shift valve return spring*
12 shift valve*
12 modulator valve*
12 shift valve spring*
Valve stop*
12 shift valve bore washer*
Trimmer valve cover (earlier smooth shift
models)
Bolt, 14-20 x 34 (4) A
Accumulator valve (earlier smooth shift
models)
Accumulator valve spring (earlier smooth
shift models)
Valve stop (earlier smooth shift models)
Accumulator valve body (earlier smooth
shift models)
Bolt, 12-20 x 212 (4) A
First clutch tube
Governor tube (2)
Governor screen assembly (earlier models)
Torque
A
lb ft
812
Nm
1116
* Second gear start models only
Foldout 13
F OLDOUT 13
39
46
44
45
43
42
40
46
41
43
42
37
36
29
26
22
38
49
34
76
51
30
15
86
52
50
19
14
53
24
85
13
84
11
10
35
20
16
87
48
31
25
21
17
88
98
32
27
23
18
58
61
59
62
60
63
66
4
64
67
6
8
55
57
12
54
56
83
96
41
47
33
28
97
69
65
68
74
70
77
71
78
80
89
72
75
73
79
81
90
91
82
92
93
94
95
V03338
Foldout 13. Control Valve Body Assembly MT(B) 640, 643

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

Valve stop pin
Priority valve spring
Priority valve
Hold regulator valve spring
Valve stop pin
Valve plug (before S/N 66940)
Washer (after S/N 66939)
Adjusting ring (after S/N 66939)
Selector valve
Retainer pin
23 shift valve
Valve stop
Adjusting ring
Retainer pin
34 shift valve
Valve stop
Adjusting ring
Retainer pin
45 shift valve
Valve stop
Adjusting ring
Retainer pin
45 relay valve
Retainer pin
Trimmer regulator valve
Trimmer regulator valve spring
Trimmer regulator valve stop
Separator plate
Bolt, 14-20 x 134 (3) A
Modulator valve actuator pin
Modulator valve
Modulator valve spring
Washer (earlier models)
Valve stop (earlier models)
Adjusting ring
47 Modulator valve body

48 Retainer pin
49 Reverse priority bypass check ball
(after S/N 47284)
50 Control valve body
51 Third clutch trimmer valve
52 Trimmer plug
53 Valve outer spring
54 Valve inner spring (after S/N 13800)
55 Valve stop
56 First clutch trimmer valve
57 Trimmer plug
60 Valve stop
61 Second clutch trimmer valve
62 Trimmer plug
65 Valve stop
66 Valve stop (later models)
67 Accumulator valve spring (later models)
68 Accumulator valve (later models)
69 Fourth clutch trimmer valve
70 Trimmer plug
73 Valve stop
74 Trimmer valve cover
75 Bolt, 14-20 x 34 (9) (8, earlier models) A
76 Retainer pin (2)
77 34 relay valve
78 34 relay valve spring
79 Valve stop (later models)
80 23 relay valve
81 23 relay valve spring
82 Spacer
83 Governor tube (2)
84 Governor screen assembly (earlier models)
85 Trimmer tube
86 Low clutch feed tube
87 Drive tube
88 Main knockdown tube (before S/N 47285)
Torque
A
lb ft
812
Nm
1116
Foldout 14
F OLDOUT 14
39
46
45
44
43
42
40
46
41
43
83
42
41
47
84
37
48
36
29
33
28
26
22
85
38
31
25
21
17
35
32
27
23
49
34
87
76
20
16
88
51
30
15
52
50
19
14
53
24
13
11
10
58
61
59
62
9
4
60
63
66
64
67
6
8
55
57
12
54
56
18
86
69
65
68
70
77
71
78
80
74
72
79
73
81
82
75
V03339
Foldout 14. Control Valve Body Assembly MT(B) 650, 653

15,A
1
2
3
4
5
6
7
Modulated lockup valve body assembly

Modulated lockup valve body
Retainer pin
Modulated lockup valve spring
Modulated lockup valve stop
Adjusting ring
15,B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Oil transfer plate

Separator plate
Low shift valve assembly
Valve body
Retainer pin
Retainer pin
12 relay valve
Valve stop
12 shift valve
Valve stop
Washer
Adjusting ring
Foldout 15
F OLDOUT 15
A
3
2
6
7
V01919
Foldout 15,A. Modulated Lockup Valve Body Assembly
Foldout 15,B. Low Shift Valve Body Assembly MT(B) 650, 653
F OLDOUT 16
1
2
3
4
5
6
7
8
Parking brake assembly, 12 x 4

Shield
Lockwasher, 58 (4)
Bolt, 58-11 x 138 (4) A
Brake shoe assembly
Parking brake assembly, 12 x 3
Lockwasher, 58 (4)
Bolt, 58-11 x 138 (4)
Torque
A
lb ft
117140
Nm
159190
Foldout 16. Parking Brake Assemblies

17,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
17,B
Sealring
Flared tube 90 elbow B
Converter-out hose assembly C
Hose clamp
Hex head bolt, 516-18 x 1116 D
Sealring
Flared tube connector B*
Flared tube connector B*
Sealring
Nut, 516-18 hex H
Lockwasher, 516
Hose clamp bracket
Sealring
Flared tube 90 elbow B
Clutch feed hose assembly A
Flared tube 90 fitting G
Check valve
Flared tube 90 elbow G
Internal snapring (3)
Accumulator spring retainer (3)
Accumulator inner spring (3)
Accumulator outer spring (3)
Accumulator piston sealring (3)
Accumulator piston (3)
Accumulator piston sealring (3)
Accumulator cover gasket
Accumulator cover assembly
Hex head pipe plug, 18 NPTF E
Hex head pipe plug, 18 NPTF E
Accumulator cover
Flat washer, 10 mm (13)
Bolt, M10 x 1.5 x 50 mm (13) F
Flat washer, sealring (2)
Flanged bolt, M10 x 1.5 x 50 (2) F
Governor assembly
Governor cover
Bolt, M8 x 1.25 x 25 mm (4) D
Torque
A
B
C
D
E
F
G
H
lb ft
1620
2535
5565
1316
45
3035
1216
1012
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Nm
2227
3447
7588
1822
57
3948
1622
1416
* OEM supplied filter assembly is located between connectors 7 and 8.
Retarder valve gasket (2)

Separator plate
Bolt, hex, M10 x 1.5 x 45 (2) A
Bolt, hex, M10 x 1.5 x 100 (10) A
Retarder control valve assembly
Bolt, hex, M6 x 1 x 80 (4) B
Lockwasher, 6 mm (4)
Retarder valve body top cover
Retarder valve body top cover gasket
Sealring
Sealring
Piston
Retarder valve
Retarder valve spring
Retarder valve body
Pipe plug, 12 NPTF D
Pipe plug, 14 NPTF E
Pipe plug, 116 NPTF F
Retarder cutoff valve
Retarder cutoff valve spring
Gasket
Regulating valve assembly
Oil transfer plate
Gasket
Regulating valve body
Charging valve spring
Charging valve
Sealring
Plug, hex socket, 78-14 UNF G
Charging pressure orifice plug
Retarder-pressure regulator valve
Retarder-pressure regulator valve spring, inner
Retarder-pressure regulator valve spring, outer
Valve plug
Cover gasket
Valve body cover
Bolt, hex, M10 x 1.5 x 35 (2) A
Bolt, hex, M8 x 1.25 x 50 (2) C
Bolt, hex, M8 x 1.25 x 60 (4) C
Bolt, hex, M8 x 1.25 x 80 (2) C
Bolt, hex, M8 x 1.25 x 90 (2) C
Torque
A
B
C
D
E
F
G
lb ft
3035
47
1316
1620
810
34
5070
Nm
3948
69
1822
2227
1114
46
6895
Foldout 17
F OLDOUT 17
A
Foldout 17,A. Retarder Accumulators and Governor
Foldout 17,B. Retarder Control Valve

18,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
18,B
Retarder housing gasket

Retarder housing assembly
Housing assembly
Governor bushing
Retarder housing and bushing assembly
Retarder housing
Dowel pin
Sleeve
Retainer and ball assembly
Speedometer bushing
Hex head pipe plug, 18 NPTF B
Governor filter kit
Governor filter
Sealring
Hex socket plug, 78-14 UNF C
Hex head pipe plug, 14 NPTF D
Retarder priority valve
Retarder priority valve spring
Valve stop
Valve stop pin
Elbow, flared tube, 45 D
Hex head pipe plug, 18 NPTF B
Output shaft spacer
Ball bearing
Internal snapring
Output shaft oil seal
Nut, hex, self-locking F
Bolt, hex, M12 x 1.75 x 130 (3) A
Plug, speedo, 0.8125-20 UNEF-2A G
Torque
A
B
C
D
E
F
G
lb ft
5363
45
5070
810
1620
600800
2030
1 Internal snapring
2 Bolt, M10 x 1.5 x 35 mm
(6, some models, 7) A
3 Flat washer, 10 mm (6, some models, 7)
4 Retarder stator
5 Stator sealring
6 Retarder external-splined clutch plate (5)
7 Retarder internal-splined clutch plate (6)
8 Output shaft assembly (MTB 643 only)
9 Roller bearing assembly (MTB 643 only)
10 Lube orifice plug (MTB 643 only)
11 Output shaft (MTB 643 only)
12 Sealring (2)
13 Retarder rotor hub
14 Retarder rotor assembly
15 Retarder clutch backplate
Torque
A
lb ft
2935
Nm
3948
Nm
7285
57
6895
1114
2227
8141085
2740
Foldout 18
F OLDOUT 18
B
1
2 3
4
6
7
9
10
11
12
14
12
13
15
V03321
Foldout 18,A. Retarder Housing
Foldout 18,B. Retarder Clutch

19,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
19,B

Bolt, hex, M12 x 1.75 x 60 (11) A
Ball bearing
Bolt, M12 x 1.75 x 45 (6) A
Retarder adapter housing assembly
Hex head pipe plug,14 NPTF B
Adapter housing and sleeve assembly
Sleeve
Pin
Adapter housing
Hex head pipe plug,18 NPTF (2) C
Sealring (14)
Flat washer, 12 (14)
Bolt, hex head, 12-13 x 2 (14) D
Adapter housing sealring
Retarder piston (selective)
ID No. 5 0.7360.740 inch (18.718.8 mm)
ID No. 6 0.7680.772 inch (19.519.6 mm)
ID No. 7 0.7990.803 inch (20.320.4 mm)
Piston return spring retainer
External snapring
Torque
A
B
C
D
E
lb ft
5363
810
45
8197
8
Nm
7285
1114
57
110132
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Roller bearing assembly

Output shaft assembly
Bushing
Cup plug
Output shaft
Bearing inner race and rollers
Bolt, hex, M12 x 1.75 x 90 (12) (11, earlier
models) A
Flat washer, 12 mm (12) (11, earlier models)
Output shaft spacer
Bolt, hex, M12 x 1.75 x 45 (5) A
Retarder adapter housing assembly
Bearing outer race
Adapter housing and sleeve assembly
Adapter housing
Sleeve
Pin
Hex head pipe plug,18 NPTF (2) C
Sealring (14)
Flat washer, 12 (14)
Bolt, hex head, 12-13 x 512 (14) D
Adapter housing sealring
Retarder piston (selective)
ID No. 5 0.7360.740 inch (18.718.8 mm)
ID No. 6 0.7680.772 inch (19.519.6 mm)
ID No. 7 0.7990.803 inch (20.320.4 mm)
Piston return spring retainer
External snapring
Torque
A
B
C
D
E
lb ft
5363
810
45
8197
8
Nm
7285
1114
57
110132
11
Foldout 19
F OLDOUT 19
B
1
8
15
14
3
2
16
5
19
20
13
14
18
11
21
7
12
8
2
16
15
17
23
10
22
17
13
10
4
18
19
24
20
25
26
27
21
28
22
5
6
23
29
11
12
24
30
25
31
26
32
27
33
E03337.01
E03336.01
Foldout 19,A. MTB 643 Retarder Adapter
Foldout 19,B. MTB 653 Retarder Adapter

MT 600 Service Manual SM1317 199907

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SM1317EN

Printed in the U.S.A.

Copyright 1996 General Motors Corp.

and Chemical Corporation.

Copyright 1996 General Motors Corp.

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Copyright 1996 General Motors Corp.

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

Section 1. GENERAL INFORMATION

Section 2. DESCRIPTION AND OPERATION

211. FOURTH CLUTCH

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

222. REAR COVER

227. TORQUE PATHS THROUGH THE

Section 3. PREVENTIVE MAINTENANCE

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

37. TRANSMISSION FLUID

d. Stall Test Procedures Vehicles

317. REPLACEMENT OF COMPONENTS WHILE

b. Stall Test Preparation . . . . . . . . . . . . . . .327

320. OUTPUT RETARDER TROUBLESHOOTING BEFORE REMOVAL

c. Stall Test Procedures Vehicles

321. TROUBLESHOOTING TRANSMISSION

314. OIL COOLER . . . . . . . . . . . . . . . . . . . . . . .326

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

322. TROUBLESHOOTING PROCEDURES

Section 4. GENERAL OVERHAUL

c. External Pipe Plugs, Hydraulic

47. REMOVING (OR INSTALLING)

48. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . 418

44. CAREFUL HANDLING . . . . . . . . . . . . . . . .42

410. TORQUE SPECIFICATIONS. . . . . . . . . . 418

45. CLEANING AND INSPECTION

411. SELECTIVE PARTS . . . . . . . . . . . . . . . . . 418

46. ASSEMBLY PROCEDURES

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

56. REMOVAL OF HYDRAULIC COMPONENTS

514. REMOVAL OF LOW CLUTCH, LOW

Section 6. REBUILD OF SUBASSEMBLIES

64. MODULATED LOCKUP VALVE BODY

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

69. FORWARD CLUTCH AND TURBINE SHAFT

618. OUTPUT RETARDER HOUSING

612. GEAR UNIT AND MAIN SHAFT ASSEMBLY

623. CLUTCH STACK MEASUREMENT

613. GEAR UNIT AND MAIN SHAFT ASSEMBLY

624. PLANETARY CARRIER ASSEMBLIES

614. GEAR UNIT AND MAIN SHAFT ASSEMBLY

Section 7. ASSEMBLY OF TRANSMISSION

Copyright 1996 General Motors Corp.

MT(B) 640, 643, 650, 653 AUTOMATIC TRANSMISSIONS

c. Rear Cover MT 640, 643. . . . . . . . . . .73

77. INSTALLING RETARDER EXTERNAL

Section 8. WEAR LIMITS AND SPRING DATA

Section 9. CUSTOMER SERVICE

76. INSTALLATION OF OIL FILTER, PAN,

Copyright 1996 General Motors Corp.