NMWR9-2520-5941 M923 Transmissions.pdf

U.S. ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND

WARREN, MICHIGAN 48397-5000

22 OCTOBER 2004

NMWR 9-2520-594*

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

FOR

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

This publication is not available through the AG publication centers. This publication is available through U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CHMM, Warren, Michigan 48397-5000.

*This NMWR supersedes DMWR 9-2520-522, undated.

NMWR 9-2520-594

a/b blank

WARNING SUMMARY

All personnel must wear eye protection when opening container.

Transmission container may be pressurized. Ensure pressure is released before opening container.

Failure to do so may result in injury to personnel.

Lifting device must have a weight capacity greater than 767 lb (348 kg). Failure to comply may cause injury to personnel and/or damage to equipment.

Torque converter retaining strap must be installed prior to removing transmission from container.

Without a retaining strap, a downward tilt at the front of transmission will cause the torque converter to fall free of transmission. Injury to personnel and damage to torque converter may occur.

All personnel must stand clear during lifting operations. A snapped cable or swinging or shifting load may cause injury to personnel. Do not remove hoist chain from transmission until transmission is stable in holding fixture base, or injury to personnel may result.

Compressed air source must not exceed 30 psi (207 kPa). When cleaning with compressed air, eyeshields must be worn. Failure to do so may result in injury to personnel.

Main-pressure regulator valve spring is under approximately 65 lb (289 N) of compression. Do not remove retaining snapring or retaining pin until compressor is in place. Regulator valve spring may fly out, causing injury to personnel.

Piston return spring is under great compression. Do not remove snapring until pressure is applied to spring retainer, or piston return spring may fly out, causing injury to personnel. Eye protection must be worn at all times.

Painting must be performed in a well-ventilated and protected area that is clean and dry. Failure to comply may result in injury to personnel.

Center support replacement sleeve is extremely hot. Wear heat resistant gloves to avoid contact with center support hub replacement sleeve. Failure to do so may result in personnel injury.

Regulator valve spring is under approximately 65 lb (289 N) of compression. Make sure retaining snapring or retaining pin is properly installed before removing compressor. Regulator valve spring may fly out, causing injury to personnel.

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). Failure to comply may result in injury to personnel.

Many small parts of control valve and auxiliary control valves are under spring tension and can fly out forcefully during disassembly. Safety glasses must be worn during disassembly of control valve, or injury to personnel may occur.

Eye protection must be used by all personnel. Loose clothing must not be worn in close proximity to rotating drill. Do not perform this procedure unless proper machine tools and a machine tool operator are available. Failure to comply may cause damage to equipment and/or injury to personnel.

A/B blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

The date of issue for original pages/work pages for this NMWR is:

Original 22 OCTOBER, 2004

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 286.

TOTAL NUMBER OF WORK PACKAGES IS 33.

THE PAGES/WORK PACKAGES CONSISTS OF THE FOLLOWING:

Page No. . . . . . . . . . . . . . .Change No.*

Warning a Warning b blank A B blank i ii blank iii iv blank v-vii viii blank

WP 0001 00 – WP 0033 00

Index 1 – Index 2 . . . . . . . . . . . . . . . . . .0 0

*Zero in this column indicates original page.

NMWR 9-2520-594*

i/ii blank

*This NMWR supersedes DMWR 9-2520-522, undated.

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

FOR

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

U.S. ARMY TANK-AUTOMOTIVE

AND AMRAMENTS COMMAND

WARREN, MICHIGAN 48397-5000

22 OCTOBER 2004

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is TACOM-TECH- PUBS@ria.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

iii/iv blank

TABLE OF CONTENTS

Work Package/Page No.

How to Use This National Maintenance Work Requirement (NMWR) . . . . . . . . . . . . . . . . . . . . . . . . . . . v

CHAPTER 1 GENERAL INFORMATION AND DATA

List of Acronyms/Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001 00-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002 00-1 Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003 00-1 Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004 00-1 General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . WP 0005 00-1

CHAPTER 2 OVERHAUL INSTRUCTIONS

Mounting Transmission on Holding Fixture . . . . . . . . . . . . . . . . WP 0006 00-1 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007 00-1 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008 00-1 Oil Pump and Front Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009 00-1 Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010 00-1 Fourth Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011 00-1 Center Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012 00-1 Gear Unit and Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013 00-1 Rear Cover and Low Planetary Carrier . . . . . . . . . . . . . . . . . . . . WP 0014 00-1 Adapter Housing and First Clutch . . . . . . . . . . . . . . . . . . . . . . . . WP 0015 00-1 Control, Low Trimmer, Low Shift Signal, Modulated Lockup, and Modulator Valves . . . . . . . . . . . . . . . . WP 0016 00-1 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017 00-1 Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018 00-1 Sun Gear Shaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . WP 0019 00-1 Center Support Rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020 00-1 Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021 00-1 Transmission Testing and Test Report . . . . . . . . . . . . . . . . . . . . . WP 0022 00-1 Preparing Transmission for Storage and Final

Inspection Report (FIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023 00-1

CHAPTER 3 SUPPLEMENTAL INFORMATION

Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024 00-1 Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025 00-1 Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026 00-1 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . WP 0027 00-1 Mandatory Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028 00-1 Tools and Special Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029 00-1 Parts Required for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030 00-1 Repair Parts Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031 00-1 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032 00-1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0033 00-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1 v

HOW TO USE THIS

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

INTRODUCTION

This section explains the basic organization, contents, format, and special features of this NMWR. After reading this section, spend some time reviewing the NMWR to familiarize yourself with the contents and layout. This will enable you to locate information easily and reduce the time needed to complete required procedures.

ORGANIZATION AND CONTENTS

This NMWR is divided into two main chapters. Chapter 1 presents general information and preliminary data. Chapter 2 contains general and detailed maintenance procedures as well as specific tool, equipment, and parts information. The following table provides an overview of the material contained in each chapter of this NMWR.

Chapter 1 • Definition of acronyms/abbreviations used throughout the NMWR

• Basic information about the component, along with general guidelines and criteria for inspection and repair or replacement

• Detailed equipment description and data

• Component Checklist

Chapter 2 • General maintenance information

• Detailed maintenance procedures for disassembly, inspection, repair or replacement, and assembly

• Supplementary information covering torque limits, wear limits, expendable and durable items, mandatory replacement parts, tools and special tools, repair parts, and reference publications

You can locate specific information in the NMWR by using either the Table of Contents, located at the front of the NMWR, or the alphabetical subject Index, located at the back of the NMWR.

Table 1. NMWR Contents.

vi

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Contd)

FORMAT

Work Package (WP) Format

Each chapter in this NMWR is divided into WPs, which group data into stand-alone informational or task-oriented units. As shown in table 1, chapter 1 contains informational WPs, while chapter 2 contains primarily task-oriented WPs (maintenance procedures), followed by supplementary information WPs.

Here are some important things to know about the WP format:

• Each WP has its own identification number, which appears in the upper right corner of each page. WPs are numbered sequentially throughout the manual.

• Each WP starts with page number 1. Page numbers appear at the bottom of the pages, following the WP number.

• Informational WPs begin with a listing of the specific topics covered, in the order in which they appear in the WP. This listing provides you with a quick overview of each WP and enables you to locate specific information easily.

• Each task-oriented WP begins with an Initial Setup list that identifies all tools, mandatory replacement parts, personnel, and other materials needed to complete the procedure in the WP.

Before you begin a procedure, review the Initial Setup information to ensure that all requirements have been met.

• The task-oriented WPs (maintenance procedures) appear in the manual in the order of logical work sequence. This format makes the NMWR easy to follow and helps improve efficiency as you progress through the procedures.

Text and Illustration Modular Layout

Throughout this NMWR, WPs are set up in two-page modular layouts. This means that illustrations appear either on the same page as, or on the page facing, the step you are performing. This feature eliminates the need to search for illustrations that correlate with each procedural step.

In addition, procedural text is cross-referenced to numerical callouts in the illustrations, helping you immediately identify and locate specific parts mentioned. Callout numbers referencing the illustrations appear in parentheses in the text.

vii/viii blank

HOW TO USE THIS NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR) (Contd)

SPECIAL FEATURES

Illustration Features

This NMWR utilizes a variety of illustration methods, such as locator views and exploded views, to help you locate and identify parts easily. Each illustration is identified by a title printed below it.

The illustrations contain numerical callouts to identify parts, components, etc. mentioned in the text.

Generally, callouts appear in clockwise order in the illustrations, beginning at the 11 o’clock position.

A special feature of this NMWR is that callout numbers for mandatory replacement parts are circled in the illustrations. This visually distinguishes mandatory replacement parts from those that may be repairable or otherwise reusable.

Supplemental Information

The WPs at the end of this NMWR contain supplemental information that supports the procedures in the manual. This information is cross-referenced to the items listed in the Initial Setup section of each task-oriented WP. The following supplemental information is included in this NMWR:

• Torque Limits—Torque specifications for all fasteners used to assemble the component being overhauled in this NMWR

• Spring Specifications—Specification tables and exploded views for all springs used in the MT654 transmission

• Wear Limits—Location/description and wear limits for parts used in this NMWR

• Expendable and Durable Items—National Stock Number (NSN), description, Commercial and Governments Entity Code (CAGEC), Part Number (P/N), and description for all expendable and durable items necessary to operate or maintain the equipment used in this NMWR

• Mandatory Replacement Parts—Names, P/N, and NSN for all parts that must be replaced during overhaul of the component

• Tools and Special Tools—Name, NSNs, and CAGECs for common and special tools required to perform the procedures in this NMWR

• Parts Required for Testing—Components to be installed prior to testing transmission

• Repair Parts—Source, Maintenance, and Recoverability (SMR) code; NSN; CAGEC; P/N; and quantity for all parts required for the procedures in this NMWR

• References—All publications referenced in this NMWR

CHAPTER 1

GENERAL INFORMATION AND DATA

FOR

TRANSMISSION, AUTOMATIC

MODEL MT654

M939A1/A2 VEHICLES

NMWR 9-2520-594 0001 00

0001 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

LIST OF ACRONYMS/ABBREVIATIONS

SCOPE

This Work Package (WP) lists acronyms and abbreviations that appear in this NMWR.

NMWR 9-2520-594 0001 00

0001 00-2

LIST OF ACRONYMS/ABBREVIATIONS (Contd)

ACRONYM/ DEFINITION

ABBREVIATION

AEPS Army Electronic Product Support

AOAP Army Oil Analysis Program

CAGEC Commercial and Government Entity Code

CPC Corrosion Prevention and Control

ECP Engineering Change Proposal

EDRS Electronic Deficiency Reporting System

ESD Electrostatic Discharge

EIR Equipment Improvement Recommendations

FIR Final Inspection Report

MAC Maintenance Allocation Chart

MEL Maintenance Expenditure Limit

NMWR National Maintenance Work Requirement

NSN National Stock Number

P/N Part Number

PQDR Product Quality Deficiency Report

QDR Quality Deficiency Report

SMR Source, Maintenance, and Recoverability

SRA Specialized Repair Activity

TAMMS The Army Maintenance Management System

UOC Usable On Code

WP Work Package

END OF WORK PACKAGE

NMWR 9-2520-594 0002 00

0002 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

GENERAL INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Scope; Maintenance Forms, Records, and Reports; Reporting Equipment Improvement Recommendations (EIRs); Corrosion Prevention and Control (CPC); Preparation for Storage or Shipment; Warranty Information; Quality of Material; Safety, Care, and Handling; Engineering Change Proposals (ECPs);

Deviations and Exceptions; and Cost Considerations.

SCOPE

This NMWR is for use by maintenance technicians at certified repair sites. The instructions in this NMWR apply to MT654 automatic transmissions. In case of conflict with other information, the data contained in this NMWR shall take precedence. The condition of the transmission after overhaul shall be that utility and performance are returned to a near-zero-time/near-zero-miles or like-new condition.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards.

Components that are found to be worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

Before performing any overhaul activity, the maintenance technician shall become familiar with all procedures in this NMWR.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 738-750, Functional Users Manual for The Army Maintenance Management System (TAMMS).

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR’S)

If this transmission needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know what you don’t like about the design or performance. The preferred method for submitting Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. This is a secured site requiring a password that can be applied for on the front page of the website. If the above method is not available to you, put it on an SF 368, Product Quality Deficiency Report (PQDR), and mail it to us at:

Department of the Army, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-TR- E/PDQR Mail Stop 420, 6501 E. 11 Mile Road, Warren, MI 48397-5000. We’ll send you a reply.

0002 00-2

GENERAL INFORMATION (Contd)

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problem with this item be reported so that the problem can be corrected and improvements made to prevent the problem in the future.

While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

If a corrosion problem is identified, it can be reported using an SF 368, Product Quality Deficiency Report. Use of key words, such as corrosion, rust, deterioration, or cracking, will ensure that the information is identified as a CPC problem.

The form should be submitted to the address specified in DA PAM 738-750, Functional Users Manual for The Army Maintenance Management Systems (TAMMS).

PREPARATION FOR STORAGE

To prepare the automatic transmission for storage, refer to WP 0023 00. Additional information can be found in TM 746-10, General Packaging Instructions for Field Use, Marking, Packing, and Shipment of Supplies and Equipment.

WARRANTY INFORMATION

The MT654 transmission will be covered by warranty. For warranty information, contact the Contracting Officer or National Maintenance Management at Department of the Army, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CIM, Mail Stop 419, 6501 E. 11 Mile Road, Warren, MI 48397-5000, or contact the Equipment Manager at Department of the Army, U.S.

Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CH, Mail Stop 420, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material requirements are not stated in this manual, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to this automatic transmission.

SAFETY, CARE, AND HANDLING

1. Adequate safety precautions will be provided for the performance of overhaul operations. These precautions will include safety in work environment, selection and usage of equipment, and procedures provided for performing all operations. Inspection, which follows completion of overhaul procedures, will ensure equipment compliance with applicable safety standards.

2. Supplies and materials such as cleaning fluids, sealers, adhesives, oils, and other products used in this NMWR may be dangerous or harmful if safety precautions are not observed. Read manufacturers’ warnings and cautions on product labels before using and observe all recommended safety precautions.

3. Ensure proper procedures are followed during lifting of heavy items. Follow all warnings and cautions identified in this NMWR.

0002 00-3/4 blank

GENERAL INFORMATION (Contd)

END OF WORK PACKAGE

ENGINEERING CHANGE PROPOSALS (ECP’S)/DEVIATIONS AND EXCEPTIONS

ECPs will be submitted using DD Form 1693, Engineering Change Proposal (Short Form). Completed forms should be mailed directly to Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CHMM, Warren, Michigan 48397-5000. A reply will be furnished to you.

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of the overhaul while considering cost factors. A determination shall be made on all subassemblies/assemblies to replace a worn or damaged component that is available in supply if acquisition cost is less than the cost to repair/restore it to the NMWR standard. The cost to repair/restore any individual item shall not exceed the standard Maintenance Expenditure Limit (MEL) of 80% (percent). For parts/components that are not available or that exceed the MEL, a request for deviation or exception to this MEL will be processed in accordance with ISO 9001 Series standards or equivalent on a case-by-case basis. Submit a request for deviation or exception to the Equipment Manager at Department of the Army, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CH, Mail Stop 420, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

NMWR 9-2520-594 0003 00

0003 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

EQUIPMENT DESCRIPTION AND DATA

IDENTIFICATION

Equipment Data Plate

A transmission has three identifying codes: a part number, a serial number, and a date of manufacture.

These codes are found on the equipment data plate located on the lower right rear of the transmission housing. (See figure 1.) The serial and part numbers are used when ordering parts. The dates of manufacture and serial number are sometimes used in service bulletins to isolate a concern or update to a specific range of transmissions.

The M939A2 series vehicles are equipped with one of two Allison MT654 transmissions. A transmission with Part Number (P/N) 6885292 is referred to as an earlier model transmission. P/N 23040127 is used to identify a later model transmission. The major differences between models are in the converter hub and in the use of a different configuration pump in later model transmissions. These differences do not affect the interchangeability of the transmission assemblies. They do, however, affect the interchangeability of some of the internal components. Where non-interchangeability affects a component, it is noted in the Repair Parts Work Package (WP 0032 00).

Figure 1. Equipment Data Plate.

0003 00-2

EQUIPMENT DESCRIPTION AND DATA (Contd)

Replacement Equipment Data Plate

If the original equipment data plate is missing, damaged, or illegible, a new plate must be installed in the original location. If the information on the original plate is legible, copy it to the new plate using 1/4-in. (6.35-mm) stamps. If the information on the original equipment data plate is not legible or is incomplete, contact the TACOM contracting officer.

Overhaul Data Plate

After a transmission has been overhauled, tested, and documented to be serviceable, an overhaul data plate is attached to the right-hand side of the transmission. (See figure 2.) The data plate provides the transmission national stock number, serial number, date of overhaul, a code identifying the overhaul facility and work order number.

NOTE

The overhaul data plate may be locally fabricated. Overhaul data plate must be placed as seen in figure 2.

The following information is to be scribed on the overhaul data plate:

NSN – Transmission National Stock Number Serial Number – Must agree with number stamped on equipment data plate Overhauled At – Overhaul facility code Work Order Number – Six to eight digit number assigned to this overhaul Date – Three-letter abbreviation for month; last two digits for year (e.g., Oct 03 for October 2003)

Figure 2. Overhaul Data Plate.

0003 00-3/4 blank

END OF WORK PACKAGE

EQUIPMENT DESCRIPTION AND DATA (Contd)

GENERAL INFORMATION

The MT654 is a fully automatic, five-speed transmission. Directing engine torque through four multiple-disc, hydraulically actuated clutches and three planetary gear sets provides the five forward gear ratios and a single reverse gear ratio. The hydraulic pressure needed to operate the clutches, lubricate the moving parts, and provide cooling is produced by a torque converter driven, gear-type pump. The torque converter, linking the engine and transmission, is a three-element type with an integral lockup clutch.

GENERAL SPECIFICATIONS

Manufacturer: Allison Transmission

Model: MT654

Weight (dry):

Early Model (P/N 6885292) 767 lb (348 kg) Late Model (P/N 23040127) 685 lb (311 kg)

Torque Converter: Single-stage, poly-phase, three-element w/lockup clutch

Gear Ratios:

Gear Clutch Applied Ratio Neutral Low First Forward and Low 4.17:1 Second Forward and First 1.21:1 Third Forward and Second 1.66:1 Fourth Forward and Third 1.27:1 Fifth Forward and Fourth 1.00:1 Reverse Fourth and Low 10:70:1

Lubrication:

Fluid type: DEXRON® III or SAE 10W: oil, lubricant

Fluid Capacity:

Rebuild: 23 U.S. quarts (21.8 liters)

Refill: 17 U.S. quarts (16.1 liters)

Pump: Internal/external gear Positive displacement Torque converter driven

NMWR 9-2520-594 0004 00

0004 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

COMPONENT CHECKLIST

THIS WORK PACKAGE (WP) COVERS:

Scope; Component Checklist Instructions.

SCOPE

The purpose of the Component Checklist is to identify the component and its condition as received. This information comes from shipping labels, attached tags, and visual inspection.

COMPONENT CHECKLIST INSTRUCTIONS

1. Make a copy of the Component Checklist (table 1) and fill in the information as requested.

Identifying information: Fill in the required information at top of the Component Checklist.

NOTE

If there is any damage to container or component, or any parts are missing from component, refer to the work directive/contract for instructions.

Item 1. Container check

Visually check container for evidence of damaged or missing parts. Note any damaged or missing parts.

Item 2. Component check

Visually check component for evidence of damage or missing parts. Note any damage or missing parts.

2. Upon completion of the Component Checklist, remove all tags and documents from component.

Develop a record file for the component. Include the tags and documents, AOAP data (if available), completed Component Checklist, Test Report, and Final Inspection Report (FIR) in the record file.

The Test Report will be completed during final testing of the rebuilt component. The FIR will be completed when preparing component for storage.

NMWR 9-2520-594 0004 00

0004 00-2

COMPONENT CHECKLIST (Contd)

ITEM TEST/ CONDITION RECOMMENDED MAINTENANCE

NO. INSPECTION ACTION

END OF WORK PACKAGE

Table 1. Component Checklist.

COMPONENT CHECKLIST

DATE RECEIVED: INSPECTOR:

NOMENCLATURE/PART NAME: NSN:

SERIAL #: MODEL #:

1.

2.

Container check

Component check

NMWR 9-2520-594 0005 00

0005 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

GENERAL MAINTENANCE INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Scope; Precautions; Special Processes; Tools and Equipment; Disassembly; Cleaning;

Inspection—Acceptance and Rejection Criteria; Repair or Replacement; and Assembly.

SCOPE

This WP contains general maintenance information pertaining to disassembly, cleaning, inspection, repair, and assembly of the automatic transmission components. Detailed information will be found in specific WPs.

Maximum overhaul of parts to like-new condition will be mandatory. Parts, components, assemblies, or subassemblies found to be worn or defective beyond limits established by this NMWR will be disposed of in accordance with appropriate directives and, in the case of commercial contracts, as specified in the contract. In instances where new or rebuilt parts, components, assemblies, or subassemblies are unavailable, items will be reviewed on a case-by-case basis. Tolerances and wear limits set forth herein are the minimum acceptable standards.

0005 00-2

GENERAL MAINTENANCE INFORMATION (Contd)

PRECAUTIONS

All material-handling equipment shall be adequate to ensure safe working conditions for personnel and efficient processing of items.

The component shall be properly mounted on a fixture for disassembly and assembly to ensure safe working conditions.

Follow all WARNINGS, CAUTIONS and NOTES included in specific WPs to ensure personnel safety and prevent damage to equipment.

SPECIAL PROCESSES

Special processes and equipment required for overhaul operations, as specified in this NMWR, are defined or referenced at the point of their application. When a special process is required, the overhaul activity (when requested) shall provide evidence of compliance with controlling specifications. Following is a summary of some of the special processes that may be required for this NMWR.

Table 1. Special Processes.

Cadmium Plating

Chemical Conversion Films for Aluminum and Aluminum Alloys

Liquid Penetrant Inspection

Magnetic Particle Inspection

Phosphate Coating

The process described in QQ-P-416A, Cadmium Plating (Electrodeposited) is used in plating nuts, bolts, etc.

MIL-C-5541E, Chemical Conversion Coatings on Aluminum and Aluminum Alloys, Type 1, is used as a touch-up for damaged anodic coatings. MIL-A-8625, Anodic Coating for Aluminum and Aluminum Alloys, is used as a paint base. MIL-C-5541E is not suitable for use on interiors of oil-filled castings.

E 1417, Standard Practice for Liquid Penetrant Examination, is followed when using fluorescent or visible dye to detect cracks, flaws, etc., open to the surface of any nonporous metal.

E 1444, Magnetic Particle Inspection Process, is used to detect cracks, etc., at or below surface of ferrous (ferromagnetic) metals.

Use process described in TT-C-490E, Cleaning Methods for Ferrous Surfaces and Pretreatment for Organic Coatings, Type 1, light phosphate coating will be applied for ferrous metal for corrosion protection paint.

SPECIAL PROCESS DESCRIPTION

0005 00-3

GENERAL MAINTENANCE INFORMATION (Contd)

TOOLS AND EQUIPMENT

Tools and locally prefabricated tools and equipment required to overhaul this component can be found in the Tools and Special Tools List, WP 0029 00.

Torque wrench specifications are given in text, as applicable. Metric equivalents are in parentheses following the U.S. standard measurement. (Example: Tighten oil pump mounting bolts 33–40 lb-ft (45–54 N•m).) Standard capscrew markings and torque specifications are found in Torque Limits, WP 0024 00. Tolerances, torque values, and adjustments are provided in each WP as necessary.

DISASSEMBLY

Each appropriate WP will contain specific instructions for disassembly of the components.

Take care in handling parts during disassembly. Nicks, scratches, or other damage caused by careless handling may cause premature failure of equipment.

Matched, married, or mated items (examples: bearings and races, covers and housings, and some gear sets) should be fastened together or otherwise identified as parts being processed together. If one part fails inspection, both parts must be replaced as a set.

CLEANING

WARNING

Compressed air used for cleaning purposes must not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

Failure to comply may result in injury to personnel.

CAUTION

Block all ports and mask machined surfaces of aluminum castings before using the following cleaning procedures.

Failure to comply may result in damage to equipment.

Do not separate or intermix matched, married, or mated parts during cleaning operations. Refer to DISASSEMBLY above.

For authorized cleaning materials, refer to TM-9-247, Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance Material and Related Materials Including Chemicals.

Remove all rust and surface scale using a wire brush, sand blast, grit blast, or other effective methods in accordance with standard procedures.

Clean all bearings in accordance with TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings.

All control valve parts must be handled carefully to avoid nicking, chipping, and scratching of these precision parts. Dry parts individually with lint-free cloth.

Follow special cleaning procedures outlined in individual WPs.

0005 00-4

GENERAL MAINTENANCE INFORMATION (Contd)

INSPECTION—ACCEPTANCE AND REJECTION CRITERIA

NOTE

All components subjected to magnetic particle inspection shall be demagnetized prior to assembly.

All components subjected to dye penetrant inspection shall be cleaned after inspection. Coat part with preservative oil as required.

Throughout this NMWR, measurements are used to confirm serviceability of items after a visual inspection. Measurements will be performed as required by quality assurance, in-process inspection, overhaul procedures, transmission test report, and Final Inspection Report (FIR).

Used components and refinished parts, recovered as products of disassembly, will be examined 100 percent to determine serviceability by contractor. Refer to the maintenance WPs, work directive, or contract for more detail.

Parts showing evidence of overheating are unrepairable by any process. Discard these parts.

WARNING

Compressed air source must not exceed 30 psi (207 kPa).

Eyeshields must be worn when cleaning with compressed air.

Failure to comply may result in injury to personnel.

NOTE

Some parts may not look exactly like illustrations.

Manufacturing methods may change part appearance, but parts are functionally the same.

Table 2. General Inspection Guidelines.

Oil passages Remove all obstructions with compressed air or by working a soft wire back and forth through oil passage and flushing it with dry cleaning solvent.

Threads (internal and external) Inspect threads for minor irregularities. For damaged thread repair, refer to table 3, Repairable Defects.

Machined surfaces Check for damage that could cause oil leakage or malfunction of the part. Refer to table 3, Repairable Defects.

Antifriction bearings Check all bearings and matching cones or races per TM 9-214. If any defects are found, replace bearing and matching race.

Control valve parts Ensure valves move freely in their respective bores when dry.

Also ensure there are no chipped edges, burred sealing ridges, or longitudinal scratches on sealing surfaces. These types of defects are unrepairable and such parts will be discarded.

Gear and spline teeth Check for nicks, burrs, or scoring. If any such conditions are found, refer to table 3, Repairable Defects.

Rotating or lockup inner parts Check for cracked rotating or lockup inner parts. If cracked, these parts must be replaced and no repair attempted.

INSPECT ACTION

0005 00-5

GENERAL MAINTENANCE INFORMATION (Contd)

REPAIR OR REPLACEMENT

Parts that are beyond wear limit tolerances, broken, cracked, or otherwise damaged may be considered for repair by special processes listed below by requesting approval from the TACOM Contracting Officer. In requesting approval, the overhaul activity will furnish:

1. Written repair procedure

2. Specifications covering the procedure

3. Reference drawing

4. Samples (when requested) of parts repaired by the applicable process listed below:

a. Cast aluminum parts may be welded in approved areas before machining to add sufficient finish stock to repair cracks, fill sand holes, etc.

b. Steel parts may be welded in approved areas before machining to add sufficient finish stock to repair cracks, flaws, etc. Weld in accordance with ASTM A488/A488M Standard Practice for Steel Castings and Welding.

c. Damaged internal threads may be repaired using threaded inserts, per NASM33537, Standard Assembly Dimensions for Insert, Screw Thread, Helical Coil, Inch Series, Coarse and Fine Thread, as stated in salvage rework drawings.

d. For static applications, spray metalizing, per C2.25/C2.25M, Metalizing Wire, may be used to repair steel or aluminum parts.

e. It is permissible to impregnate structurally sound castings (containing some porosity, including microporosity) that weep or sweat during hydrostatic or pneumatic pressure testing.

Use one of the impregnation methods specified in MIL-I-13857, Impregnation of Metal Castings, Type 1, and MIL-STD-276A, Impregnation of Porous Nonferrous Metal Castings.

f. Chrome plate, class 2, QQ-C-320, Chromium Plating (Electrodeposited). A film 0.002–0.015-in.

(0.05 to 0.38-mm) thick after finish-machining to print dimensions and surface finished specified may be used to repair damaged surfaces.

g. Electroless nickel plating, per SAE AMS-C-26074, Requirements for Coatings, Electroless Nickel, may be used to correct undersize or oversize condition. After plating, parts must meet print dimensions and surface finish specified.

h. Peening, rolling, etc. may be used in accordance with drawings.

Unrepairable Defects

Do not repair any of the following:

1. Cracked, chipped, ridged, or pitted spline or gear teeth

2. Cracked or split keyways

3. Scored or scratched bores in control valve bodies

4. Cracked or chipped snapring grooves

5. Oil channels with cracked walls or chipped edges

6. Pitted or grooved gear teeth and splines, unless otherwise indicated in this NMWR

7. Bearings and matching cones that do not meet inspection requirements per TM 9-214

8. Parts showing evidence of overheating

9. Cracked rotating or lockup inner parts

10. Chipped edges, burred sealing ridges, and longitudinal scratches on sealing surfaces of control valve parts

0005 00-6

GENERAL MAINTENANCE INFORMATION (Contd)

REPAIRABLE PART/AREA

Shaft journals

Shaft load surfaces

Flat surfaces

Casting buildup of bores

Casting crack

Control valve parts (except springs)

Machined surfaces

Damaged external threads

Damaged internal threads

Housing; castings;

and shaped, machined surfaces

Gears, splines, and shafts

Surface rust and corrosion

REPAIR PROCESS

Chrome plate

Spray metalize

Hard-facing arc weld

Weld

Weld

Chipped edges, burred sealing ridges, and longitudinal scratches on sealing surfaces are unrepairable, and such parts will be discarded.

Small burrs and scratches may be removed with a fine mill file or fine grit emery cloth. Discard components that have burrs or scratches too large to repair.

Repair threads having slight irregularities. Remove burrs with a soft stone, fine mill file, or emery cloth. Clean up slight irregularities by running thread die of correct size over thread. Discard components not repairable.

Repair threads in tapped holes having minor irregularities by retapping with correct size previously used hole tap. Drill-out tapped holes having badly damaged threads and install a threaded insert. Follow kit manufacturer’s and MS33537 instructions. When drilling, the land width (space between holes, or between edge of hole and edge of material) must measure no less than three-fourths of the hole diameter. Discard components not repairable.

Unless otherwise indicated, use fine emery cloth, crocus cloth, or soft stone to repair minor nicks, burrs, and scoring. Minor surface irregularities on noncontact surfaces do not need repair. Discard components not repairable.

Use crocus cloth, fine mill file, or soft stone to remove minor nicks, burrs, and scoring. Welding, grinding, machining, plating, etc. of gear or splined teeth to correct defects is not authorized. Discard components not repairable.

Remove surface rust and corrosion from all internal parts and surfaces.

Mechanical and/or chemical methods may be used. Use fine emery cloth, crocus cloth, or soft stone to remove minor surface rust and corrosion.

Do not assemble components having rusted or corroded parts. Corrosion or rust may flake off and cause damage to component while circulating in oil during operation. Discard components not repairable.

REPAIR OR REPLACEMENT (Contd)

Repairable Defects

Table 3. Repairable Defects.

0005 00-7/8 blank

GENERAL MAINTENANCE INFORMATION (Contd)

ASSEMBLY

Cleanliness is essential in all component assembly operations. Dust and dirt, even in minute quantities, are abrasive. Parts must be kept clean.

See individual WPs for specific assembly instructions.

Replace any part that does not pass visual inspection or that is outside specified wear limits listed in the maintenance WPs or in WP 0026 00.

Follow WP instructions for coating bearings, bushings, gears, shafts, seals, friction parts, and other contact surfaces with operating oil (differential oil for differential parts, transmission fluid for transmission parts, etc.) to ensure lubrication of parts during initial operation after overhaul. For additional information on bearing lubrication and installation, refer to TM 9-214.

Seal handling:

1. Do not open seal packets until ready to install seal. Seals may become contaminated with dust or dirt and some types of seals can absorb moisture, which may cause damage during installation and/or shorten the lifespan of the seals.

2. Ensure lip-type seals are installed so spring-loaded lip faces toward lubricant.

Automatic transmissions:

1. Prior to final assembly of clutch packs, soak automatic transmission discs in Dexron® III or SAE 10W fluid for a minimum of 2 minutes if using old discs, or 20 minutes if using new discs.

2. Apply a generous coating of oil-soluble grease to clutch piston cavities immediately before installation of clutch pistons.

Tighten all capscrews, screws, bolts, nuts, and fittings to torque values as specified in maintenance WPs and in torque specifications in WP 0024 00.

For parts identification, refer to WP 0032 00.

CHAPTER 2

SUPPLEMENTAL INFORMATION

FOR

TRANSMISSION, AUTOMATIC

MODEL MT654

M939A1/A2 VEHICLES

NMWR 9-2520-594 0006 00

0006 00-1

Tools and Special Tools General mechanic’s tool kit: automotive

(Item 21, WP 0029 00) Transmission holding fixture

(Item 24, WP 0029 00) Holding fixture base (Item 26, WP 0029 00) Holding fixture adapter set

(Item 25, WP 0029 00) Optional mounting fixture

(Item 65, WP 0029 00) Chains Lifting device

Materials/Parts PTO cover gasket

(Table 1, Item 1, WP 0028 00)

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

MOUNTING TRANSMISSION ON HOLDING FIXTURE

REMOVAL FROM SHIPPING CONTAINER AND INSTALLATION ON HOLDING FIXTURE

INITIAL SETUP:

0006 00-2

MOUNTING TRANSMISSION ON HOLDING FIXTURE (Contd)

NMWR 9-2520-594 0006 00

REMOVAL FROM SHIPPING CONTAINER

WARNING

All personnel must wear eye protection when opening container.

Transmission container may be pressurized. Ensure pressure is released before opening container. Failure to do so may result in injury to personnel.

1. Push in on pressure release button (1) to depressurize container.

2. Remove twenty nuts (3), washers (4), and screws (10) from upper (2) and lower (13) container sections.

3. Install chains and lifting device on upper container (2).

WARNING

All personnel must stand clear during lifting operations.

A swinging or shifting load may cause injury to personnel.

All personnel must wear eye protection.

Lifting device must have a weight capacity greater than 767 lb (248 kg). Failure to comply may cause injury to personnel and/or damage to equipment.

4. Remove upper container section (2) and gasket (18) from lower container section (13). Discard container gasket (18) if damaged.

5. Remove two screws (8), washers (9), nuts (11), attaching top container mounting bracket (7) to lower container mounting bracket (14).

6. Remove four nuts (12), washers (16), and screws (15) from lower container mounting bracket (14).

WARNING

Lifting device must have a weight capacity greater than 767 lb (248 kg). Failure to comply may cause injury to personnel and/or damage to equipment.

7. Using suitable lifting equipment, remove transmission (17) from lower container section (13).

8. Remove two screws (5) and washers (6) attaching top container mounting bracket (7) to transmission (17). Remove top container mounting bracket (7).

NOTE

Plug all openings, including oil line fittings, vent tubes, and oil dipstick tube before cleaning.

9. Clean outside of transmission (17) before performing any procedures.

0006 00-3

NMWR 9-2520-594 0006 00

Figure 1. Transmission and Container.

0006 00-4

NMWR 9-2520-594 0006 00

INSTALLATION ON HOLDING FIXTURE

NOTE

Perform step 1 if transmission is equipped with PTO cover.

1. Remove six screws (4), power takeoff cover (3), and gasket (2) from transmission (1). Discard gasket (2).

NOTE

If transmission was equipped with PTO, attach holding fixture with six washers, two nuts, and four screws.

2. Mount adapter plate (11) and holding fixture (10) on transmission (1) with six washers (5) and screws (6).

WARNING

All personnel must stand clear during lifting operations. A snapped cable or swinging or shifting load may cause injury to personnel. Do not remove hoist chain from transmission until transmission is stable in holding fixture base, or injury to personnel may result.

NOTE

Transmission may be mounted on any overhaul stand or holding fixture. However, front, rear, and bottom of transmission must be accessible for removal and installation of components. Refer to figure 4 for a different style holding fixture.

3. Using lifting device and chain, lift transmission (1) and holding fixture (10) into position and install in holding fixture base (7). Secure with pin (8) and setscrew (9).

4. Remove chain and lifting device from transmission (1).

Figure 2. PTO Cover Removal.

0006 00-5/6 blank

NMWR 9-2520-594 0006 00

END OF WORK PACKAGE

Figure 3. Mounting Transmission on Holding Fixture.

Figure 4. Optional Transmission Mounting Fixture.

NMWR 9-2520-594 0007 00

0007 00-1

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

TRANSMISSION, AUTOMATIC

M939A1/A2

NSN 2520-01-117-3010 P/N 5704512 MT654 TRANSMISSION

W/CONTAINER

NSN 8145-01-117-4978 P/N 12277382 CONTAINER

TRANSMISSION DISASSEMBLY

INITIAL SETUP:

Tools and Special Tools General mechanic’s tool kit, automotive:

(Item 21, WP 0029 00) Center support lifter (Item 4, WP 0029 00) Gear unit lifter (Item 20, WP 0029 00) Front support lifter (Item 17, WP 0029 00) Valve body lifter (Item 62, WP 0029 00) Seal and dust shield remover (slide hammer)

(Item 11, WP 0029 00) 2 3/4-in. socket 3/4-in. drive impact wrench Lifting sling

0007 00-2

TRANSMISSION DISASSEMBLY (Contd)

NOTE

If water is present in transmission, replace all clutch plates and discs.

1. Using 2 3/4-in. socket and an impact gun, remove locknut (3) from transmission output shaft (1).

Discard locknut (3).

2. If necessary, use mechanical puller to remove universal joint yoke (2) from transmission output shaft (1).

3. Using seal and dust shield remover tool (slide hammer), remove rear output shaft dust shield (4) and seal (5). Discard seal (5).

4. Disconnect lubrication tube (10) at transmission fitting (9).

5. Disconnect lubrication tube (8) at transmission fitting (7).

6. Remove four screws (13) and washers (12) attaching mounting bracket (11) to transmission (6).

7. Remove mounting bracket (11) from transmission (6).

8. Remove transmission fittings (9) and (7) from transmission (6).

Figure 1. Universal Joint Yoke Removal.

Figure 2. Lubrication Tube and Control Valve Removal.

0007 00-3

TRANSMISSION DISASSEMBLY (Contd)

9. Remove four nuts (14), washers (15), and screws (17) securing converter retaining strap (16) to transmission (6).

10. Remove two screws (19) and converter retaining strap (16) from torque converter (18).

11. Rotate transmission (6) to upright position. Using lifting sling, remove torque converter (18) from transmission (6).

Figure 3. Torque Converter Retaining Strap Removal.

Figure 4. Optional Torque Converter Retaining Strap.

Figure 5. Torque Converter Removal.

15 16

14 15

LIFTING SLING

0007 00-4

TRANSMISSION DISASSEMBLY (Contd)

NOTE

Have container ready to catch oil.

12. Before turning transmission (5) so oil pan (3) faces up, remove drainplug (1) and drainplug gasket

(2) from oil pan (3) and allow oil to drain. Discard drainplug gasket (2).

13. Remove twenty-one screws (6), oil pan (3), and oil pan gasket (4) from transmission (5). Discard oil pan gasket (4).

14.…