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SUBJECT
DATE
Split Rod Bushing Repair
October 2015
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0140
Platform
Section Title
DT12
Transmissio Split Rod Bushing Repair
n
All information subject to change without notice.
10 11-15 Copyright © 2015 DETROIT DIESEL CORPORATION
Change
This is a new section.
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2 Split Rod Bushing Repair
2
Split Rod Bushing Repair
NOTE: You may also refer to video on DDCSN Support/Multimedia/DT12 Transmission Split-Pin Bushing Repair
for tool usage and procedure.
Required tools - 11.5mm drill bit, 12mm ream bore, and a brass hammer.
Repair as follows:
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2.
3.
4.
5.
6.
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Disconnect the main and auxiliary batteries, if equipped.
Remove the transmission. Refer to section "Removal of the Transmission".
Remove the Shift Controller. Refer to section "Removal of the Shift Controller".
Remove the Shift Actuator.
Install drill jig.
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 10 11-15
10 11-15
7. Coat a paper rag with heavy grease and place it inside the transmission housing, in such a way to retain the chips
created by drilling out the transmission case.
NOTICE: The original bore diameter is almost the same diameter of the drill. During the drilling process the bit will
have the tendency to grab and twist, potentially pointing the drill away from the intended centerline of the hole.
Control the plunge rate and drill rpm to reduce the risk of damage to the case.
NOTE: The guide block is sized to control the ream diameter; the drill needs to be visually centered in the block
while drilling.
8. Grease the drill bit and bore the hole. Use high revs, keep the drill centered in the block, and slowly plunge through the
case.
9. Clear the loose chips and remove the rag.
All information subject to change without notice.
10 11-15 Copyright © 2015 DETROIT DIESEL CORPORATION
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2 Split Rod Bushing Repair
10.
11.
12.
13.
14.
Grease the reamer and a new catch rag.
Ream the hole, using low revs, taking time to clean and re-grease as needed.
Clear any loose chips and remove the rag.
Remove the guide block and clean the any remaining chips and grease.
Install the split bushing, with the split in the 12 o'clock (1), until flush with the outer surface of the case.
15.
16.
17.
18.
19.
Test fit the split rod, to confirm it fits correctly in the bushing.
Install the shift actuator.
Coat the shift pin with transmission oil and install it.
Install the shift controller. Refer to section "Installation of the Shift Controller".
Install the transmission. Refer to section "Installation of the Transmission".
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
20. Connect the batteries.
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
21. Start the engine and charge the air system.
22. Perform the transmission learn procedure.
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All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 10 11-15
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