Maxitorq t305 - Service

TRANSMISSION
T305 JANUARY 2003
SERVICE MANUAL (NEW ISSUE)

10-115
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TRANSMISSION
T305
SERVICE MANUAL
JANUARY 2003 © MACK TRUCKS, INC. 2003

(NEW ISSUE) 10-115
front.fm Page ii Tuesday, September 10, 2002 2:45 PM
ATTENTION
The information in this manual is not all inclusive and
cannot take into account all unique situations. Note that
some illustrations are typical and may not reflect the
exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this
publication are based on information that was current at
the time of publication.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including (but not limited to) electronic,
mechanical, photocopying, recording, or otherwise
without prior written permission of Mack Trucks, Inc.
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TABLE OF CONTENTS
TABLE OF CONTENTS
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of Three-Digit Numerical Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Identification Stamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description of Transmission Stamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
T305 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gear Ratios and Shift Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T305 Shifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Double Clutching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
T305 Power Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION MAJOR COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Magnetic Oil Filter Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRANSMISSION DISASSEMBLY PROCEDURES [320] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BENCH PROCEDURES — TRANSMISSION COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . 38
Main Case Shift Cover Disassembly [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Main Drive Pinion Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mainshaft Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mainshaft Rear Bearing Cover Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Countershaft Front Bearing Cover Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Countershaft Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Countershaft Rear Bearing Cover Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Reverse Idler Gear Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Bearings [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Gears [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Shifter Forks, Sliding Clutches and Shift Rails [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Oil Seals [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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TABLE OF CONTENTS
BENCH PROCEDURES — TRANSMISSION COMPONENT REASSEMBLY . . . . . . . . . . . . . . . . 70
Reverse Idler Gear Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Countershaft Rear Bearing Cover Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Countershaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Countershaft Front Bearing Cover Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Mainshaft Rear Bearing Cover Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Mainshaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Main Drive Pinion Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Main Case Shift Cover Reassembly [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
TRANSMISSION REASSEMBLY PROCEDURES [320] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
T305 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
T305 Gear Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
T305 Fits and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
General Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Transmission Specifications and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
TRANSMISSION DISASSEMBLED VIEWS [320] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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NOTES
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INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:
Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.
Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.
Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.
A procedure, practice, or condition that is essential to emphasize.
A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.
Page 2
INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle, always be seated in the driver’s seat, place the
transmission in neutral, be sure that parking brakes are set, and
disengage the clutch.
2. Before working on a vehicle, place the transmission in neutral, set the
parking brakes, and block the wheels.
3. Before towing the vehicle, place the transmission in neutral and lift the
rear wheels off the ground, or disconnect the driveline to avoid damage to
the transmission during towing.
Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.
REMEMBER,
SAFETY. . .IS NO ACCIDENT!
Page 3
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every r Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
r NEVER run engine indoors unless exhaust
potentially hazardous situations and taking
fumes are adequately vented to the outside.
necessary precautions. Performing service
procedures correctly is critical to technician safety r Be aware of hot surfaces. Allow engine to
and safe, reliable vehicle operation. cool sufficiently before performing any
service or tests in the vicinity of the engine.
The following list of general shop safety practices
r Keep work area clean and orderly. Clean up
can help technicians avoid potentially hazardous
any spilled oil, grease, fuel, hydraulic fluid,
situations and reduce the risk of personal injury.
etc.
DO NOT perform any services, maintenance
procedures or lubrications until this manual has r Only use tools that are in good condition,
been read and understood. and always use accurately calibrated torque
wrenches to tighten all fasteners to specified
r Perform all service work on a flat, level
torques. In instances where procedures
surface. Block wheels to prevent vehicle
require the use of special tools which are
from rolling.
designed for a specific purpose, use only in
r DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
r Do not store natural gas powered vehicles
vehicle.
indoors for an extended period of time
r ALWAYS wear safety glasses and protective (overnight) without first removing the fuel.
shoes. Avoid injury by being aware of sharp
r Never smoke around a natural gas powered
corners and jagged edges.
vehicle.
Page 4
INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 300 — CLUTCH, TRANSMISSION,
TRANSFER CASE AND PTO
CODE
GROUP 400 — STEERING, AXLES, WHEELS
Explanation of Three-Digit AND TIRES, DRIVELINE
Numerical Code
GROUP 500 — BRAKES, AUXILIARY
The organization of MACK service manuals has SYSTEMS
been upgraded to standardize manual content
according to a reference system based on GROUP 600 — CAB, TRUCK BODY
component identification. The reference system
will help link the information contained in this GROUP 700 — ELECTRICAL
publication with related information included in
other MACK service-warranty publications, such The second two digits of the three-digit code are
as associated service bulletins, warranty used to identify the system, assembly or
manuals, and MACK Service Labor Time subassembly, as appropriate, within each of the
Standards. groupings. The codes applicable to this
publication are shown at the beginning of each
The system is based on a numerical code, the procedure, as necessary, to guide you to specific
first digit of which identifies the general component information.
component grouping as listed here:
Additionally, a two-character alpha code (i.e.,
GROUP 000 — GENERAL DATA [GA] Case, Main) may be shown with each
operation. This alpha code, in combination with
GROUP 100 — CHASSIS the three-digit Group number, identifies the
specific assembly, subassembly or part, and
GROUP 200 — ENGINE directly relates to the first five positions of the
operation code listed in the MACK Service Labor
Time Standards.
Numerical Code Example
Page 5
INTRODUCTION
CONVERSION CHART
Conversion Units Multiply By:
Length Calculations
Inches (in) to Millimeters (mm) 25.40
Inches (in) to Centimeters (cm) 2.540
Feet (ft) to Centimeters (cm) 30.48
Feet (ft) to Meters (m) 0.3048
Yards (yd) to Centimeters (cm) 91.44
Yards (yd) to Meters (m) 0.9144
Miles to Kilometers (km) 1.609
Millimeters (mm) to Inches (in) 0.03937
Centimeters (cm) to Inches (in) 0.3937
Centimeters (cm) to Feet (ft) 0.0328
Centimeters (cm) to Yards (yd) 0.0109
Meters (m) to Feet (ft) 3.281
Meters (m) to Yards (yd) 1.094
Kilometers (km) to Miles 0.6214
Area Calculations
Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2
Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452
Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0
Square Feet (sq-ft) to Square Meters (sq-m) 0.0929
Square Yards (sq-yd) to Square Meters (sq-m) 0.8361
Square Miles (sq-miles) to Square Kilometers (sq-km) 2.590
Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155
Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155
Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076
Square Meters (sq-m) to Square Feet (sq-ft) 10.76
Square Meters (sq-m) to Square Yards (sq-yd) 1.196
Square Kilometers (sq-km) to Square Miles (sq-miles) 0.3861
Volume Calculations
Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387
Cubic Inches (cu-in) to Liters (L) 0.01639
Quarts (qt) to Liters (L) 0.9464
Gallons (gal) to Liters (L) 3.7854
Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646
Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102
Liters (L) to Cubic Inches (cu-in) 61.024
Liters (L) to Quarts (qt) 1.0567
Liters (L) to Gallons (gal) 0.2642
Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308
Page 6
INTRODUCTION
Weight Calculations
Ounces (oz) to Grams (g) 28.5714
Pounds (lb) to Kilograms (kg) 0.4536
Pounds (lb) to Short Tons (US tons) 0.0005
Pounds (lb) to Metric Tons (t) 0.00045
Short Tons (US tons) to Pounds (lb) 2000
Short Tons (US tons) to Kilograms (kg) 907.18486
Short Tons (US tons) to Metric Tons (t) 0.90718
Grams (g) to Ounces (oz) 0.035
Kilograms (kg) to Pounds (lb) 2.205
Kilograms (kg) to Short Tons (US tons) 0.001102
Kilograms (kg) to Metric Tons (t) 0.001
Metric Tons (t) to Pounds (lb) 2205
Metric Tons (t) to Short Tons (US tons) 1.1023
Metric Tons (t) to Kilograms (kg) 1000
Force Calculations
Ounces Force (ozf) to Newtons (N) 0.2780
Pounds Force (lbf) to Newtons (N) 4.448
Pounds Force (lbf) to Kilograms Force (kgf) 0.456
Kilograms Force (kgf) to Pounds Force (lbf) 2.2046
Kilograms Force (kgf) to Newtons (N) 9.807
Newtons (N) to Kilograms Force (kgf) 0.10196
Newtons (N) to Ounces Force (ozf) 3.597
Newtons (N) to Pounds Force (lbf) 0.2248
Torque Calculations
Pound Inches (lb-in) to Newton Meters (N•m) 0.11298
Pound Feet (lb-ft) to Newton Meters (N•m) 1.3558
Pound Feet (lb-ft) to Kilograms Force per Meter (kgfm) 0.13825
Newton Meters (N•m) to Pound Inches (lb-in) 8.851
Newton Meters (N•m) to Pound Feet (lb-ft) 0.7376
Newton Meters (N•m) to Kilograms Force per Meter (kgfm) 0.10197
Kilograms Force per Meter (kgfm) to Pound Feet (lb-ft) 7.233
Kilograms Force per Meter (kgfm) to Newton Meters (N•m) 9.807
Radiator Specific Heat Dissipation Calculations
British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/°C) 0.000293
Kilowatt per Degree Celsius (kW/°C) to British Thermal Unit per Hour (BTU/hr) 3414.43
Temperature Calculations
Degrees Fahrenheit (°F) to Degrees Celsius (°C) (°F32) 0.556
Degrees Celsius (°C) to Degrees Fahrenheit (°F) (1.8 x °C) + 32
Page 7
INTRODUCTION
Pressure Calculations
Atmospheres (atm) to Bars (bar) 1.01325
Atmospheres (atm) to Kilopascals (kPa) 101.325
Bars (bar) to Atmospheres (atm) 0.98692
Bars (bar) to Kilopascals (kPa) 100
Bar (bar) to Pounds per Square Inch (psi) 14.5037
Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377
Inches of Water (in H2O) to Kilopascals (kPa) 0.2491
Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895
Pounds per Square Inch (psi) to Bar (bar) 0.06895
Kilopascals (kPa) to Atmospheres (atm) 0.00987
Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612
Kilopascals (kPa) to Inches of Water (in H2O) 4.01445
Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145
Power Calculations
Horsepower (hp) to Kilowatts (kW) 0.74627
Kilowatts (kW) to Horsepower (hp) 1.34
Fuel Performance Calculations
Miles per Gallon (mile/gal) to Kilometers per Liter (km/L) 0.4251
Kilometers per Liter (km/L) to Miles per Gallon (mile/gal) 2.352
Velocity Calculations
Miles per Hour (mile/hr) to Kilometers per Hour (km/hr) 1.609
Kilometers per Hour (km/hr) to Miles per Hour (mile/hr) 0.6214
Volume Flow Calculations
Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32
Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531
Page 8
VISUAL IDENTIFICATION
Page 9
TRANSMISSION 1
IDENTIFICATION
Unit Identification Stamping
The following model code information is stamped
on the left side of the transmission, toward the
rear of the main box casing.
Figure 1 — Location of Identification Stamping on Left Side of Case
Page 10
Description of Transmission Stamp 2
The following model code information is stamped

on the left side of the transmission, toward the
rear of the main case.
Figure 2 — Unit Identification Stamping

1. Unit Symbol Identification
T = Transmission
3 = 300 series
05 = Usable forward speeds
2. Transmission Serial No.
3. Transmission Assembly (Part) No.
* = digits may vary
4. Specific variant of the base assembly
number (variant to item No. 3)
Page 11
3
Figure 3 — Cutaway View of T305 Transmission
Page 12
DESCRIPTION AND OPERATION
Page 13

DESCRIPTION AND The bearings are housed in cast-iron bearing
retainers (covers). Tapered roller bearings are
OPERATION used at each end of the three countershafts.
T305 Transmission All gears are of the spur-type design and are in
constant mesh with mating gears. All shifting is
DESCRIPTION done by forks and sliding clutches. The shift rails
The T305 transmission is a member of a new and forks are integral with the shift cover.
family of MACK transmissions designated as
MAXITORQUE® ES (T300) Series transmissions. A single gear shift lever is used to shift through a
These transmissions are the next evolution of the standard “H” pattern.
durable triple-countershaft transmissions. New
features and product enhancements have been The three countershafts of the T305 are equally
engineered into these transmissions to provide a spaced around the mainshaft. This design
wide range of advantages which include the distributes the load equally among the three
following: countershafts, thus keeping normal deflection
and gear tooth loading to a minimum.
r New and revised gear ratios for greater 4
overall range and versatility
r Lower “LOs” in forward and reverse for
superior site maneuvering
r Improved shift quality through the use of a
new sliding clutch with a fine-pitch tooth
design versus the coarse-pitch tooth design
of previous transmissions
r Enhanced durability
r Weight reduction versus previous
transmissions
This transmission consists of a compact

transmission case which houses the five forward
speed gear sets plus a reverse gear set. Thus,
the T305 has five forward speeds and one
reverse speed.
The transmission case and bell housing are a

Figure 4 — Equal Torque Distribution
one-piece casting, made from aluminum and
heat-treated for strength.
Page 14

Gear Ratios and Shift Pattern
5
Figure 5 — T305 Transmission Shift Pattern
T305 GEAR RATIOS

N — Neutral
R — Reverse
Gear Ratio
1 5.24
2 3.05
3 1.73
4 1.00
5 .60
R 5.38
T305 Shifting Instructions Double Clutching

The T305 is a five-speed overdrive transmission As with all non-synchronized transmissions,
designed for general highway or vocational use. “double clutching” is necessary on downshifts as
This is a non-synchronized model that shifts well as upshifts. “Double clutching” is a means of
through the use of a single shift lever in the bringing the speed of the transmission gears into
traditional “H” pattern. Start out in first gear and synchronization so that the shift can be made
shift up to second, third, fourth and fifth, double without gear clash. Engine RPM is used to speed
clutching from one gear to the next. up the transmission countershaft for a downshift,
or to slow the countershaft down for an upshift.
Downshift in reverse order, double clutching
through each gear. Proceed as follows:
1. Depress the clutch pedal and shift to neutral.
2. Release the clutch pedal and accelerate
Be careful not to overspeed the engine during engine (for downshift), or allow engine to
downshifting. Damage to powertrain components slow down (for upshift), until engine speed
may result. approximates the road speed of the gear to
be selected.
3. Depress the clutch pedal and complete the
shift to the desired gear. Release the clutch
pedal.
Page 15

T305 Power Flow Diagrams 9
Figure 9 — Fourth Speed

10
Figure 6 — First Speed

7
Figure 10 — Fifth Speed

11
Figure 7 — Second Speed

8
Figure 11 — Reverse Speed
Figure 8 — Third Speed
Page 16

Lubrication gears on that countershaft spin, a constant spray
of oil is directed to all internal parts of the
SPLASH LUBRICATION transmission. The oil cools as it circulates over
All parts inside the transmission are lubricated by the aluminum case. Troughs and passages, cast
a splash-and-gravity system. Only the lower into the inside of the case, capture and direct oil
countershaft dips into the lubrication oil. As the to the bearings.
12
Figure 12 — Splash Lubrication
TRANSMISSION CASE OIL COOLER LINE 13
PLUGS
An integral oil cooler pump system has been
developed for MACK transmissions. The oil
cooler is optional for engine ratings under 400 hp
and chassis ratings under 80,000 GVW.
The oil cooler system is required when the

engine rating is equal to or exceeds 400 hp, or
the chassis rating is greater than 80,000 GVW.
On transmissions that are not built with oil cooler

pump systems, the tube line openings are
plugged or capped. The main suction tube area
contains a metal plug threaded into the case and
Figure 13 — Transmission Case Oil Cooler Line Plugs
the outlet fitting area receives a plastic cap.
1. Outlet Plastic Cap 2. Suction Tube Plug
Page 17

MAGNETIC OIL FILTER
A magnetic oil filter assembly is built into the right
side of the transmission case. It consists of a
magnetic plug which removes ferrous metallic
particles from the passing oil. After passing the
magnetic plug, oil returns (by gravity) down into
the transmission case sump. The magnetic plug
is removable from the outside of the transmission
without the necessity of draining the oil since this
plug is above the oil level. The drain plug at the
bottom of the case is also magnetic.
14
Figure 14 — Plug Locations
1. Magnetic Filter Plug 3. Oil Drain Plug

2. Transmission Oil 4. Oil Fill and Level Plug
Temperature Sensor
Page 18
COMPONENT LOCATOR
COMPONENT LOCATOR
Page 19
COMPONENT LOCATOR
TRANSMISSION MAJOR COMPONENT LOCATIONS
15
Figure 15 — Component Locations for T305 Transmissions
1. Main Drive Pinion Assembly 4. Drive Flange (Yoke) 7. Countershaft Front Bearing Cover
2. Case Shift Cover Assembly 5. Countershaft Rear Bearing Cover 8. Mainshaft Assembly
3. Mainshaft Rear Bearing Cover 6. Countershaft Assembly
Page 20
TROUBLESHOOTING
TROUBLESHOOTING
Page 21
TROUBLESHOOTING
TROUBLESHOOTING CHARTS
NOISY TRANSMISSION
Probable Cause Remedy
a. Low oil level a. Fill to correct level.
b. Wrong oil used b. Drain and refill with correct oil.
c. Mismatched carrier ratios c. Install correct matched gearing.
d. Resonating (ringing) driveshaft d. Install suitable dampening material, then high-speed
balance the driveshaft.
e. Side-mounted PTO mounted too loose or too tight e. Reinstall PTO correctly.
f. Loose bell housing to flywheel housing capscrews f. Install new capscrews using Loctite®.
g. Incorrect clutch driven disks used g. Install correct clutch driven disks.
h. Gears worn, chipped, rough, cracked h. Replace gears.
i. Bearings worn, cracked, corroded, galled, etc. i. Replace bearings.
HARD SHIFTING
a. Incorrect driving practices a. Train driver in correct driving practices.
b. Low oil level b. Fill to correct level.
c. Improperly adjusted clutch, clutch linkage, clutch brake or c. Adjust properly.
shift linkage
d. Wrong oil used d. Drain and refill with correct oil.
e. Remote shift linkage not lubricated e. Clean and lubricate.
f. Shift lever binding or interference f. Relieve binding or interference.
g. Poppet balls binding in their holes g. Clean holes and balls.
h. Loose setscrews in shifters or shift forks h. Tighten to correct torque.
i. Worn spigot bearing i. Replace bearing.
j. Clutch brake tangs broken j. Replace clutch brake.
k. Clutch disks worn into main drive pinion shaft splines k. Replace clutch disks and main drive pinion.
l. Mainshaft snap ring or thrust washer failure l. Replace snap rings or thrust washers.
Page 22
TROUBLESHOOTING
GEAR DISENGAGEMENT (JUMPING OUT OF GEAR)
a. Excessive weight and/or length of gear shift lever and/or a. Replace with standard lever and/or knob.
knob
b. Shift lever interference b. Remove interference.
c. Improperly adjusted remote control linkage c. Adjust properly.
d. Worn or loose mounting insulators d. Replace insulators.
e. Loose, broken or missing capscrews between clutch e. Replace capscrews, check threads in case.
housing and flywheel housing
f. Weak or broken shifter rail poppet springs f. Replace springs.
g. Bent or worn shifter forks g. Replace forks.
h. Broken snap rings h. Replace snap rings.
i. Shift rail bent or poppet notches worn i. Replace shift rail.
j. Worn taper or chipped teeth on sliding clutch teeth j. Replace sliding clutch, and mating gear if its clutch teeth
are damaged.
k. Worn or damaged spigot bearing k. Replace bearing.
l. Engine flywheel housing misalignment l. Realign properly.
m. Chassis resonant ride m. Correct resonance.
OIL LEAKS
a. Oil level too high a. Drain to correct level.
b. Drain plug, fill plug or magnetic filter plug loose b. Tighten plugs.
c. Loose or missing capscrews (Example: Left or right upper c. Tighten or replace.
through bolt)
d. Improper lubricant used d. Drain and refill with correct oil.
e. Clogged air breather e. Clean or replace.
f. Gaskets or O-rings broken, shifted or squeezed out of f. Replace gaskets or O-rings.
position
g. Worn oil seals g. Replace seals.
i. Porous case or housing i. Replace case or housing.
BEARING FAILURE
a. Dirt in system a. Clean system, replace bearings as needed, flush and refill
with clean lubricant.
b. Wrong grade of oil, or contaminated oil b. Clean system, replace bearings as needed, flush and refill
with clean lubricant.
c. Excessive vibrations c. Eliminate vibrations, replace bearings.
d. Binding or seized propeller shaft slip yoke d. Clean and replace as needed.
e. Improper bearing clamping e. Replace bearings and re-clamp using correct procedures.
f. Improper bearing installation (preloads, etc.) f. Replace using correct procedures.
Page 23
NOTES
Page 24
MAINTENANCE
MAINTENANCE
Page 25
MAINTENANCE
TRANSMISSION 17
MAINTENANCE
Checking Oil Level
Perform oil level check when the oil is at

operating temperature. The vehicle must be in a
level position, both front-to-rear and side-to-side.
Figure 17 — Correct Oil Level
r Check the transmission oil level at the
intervals specified in the Maintenance and r If oil can only be felt by reaching the finger
Lubrication Manual (TS494). down into the unit, the oil level is too low.
18
r To check the oil level in the transmission,

first remove the filler plug (2) from the right
side of the main case.
16
Figure 18 — Incorrect Oil Level
r Add specified make-up oil, if needed, until

the oil is level with the bottom of the filler
Figure 16 — Oil Filler and Check Plug plug hole. Do NOT overfill. Use oil of the
proper specification. MACK-approved gear
1. Magnetic Filter Plug (Not 2. Oil Filler and Check Plug oils can be found on the internet at
for Level Check) www.macktrucks.com.
r Reinstall and tighten the oil filler plug
r The oil must be level with the bottom of the
(Figure 16) as follows:
filler plug hole as determined by feel or by
visual inspection. 1. Check that the O-ring on the plug is not
cut or damaged. Replace as necessary.
2. Install the plug and tighten to
35–50 lb-ft (47–68 N•m) of torque.
Be careful not to burn your finger in hot gear
oil when checking the oil level in the
transmission.
Page 26
MAINTENANCE
Changing Oil OIL FILL
r Remove the oil filler plug (2) (Figure 20),
then fill the transmission using specified oil
until the oil is level with the bottom of the
Preserve the environment! Drained gear oil is filler plug hole (also see Figure 17). Do NOT
classified as a hazardous toxic material which overfill.
must be recovered, handled, stored and disposed r Reinstall and tighten the oil filler plug as
of according to applicable State or Federal follows:
guidelines.
1. Check that the O-ring on the plug is not
cut or damaged.
CHANGE INTERVAL 2. Install the plug and tighten to
r Change the oil at intervals specified in the 35–50 lb-ft (47–68 N•m) of torque.
20
Maintenance and Lubrication Manual
(TS494).
DRAINING OIL
r Before draining oil from the transmission,
the oil should be at normal operating
temperature.
r Remove the magnetic drain plug (Figure 19)
from the bottom of the transmission main
case and drain the hot oil into an industry-
approved recovery container.
r Clean and replace the magnetic drain plug,
then torque the plug to 25–30 lb-ft
(34–41 N•m). Figure 20 — Oil Filler and Check Plug
19
1. Magnetic Filter Plug (Not 2. Oil Filler and Check Plug

for level check)
Be sure to add oil to the transmission through the

filler hole, NOT the magnetic filter plug hole.
Damage to the transmission and seals may occur
due to overfilling. The magnetic oil filter hole is
higher on the transmission case than the filler
hole.
Figure 19 — Plug Locations
1. Magnetic Filter Plug 3. Oil Drain Plug

2. Oil Temperature Sensor 4. Oil Fill and Level Plug
Page 27
MAINTENANCE
Magnetic Oil Filter Plug
Remove the magnetic oil filter plug and clean the
magnet in the plug every time the oil is changed.
Reinstall the magnetic plug. Tighten the plug to
20–23 lb-ft (27–31 N•m) torque.
Air Breathers
The T305 has one air breather located on the
case top cover. The air breather should be
removed every time the oil is changed and
cleaned with a suitable solvent. Also check to be
sure that airflow through the breather is
unobstructed. Reinstall breather into case top
cover and tighten until snug.
Page 28
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
Page 29
REPAIR INSTRUCTIONS
TRANSMISSION 4. Remove the transmission case shift cover
assembly.
DISASSEMBLY PROCEDURES 22
[320]
Unless a complete overhaul is necessary, remove

only those parts required to gain access to faulty
parts. Do not disturb parts with a heavy press fit
(interference fit) unless replacement is
necessary. When replacement is necessary, use
proper press setups and pullers so that usable
parts are not damaged.
1. Clean the transmission externally and mount

it in an overhaul stand. Drain the lubricant
into an approved catch container. Figure 22 — Removing Case Shift Cover
2. Remove the clutch shafts, yoke and clutch
brake (if equipped). 5. Remove the drive yoke or drive flange by
first separating the capscrew and clamp
3. With transmission in neutral, remove the plate.
transmission case shift cover capscrews. 23
21
Figure 21 — Removing Case Cover Capscrews
Figure 23 — Removing Clamp Plate and Capscrew
6. Remove the drive yoke (flange), using a

suitable puller such as J 07804-A or
equivalent.
Page 30
REPAIR INSTRUCTIONS
24 25
Figure 25 — Mark Front Countershaft Bearing Covers

for Placement
26
Figure 24 — Removing Drive Yoke (Drive Flange)
7. Verify that the transmission is in neutral.

8. Number the front and rear countershaft
bearing covers using a grease pencil. Write Figure 26 — Mark Rear Countershaft Bearing Covers for
number 1 on the upper right front cover Placement
(viewed from front), number 2 on the upper
left front cover (viewed from front) and
number 3 on the lower front cover. Write
number 1 on the upper left rear cover
(viewed from rear), number 2 on the upper
right rear cover (viewed from rear) and
number 3 on the lower rear cover.
Page 31
REPAIR INSTRUCTIONS
9. Position the transmission case horizontally. 29
Remove the main drive pinion bearing cover

capscrews.
27
Figure 29 — Removing Main Drive Pinion Assembly

from Case
12. Remove the fourth/fifth sliding clutch.

30
Figure 27 — Removing Main Drive Pinion Bearing Cover
Capscrews
10. Remove the main drive pinion bearing cover

assembly. Jackscrew holes are provided to
assist the removal.
28
Figure 30 — Removing Fourth/Fifth Sliding Clutch
13. Remove the No. 2 (upper left) countershaft

front bearing cover capscrews.
31
Figure 28 — Using Jackscrews to Remove Main Drive

Pinion Bearing Cover Assembly
11. Remove main drive pinion assembly from

the case.
Figure 31 — Removing No. 2 Countershaft Front Bearing

Cover Capscrews
Page 32
REPAIR INSTRUCTIONS
14. Remove the No. 2 (upper left) countershaft 15. Remove the No. 2 (upper right) countershaft
front bearing cover using jackscrews. rear bearing cover capscrews.
32 34
Figure 32 — Removing No. 2 Countershaft Front Bearing Figure 34 — Removing No. 2 Countershaft Rear Bearing
Cover Using Jackscrews Cover Capscrews
33
16. Remove the jackscrew plugs from the

countershaft rear bearing covers.
Pry the plugs loose using a thin knife edge or

similar tool. Do not cut through plugs during
removal. Save for reuse or replace if necessary.
35
Figure 33 — No. 2 Countershaft Front Bearing Cover

Removed
Figure 35 — Removing Jackscrew Plugs from

Countershaft Rear Bearing Covers
Page 33
REPAIR INSTRUCTIONS
17. Remove the No. 2 (upper right) countershaft 18. Remove the mainshaft rear bearing cover
rear bearing cover using jackscrews. capscrews.
36 38
Figure 36 — Using Jackscrews to Remove No. 2 Figure 38 — Removing Mainshaft Rear Bearing Cover
Countershaft Rear Bearing Cover Capscrews
37
19. Remove the mainshaft rear bearing cover

jackscrew plugs.
Pry the plugs loose using a thin knife edge or

similar tool. Do not cut through plugs during
removal. Save for reuse or replace if necessary.
20. Remove the mainshaft rear bearing cover

using jackscrews.
39
Figure 37 — No. 2 Countershaft Rear Bearing Cover

Removed
Figure 39 — Removing Mainshaft Rear Bearing Cover

Using Jackscrews
Page 34
REPAIR INSTRUCTIONS
40 42
Figure 40 — Mainshaft Rear Bearing Cover Removed

Figure 42 — Using Tool J 34630 to Remove Reverse Idler
21. Move mainshaft out of the way. Remove the Shaft
43
No. 2 (upper right, when viewed from rear)
countershaft from the transmission case.
41
Figure 43 — Removing Reverse Idler Gear and Shaft

44
Figure 41 — Removing No. 2 Countershaft from

Transmission Case
Place the transmission in the vertical position

(rear end up) for the following procedure.
22. Remove the upper right reverse idler shaft

plug (next to No. 2 countershaft location)
using a knife edge or similar tool. Do not cut
through plugs during removal. Save for
reuse or replace if necessary.
23. Using tool J 34630 or slide hammer, remove Figure 44 — Reverse Idler Gear and Shaft Removed
the upper right reverse idler shaft. To
prevent damage to the reverse idler gear,
catch the gear as it separates from the shaft.
Page 35
REPAIR INSTRUCTIONS
24. Remove the No. 1 (upper left) countershaft 29. Reach through the case top opening to slide
rear bearing cover capscrews. the reverse gear and reverse/first clutch
25. Remove the No. 1 (upper left) countershaft forward.
47
rear bearing cover using jackscrews.
26. Remove the mainshaft rear bearing thrust
spacer from the mainshaft.
27. Remove the rear snap ring from the
mainshaft using snap ring pliers.
The rear snap ring on the mainshaft requires

metric snap ring pliers for removal.
45
Figure 47 — Slide Reverse Gear and Reverse/First

Clutch Forward
30. Using a pry bar, move the rear end of the

upper left (No. 1) countershaft away from the
mainshaft as far as possible without
damage. Block the countershaft in this
position using wadding made from rags.
48
Figure 45 — Removing Spacer and Rear Snap Ring from

the Mainshaft
28. Using suitable snap ring pliers, remove the

snap ring from inside the reverse gear.
46
Figure 48 — Moving and Blocking No. 1 Countershaft

Away from Mainshaft
Figure 46 — Reverse Gear Snap Ring
Page 36
REPAIR INSTRUCTIONS
31. Tip the front end of the mainshaft upward 33. Remove the upper left reverse idler shaft
and remove it from the case. plug (next to No. 1 countershaft) using a thin
knife edge or similar tool.
34. Using tool J 34630 or slide hammer, remove
the upper left reverse idler shaft. To prevent
The reverse gear is free on the mainshaft and damage to the reverse idler gear, catch the
can fall off when removing the mainshaft. To gear as it separates from the shaft.
prevent it from falling off, slide it back as the
mainshaft is removed and leave it in the case. 35. Remove the lower No. 3 countershaft rear
bearing cover capscrews.
49
36. Remove the No. 3 countershaft rear bearing
cover using jackscrews.
37. Remove the lower reverse idler shaft plug
(next to No. 3 countershaft) using a thin
knife edge or similar tool.
38. Using tool J 34630 or slide hammer, remove
the lower reverse idler shaft. To prevent
damage to the reverse idler gear, catch the
gear as it separates from the shaft.
39. Remove the No. 1 (upper left, when viewed
from rear) countershaft by pulling and tilting
the front end upward.
51
Figure 49 — Removing Mainshaft
32. Remove the upper left through bolt.

50
Figure 51 — Removing the No. 1 Countershaft
Figure 50 — Removing Upper Left Through Bolt
Page 37
REPAIR INSTRUCTIONS
40. Remove the No. 3 (lower) countershaft by BENCH PROCEDURES —
pulling and tilting the front end upward.
52 TRANSMISSION COMPONENT
DISASSEMBLY
Unless a complete overhaul is necessary, remove

only the parts that are required to repair the
assembly. Do not disturb parts that have a heavy
press fit (interference fit) unless replacement of
the part is necessary. When replacement is
necessary, use proper pullers and press setups
to prevent damage to usable parts.
Figure 52 — Removing the No. 3 Lower Countershaft Main Case Shift Cover Disassembly
[323]
41. Remove the remaining No. 1 (upper right)
and No. 3 (lower) countershaft front bearing 54
cover capscrews.
42. Remove the remaining No. 1 (upper right)
and No. 3 (lower) countershaft front bearing
covers using jackscrews.
53
Figure 54 — Main Case Shift Cover Locator View

55
Figure 53 — Remaining No. 1 and No. 3 Countershaft

Front Bearing Covers
Figure 55 — Shift Cover Assembly
Page 38
REPAIR INSTRUCTIONS
56
Figure 56 — Exploded View of Main Case Shift Cover
1. 4th/5th Shift Fork 10. 4th/5th Rocker Arm 18. 1st/Reverse Shift Rail
2. 2nd/3rd Shift Fork 11. Bushing 19. Interlock Ball
3. 1st/Reverse Shifter 12. Washer 20. Interlock Pin
4. Shifter Body Spring 13. Poppet Ball 21. 2nd/3rd Shift Rail
5. Shifter Body Plunger 14. Poppet Ball Spring 22. Interlock Ball
6. 1st/Reverse Shift Fork 15. 4th/5th Rocker Pin Hardware 23. 4th/5th Shift Rail
7. 4th/5th Shifter 16. Pipe Plug 24. 1st/Reverse Shifter Ball
8. 4th/5th Rocker Pin 17. Breather 25. 1st/Reverse Shifter Spring
9. Washer
Page 39
REPAIR INSTRUCTIONS
1. Remove the setscrew from the first/reverse 2. Remove the setscrew from the first/reverse
shift fork. shifter.
57 58
Figure 58 — Removing Setscrew from First/Reverse

Shifter
Figure 57 — Removing Setscrew from First/Reverse

Shift Fork
Page 40
REPAIR INSTRUCTIONS
3. Slide the first/reverse shift rail toward the 4. Remove the first/reverse shift fork from the
front of the cover. cover.
59 60
Figure 60 — Removing First/Reverse Shift Fork
Figure 59 — Sliding First/Reverse Shift Rail Toward

Front of Cover
Page 41
REPAIR INSTRUCTIONS
5. Push the first/reverse shift rail forward using 6. Remove the poppet ball and spring from the
a metal bar or large screwdriver. Hold a first/reverse shift rail vertical pocket in line
shop towel over the top opening. The shop with the rail.
towel prevents the spring and ball under the
rail from popping out and becoming lost.
A magnet is helpful in removing the poppet ball

and spring.
Poppet balls are spring loaded and may cause
62
injury when released.
61
Figure 61 — Pushing First/Reverse Shift Rail Forward
Figure 62 — Removing Poppet Ball and Spring
Page 42
REPAIR INSTRUCTIONS
7. Remove the interlock ball from the horizontal 8. Continue sliding the first/reverse shift rail
pocket between the first/reverse shift rail forward to remove the first/reverse shifter.
and the second/third shift rail. 64
63
Figure 64 — Removing First/Reverse Shifter
Figure 63 — Removing Interlock Ball
Page 43
REPAIR INSTRUCTIONS
9. Slide the first/reverse shift rail clear from the 10. Remove the setscrew from the second/third
shift cover and, at the same time, remove shift fork.
the fourth/fifth shift fork. 66
65
Figure 66 — Removing Setscrew from Second/Third

Shift Fork
Figure 65 — Removing Fourth/Fifth Shift Fork
Page 44
REPAIR INSTRUCTIONS
11. Push the second/third shift rail forward using 12. Remove the poppet ball and spring from the
a metal bar or large screwdriver. Hold a second/third shift rail vertical pocket in line
shop towel over the top opening. The shop with the rail.
towel prevents the spring and ball under the
rail from popping out and becoming lost.

and spring.
Poppet balls are spring loaded and could
68
cause injury when they are released.
67
Figure 67 — Pushing Second/Third Shift Rail Forward
Page 45
REPAIR INSTRUCTIONS
13. Remove the interlock ball from the horizontal 14. Remove the interlock pin from the second/
pocket between the second/third shift rail third shift rail.
and the fourth/fifth shift rail. 70
69
Figure 70 — Removing Pin from Second/Third Rail

Figure 69 — Removing Interlock Ball
Page 46
REPAIR INSTRUCTIONS
15. Slide the second/third shift rail further 73
forward and remove the second/third shift

fork.
71
Figure 73 — Removing Setscrew from Fourth/Fifth

Shifter
18. Push the fourth/fifth shift rail forward using a

metal bar or large screwdriver. Hold a shop
towel over the top opening. The shop towel
prevents the spring and ball under the rail
from popping out and becoming lost.
Poppet balls are spring loaded and could

cause injury when they are released.
74
Figure 71 — Removing Second/Third Shift Fork
16. Continue sliding the second/third shift rail

until it clears the cover.
72
Figure 72 — Removing Second/Third Shift Rail
17. Remove the setscrew from the fourth/fifth

shifter. Figure 74 — Pushing Fourth/Fifth Rail Forward
Page 47
REPAIR INSTRUCTIONS
19. Continue sliding the fourth/fifth shift rail 76
forward out of the shift cover. At the same

time, remove the fourth/fifth shifter.
75
Figure 75 — Removing Fourth/Fifth Shifter 21. Remove the poppet ball and spring and
interlock plunger and spring from the first/
20. Remove the poppet ball and spring from reverse shifter.
77
under the fourth/fifth shift rail.

and spring.
Figure 77 — Disassembling First/Reverse Shifter
Page 48
REPAIR INSTRUCTIONS
22. Remove the reverse light switch from the 23. Remove the reverse light switch rod.
shift cover. 79
78
Figure 78 — Removing Reverse Light Switch
Figure 79 — Removing Reverse Light Switch Rod
Page 49
REPAIR INSTRUCTIONS
24. Remove the nut and washers from the 81
fourth/fifth pin.
80
Figure 81 — Recovering Lock Washer, Flat Washer and

Nut
Figure 80 — Loosening Fourth/Fifth Pin Nut
Page 50
REPAIR INSTRUCTIONS
25. Remove the fourth/fifth pin and rocker arm.
82
Main Drive Pinion Disassembly
[322]
84
Figure 84 — Main Drive Pinion Locator View

85
Figure 82 — Removing Fourth/Fifth Pin and Rocker Arm
26. Remove the shift cover breather vent.

83
Figure 83 — Removing Breather Vent
Figure 85 — Exploded View of Main Drive Pinion
1. Main Drive Pinion Shaft 7. Bearing

2. Spigot Bearing 8. Spiral Snap Ring
3. Snap Ring 9. Gasket
4. Main Drive Pinion Gear 10. Pinion Bearing Cover
5. Spiral Snap Ring 11. Oil Seal
6. Snap Ring
Page 51
REPAIR INSTRUCTIONS
1. Remove the spiral snap ring from the end of 3. Remove the spigot bearing snap ring from
the main drive pinion shaft inside the main the main drive pinion using suitable snap
drive pinion gear. Roll the snap ring out of ring pliers.
the groove and over the shoulder of the 88
main drive pinion using a flat-blade

screwdriver.
86
Figure 88 — Removing Spigot Bearing Snap Ring

Figure 86 — Removing Snap Ring from Main Drive
Pinion 4. Remove spigot bearing from inside the end
of the main drive pinion shaft.
89
The action of removing the snap ring may destroy

the snap ring. Make sure a replacement snap ring
is available.
2. Remove the main drive pinion gear by lifting

it straight up.
87
Figure 89 — Spigot Bearing Removed from Main Drive

Pinion Shaft
Figure 87 — Main Drive Pinion Removed from Shaft
Page 52
REPAIR INSTRUCTIONS
5. Remove the main drive pinion cover bearing 7. Remove the main drive pinion bearing spiral
snap ring using suitable snap ring pliers. snap ring using a small flat-blade
90
screwdriver. Roll the spiral snap ring out of
the groove to release.
92
Figure 90 — Removing Main Drive Pinion Cover Bearing

Snap Ring
Figure 92 — Removing Spiral Snap Ring from Main Drive
6. Separate the main drive pinion shaft and Pinion
bearing assembly from the main drive pinion
bearing cover.
91
The action of removing the spiral snap ring may

destroy the snap ring. Make sure a replacement
snap ring is available.
8. Place the main drive pinion shaft and

bearing into a suitable press and remove the
bearing.
Figure 91 — Removing Main Drive Pinion Assembly

from Main Drive Pinion Cover
Page 53
REPAIR INSTRUCTIONS
93
Mainshaft Disassembly [322]
95
Figure 95 — Mainshaft Locator View
On current-production T305 mainshafts, it is not

possible to remove the mainshaft gears, thrust
washers, sliding clutches and snap rings from the
rear of the shaft. The exceptions are the reverse
Figure 93 — Pressing Bearing off Main Drive Pinion
Shaft gear and its internal snap ring and the mainshaft
spacer and spacer snap ring. With these shafts,
9. Remove the oil seal from the main drive disassembly should be done from the front of the
pinion bearing cover using a hammer and a shaft.
blunt punch.
1. Slide the reverse gear from the rear of the
mainshaft (if not previously done).
96
Removing the oil seal destroys the seal. Make

sure a replacement oil seal is available.
94
Figure 96 — Removing Reverse Gear from Mainshaft
Figure 94 — Removing Main Drive Pinion Bearing Cover

Oil Seal
Page 54
REPAIR INSTRUCTIONS
97
Figure 97 — Exploded View of Mainshaft
1. Snap Ring 12. Thrust Washer 23. Thrust Washer

2. Thrust Washer 13. Snap Ring 24. Snap Ring
3. Fifth Speed Gear 14. Sliding Clutch 25. Sliding Clutch
6. Snap Ring 17. Second Speed Gear 28. Reverse Speed Gear
7. Bearing Inner Race 18. Thrust Washer 29. Thrust Washer
8. Mainshaft 19. Snap Ring 30. Snap Ring
9. Third Speed Gear 20. Snap Ring 31. Snap Ring
10. Snap Ring 21. Thrust Washer 32. Spacer
11. Thrust Washer 22. First Speed Gear
Page 55
REPAIR INSTRUCTIONS
2. Working at the opposite end of the 4. Slide the third speed gear from the
mainshaft, remove snap ring that retains the mainshaft.
fifth speed gear on the mainshaft. Use 100
suitable snap ring pliers.

98
Figure 100 — Removing Third Speed Gear
Figure 98 — Removing Fifth Speed Gear Snap Ring 5. Remove the third speed gear external- and
internal-toothed thrust washers.
3. Remove the internal- and external-toothed 101
thrust washers and fifth speed gear from the

mainshaft.
99
Figure 101 — Removing Third Speed Gear External- and

Internal-Toothed Thrust Washers
Figure 99 — Removing Internal- and External-Toothed
Thrust Washers and Fifth Speed Gear
Page 56
REPAIR INSTRUCTIONS
6. Remove the second/third sliding clutch snap 8. Remove the second speed gear mainshaft
ring using suitable snap ring pliers. snap ring using suitable snap ring pliers.
102 104
Figure 102 — Removing Sliding Clutch Snap Ring Figure 104 — Removing Second Speed Gear Snap Ring
7. Remove the second/third sliding clutch from 9. Remove the second speed gear internal-
the mainshaft. Slide straight off splines. and external-toothed thrust washers.
103 105
Figure 103 — Removing Second/Third Sliding Clutch Figure 105 — Removing Internal- and External-Toothed
Thrust Washers
Page 57
REPAIR INSTRUCTIONS
10. Remove the second speed gear from the 13. Remove the first/reverse sliding clutch snap
mainshaft. Slide straight off the shaft. ring from the mainshaft using suitable snap
106
ring pliers. Then, remove the first/reverse
sliding clutch from the mainshaft.
108
Figure 106 — Removing Second Speed Gear from

Mainshaft
Figure 108 — Removing First/Reverse Sliding Clutch
11. Slide first speed gear from the mainshaft from Mainshaft
and remove the gear snap ring, if necessary.
14. Working from the front of the mainshaft,
12. Remove the first speed gear internal- and
remove the reverse speed gear mainshaft
external-toothed thrust washers from the
snap ring using suitable snap ring pliers.
mainshaft.
107 Also remove the internal- and external-
toothed thrust washers from the shaft.
109
Figure 107 — Removing Internal- and External-Toothed

Thrust Washers Figure 109 — Removing Snap Ring and Internal- and
External-Toothed Thrust Washers
1. First/Reverse Sliding 3. External-Toothed Thrust
Clutch Washer
2. Internal-Toothed Thrust
Washer
Page 58
REPAIR INSTRUCTIONS
15. Remove the snap ring that retains the spigot Mainshaft Rear Bearing Cover
bearing inner race to the mainshaft using
suitable snap ring pliers. Disassembly [322]
110
112
Figure 110 — Removing Spigot Bearing Inner Race Snap Figure 112 — Mainshaft Rear Bearing Cover Locator
Ring View
113
16. Remove the spigot bearing inner race using
a suitable puller.
111
Figure 113 — Exploded View of Mainshaft Rear Bearing

Cover
Figure 111 — Removing Spigot Bearing Inner Race 1. Rear Bearing Cover 4. Bearing
2. Oil Seal 5. Snap Ring
3. Gasket
Page 59
REPAIR INSTRUCTIONS
1. Remove the bearing snap ring from the rear 3. Remove the oil seal from the mainshaft rear
bearing cover using suitable snap ring pliers. bearing cover using a hammer and blunt
114
punch. Drive the seal out from the opposite
side. Discard the cover gasket.
116
Figure 114 — Removing Rear Cover Snap Ring
2. Remove the mainshaft rear bearing from the Figure 116 — Using Hammer and Blunt Punch to
bearing cover. Remove Oil Seal
115
This action destroys the oil seal. Make sure a

replacement oil seal is readily available.
4. Thoroughly clean the mainshaft rear bearing

cover and bearing, and inspect for damage.
Figure 115 — Removing Bearing from Mainshaft Rear

Bearing Cover
Page 60
REPAIR INSTRUCTIONS
Countershaft Front Bearing Cover
Disassembly [322]
117
This action may destroy the bearing cone. Before
removing, make sure that the bearing requires
replacement and that replacement bearings are
readily available.
119
Figure 117 — Countershaft Front Bearing Cover Locator

View
118
Figure 119 — Removing O-Ring from Shoulder of

120
Figure 118 — Exploded View of Countershaft Front

Bearing Cover
1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Figure 120 — Removing Bearing Cone from
The following disassembly procedure applies to
all countershaft front bearing covers. 3. Thoroughly clean the bearing cover and
inspect for damage.
1. Remove the O-ring from the shoulder of the
countershaft front bearing cover.
2. Remove the bearing cone from the
countershaft front bearing cover using a
suitable puller.
Page 61
REPAIR INSTRUCTIONS
Countershaft Disassembly [322] The following disassembly procedure applies to
all three countershafts.
121
1. Press the countershaft main drive gear off
the countershaft.
123
Figure 121 — Countershaft Locator View

122
Figure 123 — Pressing Main Drive Gear off Countershaft
Figure 122 — Exploded View of Countershaft
1. Bearing Cup 6. Second Speed Gear

2. Main Drive Gear 7. Bearing Cone
3. Fifth Speed Gear 8. Countershaft
4. Third Speed Gear 9. Key
5. Spacer
Do not attempt to press-remove the first or

reverse gear from the front countershaft.
These gears are integral with the shaft and
could explode if press pressure is applied.
Page 62
REPAIR INSTRUCTIONS
2. Press the fifth speed gear off the 3. Press the third speed gear off the
countershaft. countershaft.
124 125
Figure 125 — Pressing Third Speed Gear off

Countershaft
Figure 124 — Pressing Fifth Speed Gear off
Countershaft
Page 63
REPAIR INSTRUCTIONS
4. Remove the spacer (located between the 6. Press the bearing cone off the rear of the
third and second speed gears) from the countershaft using suitable press tools.
countershaft.
126
This action may destroy the bearing cone. Before

removing, make sure that the bearing requires
replacement and that replacement bearings are
readily available.
128
Figure 126 — Removing the Spacer
5. Press the second speed gear from the

countershaft.
127
Figure 128 — Pressing off Bearing Cone
7. Remove the key from the keyway of the

countershaft.
129
Figure 127 — Pressing Second Speed Gear off

Countershaft
Figure 129 — Removing Key
Page 64
REPAIR INSTRUCTIONS
8. Remove the bearing cup from the 132
countershaft main drive gear using a

suitable puller.
130
Figure 132 — Exploded View of Countershaft Rear

Bearing Cover
1. Bearing Cup 3. Shim(s)

2. O-Ring 4. Bearing Cover
The following disassembly procedure applies to

all three countershaft rear bearing covers.
1. Remove the shims and O-ring from the
shoulder of the countershaft rear bearing
cover. Tag the shims and record the
markings on the shims for use during
assembly.
133
Figure 130 — Removing Bearing Race from Main Drive

Gear
Countershaft Rear Bearing Cover

Disassembly [322]
131
Figure 133 — Removing Cover Shims and O-Ring
Figure 131 — Countershaft Rear Bearing Cover Locator

View
Page 65
REPAIR INSTRUCTIONS
2. Remove the bearing cup from the bearing 136
cover using a suitable puller.

134
Figure 136 — Exploded View of Reverse Idler Shaft
1. Thrust Washer 3. Bearing

Figure 134 — Removing Bearing Cup from Cover 2. Reverse Idler Gear 4. Reverse Idler Shaft
3. Thoroughly clean the bearing cover and Reverse idler gear disassembly applies to all
inspect for damage. reverse idler gears.
r Press the reverse idler bearing out of the
Reverse Idler Gear Disassembly reverse idler gear using a suitable driver.
137
[322]
135
Figure 135 — Reverse Idler Gear Locator View
Figure 137 — Pressing Out Reverse Idler Gear Bearing
Page 66
REPAIR INSTRUCTIONS
INSPECTION OF PARTS Gears [322]
Replace all gears having teeth that show signs of
Inspection and Cleaning abrasive wear, scratching (except normal
Thoroughly clean the case, cover and all other manufacturing tool marks), ridging, scoring,
parts of the transmission. Remove all grease, oil surface fatigue, pitting, spalling, corrosive wear,
and foreign matter, using a suitable safety digging in or cracking. Gears should always be
solvent. Dry the parts with moisture-free inspected by magnaflux (or a similar system) for
compressed air. cracks which would not otherwise be detected.
Bearings [322] Shifter Forks, Sliding Clutches and

Shift Rails [323]
Soak bearings in fresh clean solvent to loosen all
hardened grease and foreign matter until the Replace forks and/or sliding clutches when the
bearings are clean. Blow them dry with filtered, side clearance (A) between the fork and sliding
moisture-free compressed air. clutch groove exceeds the specified limit found in
T305 Fits and Limits in the SPECIFICATIONS
section.
138
Do not spin the bearings with compressed air.

Doing so can damage the bearings.
Inspect each bearing for flaking, cracks,

fractures, cavities, indentations, measurable
wear, brinelling, fretting, corrosion, nicking, cage
wear or deformation and other damage. If any of
these conditions are present, the bearing should
be replaced.
Apply a light coat of fresh, clean, specified gear

oil to the bearings. (Refer to Recommended SAE
Grade Gear Oil in Transmission Specifications
and Capacities.) Turn the races and bearings
slowly by hand to be sure they move freely and
are smooth. If there is resistance to movement, or
the bearings or races feel rough, replace the
bearing.
If a bearing cone or cup needs replacement, a

complete new assembly, including cup and
mating cone, is required.
Do not remove a new bearing from its packing
before time of installation. Never clean protective
grease from new bearings. Figure 138 — Fork and Clutch Detail
Do not handle bearings with dirty hands. Rags
must be clean and lint free. 1. Sliding Clutch 2. Shift Fork
Clean bearings which are satisfactory for

installation. Wrap the bearings in clean, lint-free
cloth and store for assembly.
Page 67
REPAIR INSTRUCTIONS
Replace shift rails if they are cracked in either the Be careful when installing a shaft through a new
poppet or setscrew holes. If the clearance seal (or seal over shaft). Lubricate the shaft
between the shift rail and housing (cover) bore before inserting it through the seal. Splines,
exceeds 0.010 inch (0.254 mm) maximum, keyways and holes in a shaft can damage seals
determine which part is worn before replacing. unless care is taken. Lubricate the seal to prevent
Shaft wear can be checked by measuring the damage during the initial start-up period, before
shaft at an unworn location. Then measure the normal lubrication begins. Keep anti-seize and
shaft at the worn area and compare sealing compounds away from oil seals.
measurements. When measuring a shift rail, the
reading should be an average of diameter If an oil seal does not have a preapplied sealant
measurements taken at four locations. Compare on its outer diameter, apply an appropriate sealer
one side of the shaft to the other, AB–CD as around the outside diameter to prevent leaks.
shown in Figure 139.
139
Lip-type oil seals are precision made and require
close attention and care during installation. The
quality of the installation method and the tools
used directly affect the life of the seal. Do not use
a block of wood or discarded bearing as a
substitute for the proper seal driver.
For the seal to function properly, install it squarely

with respect to the shaft center line. The seal
should be kept square within 0.010 inch
(0.254 mm) Total Indicated Runout (TIR).
Squareness of the seal to the shaft is controlled
by using the proper seal installation tools as
shown in the next two illustrations.
Press seals into housings using smooth, even

Figure 139 — Measuring Shift Rail pressure to prevent cocking or distorting the seal.
Gently press the seal into place. Correct
Oil Seals [321] installation depth is achieved as the driver tool
bottoms against the positioning tool as shown.
140
When an overhaul is required, replace all oil
seals. Be careful to ensure that the sealing
surface of any seal is not damaged, turned back
or cut. A nick on a shaft sealing surface can cut
the seal. Remove sharp edges that can damage
the seal (chamfer edges if possible).
Be careful when using any abrasive polishing

methods such as emery or crocus cloth on a
sealing surface. It is possible to leave micro-
grooves on the sealing surface. This can cause
oil to leak past the sealing lip(s) of the oil seal.
With this condition, a new seal will not stop the oil
leak.
Figure 140 — Main Drive Pinion Oil Seal Tools
Page 68
REPAIR INSTRUCTIONS
141
General Reassembly Instructions
Refer to “T305 Torque Specifications” on page
110 and “T305 Fits and Limits” on page 112 in the
SPECIFICATIONS section.
All working metal parts, especially the bearings,

should be coated with fresh, clean, specified gear
oil while the transmission is being reassembled.
This ensures immediate lubrication and helps
prevent parts seizure during initial start-up. (Refer
to Recommended SAE Grade Gear Oil in
Transmission Specifications and Capacities.)
When installing bearings, use proper bearing

drivers. When pressing a bearing onto a shaft,
Figure 141 — Mainshaft Rear Bearing Cover Oil Seal
Tools apply force only to the inner race of the bearing.
When pressing a bearing into a housing (bearing
cover), apply force only to the outer race. Do not
General Inspection apply force that is transmitted through the bearing
rollers, balls or cage. Damage and premature
A cracked transmission case should be replaced. bearing failure can result. Always apply even
Check all components for wear or damage. pressure to the bearing to prevent it from cocking
Replace all parts as required. Replace all or distorting during installation.
gaskets, O-rings and any part that shows
mutilation or damage. Repair all stripped threads As moving parts are installed, check the parts
using a thread repair insert that is compatible with frequently to see that they are moving freely.
patch-lock type capscrews.
Page 69
REPAIR INSTRUCTIONS
BENCH PROCEDURES — 2. Press the bearing until flush with the gear
surface. The bearing must not protrude on
TRANSMISSION COMPONENT either side of the gear surface. Verify that
REASSEMBLY the bearing is flush or below flush by using a
straightedge across the gear surface.
Reverse Idler Gear Reassembly
[322]
142 When reverse idler gear bearings are replaced, it
is also necessary to replace the reverse idler gear
shafts. The surface of the idler gear shaft is used
as the inner race of the needle bearing used in
the reverse idler gear.
144
Figure 142 — Reverse Idler Gear Locator View

143
Figure 143 — Exploded View of Reverse Idler Gear
1. Thrust Washer 3. Bearing Figure 144 — Pressing Bearing into Gear

2. Reverse Idler Gear 4. Reverse Idler Shaft
3. Verify correct fit of idler gear shaft to idler
The following reassembly procedure applies to all gear bearing. The gear should rotate freely
three reverse idler gears. on the shaft, with no binding or excessive
looseness.
1. Install a new bearing into the reverse idler
gear, using a leader or piloted-type
assembly tool or driver. Always assemble
the bearing with the stamped end
(identification marks) against the angled
shoulder of the press tool.
Page 70
REPAIR INSTRUCTIONS
Countershaft Rear Bearing Cover Countershaft rear bearing cover reassembly
applies to all countershaft rear bearing covers.
Reassembly [322]
r Press the bearing cup into the cover using a
145
suitable driver.
147
Figure 145 — Countershaft Rear Bearing Cover Locator

View
146
Figure 147 — Pressing Bearing Cup into Cover

Bearing Cover
1. Bearing Cup 3. Shim(s)

Page 71
REPAIR INSTRUCTIONS
Countershaft Reassembly [322] The following reassembly procedure applies to all
three countershafts.
148
1. Press a new bearing cup into the
countershaft main drive gear using a
suitable driver.
150
Figure 148 — Countershaft Locator View

149
Figure 150 — Pressing Bearing Cup into Gear

Figure 149 — Exploded View of Countershaft
2. Install the key into the keyway of the
1. Bearing Cup 6. Second Speed Gear countershaft using a soft-faced mallet.
2. Main Drive Gear 7. Bearing Cone 151
3. Fifth Speed Gear 8. Countershaft

5. Spacer
Do not attempt to press first or reverse gear

from the front countershaft. These gears are
integral with the shaft and could explode if
press pressure is applied.
Figure 151 — Installing Key
Page 72
REPAIR INSTRUCTIONS
3. Press a new bearing cone onto the rear end 153
of the countershaft using a suitable driver.

Apply force to the inner race of the bearing
only.
152
Figure 153 — Pressing Second Speed Gear onto

Countershaft
5. Install the second/third spacer (align spacer

keyway with key) and then press the third
Figure 152 — Pressing Rear Bearing Cone onto speed gear onto the countershaft.
Countershaft 154
4. Press the second speed gear onto the

countershaft.
Some second speed gears have a recess in one

side. The recess must face the rear end of the
countershaft when installed.
Figure 154 — Pressing Third Speed Gear onto

Countershaft
Page 73
REPAIR INSTRUCTIONS
6. Press the fifth speed gear onto the 7. Press the main drive gear onto the
countershaft. countershaft. The protruding hub of the gear
155
is placed next to the fifth speed gear.
156
Figure 155 — Pressing Fifth Speed Gear onto

Countershaft
Figure 156 — Pressing Main Drive Gear onto
Countershaft
Page 74
REPAIR INSTRUCTIONS
Countershaft Front Bearing Cover The following countershaft front bearing cover
reassembly procedure applies to all countershaft
Reassembly [322] front bearing covers.
157
1. Press a new bearing cone onto the
countershaft front bearing cover using a
suitable driver. Apply force to the inner race
of the bearing only.
159
Figure 157 — Countershaft Front Bearing Cover Locator

View
158
Figure 159 — Pressing Bearing onto Cover
2. Install the large O-ring onto the shoulder of

the front bearing cover.
160
Figure 158 — Exploded View of Front Countershaft

Front Bearing Cover
1. O-Ring 3. Front Bearing Cover

2. Bearing Cone
Figure 160 — Installing O-Ring onto Front Cover
Page 75
REPAIR INSTRUCTIONS
Mainshaft Rear Bearing Cover 1. Press a new oil seal into the mainshaft rear
bearing cover.
Reassembly [322] 163
161
Figure 161 — Mainshaft Rear Bearing Cover Locator

View
162
Figure 163 — Pressing Oil Seal into Mainshaft Rear

Bearing Cover
2. Install a new bearing into the cover using a

suitable driver. Apply force to the outer race
only.
164

Cover
1. Rear Bearing Cover 4. Bearing

2. Oil Seal 5. Snap Ring
3. Gasket
Figure 164 — Pressing Bearing into Rear Bearing Cover
Page 76
REPAIR INSTRUCTIONS
3. Install the snap ring that retains the bearing Mainshaft Reassembly [322]
into the rear bearing cover, using suitable
167
snap ring pliers.
165
Figure 167 — Mainshaft Locator View

Figure 165 — Installing Snap Ring 1. Install the inner race of the spigot bearing
using a suitable driver and press.
4. Install the mainshaft rear bearing cover 168
gasket, using sealant between the cover and
the gasket. Make sure to align the oil
passage holes in the gasket with the oil
passage holes in the cover.
166
Figure 168 — Installing Spigot Bearing Inner Race
2. Install the inner race snap ring using suitable

snap ring pliers.
Figure 166 — Installing Cover Gasket
Page 77
REPAIR INSTRUCTIONS
169

7. Bearing Inner Race 18. Thrust Washer 29. Thrust Washer
8. Front Mainshaft 19. Snap Ring 30. Snap Ring
10. Snap Ring 21. Thrust Washer 32. Mainshaft Spacer
11. Thrust Washer 22. First Speed Gear
Page 78
REPAIR INSTRUCTIONS
4. Continuing to work from the front of the
mainshaft, install the first/reverse sliding
clutch onto the mainshaft. Also, install the
On T305 mainshafts, it is not possible to build up first speed gear mainshaft snap ring into the
the mainshaft gears, thrust washers, sliding third groove from the rear of the shaft to
clutches and snap rings from the rear of the shaft. secure the sliding clutch in place.
The exceptions are the reverse gear and its 171
internal snap ring and the mainshaft spacer and

spacer snap ring. With these shafts, reassembly
should be done from the front of the shaft.
3. Working at the front of the mainshaft, install

the reverse speed gear external-toothed
thrust washer followed by the internal-
toothed thrust washer onto the mainshaft
and slide all the way to the rear. Oil grooves
on the external-toothed thrust washer face
forward. Also, install the reverse speed gear
mainshaft snap ring in the second groove
from the rear end of the mainshaft, using
suitable snap ring pliers.
170
Figure 171 — Installing Snap Ring and Sliding Clutch
5. Install the first speed gear internal-toothed

thrust washer, followed by the external-
toothed thrust washer onto the mainshaft
until they contact the first speed gear
mainshaft snap ring. Oil grooves on the
external-toothed thrust washer face
rearward.
172
Figure 170 — Installing Snap Ring and Internal- and

Figure 172 — Installing First Speed Gear Internal- and

External-Toothed Thrust Washer
1. First/Reverse Sliding 3. External-Toothed Thrust

Clutch Washer
2. Internal-Toothed Thrust
Washer
Page 79
REPAIR INSTRUCTIONS
6. Install the first speed gear onto the 10. Install the second speed gear external-
mainshaft with the clutch teeth facing toothed thrust washer (oil grooves toward
rearward. front of shaft) and internal-toothed thrust
washer over the mainshaft and into the gear.
7. Install the first speed gear internal snap ring 175
using suitable snap ring pliers.
8. Continuing to work from the front of the
mainshaft, install the second speed gear
with the clutch teeth facing forward.
173
Figure 175 — Installing External- and Internal-Toothed

Thrust Washers
11. Install the second speed gear mainshaft

snap ring into the fourth groove on the
Figure 173 — Installing Second Speed Gear mainshaft and then install the second/third
sliding clutch.
176
9. Install the second speed gear internal snap
ring using suitable snap ring pliers.
174
Figure 176 — Installing Second/Third Sliding Clutch
Figure 174 — Installing Second Speed Gear Snap Ring
Page 80
REPAIR INSTRUCTIONS
12. Install the third speed gear mainshaft snap 14. Install the internal snap ring into the snap
ring into the fifth groove from the rear on the ring groove of the third speed gear, using
mainshaft, using suitable snap ring pliers. suitable snap ring pliers.
177 179
Figure 177 — Installing Second/Third Sliding Clutch

Snap Ring
Figure 179 — Installing Third Speed Gear Snap Ring
13. Install the third speed gear internal-toothed
thrust washer and external-toothed thrust 15. Install the third speed gear onto the
washer onto the mainshaft (oil groove side mainshaft from the front of the shaft. The
of external washer faces rearward). clutch teeth on the gear should face
178 rearward.
16. Install the snap ring into the snap ring
groove of the fifth speed gear, using suitable
snap ring pliers.
180
Figure 178 — Installing Third Speed Gear Internal- and

Figure 180 — Installing Snap Ring into Fifth Speed Gear
Page 81
REPAIR INSTRUCTIONS
17. Install the external-toothed thrust washer 19. Install the snap ring (sixth groove from the
inside the fifth speed gear, with the oil rear of shaft) on the mainshaft for the fifth
groove side of the washer facing forward. speed gear.
181
Reverse speed gear, gear spacer and reverse

gear and spacer snap rings will be installed into
position on the mainshaft during mainshaft
installation into the case.
183
Figure 181 — Installing External-Toothed Thrust Washer
18. Install the fifth speed gear onto the

mainshaft with the clutch teeth of the gear
facing forward. Then install the internal-
toothed thrust washer.
182
Figure 183 — Installing Snap Ring
Figure 182 — Installing Fifth Speed Gear and

Internal-Toothed Thrust Washer
Page 82
REPAIR INSTRUCTIONS
Main Drive Pinion Reassembly [322] 1. Press the ball bearing onto the main drive
pinion shaft. Support the inner race of the
184
bearing while pressing.
186
Figure 184 — Main Drive Pinion Locator View

185
Figure 186 — Installing Main Drive Pinion Bearing
1. Press 4. Main Drive Pinion Shaft

2. Spacer Tube 5. Sleeve
3. Driver 6. Bearing
2. Install the spiral snap ring to retain the

bearing, using a circular motion while
pressing the snap ring into the groove on the
shaft.
187

6. Snap Ring
Figure 187 — Installing Spiral Snap Ring
Page 83
REPAIR INSTRUCTIONS
3. Position a new oil seal in the main drive 5. Press the main drive pinion shaft and
pinion bearing cover. bearing assembly into the main drive pinion
188
bearing cover.
190
Figure 188 — Positioning Bearing Cover Oil Seal
4. Install the main drive pinion bearing cover oil

seal, using a suitable driver and hammer.
189
Figure 190 — Installing Main Drive Pinion Assembly into

Pinion Bearing Cover
6. Install the main drive pinion bearing snap

ring using suitable snap ring pliers.
The large snap ring is very difficult to

compress and may fly off the snap ring pliers
causing injury.
Figure 189 — Installing Bearing Cover Oil Seal One side of the large snap ring is beveled and
faces out. The flat side of the snap ring goes
against the bearing.
Page 84
REPAIR INSTRUCTIONS
191
9. Install the main drive pinion gear onto the
pinion shaft, and install the spiral snap ring
using a circular motion while pressing the
snap ring tightly into the groove.
193
Figure 191 — Installing Snap Ring into Main Drive Pinion

Bearing Cover
7. Install the spigot bearing into the end of the

main drive pinion shaft by hand. Figure 193 — Installing Main Drive Pinion Gear and
Spiral Snap Ring
10. Install a new bearing cover gasket using

Drawn cup needle bearings (spigot bearings) sealant between the gasket and cover. Make
have a specific direction in which they must be sure the oil passage hole and capscrew
installed. The radius end of the bearing must be holes in the gasket align with the cover
installed first. The flat end of the bearing faces holes.
194
out.
8. Install the snap ring that retains the spigot

bearing.
192
Figure 194 — Installing Main Drive Pinion Bearing Cover

Gasket
Figure 192 — Installing Snap Ring
Page 85
REPAIR INSTRUCTIONS
Main Case Shift Cover Reassembly 2. Install the fourth/fifth pin and rocker arm.
197
[323]
195
Figure 195 — Main Case Shift Cover Locator View
1. Install the breather vent into the main case

shift cover.
196
Figure 197 — Installing Fourth/Fifth Pin and Rocker Arm
Figure 196 — Installing Breather Vent
Page 86
REPAIR INSTRUCTIONS
3. Install the fourth/fifth pivot pin lock washer, 199
flat washer and nut. Tighten nut to

40–50 lb-ft (54–68 N•m) torque.
198
Figure 199 — Tightening Nut
Figure 198 — Installing Washers and Nut
Page 87
REPAIR INSTRUCTIONS
200
1. 4th/5th Shift Fork 10. 4th/5th Rocker Arm 18. 1st/Reverse Shift Rail
7. 4th/5th Shifter 16. Pipe Plug 24. 1st/Reverse Shifter Ball
9. Washer
Page 88
REPAIR INSTRUCTIONS
4. Install the reverse light switch rod and 6. Slide the fourth/fifth shift rail into the cover.
reverse light switch. At the same time, install the fourth/fifth
201
shifter onto the shift rail.
203
Figure 201 — Installing Reverse Light Switch

Figure 203 — Installing Shift Rail and Shifter
5. Install the poppet ball and spring for the
fourth/fifth shift rail.
202
Figure 202 — Installing Poppet Ball and Spring
Page 89
REPAIR INSTRUCTIONS
7. Press the poppet ball down while sliding the 8. Align the setscrew in the fourth/fifth shifter
fourth/fifth shift rail over the ball. A hollow with the notch in the shift rail. Tighten the
tube works well to press down the ball. setscrew to 35–50 lb-ft (47–68 N•m) torque.
204 205
Figure 205 — Tightening Setscrew
Figure 204 — Pressing Poppet Ball Down 9. Slide the second/third shift rail into the shift
cover. At the same time, install the second/
third shift fork onto the shift rail.
206
Figure 206 — Installing Second/Third Shift Rail
Page 90
REPAIR INSTRUCTIONS
207
10. Install the interlock pin into the second/third
shift rail.
208
Figure 207 — Installing Second/Third Shift Fork Figure 208 — Installing Pin into Second/Third Shift Rail
Page 91
REPAIR INSTRUCTIONS
11. Install the interlock ball between the second/ 12. Install the poppet ball and spring for the
third shift rail and the fourth/fifth shift rail. second/third shift rail.
209 210
Figure 209 — Installing Interlock Ball Between Rails
Page 92
REPAIR INSTRUCTIONS
13. Press the poppet ball down while sliding the 14. Align the setscrew in the second/third shift
second/third shift rail over the ball. A hollow fork with the notch in the shift rail. Tighten
tube works well to press down the ball. the setscrew to 35–50 lb-ft (47–68 N•m)
211
torque.
212
Figure 211 — Pressing Poppet Ball Down

Page 93
REPAIR INSTRUCTIONS
15. Slide the first/reverse shift rail into the shift 17. Install the first/reverse shifter onto the shift
cover. At the same time, install the fourth/ rail behind the fourth/fifth shift fork.
fifth shift fork onto the shift rail. 215
213
Figure 215 — Installing First/Reverse Shifter
Figure 213 — Installing Fourth/Fifth Shift Fork
16. Install the poppet ball and spring into the

first/reverse shifter followed by the spring
and plunger. Depress the poppet ball and
spring in the shifter to allow the spring and
plunger to pass.
214
Figure 214 — Exploded View of First/Reverse Shifter
Page 94
REPAIR INSTRUCTIONS
18. Install the interlock ball between the first/ 19. Install the poppet ball and spring for the first/
reverse shift rail and the second/third shift reverse shift rail.
rail. 217
216
Figure 216 — Installing Interlock Ball

Page 95
REPAIR INSTRUCTIONS
20. Press the poppet ball down while sliding the 21. Install the first/reverse shift fork onto the
first/reverse shift rail over the ball. A hollow first/reverse shift rail.
tube works well to press down the ball. 219
218
Figure 219 — Installing First/Reverse Shift Fork
Figure 218 — Pressing Poppet Ball Down
Page 96
REPAIR INSTRUCTIONS
22. Continue sliding the shift rail as shown. 23. Align the setscrew in the first/reverse shifter
220
with the notch in the shift rail. Tighten the
setscrew to 35–50 lb-ft (47–68 N•m) torque.
221
Figure 220 — Sliding First/Reverse Shift Rail
Page 97
REPAIR INSTRUCTIONS
24. Align the setscrew in the first/reverse shift
fork with the notch in the shift rail. Tighten
the setscrew to 35–50 lb-ft (47–68 N•m)
torque.
222
Page 98
REPAIR INSTRUCTIONS
TRANSMISSION REASSEMBLY 3. Align the flat on the end of the reverse idler
shaft with the mark made along the edge of
PROCEDURES [320] the shim pack.
225
1. Temporarily position a shim pack over the
No. 3 position countershaft rear bearing
cover opening of the case and mark the
overhang of the shim to prevent interference
with the flat on the reverse idler shaft.
223
Figure 225 — Aligning Reverse Idler Shaft with Marks
4. Maintaining mark alignment, tap the reverse

idler shaft into the case until it bottoms,
using a brass hammer.
226
Figure 223 — Marking Shim Pack
2. Install the reverse idler shaft into the

opening provided next to the opening for the
No. 3 (lower) countershaft. As the reverse
idler shaft is inserted into the case, install (in
order) reverse idler gear and thrust washer
onto the shaft from inside the case.
224
Figure 226 — Tapping Reverse Idler Shaft into Place
5. Install the upper left through bolt using

silicone sealer on the threads. Tighten the
through bolt to 40–50 lb-ft (54–68 N•m)
torque. Install upper right through bolt if
removed.
Figure 224 — Order of Reverse Idler Shaft and

Components
Page 99
REPAIR INSTRUCTIONS
227
9. Install the No. 3 (lower) countershaft into the
transmission case by tipping into position.
228
Figure 227 — Installing Through Bolt
6. Locate the stamped letter “O” on the front of

each countershaft fifth speed gear. Paint the Figure 228 — Installing Lower No. 3 Countershaft into
Main Case
corresponding gear tooth on the front and
top with white paint. If there is no stamped
letter, mark the gear tooth that is directly in 10. Place the transmission in the vertical
line with the key between the gear and the position to center the countershaft over the
countershaft. front bearing.
7. Locate the three stamped letters on the front SETTING COUNTERSHAFT BEARING
face of the mainshaft fifth speed gear. Paint PRELOAD
the gear teeth on each side of the marked
11. Working at the rear of the No. 3 (lower)
tooth space. If there are no stamped letters,
countershaft, temporarily install the
count the number of gear teeth (result
countershaft rear bearing cover, leaving the
should be divisible by three). Paint three
capscrews loose. Do not use shims or
white marks, each 120 degrees apart, on the
O-rings at this time. Measure the space
gear face at the tooth spaces between the
between the cover and the transmission
teeth.
case using two feeler gauge sets. Two or
8. Install the No. 1 (upper right) and No. 3 more measurements should be taken to
(lower) countershaft front bearing covers average the results.
and capscrews (make sure O-rings are in
place). Tighten the capscrews to 36–54 lb-ft
(49–73 N•m) torque.
A more accurate measurement can be obtained if
the transmission is in a vertical position and the
cover is hand-held firmly against the countershaft
rear bearing.
Page 100
REPAIR INSTRUCTIONS
229
13. After determining the correct shim thickness,
install the O-ring and shim pack onto the
countershaft rear cover.
230
Figure 229 — Measuring Space Between Cover and

Case
12. Remove the cover and add enough shims to Figure 230 — Installing Shim Pack and O-Ring
bring the space under the cover to zero.
Then remove enough shim thickness to get 14. Install the No. 3 lower countershaft rear
the required 0.003–0.007 inch preload. cover by aligning and lightly tapping the
Example: cover in place. Tighten the bolts to
36–54 lb-ft (49–73 N•m) torque.
231
r Begin the procedure using no shims
under the cover.
r Measure space under the cover. For

this example the space is 0.100 inch.
r A 0.100 inch shim pack is needed to

“fill” the measured space.
r Remove (subtract) 0.003–0.007 inch

shims from the pack to get the specified
preload on the bearings.
r To obtain the required

0.003–0.007 inch preload, final shim
pack thickness must be
0.093–0.097 inch. Figure 231 — Installing Countershaft Rear Bearing
Cover
15. Install the No. 1 (upper left) reverse idler

shaft and gear as described in the steps for
Preload is “negative end play” or “crush.” It the lower reverse idler shaft and gear
cannot be measured directly. It must be done installation.
carefully, as described, to get the correct preload.
16. Tip into position the No. 1 countershaft
(upper left, when viewed from rear).
Page 101
REPAIR INSTRUCTIONS
17. Pry the No. 1 countershaft to the outside 20. Position the mainshaft, No. 3 (lower)
using a suitable pry bar. Block the rear end countershaft and No. 1 (upper left, when
of the countershaft off-center using a folded viewed from rear) countershaft so that the
rag. timing marks on the fifth speed gear of each
shaft are aligned. Roll the shafts into place
18. Install the mainshaft reverse gear into the
and make sure gear timing is correct.
case to prepare for mainshaft installation. 233
The reverse gear is free on the mainshaft and

can fall off during mainshaft installation. To
prevent it from falling off, place it in the case
before the mainshaft is installed.
19. Install the mainshaft into the case by first

lowering the rear end of the mainshaft into
the case. Then insert the rear end of the
mainshaft into and through the reverse gear.
232
Figure 233 — Timing the Gears with Mainshaft in Place
21. Install the No. 2 reverse idler shaft and gear

as described for the lower reverse idler shaft
and gear installation. Move the reverse
speed gear on the mainshaft as far forward
as possible. When installing the reverse idler
shaft and gear, make sure that the thrust
washer is held in place. Install the plug into
the reverse idler shaft if not previously done.
234
Figure 232 — Installing Mainshaft into Case
To ease mainshaft installation, tilt the

transmission with the front of the transmission
elevated slightly. This ensures that the reverse Figure 234 — Installing No. 2 Reverse Idler Shaft and
speed gear remains in place during mainshaft Gear
installation.
Page 102
REPAIR INSTRUCTIONS
22. Shift the first/reverse sliding clutch rearward 237
to allow the gear teeth on the reverse speed

gear and the reverse idler gears to engage.
Move the gear and sliding clutch toward the
rear until contact with the snap ring occurs.
Temporarily install a folded rag between the
first and reverse speed gears to hold them in
place.
Make sure that the previously installed reverse

gear external-toothed thrust washer engages the
gear splines correctly before sliding the reverse Figure 237 — Reverse Gear Snap Ring Installed
gear backwards.
235 24. Install the last snap ring into the groove on
the mainshaft, using suitable metric snap
ring pliers. Then, install the spacer (thrust
washer) onto the mainshaft against the snap
ring just installed.
The rear snap ring on the mainshaft requires

metric snap ring pliers for installation.
238
Figure 235 — Sliding First/Reverse Sliding Clutch and

Reverse Speed Gear to Engage Gear Teeth
23. Install the snap ring into the inside of the

reverse gear.
236
Figure 238 — Installing Last Snap Ring and Spacer onto

Mainshaft
Figure 236 — Installing Reverse Gear Snap Ring
Page 103
REPAIR INSTRUCTIONS
239
25. Install the mainshaft rear bearing cover and
gasket and tighten the capscrews to
40–50 lb-ft (54–68 N•m) torque.
241
Figure 241 — Tightening Mainshaft Rear Bearing Cover

Capscrews
26. Install the No. 2 (upper right) countershaft

and align the timing marks on the
countershaft with the marks on the
mainshaft. All three countershafts and
mainshaft timing marks should be aligned at
this point.
242
Figure 239 — Spacer Installation
1. Oil Groove 2. Oil Grooves Face

Forward
240
Figure 242 — Gear Timing Marks Aligned
Figure 240 — Reverse Gear Spacer Installed
Page 104
REPAIR INSTRUCTIONS
27. Install the No. 2 (upper left, as viewed from 29. Install the No. 1 (upper left) and No. 2 (upper
the front) countershaft front bearing cover right) countershaft rear bearing covers.
and capscrews making sure the O-ring is in Determine shim pack thickness for proper
place. Pull up on the countershaft with one bearing preload adjustment, as described
hand and wiggle the cover into place. A earlier for the No. 3 (lower) countershaft.
slight tap may be required to seat the cover. Tighten the rear cover capscrews to
36–54 lb-ft (49–73 N•m) torque.
30. Working at the front of the mainshaft, install
the fourth/fifth sliding clutch.
Do not attempt to pull cover into place using the 245
cover capscrews. Damage to the cover or

bearing can result.
243
Figure 245 — Installing Fourth/Fifth Sliding Clutch
31. Install the main drive pinion bearing cover

gasket. Make sure the rubber sealing
Figure 243 — Installing No. 2 Countershaft Front material on the gasket is facing the bearing
Bearing Cover
cover.
246
28. Tighten the No. 2 countershaft front bearing
cover capscrews to 36–54 lb-ft (49–73 N•m)
torque, using torque wrench J 1313-B or
equivalent.
244
Figure 246 — Installing Cover Gasket with Sealing

Material Facing Cover
Figure 244 — Tightening Countershaft Front Bearing

Cover Capscrews
Page 105
REPAIR INSTRUCTIONS
32. Align the main drive pinion bearing cover 34. Install the main drive pinion bearing cover
gasket. Make sure the hole in the cover capscrews. Then tighten to 36–54 lb-ft
gasket aligns with the oil passage in the (49–73 N•m) torque, using torque wrench
pinion cover. J 1313-B or equivalent.
247
Main drive pinions for these transmissions are

designed with 0.069–0.071 inch
(1.750–1.803 mm) (three degrees) backlash
between the shaft splines and the mating splines
of the main drive pinion gear. This amount of
backlash was designed to eliminate a rattling
noise that can occur when the engine is idling
with the clutch engaged.
249
Figure 247 — Aligning Cover and Gasket Oil Holes
33. Before installing the main drive pinion

assembly, make sure to align the oil
passage hole in the cover with the oil
passage hole in the case.
248
Figure 249 — Tightening Main Drive Pinion Bearing

Cover Capscrews
Figure 248 — Aligning Pinion Cover Oil Hole with Hole in

Case
Make sure the oil passageways in the gasket,

cover and case are aligned.
Page 106
REPAIR INSTRUCTIONS
35. Install the drive yoke (flange), clamp plate 39. Make sure the shifters on the top cover and
and retaining capscrew onto the rear of the the sliding clutches on the mainshaft are in
mainshaft. the neutral position for shift fork alignment.
250 251
Figure 250 — Installing Yoke (Flange) Clamp Plate and

Capscrew
To install the drive yoke (flange) retaining

capscrew, place at least two gears in the main Figure 251 — Main Shift Cover Assembly
case into engagement. This is done to lock the
gearing and prevent it from rotating while 40. Align the shift forks with the sliding clutches
tightening the drive yoke retainer. and install the transmission case top cover.
252
36. Reach into the main case top opening and

move at least two sliding clutches into
engagement. This locks two different gears
to the mainshaft and prevents the gears and
shaft of the transmission from rotating.
37. Tighten the drive yoke (flange) to the
specified torque. When finished, make sure
all gear sliding clutches are returned to the
normal neutral positions.
38. Install a new transmission case top cover
gasket. Use a small amount of adhesive or
grease to hold it in place.
Figure 252 — Installing Case Top Cover
Page 107
REPAIR INSTRUCTIONS
41. Install the lifting brackets at the front and 42. Install the remaining top cover capscrews
rear of the transmission case top cover as and tighten to 24–36 lb-ft (33–49 N•m)
shown. torque.
254
The lift bracket capscrews are slightly longer than

the remainder of the top cover capscrews. Make
sure the longer capscrews are used to secure the
lift brackets.
253
Figure 254 — Tightening Top Cover and Lift Bracket

Capscrews
Figure 253 — Lifting Bracket Placement
1. Front Lift Bracket 2. Rear Lift Bracket
Page 108
SPECIFICATIONS
SPECIFICATIONS
Page 109
SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
T305 Torque Specifications
255
Figure 255 — T305 Torque Specifications
Item Location Torque — Lb-Ft (N•m)

1 Main Drive Pinion Bearing Cover Capscrews* 36–54 (49–73)
2 Top Cover Capscrews* 24–36 (33–49)
3 Fourth/Fifth Rocker Pin Locknut 40–50 (54–68)
4 Shifter and Shift Fork Setscrews 35–50 (47–68)
5 Upper Through Bolt* 40–50 (34–68)
6 Mainshaft Rear Bearing Cover Capscrews* 40–50 (54–68)
7 Drive Flange (or Yoke) Clamp Plate Capscrew 494–600 (670–814)
8 Countershaft Rear Bearing Cover Capscrews* 36–54 (49–73)
9 Drain Plug 25–30 (34–41)
10 Countershaft Front Bearing Cover Capscrews* 36–54 (49–73)
— Filler Plug 35–50 (47–68)
— Magnetic Filter Plug 20–23 (27–31)
— Transmission Case 8-Hole PTO Cover Screws* 36–54 (49–73)
— Transmission Case 6-Hole PTO Cover Screws* 24–36 (33–49)
* Indicates that fastener has epoxy-coated threads. Fastener can be reused a maximum of five times.
Page 110
SPECIFICATIONS
T305 Gear Identification
256
Figure 256 — Gear Identification
GEAR IDENTIFICATION CHART

Mainshaft Gears Number of Teeth Outside Diameter (Inches)
1. Main Drive Pinion (Fourth-Straight Through) 36 6.162
2. Fifth Speed 27 4.692
3. Third Speed 48 7.630
4. Second Speed 51 9.156
5. First Speed 57 10.307
6. Reverse 54 9.601
Countershaft Gears
7. Main Drive Gear (Fourth) 43 7.052
8. Fifth (PTO) 54 8.514
9. Third 33 5.487
10. Second 20 3.952
11. First 13 2.814
12. Reverse Idler 24
13. Reverse 12 2.625
Page 111
SPECIFICATIONS
T305 Fits and Limits
ALL FORKS AND SLIDING CLUTCHES
Minimum New Maximum New Maximum Wear

Clearance between fork pad 0.005 inches 0.020 inches 0.050* inches
and clutch groove
*If unit has experienced disengagement, clearance must not exceed 0.030 inches maximum.
257
Figure 257 — Shift Fork and Sliding Clutch Clearance

Example
Page 112
SPECIFICATIONS
SHIFT RAILS TO SHIFT COVER BORES
258
Figure 258 — Main Case Shift Cover and Shift Rail Clearance Example
SHIFTER AND POPPET BALL SPRING LENGTHS
Springs Free Length (A) Load (B) Length Under Load (C)
First/Reverse Shifter Ball Spring 1.562 in. 41.8 ± 5 lbs. 0.875 in.
First/Reverse Shifter Plunger Spring 1.500 in. 22.0 ± 2 lbs. 0.625 in.
Shift Rail Poppet Ball Springs (3) 2.251 in. 42.4 ± 3 lbs. 1.539 in.
Page 113
SPECIFICATIONS
259
Figure 259 — Checking Spring Length Under Load
Page 114
SPECIFICATIONS
General Tolerances
260
Figure 260 — T305 Transmission General Tolerances
Component Specification
1. Mainshaft Third-to-Fifth Speed Gear (Floating Gear) End 0.024–0.081 inch
Play
2. Mainshaft First-to-Second Speed Gear (Floating Gear) 0.020–0.080 inch
End Play
3. Mainshaft Reverse Gear-to-Gear Spacer (Floating Gear) 0.015–0.095 inch (shaft seated)
End Play
4. Reverse Idler Gear 0.010–0.090 inch (shaft flush with case wall)
5. Countershaft Bearing Preload 0.003–0.007 inch
Page 115
SPECIFICATIONS
Transmission Specifications and Capacities
Make Mack Trucks, Inc.

Model T305 (5-Speed Overdrive)
Type Overdrive, Triple Countershaft
Dry Weight 444 Lbs. (201 kg)
Control Selective, One Lever Manual
Speeds Five Forward, One Reverse
Bell Housing SAE No. 1, Integral with Main Case
Case Cast Aluminum, Heat Treated
Gear Type Spur
Seal Type Positive Lip
Shaft Splines Fine Pitch Rolled Involute
Lubrication Splash Lubrication
Oil Filter Magnetic Filter Plug
Drain Plug Magnetic
Power Take-Off Provisions:
Left Side STD. SAE 8-Hole
Right Side STD. SAE 6-Hole
Option Rear PTO Drive
Oil Capacity Approx. 20 Pints (Depends on angle of installation in chassis)
Recommended SAE grade gear oil for all

temperature operations:
Mack® GO-J and GO-J Plus* or TO-A PLUS*

specification
r 90, 140, 80W-90, 80W-140, 85W-140 for
Mineral Base
r SAE 50, 75W-90, 75W-140, 80W-140 for
Synthetic Base
* GO-J Plus and TO-A PLUS is required for Mack

geared component extended service drain
intervals.
Visit Mack Trucks, Inc. internet web site at

www.macktrucks.com for MACK-approved oil
suppliers.
Page 116
SPECIAL TOOLS & EQUIPMENT
Page 117

SPECIAL TOOLS
TOOLS
J 34629 Snap Ring Pliers Set
J 34630 Reverse Idler Shaft Removal Tool
J 29048 Tapered Feeler Gauge
J 29369-1 Bearing Puller
J 29369-2 Bearing Puller
J 2619-01 Slide Hammer
J 39477-1 Bar-Type Puller
J 8176 Bearing Separator
J 24407 30–250 lb-ft Torque Wrench
J 7379 100–600 lb-ft Torque Wrench
OEM-4052 Internal Puller
J 07804-A Drive Yoke and Flange Puller
Above tools are available from:
KENT-MOORE
O.E. TOOL & EQUIPMENT GROUP
SPX CORPORATION
28635 MOUND ROAD
WARREN, MICHIGAN 48092-3499
Phone: 1-800-328-6657
Fax: 1-800-578-7375
Page 118
DISASSEMBLED VIEWS
DISASSEMBLED VIEWS
Page 119
DISASSEMBLED VIEWS
TRANSMISSION DISASSEMBLED VIEWS [320]
261
1. 4th/5th Shift Fork 10. 4th/5th Rocker Arm 18. 1st/Reverse Shift Ball
7. 4th/5th Rocker Shifter 16. Pipe Plug 24. 1st/Reverse Shifter Ball
9. Washer
Page 120
DISASSEMBLED VIEWS
262

6. Snap Ring
Page 121
DISASSEMBLED VIEWS
263
1. Snap Ring 12. Thrust Washer — Internal-Toothed 23. Thrust Washer — Internal-Toothed
2. Thrust Washer — Internal-Toothed 13. Snap Ring 24. Snap Ring
4. Thrust Washer — External-Toothed 15. Snap Ring 26. Snap Ring
5. Snap Ring 16. Thrust Washer — Internal-Toothed 27. Thrust Washer — Internal-Toothed
7. Bearing Inner Race 18. Thrust Washer — External-Toothed 29. Thrust Washer — External-Toothed
8. Front Mainshaft 19. Snap Ring 30. Snap Ring
10. Snap Ring 21. Thrust Washer — External-Toothed 32. Thrust Washer (Spacer)
11. Thrust Washer — External-Toothed 22. First Speed Gear
Page 122
DISASSEMBLED VIEWS
264 266

Cover Figure 266 — Exploded View of Countershaft
1. Rear Bearing Cover 4. Bearing 1. Bearing Race 6. Second Speed Gear

2. Oil Seal 5. Snap Ring 2. Main Drive Gear 7. Bearing Cone
3. Gasket 3. Fifth Speed Gear 8. Countershaft
265
5. Spacer
267
Figure 265 — Exploded View of Countershaft Front

Bearing Cover
1. O-Ring 3. Front Bearing Cover Bearing Cover
2. Bearing
1. Bearing Cup 3. Shim
Page 123
DISASSEMBLED VIEWS
268
Figure 268 — Exploded View of Reverse Idler Gear
1. Thrust Washer 3. Bearing

2. Reverse Idler Gear 4. Reverse Idler Shaft
Page 124
Index.fm Page 125 Tuesday, September 10, 2002 3:01 PM
INDEX
INDEX
Page 125
INDEX
A L
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . .2 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 17
AIR BREATHERS . . . . . . . . . . . . . . . . . . . . . .28
M
B
MAGNETIC OIL FILTER PLUG . . . . . . . . . . . 28
BEARINGS [322] . . . . . . . . . . . . . . . . . . . . . . .67 MAIN CASE SHIFT COVER
BENCH PROCEDURES — TRANSMISSION DISASSEMBLY [323] . . . . . . . . . . . . . . . . 38
COMPONENT DISASSEMBLY . . . . . . . . .38 MAIN CASE SHIFT COVER
BENCH PROCEDURES — TRANSMISSION REASSEMBLY [323] . . . . . . . . . . . . . . . . . 86
COMPONENT REASSEMBLY . . . . . . . . .70 MAIN DRIVE PINION
DISASSEMBLY [322] . . . . . . . . . . . . . . . . 51
C MAIN DRIVE PINION
CHANGING OIL . . . . . . . . . . . . . . . . . . . . . . . .27 REASSEMBLY [322] . . . . . . . . . . . . . . . . . 83
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .26 MAINSHAFT DISASSEMBLY [322] . . . . . . . . 54
CONVERSION CHART . . . . . . . . . . . . . . . . . . .6 MAINSHAFT REAR BEARING COVER
COUNTERSHAFT DISASSEMBLY [322] . . . .62 DISASSEMBLY [322] . . . . . . . . . . . . . . . . 59
COUNTERSHAFT FRONT BEARING MAINSHAFT REAR BEARING COVER
COVER DISASSEMBLY [322] . . . . . . . . . .61 REASSEMBLY [322] . . . . . . . . . . . . . . . . . 76
COUNTERSHAFT FRONT BEARING MAINSHAFT REASSEMBLY [322] . . . . . . . . . 77
COVER REASSEMBLY [322] . . . . . . . . . .75
O
COUNTERSHAFT REAR BEARING
COVER DISASSEMBLY [322] . . . . . . . . . .65 OIL SEALS [321] . . . . . . . . . . . . . . . . . . . . . . . 68
COUNTERSHAFT REAR BEARING
COVER REASSEMBLY [322] . . . . . . . . . .71 R
REVERSE IDLER GEAR
D
DISASSEMBLY [322] . . . . . . . . . . . . . . . . 66
DESCRIPTION AND OPERATION . . . . . . . . .14 REVERSE IDLER GEAR
DESCRIPTION OF TRANSMISSION REASSEMBLY [322] . . . . . . . . . . . . . . . . . 70
STAMP . . . . . . . . . . . . . . . . . . . . . . . . . . .11
DOUBLE CLUTCHING . . . . . . . . . . . . . . . . . .15 S
SAFETY INFORMATION . . . . . . . . . . . . . . . . . 2
E
SERVICE PROCEDURES AND
EXPLANATION OF NUMERICAL CODE . . . . .5 TOOL USAGE . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF THREE-DIGIT SHIFTER FORKS, SLIDING CLUTCHES
NUMERICAL CODE . . . . . . . . . . . . . . . . . .5 AND SHIFT RAILS [323] . . . . . . . . . . . . . . 67
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 118
G
T
GEAR RATIOS AND SHIFT PATTERN . . . . .15
GENERAL INSPECTION . . . . . . . . . . . . . . . . .69 T305 FITS AND LIMITS . . . . . . . . . . . . . . . . 112
GENERAL REASSEMBLY T305 GEAR IDENTIFICATION . . . . . . . . . . . 111
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . .69 T305 POWER FLOW DIAGRAMS . . . . . . . . . 16
GENERAL TOLERANCES . . . . . . . . . . . . . .115 T305 SHIFTING INSTRUCTIONS . . . . . . . . . 15
T305 TORQUE SPECIFICATIONS . . . . . . . . 110
I T305 TRANSMISSION . . . . . . . . . . . . . . . . . . 14
INSPECTION AND CLEANING . . . . . . . . . . . .67 TRANSMISSION DISASSEMBLED
INSPECTION OF PARTS . . . . . . . . . . . . . . . .67 VIEWS [320] . . . . . . . . . . . . . . . . . . . . . . 120
Page 126
INDEX
TRANSMISSION DISASSEMBLY TRANSMISSION SPECIFICATIONS . . . . . . 110
PROCEDURES [320] . . . . . . . . . . . . . . . . .30 TRANSMISSION SPECIFICATIONS
TRANSMISSION IDENTIFICATION . . . . . . . .10 AND CAPACITIES . . . . . . . . . . . . . . . . . . 116
TRANSMISSION MAINTENANCE . . . . . . . . .26 TROUBLESHOOTING CHARTS . . . . . . . . . . 22
TRANSMISSION MAJOR COMPONENT
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .20 U
TRANSMISSION REASSEMBLY UNIT IDENTIFICATION STAMPING . . . . . . . . 10
PROCEDURES [320] . . . . . . . . . . . . . . . . .99
Page 127
NOTES
Page 128
TRANSMISSION
T305
SERVICE MANUAL
PRINTED IN U.S.A.
10-115 © MACK TRUCKS, INC. 2003

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TRANSMISSION

T305 JANUARY 2003

SERVICE MANUAL (NEW ISSUE)

PLEASE LET US KNOW!

Thank You For Your Assistance

DO NOT STAPLE — USE TRANSPARENT TAPE

FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE

BUSINESS REPLY MAIL

POSTAGE WILL BE PAID BY ADDRESSEE

SERVICE PUBLICATIONS (RTS), 6S3

FOLD ALONG THIS LINE

JANUARY 2003 © MACK TRUCKS, INC. 2003

Activities associated with Danger indicate that death or serious personal

A procedure, practice, or condition that is essential to emphasize.

Numerical Code Example

Figure 1 — Location of Identification Stamping on Left Side of Case

The following model code information is stamped

Figure 2 — Unit Identification Stamping

Figure 3 — Cutaway View of T305 Transmission

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

DESCRIPTION AND OPERATION

This transmission consists of a compact

The transmission case and bell housing are a

DESCRIPTION AND OPERATION

Figure 5 — T305 Transmission Shift Pattern

T305 GEAR RATIOS

T305 Shifting Instructions Double Clutching

DESCRIPTION AND OPERATION

Figure 9 — Fourth Speed

Figure 6 — First Speed

Figure 10 — Fifth Speed

Figure 7 — Second Speed

Figure 11 — Reverse Speed

Figure 8 — Third Speed

DESCRIPTION AND OPERATION

Figure 12 — Splash Lubrication

TRANSMISSION CASE OIL COOLER LINE 13

The oil cooler system is required when the

On transmissions that are not built with oil cooler

DESCRIPTION AND OPERATION

Figure 14 — Plug Locations

1. Magnetic Filter Plug 3. Oil Drain Plug

Figure 15 — Component Locations for T305 Transmissions

Perform oil level check when the oil is at

r To check the oil level in the transmission,

Figure 18 — Incorrect Oil Level

r Add specified make-up oil, if needed, until

1. Magnetic Filter Plug (Not 2. Oil Filler and Check Plug

Be sure to add oil to the transmission through the

Figure 19 — Plug Locations

1. Magnetic Filter Plug 3. Oil Drain Plug

Unless a complete overhaul is necessary, remove

1. Clean the transmission externally and mount

Figure 21 — Removing Case Cover Capscrews

Figure 23 — Removing Clamp Plate and Capscrew

6. Remove the drive yoke (flange), using a

Figure 25 — Mark Front Countershaft Bearing Covers