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Mack Maxitorque Transmission TRL1076 Manual

Pro Gear's Mack Maxitorque Transmission TRL1076 Manual to assist in identifying the parts for your
Mack Transmission unit.

If you need any assistance identifying the correct transmission unit for your truck and equipment,
contact your Mack replacement specialists at Pro Gear and Transmission.

Pro Gear stocks every part for your Mack truck including: PTO housings, mounts, driveshafts, gears,
bearings, gaskets, cable shift cover assembly, post and plate assembly, brackets, stud kits, seal
kits, lever control assembly, air shift cover assembly, direct mount pump conversion kits, stud kits
including English and metric references, CAT D&H parts and much more.

Pro Gear Transmission has same day shipping and 1000’s of products in stock and ready to ship
internationally for your next project.

For parts or service contact the Mack specialists at Pro Gear & Transmission, Inc.

1 (877) 776-4600
(407)872-1901
[email protected]

Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • [email protected]
r:

MAXITORQUE TRANSMISSION
TRL1076 and TRL1078

DESCRIPTION

The TRL1076 and TRL1078 are triple countershaft transmissions providing five forward speeds
and one reverse speed. Short in length, light in weight and easy to service, this new trans-
mission is designed for use in over the road trucks and tractors particularly in long distance
operation on varied terrain. Both transmissions are identical except for the elimination of
the upper left hand rear countershaft in the TRL1076 .

The five speed gearset is housed in a high high capacity in the shortest overall length.
strength aluminum case which is constructed By distributing the load equally among three
in two pieces for maximum convenience of shafts, normal deflection is reduced to a min-
disassembly and reassembly. See Figures imum. Another unique design is that the
1 and 2. mainshaft gears are self centered among the
three countershafts, eliminating the need for
gear bushings. The mainshaft gears are con-
nected to the mainshaft only when engaged by
a sliding clutch.

All gears of the gearset are of the spur type

design and with the exception of reverse speed
sliding gear, are in constant mesh with the
countershaft gears. Other than reverse,
driving engagement for the five forward
speeds is effected by means of the sliding
clutches. Reverse is obtained by engaging
reverse sliding spur gear with the three in-
dividually mounted idler gears. Conventional
forks spanning the sliding clutches and re-
P. T.O. OPENING COVER verse gear, move these parts in response to
the movement of the gear shifter hand control
Figure 1. Left Rear View of Transmission lever by the driver.

LUBRICATION

All rotating and sliding parts of the trans-

mission are bathed in oil from gear throw-
off when the engine is operating.

Removal of all foreign metallic particles

within the transmission is accomplished by
two magnetic oil filters, one on each side of
the case. The filter consists of an integral
open trough and baffle arrangement with a
removable sheet metal cover. At the bottom
of the baffle, a tapped hole in the case ac-
MIIGNCTIC FI LTER
PLUGS ( I EACH SIOE"I ...., commodates a large hex plug with a powerful
built-in magnet installed from outside.
Figure 2. Right Rear View of Transmission
The oil from gear throw-off is collected by
Cast iron liners are cast in aluminum case the filter and is made to pass the magnetic
at all shaft bearing locations. These liners plugs which pull all ferrous metal particles
assure maximum service life plus the ad- out of the passing oil and holds them. After
vantages of light weight construction. passing the magnet, clean and chip-free oil
then rises to the outlet near the top of the
Unlike conventional transmissions, three filter and drops down into the transmission
countershafts are equally spaced around the case. A magnetic drain plug is also provided
input shaft. This design provides extremely at the bottom of the case.
6-131
When the oil is hot, as when coming in from 2. Remove hand brake parts, clutch release
a run, the oil level of the transmission should shaft and yoke.
be checked with the vehicle on level ground.
To add oil, remove plug on the right side of 3. Remove transmission case top opening
the case and fill. The level should not be covers. Cautiously remove shifter rail pop-
above the filler-plug hole. Check level at pet ball cover (cover is spring loaded), pins
interval specified in OPERATION MANUAL. and springs. See Figure 3. Poppet balls
may be removed with a magnet.
At every check or change, always remove,
clean and reinstall magnetic plugs on right
and left side of case.

To change oil, remove magnetic drain plug

and drain oil from case while hot. If neces-
sary, also flush case with flushing oil and
drain thoroughly. Clean and replace mag-
netic drain plug. Remove fill plug and fill
with recommended gear oil to level of filler
plug hole at the intervals specified in OP~
ERATION MANUAL. Reinstall filler plug.
Follow schedule instructions closely and if
operation requires it, JJlake checks and
changes more often.

SPECIFICATIONS
Figure 3. Removing Shifter Rail Poppet
Gearset, Make .. Mack (Three countershafts) Ball Cover
Model. ...... . .... TRL1076, 1078
Type ................. Five Speed 4. Remove setscrews from shifters and shift-
Control. ... Selective, single lever, er forks except second and third. Remove
manual reverse speed shifter fork front snap ring.
Speeds, Forward ... . ........ Five Withdraw shifter rails from case and at the
Rever~e . .... . .. . ... .One same time remove shifters and shifter forks.
Bell Housing, Type .............. Separable Slide reverse shifter fork snap ring forward,
Lubrication ........... . . . .. Gear throw-off then slide fork forward to be able to slide
Case, Material ........ ... . . . . . . Aluminum rear snap ring rearward. While moving rail
P. T.O. Openings forward, alternately move front and rear snap
Left Side .......... Std. SAE 8 hole rings rearward until rail is out of case.
Right Side ......... Std. SAE 6 hole
Oil Capacity, Pts. . . . . . . . . . . . . . . . . . . . . 22 NOTE

It is recommended that rear ex-

DISASSEMBLY pansion plug be removed to with-
draw the second and third shift
Main Components rail. This can be accomplished
by tapping on the shifter to drive
NOTE rail rearward. Then remove set-
s crew from the second and third
Unless a complete overhaul is shifter and remove rail, fork and
necessary, remove only those shifter from case.
parts required to gain access to
the faulty parts. Do not disturb 5. Place transmission in two gears which
parts having heavy press fits un- will lock up assembly to facilitate the re-
less replacement is necessary. moval of the drive flange clamp plate screw.
In that case, use proper press Remove drive flange clamp plate screw and
setups and pullers so that usable clamp plate. Install standard puller and re-
parts are not damaged. move drive flange from mainshaft splines.
Remove mainshaft rear bearing cover, then
1. After draining lubricant and removing slide speedometer gear off of mainshaft.
transmission from vehicle, clean externally
and mount unit in a S\\itable overhaul stand. 6. Remove main driving pinion bearing cover

6-132
capscrews and cover. See Figure 4. Tap
on gear end of main driving pinion with any- f)
Ion mallet if necessary and remove assembly 1/
from case.

Figure 6. Removing Thrust Washer

Retaining Snap Ring

Figure 4. Removing Main Driving Pinion

Bearing Cover

7. Remove fourth/fifth speed sliding clutch

from mainshaft. See Figure 5.

Figure 7. Removing Fourth Speed Gear

Selective Thrust Washer

Figure 5. Removing Fourth/Fifth Speed

Sliding Clutch

8. Through main driving pinion bearing open -

ing, remove fourth speed gear selective thrust
washer retaining snap ring. See Figure 6.
Slide fourth speed gear selective thrust wash-
er off of mainshaft. See Figure 7.

9. Carefully withdraw mainshaft from case

through rear bearing opening. See Figure 8. Figure 8. Removing Main shaft

6-133
10. Remove fourth speed gear and thrust 14. Remove front counter shaft thrust washer
washer through transmission case top cover retaining snap ring, then remove thrust wash-
opening. See Figure 9. er from countershafts. See Figures 11 and 12.

Figure 9. Removing Fourth Speed Gear

Figure 11. Removing Thrust Washer
11. Remove countershaft rear bearing cover Retaining Snap Ring
capscrews and cover. Remove power-take-
off cover capscrews and covers. Remove the
lower and right-hand rear countershaft oil
slinger front snap rings, or power-take-off
gear front snap ring when incorporated. See
Figure 10.

Figure 12. Removing Counter shaft

Thrust Washer

15. Remove mainshaft sliding clutches and

gears with thrust washers from case. See
Figures 13 and 14.
Figure 10. Removing Rear Countershaft Oil
Slinger Front Snap Ring

12. Remove the three rear countershafts

from case through rear bearing cover open-
ings. While withdrawing the lower and right-
hand counter shafts, at the same time slide oil
slinger and oil slinger retaining spring with
its front snap ring off of shaft. Where power-
take-off gear is incorporated instead of oil
slinger, slide power-take-off gear with its
front snap ring off of shaft.

13. Place main case in a vertical position.

Remove all case-to-case dowel bolts and cap-
screws. Withanylonheaded mallet, tap rear
case and separate it from the front case. Re- Figure 13. Removing First Speed
move rear case and place on bench. Sliding Clutch

6-134
-

194-425

Figure 14. Removing First Speed Gear Figure 16. Removing Pinion Bearing
Retaining Spirolox Snap Ring

16. Place transmissi.ion in a horizontal pos- Mainshaft

ition and remove countershaft front bearing
cover capscrews and covers. Remove snap
rings from outer race of countershaft front Remove mainshaft rear ball bearing position -
bearings. ing snap ring then press shaft out of rear ball
bearing. Place mainshaft in vise having soft
metal jaws and remove spigot bearing retain-
17. Position transmission vertically, then ing snap ring and bearing inner race. Re-
remove the three front countershaft assem- move reve!'se stop snap ring from shaft.
blies from case. See Figure 15.

Rear Case

Using a sharp tool, punch a hole in idler shaft

expansion plug and pry out. With a suitable
threaded puller withdraw the three idler gear
shafts from case. Remove idler gears, bear-
ings, thrustwashers, andreverse speed gear
from case. Remove countershaft roller bear-
ing retaining snap rings and bearings from
case.

Rear Countershafts

Figure 15. Removing Front Countershafts Remove countershaft rear bearing retaining
snap ring and positioning snap ring, then press
countershafts out of rear ball bearing.

SUB-ASSEMBLIES
Front Countershafts
Main Driving Pinion

Remove bearing retaining spirolox snap ring. Remove countershafts front bearing retain-
See Figure 16. Remove the ball bearing by ing snap ring. Remove countershafts front
pressing or tapping off. Turn pinion over bearing and gear retaining snap ring. Turn
• and remove retaining snap ring and spigot countershafts over and remove roller bear-
bearing. ing inner race from shafts.

6-135
.,
NOTE the shift rail and the mating housing bore ex-
ceeds . 010 inch maximum, check to deter-
(TRL-1076 only) Remove the rear mine which member is worn before replac-
rollerbearing inner race retain- ing same. Shaft wear may be checked by
ing snap ring from the upper left comparing shaft diameter at an "unwearing"
hand countershaft before remov- point as against the wear point.
ing inner race.
Oil Seals - When a complete overhaul is re-
For shops having a small capacity hydraulic quired, replace all oil seals. For complete
press, press off one countershaft gear at a details, see GENERAL DATA, page 5-1.
time. For shops having a large capacity hy-
draulic press, place countershaft assembly Replace cases found to be cracked. Check
in press, slide length of heavy tubing over all other parts for wear and damage. Re-
integral gear to engage the second speed gear place all parts as required. Replace all gas-
and remove all gears in one operation. kets, O-rings, and any part that shows mu-
tilation. Replace poppet springs that have
lost their tension. Clean up any threads that
INSPECTION show mutilation.

Clean case, covers and all other parts of

the transmission thoroughly using a suitable
cleaning solvent to remove all grease and for- REASSEMBLY
eign matter. Dry parts with moisture-free
compressed air. NOTE

Bearings - Soak bearings in a suitable clean- Refer to "Screw Torques and Ad-
ing solvent to loosen all hardened grease and justment Chart"for fits and lim-
foreign matter. Strike bearings flat against its.
block of wood several times and again im -
merse in cleaning solvent turning races slow- Sub-Assemblies
ly. Repeat these operations until bearings
are clean and then blow them dry with filter-
ed moisture-free compressed air.
NOTE
)
All working parts, especially the
CAUTION bearings,- should be coated with
SAE 30 oil while the transmission
Do not spin bearings with com - is being assembled. This will in -
pressed air as damage to the sure immediate lubrication when
bearing may result. first starting and will prevent
seizing of these parts. As mov-
Bearings - Check bearings for flaking, cracks ing parts are assembled, check
and fractures, cavities and indentations, mea- frequently to see th:lt they move
surable wear, brinelling, fretting, corrosion, freely.
seizing, galling, scoring, nicking and cage
failures. If any of these defects are apparent
in any amount, replace bearings. Main Driving Pinion

Gears - Replace gear if teeth show any sign Assemble mainshaft spigot bearing in gear
of abrasive wear, scratching, ridging, scor- end of main driving pinion and retain with snap
ing, surface fatigue, pitting, spalling, cor- ring. Turn pinion over and install pinion ball
rosive wear, digging in andcracking. Gears bearing with outer race snap ring toward pilot
may also be checked by Magnaflux or similar end of pinion. Install bearing retaining spiro-
system for cracks which would not otherwise lox snap ring. See Figure 17.
be visible.

Shifter Fork, Sliding Clutch and Shift Rail - Mainshaft

Replace forks and/or clutches if side clear- Install bearing inner race on mainshaft spigot
and retain with snap ring. Position main-
ance in groove is in excess of specified limits,
shown on "Screw Torques and Adjustment shaft in arbor press with spigot end down and )
Chart." Replace shift rails if cracked in ei- press ball bearing on shaft. Install position -
ther the poppet or stake screw holes. In the ing snap ring in outer race of ball bearing.
case of wear, whereby the clearance between Install reverse stop snap ring on shaft.
6-136
 Through top cover hole of case, install re-
verse speed gear (shifter groove of gear for-
ward).

Rear Countershafts

Install lower and right - hand counter shaft

power-take-off gear inner snap ring in groove
provided. Press rear ball bearing on end of
countershafts and retain with snap ring. In-
stall positioning snap ring in outer race of
bearings.

194-425 Front Countershafts '" See Figure 19.

Figure 17. Installing Pinion Bearing

Retaining Spirolox Snap Ring FIFTH SPEED
GEAR
GEAR
FOURTH SPEED
I
THIRD SPEED

Rear Case . GEAR RETAINING

SNAP RING
GEA

~
Install roller bearing snap ring in inner re-
taining groove of case countershaft bores.
Install and seat roller bearings against inner
snap rings, then install outer snap ring in
groove provided to retain bearings.

Position reverse idler gear shafts so that ~ \

flats on end of shaft are pointing towards cen -

ter line of countershaft bore. Start shafts
into case. Assemble roller bearing in idler BEARING
I
gear. Position assembledgear in case (round- \ INNER RACE

ed teeth of idlers forward) with thrust wash- KEY

FRONT
ers at each end, and with a nylon hammer, COUNTERSHAFT RETAINING SNAP
RING (TRL1076
tap shaft into case through thrust washers and SECOND SPEED UPPER L.H.
gear. For final seating of idler gear shafts, GEAR COUNTERSHAFT
see Figure 18. BEARING RETAINING ONLY)
SNAP RING

NOTE
Figure 19. Front Countershaft Assembly
Apply sealer around idler gear
shafts before final seating. Then Press roller bearing inner race on rear end
install expansion plugs. of countershafts.

NOTE

(TRL-1076 only) On the upper left

hand countershaft install rear
roller bearing inner race retain-
ing snap ring.

Insert gear key in countershafts and press

gears on one at a time. These gears have an
interference fit and can be pressed on cold,
but for best results, the gears should be
heated. With a heat lamp or hot oil, heat
gears 270 to 300° F. for a periodof notmore
than 1/2 hour. Oil shaft for each gear. In -
stall gear snap ring, then press ball bearings
on end of shafts. Install ball bearing retain-
Figure 18. Final Seating of Idler Gears ing snap rings.
6-137
MAIN COMPONENTS

NOTE

All working parts, especially the

bearings, should be coated with
SAE 30 oil while the transmission
is being assembled. This will in-
sure immediate lubrication when
first starting and will prevent
seizing of these parts. As mov-
ing parts are assembled, check
frequently to see that they move
freely.

1. Position transmission front case verti-

cally and install the three front countershaft Figure 21. Installing Bearing Cover
assemblies in case. See Figure 20. 0 -Ring

Figure 20. Installing Front Countershaft

Assembly
Figure 22. Installing Mainshaft Third
2. Position transmission front case hori- Speed Gear
zontally. Install front counter shaft ball bear-
ing positioning snap rings in outer race of
bearings, then tap countershaft assemblies
rearward until positioning snap ring seats
against case.

3. Position O-ring in countershaft front bear-

ing covers. See Figure 21. Install covers
with O-rings and capscrews. Tighten cap-
screws to recommended torque.

4. Place transmission front case in a verti-

cal position. Install mainshaft third speed
gear so that the three alignment "O" marks
on face of gear mate with the alignment "O"
marks on the countershafts third speed gears.
See Figure 22.

5. Install second/third speed sliding clutch

and engage with third speed gear clutch teeth. Figure 23. Installing Second/Third Speed
See Figure 23. Sliding Clutch

6-138
6. Apply a light coat of grease to thrust sur-
face of second and first speed gear. Then
place thrust washer on front face of gear hub.
See Figure 24.

Figure 26. Installing First Speed Gear

•
Figure 24. Installing Gear Thrust Washer
on Gear

7. Install second speed gear (clutch teeth to

the rear) with thrust washer over second/third
speed sliding clutch and engage with the
countershaft second speed gears. See Figure
25.

Figure 2 7. Installing First Speed

Sliding Clutch

Figure 25. Installing Second Speed Gear

8. Install first speed gear (clutch teeth to

the rear) with thrust washer and engage with
countershaft first speed gears. See Figure
26.

9. Position first speed sliding clutch on sec-

ond/third speed sliding clutch. See Figure
27.

10. Install thrust washer on each front count-

ershaft and retain with snap ring. See Fig- Figure 28. Installing Countershaft
ures 28 and 29. Thrust Washer

6-139
 13. While advancing counter shaft, install oil
slinger retaining spring on shaft. With flared
lip of slinger toward the rear, install slinger
on counter shaft splines. Compress retaining
spring with slinger and install slinger front.
snap ring in groove, provided to retain sling-
er. See Figure 31. Where power-take-off
gear is incorporated, position gear on count-
er shaft splines, then install gear front snap
ring in groove provided in shaft.

Figure 29. Installing Thrust Washer

Retaining Snap Ring

11. Paint end of front case with a good gas-

ket sealer compound and install case-to-case
gasket . Paint rim of gasket with sealer and
lower rear case assembly over assembled
countersl:lafts. Tap case into position so that
bearings are seated properly, then install
case-to-case capscrews and dowel bolts and
tighten to recommended torque.
Figure 31. Installing Oil Slinger Retaining
NOTE Front Snap Ring

The following step will include

the installation of all three rear
countershafts, ( Two counter -
shafts for TRL1076) The only 14. Observe timing "0" marks on front and
exception in the TRL1078 will be rear counter shaft splines. See Figure 32.
that the upper left-hand counter- Align timing "0" marks on rear countershaft
shaft does not require a power- with timing "0" marks on front countershaft
take-off gear or an oil slinger. and continue advancing shaft until the counter-
shaft rear bearing positioning snap ring seats
12. Position the transmission horizontally. against case.
Start rear countershaft through rear bearing
opening in case. See Figure 30.

Figure 32. Aligning Timing "0" Mark on

Figure 30. Installing Rear Countershaft Rear Countershaft with Front Countershaft

6-140
1111111

15. Install 0-rings in counter shaft rear bear-

ing covers. See Figure 33. Install covers
with capscrews and washers, then tighten cap-
screws to recommended torque.

Figure 35. Installing Mainshaft

19. Place transmission in two gears which

will lock up assembly. Tighten clamp plate
screw to recommended torque.

Figure 33. Installing.0-Rings in Rear 2 O. Install fourth speed gear selective thrust
Bearing Cover washer on mainshaft. See Figure 36.

16. Install third speed gear thrust washer in

third speed gear.

17. Install fourth speed gear in case (clutch

teeth forward) with thrust washer and engage
with countershaft gears. See Figure 34. En-
gage reverse speed sliding gear with the re-
verse idler gears.

Figure 36. Installing Fourth Speed Gear

Selective Thrust Washer

21. Install fourth speed gear selective thrust

washer retaining snap ring. See Figure 37.

Figure 34. Installing Fourth Speed Gear

18. Start mainshaft in case through gear

bearing opening. See Figure 35. Advance
shaft through reverse speed gear, second and
third speed sliding clutch and fourth speed
gear until rear bearing positioning snap ring
seats against case. Install speedometer drive
gear on shaft. Apply sealer compound and
install rear bearing cover gasket and cover.
Install cover capscrews and tighten to rec-
ommended torque. Oil lip of cover oil seal, Figure 37. Installing Thrust Washer
and install clamp plate and screw. Retaining Snap Ring
6-141
22. With two feeler gages, check between
third speed washer and fourth speed gear for
recommended end-play. See Figure 38. Re-
fer to "Screw Torques and Adjustment Chart"
for selective thrust washers to obtain rec-
ommended end-play.

Figure 40. Installing Main Driving Pinion

Bearing Cover Assembly

26. Install reverse speed fork on reverse

speed sliding gear and install first speed fork
on first speed sliding clutch. See Figures
Figure 38. Checking Mainshaft Gear 41 and 42.
End-Play

2 3. Install fourth and fifth speed sliding clutch

on splines of pinion, and engage with fourth
speed gear. See Figure 39.

Figure 41. Installing Reverse Speed

Shifter Fork

Figure 39. Installing Fourth/Fifth Speed

Sliding Clutch

24. Position and drive pinion assembly into

place being careful not to damage spigot bear-
ing.

25. Install tool J23796 in main driving pin--

ion bearing cover and carefully through cover
oil seal. This tool will eliminate the possi-
bility of cutting oil seal when installing cover
over the splined end of main driving pinion.
See Figure 40. Apply sealer compound and
install gasket and cover assembly. Remove
tool from cover assembly. Install cover cap- Figure 42. Installing First Speed
screws and tighten to recommended torque. Shifter Fork
6-142

J
27. Install first and reverse speed shifter 29. Install secondand third speed shifter on
rail through front of case and first and re- rail, see Figure 45, and continue advancing
verse speed shifter. See Figure 43. Advance rail into front support until it reaches neutral
rail through intermediate bore of case, first position. Install fork and shifter setscrew
speed fork, front snap ring, reverse speed and tighten to recommended torque.
fork and rear snap ring until rail reaches
neutral position. Install fork and shifter set-
screws and tighten to recommended torque.

Figure 45. Installing Second and Third

Speed Shifter

Figure 43. Installing First and Reverse

Shifter 30. Start fourth and fifth speed shifter rail
in hole provided in front of case. Engage
NOTE fourth and fifth speed fork with fourth and
fifth speed sliding clutch. See Figure 46.
Assemble snap rings with round-
ed edge of rings against shifter
fork. After assembling the snap
rings, rotate 30 degrees to as-
sure rings are properly seated.

28. Start second and third speed shifter rail

through hole provided in rear of case. En-
gage second and third speed fork with second
and third speed sliding clutch. See Figure
44. Advance rail through hub of fork and
intermediate bore of case.

Figure 46. Installing Fourth and Fifth

Speed Shifter Fork

Advance rail through hub of fork and inter-

mediate boreuntil rail reaches neutral posi-
tion. Install fork setscrew and tighten to rec-
ommended torque. At this point make sure
that the two shift rail oil seals and one expan-
sion plug are installed at the front of the case
Figure 44. Installing Second and Third and the two shift rail expansion plugs are in
Speed Shifter Fork place at the rear of the case.

6-143
31. Install shift rail poppet balls and springs 32. Install poppet ball cover with capscrews
in holes provided at top of case. See Figures and tighten capscrews to recommended tor-
47 and 48. que. See Figure 49.

Figure 47 . Installing Shift Rail Poppet Ball Figure 49. Tightening Shift Rail Poppet
Ball Cover Capscrews

33. Apply sealer compound to transmission

case top cover gaskets and install on case,
then install covers with capscrews and tighten
to recommended torque. Apply sealer com-
pound to surface of power-take-off covers.
Install covers with capscrews and tighten.

Figure 48. Installing Shift Rail Poppet

Ball Spring

6-144