NAVISTAR SPICER AUTOMATE-2 SERVICE MANUAL

What does this catalog contain?

NAVISTAR SPICER AUTOMATE-2 SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR SPICER AUTOMATE-2 SERVICE MANUAL includes:

• Numbered table of contents easy to use so that you can find the information you need fast.
• Detailed sub-steps expand on repair procedure information.
• Numbered instructions guide you through every repair procedure step by step.
• Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Bold figure number help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every procedure.
• Enlarged inset helps you identify and examine parts in detail.

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• Printable – Pages Or Entire Manual.
• Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE NAVISTAR SPICER AUTOMATE-2 SERVICE MANUAL

1. MAINTENANCE………………………………………………………………………………………….1
1.1. FILTER REGULATOR (FIGURE 1)………………………………………………………………..1
2. REMOVE…………………………………………………………………………………………………3
2.1. UPPER SHIFT TOWER (FIGURE 2)………………………………………………………………3
2.2. LOWER SHIFT TOWER (FIGURE 3)……………………………………………………………..4
2.3. REMOTE CONTROL………………………………………………………………………………5
2.4. RANGE CASE (FIGURES 6 AND7)……………………………………………………………….6
2.5. OPTIONAL RANGE CASE……………………………………………………………………….21
PROCEDURE FOR CONVENTIONAL VEHICLES……………………………………………….21
PROCEDURE FOR CABOVER VEHICLES……………………………………………………..23
2.6. MAIN CASE (FIGURES 50 AND 51)……………………………………………………………..25
2.7. MAINSHAFT AND COUNTERSHAFTS………………………………………………………….28
2.8. INPUT SHAFT……………………………………………………………………………………32
3. DISASSEMBLY…………………………………………………………………………………………33
3.1. GENERAL………………………………………………………………………………………..33
IMPORTANT PROCEDURE……………………………………………………………………..33
CHECK FUNCTIONING PRIOR TO DISASSEMBLY…………………………………………….33
INSPECT THOROUGHLY DURING DISASSEMBLY…………………………………………….33
REPAIR OR REPLACE WORN PARTS………………………………………………………….33
REBUILD FACILITIES……………………………………………………………………………33
CLEANLINESS…………………………………………………………………………………..33
END YOKES AND FLANGES……………………………………………………………………34
BEARINGS……………………………………………………………………………………….34
POWER TAKE-OFFS…………………………………………………………………………….34
FRONT BEARING RETAINER AND SEAL.. ……………………………………………………..34
3.2. LOWER SHIFT TOWER………………………………………………………………………….35
3.3. REMOTE CONTROL (FIGURE 84)………………………………………………………………42
3.4. MAINSHAFT AND COUNTERSHAFTS (FIGURE 110)…………………………………………..52
3.5. COUNTERSHAFT……………………………………………………………………………….56
4. CLEAN AND INSPECT…………………………………………………………………………………57
4.1. CLEAN…………………………………………………………………………………………..57
4.2. INSPECT…………………………………………………………………………………………57
CLUTCH COLLARS……………………………………………………………………………..57
GEARS…………………………………………………………………………………………..57
THRUST WASHERS…………………………………………………………………………….57
SNAP RINGS…………………………………………………………………………………….57
MAINSHAFT……………………………………………………………………………………..57
REMOTE CONTROL…………………………………………………………………………….58
BEARINGS……………………………………………………………………………………….58
HOUSINGS………………………………………………………………………………………58
5. REASSEMBLY………………………………………………………………………………………….59
5.1. MAINSHAFT AND COUNTERSHAFTS………………………………………………………….59
5.2. REMOTE CONTROL…………………………………………………………………………….62
5.3. LOWER SHIFT TOWER………………………………………………………………………….73
5.4. UPPER SHIFT TOWER (FIGURE 177)…………………………………………………………..81

6. INSTALL………………………………………………………………………………………………..82
6.1. MAIN CASE………………………………………………………………………………………82
6.2. MAINSHAFT AND COUNTERSHAFTS………………………………………………………….84
6.3. RANGE CASE……………………………………………………………………………………87
6.4. LOWER SHIFT TOWER ASSEMBLY…………………………………………………………….97
7. LUBRICATION…………………………………………………………………………………………102
7.1. RECOMMENDED LUBRICANTS……………………………………………………………….102
7.2. OIL CHANGES………………………………………………………………………………….102
7.3. REFILL………………………………………………………………………………………….102
7.4. OVERFILLING………………………………………………………………………………….102
8. TROUBLESHOOTING (MECHANICAL)………………………………………………………………103
8.1. NOISY OPERATION……………………………………………………………………………103
8.2. BEARINGS……………………………………………………………………………………..104
DIRT…………………………………………………………………………………………….104
FATIGUE………………………………………………………………………………………..104
CORROSION…………………………………………………………………………………..104
SHAFT FITS…………………………………………………………………………………….104
REMOVAL OF BEARINGS……………………………………………………………………..105
INTERCHANGEABILITY………………………………………………………………………..105
8.3. CLUTCH TROUBLESHOOTING………………………………………………………………..105
8.4. TROUBLESHOOTING CHART…………………………………………………………………106
9. TROUBLESHOOTING (ELECTRICAL)……………………………………………………………….109
9.1. TROUBLESHOOTING WITH FLASH CODES OR MPSI PROLINK PROBLEM-ACTION LIST. . .109
PROBLEM 1:……………………………………………………………………………………110
PROBLEM 2:……………………………………………………………………………………111
PROBLEM 3 :…………………………………………………………………………………..111
PROBLEM 4:……………………………………………………………………………………112
9.2. TROUBLESHOOTING WITHOUT A COMPUTER USING DIAGNOSTIC CODES. . . . . . . . . . . . . . . . .112
9.3. CONFIRMING PROPER OPERATION OF AUTO SWITCH…………………………………….114
9.4. CONFIRMING PROPER OPERATION OF GEAR POSITION SENSOR………………………..115
9.5. CONTROLLER TO TRANSMISSION WIRING HARNESS AND 10TH GEAR SHIFT
SOLENOID……………………………………………………………………………………..116
9.6. CONFIRMING PROPER OPERATION OF CONTROLLER TO TRANSMISSION WIRING
HARNESS AND 9TH GEAR SHIFT SOLENOID………………………………………………..117
9.7. CONFIRMING PROPER OPERATION OF CONTROLLER TO TRANSMISSION WIRING
HARNESS AND NEUTRAL SHIFT SOLENOID…………………………………………………117
9.8. REMOVING AND REPLACING SHIFT SOLENOIDS……………………………………………118
9.9. CONFIRMING PROPER AIR PRESSURE FROM THE AIR FILTER REGULATOR. . . . . . . . . . . . . . . .118
9.10. EMERGENCY OVERRIDE TO DISABLE AUTOMATED SHIFTS……………………………….119
9.11. CONFIRMING THE POWER SUPPLY AND TRANSMISSION CONTROLLER FUNCTIONS. . . . .119
9.12. CONFIRMING THE OVERRIDE FEATURE HAS NOT BEEN USED……. ……………………..120
9.13. CONFIRMING PROPER OPERATION OF J1922 CONTROL LINK…………………………….120
9.14. CONFIRMING PROPER OPERATION OF J1587 DATA LINK. …… …… ……. …… …… ……. .120
9.15. CONFIRMING PROPER OPERATION OF SPEED SENSOR.. …………………………………120
10. SPECIFICATIONS……………………………………………………………………………………..123
10.1. AIR LINE PIPING……………………………………………………………………………….125

10.2. TORQUE CHART……………………………………………………………………………….126
10.3. SPECIAL TOOLS……………………………………………………………………………….127
11. INTEGRAL LUBE PUMP………………………………………………………………………………127
11.1. OPTILUBE………………………………………………………………………………………127
11.2. DISASSEMBLE INTEGRAL LUBE PUMP………………………………………………………128
11.3. CLEAN AND INSPECT…………………………………………………………………………131
11.4. REASSEMBLE INTEGRAL LUBE PUMP……………………………………………………….131

Moreover

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle.
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Find our other Navistar products.

10 SPEED TRANSMISSIONS SPICER AUTOMATE-2 Model: 4000, 5000, 8100, 8200, 8300, 9200, 9300, 9400, 9600, 9700, 9800 Unit Code: 13DDE, 13DBZ, 13DCH, 13DCJ, 13DCK, 13DCL

Unit Code: 13DDE, 13DDG, 13DDH, 13DDJ, 13DDK Unit Code: 13DEE, 13DEG, 13DEH, 13DEJ, 13DEK Unit Code: 13DEL, 13DEM, 13DEN, 13DEP, 13DER Unit Code: 13DES, 13DET, 13DGD, 13DGE, 13DGG Unit Code: 13DGH, 13DGJ, 13DGK, 13DGL, 13DGM S13022X,

Formerly CTS-5219