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Fuller® Heavy-Duty Transmissions TRSM0670 EN-US

1. 121 How to Remove a Roadranger Valve 83 How to Disassemble the Range Cylinder Assembly How to Install a Roadranger Valve 84 SB TIES 124 How to Remove a Slave Valve 85 How to Disassemble the Range Cylinder Assembly How to Install a Slave Valve 86 125 How to Remove the Top 2 Valve Assembly How to Assemble the Range Cylinder Assembly 127 Transmissions with Top 2 Option Only 87 Table of Contents Transmission Overhaul Procedures Bench Service How to Disassemble the Gear Shift Lever 130 How to Assemble the Gear Shift Lever 132 How to Remove the Shift Bar Housing 134 How to Install the Shift Bar Housing 136 How to Disassemble the Standard Shift Bar FIGUSING a tito 138 How to Assemble the Standard Shift Bar Housing 141 How to Assemble the Forward Shift Bar Housing 144 How to Disassemble the Forward Shift Bar Housing 147 How to Remove the Input Shaft Assembly without Main Case disassembly 150 How to Install the Input Shaft Assembly without Main Case disassembly 152 How to Remove the Auxiliary Section with Tapered Bearings 2 2 154 How to Remove the Splitter Cylinder Assembly
2. 49 Air System Procedure 5 Symptom No or Slow Range Shift into Low Normal Operation When the Range Selector on the Shift Knob is moved down to select Low Range air pressure will flow through the Shift Knob to the P port on the Slave Valve The Slave Valve will direct air pressure through the Low Range 1 4 Rubber Hose to the Range Cylinder to shift the range There will be a brief burst of air at the Slave Valve as the High Range side of the Range Piston exhausts Likewise when High Range is selected the air pressure in the P will be exhausted at the Shift Knob This will cause the Slave Valve to direct air to the rear side of the Range Cylinder Piston The air pressure on the Low Range side will be exhausted at the Slave Valve Possible Causes Incorrect Air Line hook up Insufficient air supply to Transmission Damaged or defective Air Filter Regulator Assembly Damaged or defective Shift Knob Master Valve Damaged or defective Slave Valve Damaged or defective Range Cylinder Damaged or defective range Yoke or Yoke Bar Damaged or defective Range Synchronizer Damaged or defective gearing in Auxiliary Section of Transmission Table 14 No or Slow Range Shift into Low disconnected line Procedure Result What to Do Next Step A Place the Shift Lever in Neutral Constant air leak is detected Go to the other corresponding Check for constant air leakage at the symptom first See beginning
3. 19 Install the three 3 Tension Balls one in each Housing top Bore Install the three 3 Detent Springs one over each Tension Ball Note Make sure Interlocking System is working should not shift into 2 gears at the same time Note Make sure all Lock Screws are lockwired 143 Transmission Overhaul Procedures Bench Service How to Assemble the Forward Shift Bar Housing Special Instructions Inspect Shift Blocks and Shift Yokes for wear Apply Sealant 71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes The sealant should be applied so at least 5 complete threads are covered Apply Eaton Lockwire 1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes The wire should anchor the Cap Screw at least 2 complete 360 turns The Lockwire ends should be trimmed and bent out of the way of any part Keep Yoke Bars in Neutral while assembling Special Tools e Vise with brass jaws or wood blocks Procedure 1 Assemble the Yoke Actuator Assembly 2 From the Shift Bar Housing bottom install the Actuator Pin and Yoke Actuator 3 OntheShift Bar Housing top install the Washer and Nut 144 10 11 12 13 14 Transmission Overhaul Procedures Bench Service Assemble the 1st and Reverse Shift Yoke Assembly e Install the plunger in the 1st and Reverse Shift Yoke Bore Plunger Shank to the out
4. 2 lt gt Transmission Overhaul Procedures Bench Service How to Remove the Integral Oil Pump Special Instructions None Special Tools e Typical Service Tools Procedure 1 Remove the Cap Screws holding the Suction and Auxiliary Oil Tubes in position 2 Straighten Tube Lock on Suction Tube 3 Remove Suction Tube from Oil Pump If necessary remove O Ring from Suction Tube 226 Transmission Overhaul Procedures Bench Service 4 Remove three 3 Allen Head Cap Screws and Washers that retain the Integral Oil Pump to the Case 5 Remove the Integral Oil Pump Assembly from inside the Case 6 Remove the Integral Oil Pump Retainer Plate from inside the Case 7 If necessary the Front Case Plug can be removed from the case To remove insert a Bar from inside the Case and tap the Plug out 8 Inspect the plug O Ring for cracks and pitting Replace if damaged 227 Transmission Overhaul Procedures Bench Service How to Install the Lower Countershaft Bearings Special Instructions The Lower Reverse Idler Assembly should be installed before the Lower Countershaft The Front Bearing Inner Race must be pressed on the Countershaft front The Flanged End Driver must cover the Bearing Outer Race for proper installation Special Tools e RR1012TR 2 Bearing Driver front e RR1012TR 4 Bearing Driver rea
5. Sealant 71208 or equivalent to the Shift Bar Housing Plugs which are used to plug Oil Cooler provision holes The sealant should be applied so at least 5 complete threads are covered Apply Eaton Lockwire 1819 or equivalent to all Shift Bar Housing Assembly Set Screws in both Blocks and Yokes The wire should anchor the Cap Screw at least 2 complete 360 turns The Lockwire ends should be trimmed and bent out of the way of any part interference Keep Yoke Bars in Neutral while assembling Special Tools e Vise with brass jaws or wood blocks Procedure 1 Assemble the Yoke Actuator Assembly 2 From the Shift Bar Housing bottom install the Actuator Pin and Yoke Actuator y e o 5 5 5 29 zs 25 9 3 On the Shift Bar Housing top install the Washer and Nut 141 Transmission Overhaul Procedures Bench Service 142 4 10 11 12 13 14 Assemble the 1st and Reverse Shift Yoke Assembly e Install the Plunger in the 1st and Reverse Shift Yoke Bore Plunger Shank to the outside e Install the Spring into the Bore over the Plunger Shank e Install the Plug and tighten to compress the Spring e After Plug bottoms out back the plug out 1 to 1 1 2 turns e Complete the Block Assembly process by staking the plug through the small hole in Block With the Housing rear to the right lay the Assembly on a flat surface
6. 156 How to Remove the Auxiliary Countershaft Assembly e ets 158 How to Remove the Splitter Gear 161 How to Disassemble the Range Cylinder Assembly 162 How to Disassemble the Output Shaft Assembly 164 How to Disassemble the Synchronizer Assembly 167 How to Assemble the Synchronizer Assembly 168 How to Assemble the Output Shaft Assembly 170 How to Install the Splitter 172 How to Assemble the Range Cylinder Assembly 173 How to Install Splitter Cylinder Assembly 176 How to Install the Auxiliary Countershaft Assembly 179 How to Disassemble the Splitter Gear Bearing ASsembly ids 182 How to Assemble the Splitter Gear Bearing Assembly ERAS 183 How to Remove the Auxiliary Drive Gear Assembly 184 How to Remove the Clutch Housing with Internal Oil Tube 22020 186 How to Disassemble the Upper Reverse Idler Gear Assembly 189 How to Disassemble the Lower Reverse Idler Gear Assembly 22 191 How to Remove the Upper and Lower Countershaft Bearings 192 How to Remove the Mainshaft Assembly 194 How to Remove the Countershaft Assemblies 195 How to Disassemble the Countershaft Assemblies 197 How to Remove the Input Shaft and Main Drive 199 How
7. 2 96 Disconnect the wiring from the Switch Connect an Ohm Meter to check for continuity Place the Transmission Shift Lever in any position except Reverse If the Switch is working properly the Ohm Meter should read Open or Infinity If it is not remove the Switch and recheck it for continuity Replace as necessary Place the Transmission Shift Lever in the Reverse position If the Switch is working properly the Ohm Meter should register continuity or a small reading If it does not remove the Switch and recheck it for continuity Replace it as necessary Also check for sticking or excessive wear of the Reverse Pin How to Remove the Reverse Switch Special Instructions None Special Tools e Typical Service Tools Procedure 1 2 Remove 2 screws retaining wire terminals Remove the switch using a 7 8 Deep Well Socket or Box End Wrench In Vehicle Service Procedures 1 e 1 m rJ v rJ 1 a 9 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 97 In Vehicle Service Procedures How to Install the Reverse Switch Special Instructions None Special Tools e Typical Service Tools 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 98 1 Insert the Reverse Pin in the Reverse Switch Bore 2 Install new Gasket on Switch 3
8. Note When removing washer and Reverse Gear note their orientation Keep the Washer with the Reverse Gear 5 Remove the 1st and Reverse Sliding Clutch 202 Transmission Overhaul Procedures Bench Service 6 Remove the Offset Washer and 1st Gear 7 Remove the Flat Washer and 2nd Gear 8 Remove the Offset Washer and Sliding Clutch 9 Remove the Offset Washer and 3rd Gear 10 Remove the Flat Washer E e 5 Oo 5 i ue 5 5 2o o 1 ez 11 Remove the 4th or Overdrive Gear 12 Remove the Offset Washer 203 Transmission Overhaul Procedures Bench Service How to Disassemble the Mainshaft Assembly with Low Force Gearing Special Instructions The design of the Mainshaft with Low Force Gearing is slightly different from the standard Mainshaft It still utilizes Non Selective non adjustable Tolerance Washers but the 1st and Reverse Gears and Sliding Clutch have been redesigned In this configuration the 1st Reverse Sliding Clutch rides on a Clutch Hub and the 1st and Reverse Gears have been redesigned to accommodate this change Lay all parts on a clean bench in order of removal to facilitate assembly Special Tools e Typical Service Tools Procedure 1 Laythe Mainshaft on its side and from the front remove the 4th or Overdrive and 5th Sliding Clutch 2 Place the Mainshaft in a vertical position pilot end down Remove the Reverse
9. 37 Air System Shift Knob 9 Speed This Shift Knob contains one switch 1 The Range Selector Lever on the front of the Shift Knob is moved down to select Low Range When the Range Selector Lever is moved up High Range is selected 5 4 Component Nomenclature and Shift Knob Sectional View 1 Medallion 7 Retainer 2 Spring 8 O Ring 3 Lever 4 Cover 5 Screw 6 Ball 5 32 38 Air System Air Filter Regulator The Filter Regulator Assembly filters the vehicle supply air and regulates the pressure to 58 63 PSI Two holes in the front face of the Filter Regulator Assembly supply air to the Range Cylinder Cover The Filter Element can be removed by turning out the End Cap lt 5 D 5 5 3 gt 6 gt Component Nomenclature and Filter Regulator Sectional View 1 End Cap 4 Housing 2 O Rings 5 Cap Screws 3 Filter Element 6 Air Regulator 39 Air System Slave Valve The Slave Valve controls the supply of air to the Low and High Range sides of the Range Shift Cylinder A small Air Line from the Shift Knob Master Control Valve provides a signal pressure to the Slave Valve 19 18 sy e Cry OR 15 is Component Nomenclature and Slave Valve Countershaft Sectional View 1 Slave Valve Housing 11 Gasket 2 U Seal 12 Seal 3 Washer 13 O Ring 4 Spring 14 Piston 5 Plug 15 U Seal 6 Snap Ring 16 Cap 7 O Rings 17
10. e Check Yokes for correct alignment Replace sprung Yokes e Check lock screw in Yoke and Blocks Tighten and rewire those found loose e f Housing has been disassembled check Neutral Notches of Shift Bars for wear from Interlock Balls Sliding Clutches e Check all Shift Yokes and Yoke slots in Sliding Clutches for extreme wear or discoloration from heat e Check engaging teeth of Sliding Clutches for partial engagement pattern Splines e Check Splines on all shafts for abnormal wear If Sliding Clutch gears Companion Flange or Clutch Hub has wear marks in the Spline sides replace the specific shaft effected Synchronizer Assembly e Check Synchronizer for burrs uneven and excessive wear at contact surface and metal particles e Check Blocker Pins for excessive wear or looseness e Check Synchronizer contact surfaces on the Synchronizer cups for wear Washers e Check surfaces of all washers Washers scored or reduced in thickness should be replaced Introduction Assembly Precautions Make sure that Case interiors and Housings are clean It is important that dirt and other foreign materials are kept out of the Transmission during assembly Dirt is an abrasive and can damage polished surfaces of Bearings and Washers Use certain precautions as listed below during assembly Axial Clearances e Maintain original Axial Clearances of 0 006 0 015 in for Mainshaft Gears Bearings e UseaFlange End Bearing Driver fo
11. 1 wo Special Tools e Typical Service Tools Procedure 1 Exhaustthe Vehicle Air Tanks before continuing 2 Loosenthe nuton the fitting and slide it back out ofthe way Pull the Air Line and attached Collet from the fitting 4 Inspect the fitting Air Line Collet and Nut for damage or 1 Connector wear Replace as necessary 2 Collet 3 Nut 4 Air Line 75 In Vehicle Service Procedures How to Install Compression Type Fittings Special Instructions WARNING Asudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the Vehicle Air Tanks CAUTION Small Air Lines are available in 1 8 or 5 32 sizes Make sure 1 8 Air Lines are used with 1 8 Fittings and 5 32 Air Lines are used with 5 32 Fittings Mixing sizes can cause air leaks or damage to Fittings Special Tools e Typical Service Tools Procedure 1 Check the threads of the fitting for thread sealant If no sealant is present apply Eaton Thread Sealant 71205 or equivalent 2 Install the fitting Note Do not overtighten the nut Overtightening can Es compress the Collet too much and cause an g air line restriction 3 Install the Air Line Collet and Nut If installing a new fitting 2 3 4 place the Collet in the fitting and loosely install the Nut Do not tighten the Nut yet Insert the Air Line through the Nut 1 Conne
12. z S Transmission Overhaul Procedures Bench Service 5 Press Oil Tube firmly into place Note The Oil Tube has two different lengths Older units extend 2 3 of the way into the Main Case and newer units go into the intermediate wall Figures in the next column New Style 6 Install the Clutch Housing on the Front Box pilot it on the six studs and Front Bearing Cover 7 Install the nuts with washers on the studs torque to 35 47 Nem 90 CW rotation or 175 lb ft 237 Nem in cross pattern 8 Install the Cap Screws torque to 115 Ib ft 156 Nem in cross pattern Note Make sure all fasteners are properly torqued 242 Transmission Overhaul Procedures Bench Service 9 Install the Shift Bar Housing and Gasket Note Ensure Roll Pin and proper Cap Screw are installed in the front left corner Cap Screw length is 1 3 4 10 Install Interlock parts Pin Spring and Sleeve 21 29 11 Install Slave Valve 243 Transmission Overhaul Procedures Bench Service How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube Special Instructions None Special Tools e Typical Service Tools e A Vise with brass jaws or wood blocks Procedure 1 From the Assembly remove the Outer Oil Pump Element 2 From the Drive Shaft remove the Drive Gear Retaining Snap Ring 3 From the Pum
13. 128 Position a new Gasket on the Cylinder Housing Cover mounting surface Over the gasket position the Range Cylinder Cover Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screw threads Install the Cap Screws torque to 20 25 Ib ft 27 12 33 90 Nem In Vehicle Service Procedures 129 1 e 1 v o 1 a o Transmission Overhaul Procedures Bench Service How to Disassemble the Gear Shift Lever Special Instructions If total disassembly is needed the Roadranger Valve must be removed first Release the Spring one coil at a time Special Tools e Vise with brass jaws or wood blocks 3 mi H lt gt 11 B SUP Pd 12 1 a 5 8 6 d 7 13 8 14 9 1 Pin 8 Cap Screw 2 Bushing 9 Gasket 3 Upper Lever 10 O Ring 4 Snap Ring 11 Washer 5 Rubber Boot 12 Lower Lever 6 Spade Pin 13 Stepped Washer 7 Housing 14 Tension Spring 130 Transmission Overhaul Procedures Bench Service Procedure 1 On a Non Isolated Shift Lever remove the Roadranger Valve using the How to Remove the Roadranger Valve instructions in In Vehicle Service Procedures If the Shift Lever is equipped with a Lever Isolator remove the Snap Ring Bushing and Cross Pin to disconnect and remove the upper Lever Slide the rubber Boo
14. 14714 0 263 0 265 Purple 14715 0 268 0 270 Yellow 14716 0 273 0 275 Black 23 30 Washers for 3 Sided Key Part Size Color e o 4300830 0 244 Blue Light Blue E 4300382 0 249 White Light e 4300383 0 254 Green Light 4300384 0 259 Orange Light 4300385 0 264 Purple Light 4300386 0 269 Yellow Light 4300387 0 274 Black Light Blue 211 Transmission Overhaul Procedures Bench Service How to Assemble the Mainshaft Assembly with Non Selective Non Adjustable Tolerance Washers Special Instructions The proper Mainshaft Key must always be used with the proper design Mainshaft Washers If necessary refer to the Parts Manual for your specific model to confirm the proper parts Previous design levels can be updated to the current design Special Tools e A piece of 5 32 Air Line 1 long e Vise with brass jaws Procedure 212 1 With Mainshaft pilot end down secure the Mainshaft in a Vise equipped with brass jaws or wood blocks If previously removed install the Roll Pin in Keyway With Mainshaft pilot end down install Offset Washer flat surface up Rotate the washer until the Washer Splines and Mainshaft Splines align Start at the Mainshaft bottom and install a plastic line in the marked Keyway to lock the washer in place With Clutching teeth down position the proper gear on the Mainshaft Refer to the illustrated parts list for correct gear Install the Flat Washer Ro
15. 3 Sliding Clutch rearward Power Flow lt 5 5 5 3 gt RTO RTX adds Drm ses vbs 4th Low Split Gear 4th High Split Gear 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 3 Sliding Clutch rearward X A 4 7 Gusts DTE Obb es 5th Low Split Gear 5th High Split Gear 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward 33 Power Flow V 8 eee mis iibi i wee mee wee cdd 6th Low Split Gear 6th High Split Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward X O m ead wad ades oles eves o gp ps 7th Low Split Gear 7th High Split Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward 34 Power Flow D 5 Ed E gt 1 2 wees wae ERES OSs ee Wed Mee 8th Low Split Gear 8th High Split Gear 1 Slidin
16. Air Line a fitting or Air Line Air is definitely leaking from Slave Go to Step B Valve Exhaust Port Step B Move Range Selector down to select Air is flowing from High Range Remove Range Cylinder Cover and Low Range Supply Port on Range Cylinder repair leaking Range Piston or Remove the 1 4 1 0 rubber Air Line at Piston Seal After repair check for the High Range Supply Port on the proper Range operation Range Cylinder Feel for air flow from the open port on the Range Cylinder Notice if the air leak at the Slave Valve only occurs when the Transmission is in High Range Repeat the above test but remove the Low Range Air Hose and check with High Range selected air flow from High Range Port Repair or replace Slave Valve 47 Air System Procedure 3 Symptom Air Leak from Transmission Breather or Transmission Case is Pressurized Normal Operation There should be no measurable air flow from the Transmission Breather Possible Causes e Leak at Range Yoke Bar O Ring e Leak at Splitter Yoke Bar O Ring Table 12 Air Leak from Transmission Breather or Transmission Case is Pressurized Procedure Result What to Do Next Transmission shifted to both Low and High Range High Range Step A Listen for the air leak with the Leak is only in Low Range Leak is in both Low and Remove Range Cylinder and inspect for damaged Range Yoke Bar Yoke Bar O Ring or Range
17. Drain lube 2 From the Splitter Cylinder Cover remove the Retaining 120 Cap Screws Remove the Cover and Gasket or O Ring new design aluminum cover Remove the 3 4 Nut on the Splitter Yoke Bar From the Auxiliary rear remove the Splitter Cylinder Housing If necessary turn out the Insert Valve Retaining Nut and remove Insert Valve from Bore only present on old style 13 18 Speed If Spool Valve needs to be replaced it must be done as an entire unit which is part of the Splitter Cover Note New 13 18 Speeds Splitter Covers contain a Spool Valve that is replaced as a unit In Vehicle Service Procedures How to Install Splitter Cylinder Assembly Special Instructions Apply Eaton Lubricant 71214 or equivalent to all Shift Cylinder Assembly and Spool Valve O Rings so a film covers the entire surface of each O Ring Apply Eaton rust preventative 71213 or equivalent to all Shift Cylinder walls and Yoke Bars and cover the entire Yoke Bar surface that comes in contact with the Shift Cylinder O Ring Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks 5 o 1 N 5 Ej rJ v T rJ 17 N pemo a m 20 N i pn 9 72 52 13 18 5 p di We NA PA 90 1 Splitter Yoke Assembly 8 O Ring 2 Gasket 12 0 0 3 Splitter Cylinder 13 0 0 4 0 0 14 Breather 5
18. For the 1 4 D air Hoses install the fixed nut end first Special Tools e Typical Service Tools Procedure 1 Remove all Air Line Brackets and Ties 2 Remove swivel end 3 Remove fixed end 1 e 1 v is I5 o 79 In Vehicle Service Procedures How to Install Rubber 1 4 Air Hoses Special Instructions For the 1 4 D air Hoses install the fixed nut end first Special Tools e Typical Service Tools 80 Procedure 1 If necessary apply Eaton Thread Sealant 71205 or equivalent to threads Install and tighten fixed end first then install and tighten swivel end Replace all Air Line Brackets and Ties In Vehicle Service Procedures How to Remove the Air Filter Regulator Special Instructions The Air Filter Regulator has two 2 O Rings located between the Filter Regulator and the Auxiliary Section Special Tools e Typical Service Tools Procedure 1 Remove the Air Lines from the air Filter Regulator 2 From the Air Filter Regulator remove the two 2 Cap Screws 1 e 1 v o 1 a o 81 In Vehicle Service Procedures How to Install the Air Filter Regulator Special Instructions The Air Filter Regulator has two 2 O Rings located between the Filter Regulator and the Range Cylinder Cover Special Tools e Typical Service Tools Procedure 1
19. Install the Reverse Switch torque to 15 20 lb ft 20 34 27 12 Nem 4 Connect the wiring to the Switch In Vehicle Service Procedures How to Remove the Shift Bar Housing Special Instructions Before removing the Shift Bar Housing the Air Lines must be disconnected For models equipped with an Oil Pump and or Cooler Assemblies make sure to disconnect the Oil Line connected to the Shift Bar Housing There are three 3 sizes of Cap Screws The 1 1 2 Cap Screws are used with the Lifting Eyes The 1 1 4 are used on all other locations except the left front corner at the Roll Pin location This Cap Screw is 1 3 4 Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes Special Tools e Typical Service Tools e 1 wo v rJ 1 a o Procedure 1 From the Shift Bar Housing remove the two Retaining Cap Screws securing the Oil Cooler Remove Oil Cooler and set aside 2 Remove Slave Valve 99 In Vehicle Service Procedures 3 Remove Interlock parts Pin Spring and Sleeve 4 Fromthe Shift Bar Housing rim remove the Retaining Cap Screws 5 To break the Gasket seal jar the Shift Bar Housing 6 Remove the Shift Bar Housing 7 Inspect the Roll Pin replace if damaged 8 Remove the Gasket and clean all mounting surfaces of gasket material 9 Ifthe three 3 sets of Tension Springs and Bal
20. Key 7 Gear 8 Gear 9 Gear 10 PTO Gear 11 Drive Gear 12 Snap Ring 13 Bearing 14 Retainer Kit 15 Cap Screw a o 2 5 o an 5 25 9 2 197 Transmission Overhaul Procedures Bench Service Procedure CAUTION _ NEVER USE THE GEAR AS PRESSING BASE The narrow face width of this gear makes it very susceptible to breakage 1 Remove the front Countershaft Snap Ring 2 Placethe Countershaft in the Press as shown Using the rear face of 3rd Overdrive Speed Gear as a base press the Drive Gear PTO Gear and 3rd Overdrive Speed Gear from each Countershaft This removes the Front Bearing Inner Race from the Countershaft 3 Position the Countershaft in the Press as shown Press the next two gears from the Shaft 4 Inspect the Keys and Roll Pin Remove and replace if damaged 198 Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft and Main Drive Gear Special Instructions None Special Tools e RR1023TR Input Bearing Puller e RR1019TR Hand Maul e RR1020TR Soft Bar Procedure 1 From the Front Bearing Cover remove the six 6 Retaining Cap Screws and Cover Remove any remaining gasket material from the Case and Cover y e ez o 5 5 E dE 55 ez 9 2 If present remove and discard the Rubber Seal Ring on the Input Shaft The Ring
21. O Ring 8 Plate 18 Seal 9 Cap Screw 19 Spring 10 Cap 40 Air System Slave Valve Pre Selection System This Interlock Mechanism prevents the Slave Valve from shifting when the Transmission is engaged into gear The Air Valve Shaft is moved towards the Slave Valve by the Shift Rails when the Transmission is shifted into gear A spring pushes the Air Valve Shaft back when the Front Section is shifted into a Neutral position 5 2 5 5 3 D 5 Component Nomenclature and Slave Valve Countershaft Sectional View 1 Actuation Spring 4 Shift Bar Housing 2 Actuating Pin 5 Slave Valve 3 Air Valve Shaft 6 Alignment Sleeve 41 Air System General Troubleshooting Chart The chart on the following pages contains some of the most common problems that may occur with this Transmission along with the most common causes and solutions General Troubleshooting Chart Complaint Cause Corrective Action Noise Growl Rumble Torsional Vibration Noise may be most pronounced when Transmission is in a float low torque condition May also be confined to a particular vehicle speed Check driveline angles for proper U joint working angles Check driveline for out of balance or damage Check U joints for proper phasing Check Clutch Assembly for broken Damper Springs Check for inadequate Clutch Disc damping Transmission Bearing or Gear failure Noise may b
22. Shift Lever comes out of gear on rough roads Loose or worn Engine Mounts Check Engine Mounts for damage wear or excessive looseness Shift Lever problem Check Shift Lever Floor Boot for binding or stretching Check Shift Lever Isolator for excessive looseness or wear Check for excessive offset or overhang on the Shift Lever Check for extra equipment or extra weight added to Shift Lever or Knob Worn or broke Detent Spring or Mechanism Check for broken Detent Spring Check for excessive wear on the Detent Key of Detent Plunger Replace Detent Spring with heavier spring or add additional spring 42 General Troubleshooting Chart Continued Air System Complaint Cause Corrective Action Shift Lever Slip out Transmission comes out of gear under torque Internal Transmission problem Check for excessively worn or damaged Sliding Clutches or Shift Yokes Transmission goes to Neutral Shift lever doesn t move Low air pressure Check Air Regulator pressure Internal Transmission problem Check for excessively worn or damaged Range Sliding Clutch or Yoke No range shift or slow range shift Also see Air System Troubleshooting Transmission Air System problem Preform Air System troubleshooting procedure Check for proper air signal from Master Valve Check Air Module Test Ports for proper air delivery Range cylinder problem Check fo
23. Spring and Sleeve 7 Install Slave Valve Apply Loctite 242 to Cap Screw threads and torque to 8 12 Ib ft 10 85 16 30 Nem 102 In Vehicle Service Procedures How to Remove the Oil Seal Mechanical Speedometer Special Instructions Prior to replacing the Seal carefully inspect the Transmission to make sure the oil leakage is coming from the Seal Pay particular attention to the Speedometer parts the Rear Bearing Cover gasket surfaces Rear Countershaft Bearing Covers and Shift Bar Housing For additional information on Rear Seal service refer to the Seal Maintenance Service Brochure TRSM0912 Special Tools e Output Yoke Puller e RR1010TR Slide Hammer e RR1011TR 1 Slide Hammer Attachment e 1 m rJ v rJ 1 N 7 6 1 Bushing 5 Oil Seal with Slinger 2 Rear Bearing Cover Assembly 6 O Ring 3 Cap Screw 7 Speedometer Spacer Assembly 4 Speedometer Drive Gear 103 In Vehicle Service Procedures 104 Procedure 1 Disconnect the Driveshaft and U joint from the Output Yoke according to the OEM or Driveshaft Manufacturer s instructions Shift the Transmission into 1st Gear or Low Gear Low Range to prevent the Output Yoke from turning when you loosen the Output Shaft Nut Remove the Output Shaft Nut using a 70 mm or 2 3 4 socket See How to Remove Output Yoke Companion Flange Remove the Output Yoke If necess
24. The proper Mainshaft Key must always be used with the proper design Mainshaft Washers If necessary refer to the Parts Manual for your specific model to confirm the proper parts Special Tools e A piece of 5 32 Air Line 1 long Vise with brass jaws Procedure 1 With Mainshaft pilot end down secure the Mainshaft in a Vise equipped with brass jaws or wood blocks If previously removed install the Roll Pin in Keyway With Mainshaft pilot end down install Offset Washer flat surface up Rotate the washer until the Washer Splines and Mainshaft Splines align Start at the Mainshaft bottom and install a plastic line in the marked Keyway to lock the washer in place With Clutching teeth down position the 4th gear on the Mainshaft Install the Flat Washer Rotate the washer until the Washer Splines and Mainshaft Splines align v 2 eu 9 5 i ue 5 5 22 o 1 ez 2 5 215 Transmission Overhaul Procedures Bench Service 216 10 11 12 13 14 With Clutching teeth up and against the Spacer install the 3rd Gear Position the Offset Washer flat surface down against the Gear Rotate the washer until the Washer Splines and Mainshaft Splines align Push the Air Line up to lock the washers on the Mainshaft With the missing internal Splines aligned with the plastic line install the proper Sliding Clutch Position the next
25. To install the Air Lines and Hoses the Air Filter Regulator must be in position e 1 wo v rJ 1 a o If you are unsure of the Air Line and Hose locations see the Air System Troubleshooting Guide TRTS0920 Special Tools e Typical Service Tools e For Push to Connect Fittings the Eaton Service Tool Kit K 2394 is recommended The Kit contains the Release Tool and a Tubing Cutter Procedure 1 Replace damaged Air Fittings Air Line Fitting Types 1 1 8 tube 1 8 NPTF 2 Push to connect 3 5 32 tube 1 8 NPTF 73 In Vehicle Service Procedures 74 2 Connectthe Air Lines from the Slave Valve to the Range Cylinder 3 Connect all removed Air Lines and Hoses 4 sure the Fittings are tight and the Lines are not kinked In Vehicle Service Procedures How to Remove Compression Type Fittings Special Instructions WARNING Asudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the Vehicle Air Tanks CAUTION Small Air Lines are available in 1 8 or 5 32 sizes Make sure 1 8 Air Lines are used with 1 8 Fittings and 5 32 Lines are used with 5 32 Fittings Mixing sizes can cause air leaks or damage to Fittings Before removing the Air Lines and Hoses label or record their location gt c 1 gt rJ
26. correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www eaton com roadranger In Mexico call 001 800 826 4357 Roadranger Eaton and trusted partners providing the best products and services in the industry ensuring more time on the road Eaton Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA E TeN Roadranger Powering Business Worldwide SUPPORT
27. tightened to the proper torque Note Make sure Gaskets are used at appropriate positions In Vehicle Service Procedures 123 3 lt 7 1 N 7 rJ 9 rJ 17 5 an In Vehicle Service Procedures How to Disassemble the Range Cylinder Assembly 7 Series Special Instructions None Special Tools e Typical Service Tools 1 Shift Yoke Assembly 7 O Ring 2 Gasket 8 Nut 3 Range Cylinder 9 Gasket 4 O Ring 10 Cover 5 Piston 11 Cap Screw 6 O Ring 124 In Vehicle Service Procedures How to Disassemble the Range Cylinder Assembly 9 Series Special Instructions For RTLO XX9XX 9 Series remove the Auxiliary Section before disassembling the Range Cylinder See instructions for Removing Auxiliary Section on page 114 Special Tools e Typical Service Tools 94 2044 9149 1 8 Piston 2 Shift Yoke 9 O Ring 3 Bolt 10 0 0 4 Range Cylinder Assembly 11 Nut 5 Cap Screw 12 Gasket 6 O Ring 13 Cover 7 Yoke Bar 125 In Vehicle Service Procedures 126 Procedure 1 From the Range Cylinder Cover remove the Cap Screws Cover and Gasket 2 Clean the Gasket mounting surfaces of all gasket material 3 From the Range Cylinder Housing Bore remove the 15 16 nut 4 Fromthe Cylinder Housing Bore remove the Range Piston 5 Inspect the Range Piston O Rings remove if damaged 6
28. torque to 35 45 Ib ft 47 45 61 01 Nem 10 To finish installation see The Shimming Procedure for Tapered Bearings Transmission Overhaul Procedures Bench Service Procedure 1 install the Auxiliary Section in the vertical position With blocks under the Clutch Housing to prevent Input Shaft damage place the Transmission in the vertical position Clutch Housing down 2 Position a new gasket on the Transmission mounting surface 3 Install a Steel Bar through the Yoke 4 Attach a Lifting Chain to the Steel Bar 5 Position the Auxiliary Section over the two 2 Dowel Pins 6 Slide the Auxiliary Section down the Dowels E e 5 Oo 5 5 5 5 2 o 1 ez 7 Apply Eaton Fuller amp Sealant 71205 or equivalent to the Retaining Cap Screws 8 Install the Retaining Cap Screws torque to 35 45 Ib ft 47 45 61 01 Nem 9 Remove the Steel Bar and chain 10 To finish installation see The Shimming Procedure for Tapered Bearings Note Make sure the Input Shaft rotates 261 Transmission Overhaul Procedures Bench Service Shim Procedure without a Shim Tool for Tapered Bearings Special Instructions The shim procedure can be done in the horizontal or vertical position The procedure is done the same CAUTION Use genuine Eaton replacement gaskets for the Auxiliary Housing and Countershaft Bearing Cover Do not omit the gaskets Bear
29. 1 If previously removed in the Cylinder Housing Bore install the small O Ring 2 If previously removed on the piston O D install the Piston O Ring 3 Position a new gasket on the Cylinder Housing mounting surface 4 With the air passage towards the Rear Bearing Cover install the Cylinder Housing 5 Inside the Cylinder Housing over the Yoke Bar end install the O Ring E e 5 Oo 5 5 5 5 2 o 1 ez 6 With the recessed side up install the Splitter Cylinder Piston 7 Install the 3 4 lock nut torque to 30 36 Ib ft 41 49 Nem 177 Transmission Overhaul Procedures Bench Service 178 8 Position a new gasket or O Ring new design aluminum cover onthe Cylinder Housing Cover mounting surface The gasket air passage must align with the Housing air passage 9 Position the Splitter Cylinder Cover over the gasket or O Ring new design aluminum cover 10 New style Splitter Covers contain a Spool Valve which must be replaced as a unit with the entire Cover Old style Splitter Covers contain a separate Insert Valve that can be removed from the bottom of the Splitter Cover 11 Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screws 12 Install and torque the Retaining Cap Screws to 20 25 Ib ft 27 12 33 90 Nem 13 Refill Transmission with lube to the proper level Note Make sure the Retaining Nut and Cap Sc
30. Assemble the Integral Oil Pump without Auxiliary Oil 000 247 How to Install the Integral Oil Pump 250 How to Disassemble the Integral Oil Pump with Auxiliary Oil Tube 252 How to Assemble the Integral Oil Pump with Auxiliary Oil Tube 256 How to Install the Auxiliary Section 260 Shim Procedure without a Shim Tool for Tapered Bearings e eh 262 How to Remove the Boosted or Hydraulic Actuator and Adapter Housing 266 How to Install the Boosted or Hydraulic Actuator and Adapter Housing see 268 Introduction Purpose and Scope of Manual This manual is designed to provide information necessary to service and repair the Fuller Transmissions listed on the front How to use this Manual The service procedures have been divided into two sections In Vehicle Service Procedures and Transmission Overhaul Procedures Bench Service In Vehicle Service Procedures contain procedures that can be performed while the Transmission is still installed in the vehicle Transmission Overhaul Procedures contain procedures that are performed after the Transmission has been removed from the vehicle 3 3 5 5 5 3 gt E The procedure sections are laid out with a general heading at the
31. Depress the Relief Valve Spring and drive the Relief Valve Retention Roll Pin into the Roll Pin Bore 247 Transmission Overhaul Procedures Bench Service 248 5 f removed replace the Drive Shaft Snap Ring on the Pump Drive Shaft 6 Insert the Drive Shaft through the Pump Housing Bore 7 Install the two 2 Keys on the Drive Shaft 8 Align the Inner Element Keyways with the Drive Shaft Keys and install the Integral Oil Pump Inner Element 9 Install the Inner Element Retention Snap Ring in Drive Shaft Snap Ring groove Transmission Overhaul Procedures Bench Service 10 Install Drive Gear Key in Drive Shaft Keyway 11 Align Drive Gear Keyway with Drive Shaft Key and install the Drive Gear on the Drive Shaft 12 Install the Outer Drive Gear Retention Snap Ring in Drive Shaft groove E e 9 5 nn 1 502 as 2o o lj ez o 13 Install the Outer Integral Oil Pump Element over the Inner Element 249 Transmission Overhaul Procedures Bench Service How to Install the Integral Oil Pump Special Instructions Lubricate the Case Front Plug O Ring with Eaton Fuller amp Lubricant 71206 or equivalent Special Tools e Typical Service Tools Procedure 1 If removed replace the Front Case Pump Plug O Ring lubricate the grove of the plug install the O Ring onto the plug and then lubricate the outer diameter of the O Ring 2 Sea
32. Maul Used with Bearing and Seal Drivers for part installation removal 3 wo 5 5 3 gt E RR1020TR Soft Bar Used with hand Maul to remove parts from the Transmission Used to support the Upper Countershaft during Main Box disassembly RR1022TR Countershaft Support Tool on amp RT Series Transmissions RR1023TR Puller Input Bearing Used to remove the Input Bearing on FR amp RT Series Transmissions RR1024TR Driver Output Bearing Used to install the Output Bearing on FR amp RT Series Transmissions Shop Equipment Tool Purpose 20 Ton capacity Press To press Countershaft Gears from Countershaft Eaton Aftermarket Parts The following tools are available through Eaton Aftermarket Parts To obtain any of the tools listed contact your local Eaton Parts Distributor Tool Purpose Eaton Part Number To remove 5 32 Air Lines from Push to 5 32 Air Line Release Tool Connect Fittings P N 4301157 included in Kit K 2394 To cut plastic Air Lines smoothly and Air Line Cutting Tool squarely P N 4301158 included in Kit K 2394 11 Recommended Tools Transmission Torque Specifications Correct torque application is extremely important to assure long Transmission life and dependable performance Over tightening or under tightening can result in a loose installation and in many instances eventually cause damage to Transmission Gear
33. Offset Washer in the next available groove Rotate the washer until the Washer Splines and Mainshaft Splines align Push the Air Line up to lock the washer on the Mainshaft With Clutching teeth down position the 2nd Gear on the Mainshaft Position the Flat Washer against the Gear Rotate the washer until the Washer Splines and Mainshaft Splines align Transmission Overhaul Procedures Bench Service 15 With Clutching teeth up install the 1st Gear on the Shaft against previously installed Gear 16 Position the Offset Washer flat surface down against the Gear Rotate the Washer until the Washer Splines and Mainshaft Splines align 17 From the Mainshaft rear install the Mainshaft Key into the Spline with the Air Line Pull the Air Line from the Spline while installing the Key 21 29 18 Install the Snap Ring in the Mainshaft groove 19 Install the 1st Reverse Sliding Clutch 20 Install the Clutch Hub with the bezel facing up 21 Install the Reverse Gear 22 Remove the Mainshaft from the Vise and lay on its side Install the front Sliding Clutch into position 217 Transmission Overhaul Procedures Bench Service How to Prepare the Main Case for Assembly Thoroughly clean Main Case of metal particles Remove the gasket material from flange surfaces Inspect flange surfaces for damage Inspect Bearing Bores for damage or excessive wear Repl
34. Piston 15 Splitter Valve Replacement Kit 6 O Ring 18 Cap Screw 7 Nut 121 In Vehicle Service Procedures 122 Procedure 1 T If previously removed in the Cylinder Housing Bore install the small O Ring If previously removed on the Piston O D install the Piston O Ring Position a new gasket on the Cylinder Housing mounting surface With the air passage towards the Rear Bearing Cover install the Cylinder Housing Inside the Cylinder Housing over the Yoke Bar end install the O Ring With the recessed side up install the Splitter Cylinder Piston Install the 3 4 Lock Nut Tighten the Lock Nut to 30 36 Ib ft 41 49 Nem of torque Position a new Gasket or O Ring new design aluminum cover onthe Cylinder Housing Cover mounting surface The Gasket air passage must align with the Housing air passage Position the Splitter Cylinder Cover over the Gasket or O Ring new design aluminum cover New style Splitter Covers contain a Spool Valve which must be replaced as a unit with the entire Cover Old style Splitter Covers contain a separate Insert Valve that can be removed from the bottom of the Splitter Cover Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screws Install and torque the Retaining Cap Screws to 20 25 Ib ft 27 12 33 90 Nem Refill Transmission with lube to the proper level Note Make sure the Retaining Nut and Cap Screws are
35. Position the Air Filter Regulator 2 Apply Eaton Sealant 771205 or equivalent to the two 2 Retaining Cap Screws 3 Install the two 2 Retaining Cap Screws torque to 8 12 lb ft 10 85 16 30 Nem 82 In Vehicle Service Procedures How to Remove a Roadranger Valve Special Instructions WARNING A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the Vehicle Air Tanks must be exhausted Special Tools e Typical Service Tools Procedure rH a ix a o 1 From the Roadranger Valve Cover remove the two 2 Mounting Screws 2 Slide the Roadranger Valve Cover down 3 From the Air Fittings disconnect the Air Lines 4 From the Roadranger base loosen the Jam Nut Rotate the Roadranger Valve until the Valve is removed 5 Inspectthe parts nut Valve Cover Air Lines sheathing and O Rings from the Lever Shaft 6 Inthe Roadranger Valve inspect the Air Fittings and remove if damaged 83 In Vehicle Service Procedures How to Install a Roadranger Valve Special Instructions To position the Roadranger Valve the Range Lever must be to the front or the Splitter Button to the left when facing forward Special Tools e Typical Service Tools Procedure 84 1 T Make sure the Nut Valve Cover Air Lines sheathing and O Rings are in position on
36. Push it in as far as it will go 9 Secure the Piston with the Retaining Nut torque to 70 85 Ib ft 94 91 115 24 Nem 174 Position a new gasket on the Cylinder Housing Cover Over the gasket position the Range Cylinder Cover Apply Eaton Fuller Sealant 71205 or equivalent to the Install the Cap Screws torque to 20 25 Ib ft Transmission Overhaul Procedures Bench Service mounting surface Retaining Cap Screws 27 12 33 90 Nem 175 79 a D LI 5 2 2 e E N e 2 lt gt Transmission Overhaul Procedures Bench Service How to Install Splitter Cylinder Assembly Special Instructions Apply Eaton Lubricant 71214 or equivalent to all Shift Cylinder Assembly and Spool Valve O Rings so a film covers the entire surface of each O Ring Apply Eaton rust preventative 71213 or equivalent to all Shift Cylinder walls and Yoke Bars cover the entire Yoke Bar surface that comes in contact with the Shift Cylinder O Ring Special Tools e Typical Service Tools are needed e Vise with brass jaws or wood blocks 1 Splitter Yoke Assembly 8 O Ring 2 Gasket 12 0 0 3 Splitter Cylinder 13 0 0 4 O Ring 14 Breather 5 Piston 15 Splitter Valve Replacement Kit 6 O Ring 18 Cap Screw 7 Nut 176 Transmission Overhaul Procedures Bench Service Procedure
37. easily into the Case Bore if they are not cocked 224 Transmission Overhaul Procedures Bench Service How to Install Countershaft Assemblies Special Instructions Make sure the Countershaft Assemblies have been marked for proper position 47 tooth PTO gear in the lower position Prior to installing the Countershafts the Lower Reverse Idler Gear Assembly should be installed In addition if the Transmission is equipped with an Internal Oil Pump this should also be installed Special Tools e Toolmaker s Dye Procedure 1 On the Drive Gear of each Countershaft Assembly mark the tooth aligned with the gear Keyway and stamped with an for easy identification A highly visible color of Toolmaker s Dye is recommended for making timing marks Note Prior to installing the Countershafts the Lower Reverse Idler Gear Assembly should be installed In addition if the Transmission is equipped with an Internal Oil Pump this should also be installed 2 Place the lower 47 tooth gear Countershaft into the Main Case with the Shaft seated in the Lower Countershaft Case Bores Note Use a large hook or piece of rope to support the Countershaft if necessary 3 Place the Upper Countershaft with the 45 tooth PTO gear into the Main Case with the Shaft seated in the Upper Countershaft Case Bores 225 Y a 1 a o LI wo co S z a 5
38. hole with Case oil return hole torque to 35 45 Ib ft 47 45 61 01 Nem Note Make sure the Drive Gear is timed with the both Countershafts Note Make sure the Front Bearing Cover Cap Screws are tightened properly 233 v 1 a o 1 wo rj S 5 7 E gt z N gt 2 lt 1 gt Transmission Overhaul Procedures Bench Service How to Install the Upper Countershaft Bearings Special Instructions The Front Bearing Inner Race must be pressed on the Countershaft front The Flanged End Driver must cover the Bearing Outer Race for proper installation Temporarily use the assembled Auxiliary Drive Gear to hold the Mainshaft in the Input Shaft Pilot CAUTION The Upper Countershaft Bearings must be installed after the installation of the Mainshaft Special Tools e RR1012TR 2 Bearing Driver front e RR1012TR 4 Bearing Driver rear e RR1013TR Timing Block e RR1019TR Hand Maul Procedure Figure 3 1 Make sure the Lower Countershaft and Main Drive Gear timing marks are aligned 2 Mesh the Upper Countershaft marked tooth with the two remaining Main Drive Gear marked teeth 3 Move the Countershaft to the rear and insert the RR1013TR Timing Block to center Shaft in rear Case Bore 234 Transmission Overhaul Procedures Bench Service 4 Obtain a spare Inner Countershaft Race 5 Temporarily install a spa
39. is used only to seal the Transmission during shipment 3 From the Input Shaft groove remove the Bearing Retaining Snap Ring 199 Transmission Overhaul Procedures Bench Service 4 Use a Maul to drive the Input Shaft toward the case rear as far as possible Pull the Input Shaft forward 5 Install the RR1023TR Input Bearing Puller and remove the Input Bearing from the Case and Input Shaft or use Pry Bars or Screwdrivers to complete removal of the Bearing 6 From the Drive Gear front remove Drive Gear Spacer 7 Remove the Drive Gear Internal Snap Ring 200 Transmission Overhaul Procedures Bench Service 8 Pullthe Input Shaft forward and out of the Drive Gear 9 From inside the Case remove the Drive Gear 10 Inspect the bushing in the Input Shaft pocket replace if damaged E e 9 5 5 5 5 o 1 ez 201 Transmission Overhaul Procedures Bench Service How to Disassemble the Mainshaft Assembly Special Instructions Lay all parts on a clean bench in order of removal to facilitate assembly Special Tools e Typical Service Tools Procedure 1 Lay the Mainshaft on its side and from the front remove the 4th or Overdrive and 5th Sliding Clutch 2 Place the Mainshaft in a vertical position pilot end down 3 Remove Snap Ring if applicable 4 Remove Key Washer and Reverse Gear Mark Keyway location
40. noticeable clearance to the Main Drive Gear internal Spline Teeth This is normal 3 Install the Snap Ring the Main Drive Gear inside groove 4 Install the Spacer Washer over the Input Shaft With the Bearing External Snap Ring to the outside position the bearing on the Input Shaft 152 Transmission Overhaul Procedures Bench Service 5 Install the RR1005TR Input Bearing Driver over the Input Shaft Use a Flanged End Bearing Driver which contacts both the Bearing Inner Race and Outer Race Drive the Bearing until it contacts the Front Case 6 Install the Input Shaft Retaining Snap Ring Note Do not replace the small rubber Lip Seal It is used only to prevent leakage during shipping 00155180611 7 Install the Front Bearing Cover Apply Loctite 242 to Cap Screw threads and torque to 35 45 Ib ft 47 45 61 01 Nem 153 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Section with Tapered Bearings Special Instructions There can be different Cap Screw lengths note their location Auxiliary Sections can be removed either with the Transmission in the horizontal position or the vertical position Auxiliary Countershaft Retaining Straps may be installed to hold the Countershafts in place You can make retaining straps from 3 x 1 bar stock Auxiliary can be removed without straps use caution Special Tools e RR1002TR Auxiliary Counters
41. oat Valve edat 67 Speedometer 106 w to Di r 4900 How to Install the Oil Seal Magnetic Speedometer 108 How to Assemble Roadranger Valve A 4900 69 Ai How to Remove the Output Yoke Companion How to Remove the Air Lines and HOSES 71 110 How Install the Air Lines and Hoses 73 How to Install the Output Yoke Companion Flange How to Remove Compression Type Fittings 75 anq UE it ene sis 111 How to Install Compression Type Fittings 76 How to Remove the Output Yoke Flange and How to Remove Push to Connect Type Fittings 77 Retaining Cap Screws 112 How to Install Push to Connect Type Fittings 78 How to Install the Output Yoke Flange and Rubber 1 4 Air Hoses 79 Retaining Screws iuc cineribus 113 ow to Remove Rubber ir HOSES How to Remove the Auxiliary Section in Chassis 114 How to Install Rubber 1 4 Air Hoses 80 2 TUN the Air Filter Requlat 81 How to Install the Auxiliary Section in Chassis 116 ow to Remove the Air Filter Regulator M j How to Remove the Splitter Cylinder Assembly 119 How to Install the Air Filter Regulator 82 How to Install Splitter Cylinder Assembly
42. of Air Shift Knob Slave Valve and System Troubleshooting section Transmission Case Breather when both Low and High Range have been selected No constant leak is detected Go to Step Step B Place Shift Lever in Neutral Air flows from the Low Range Remove Range Cylinder Cover and Move Range Selector up to High Range repair leaking Range Piston or position At the rear of the Transmission Piston Seal disconnect the 1 4 Rubber Air Line from the Low Range supply port on the Range Cylinder Check for air flow from the Low Range port No air flow from Low Range step C port Step C Check for air flow from the disconnected Air flows from disconnected Go to step Air Line Air Line No air flow from Go to step D 50 Table 14 No or Slow Range Shift into Low Continued Air System Procedure Result What to Do Next Step D Install a 100 PSI Air Gauge in the The Gauge read 0 PSI Go to step F disconnected Air Line end With the Shift Lever in Neutral move the Range Selector down to select Low Range Observe the Gauge The Gauge reads pressure but Replace the Filter Regulator and check is lower than 58 PSI or higher for proper range operation than 63 PSI The Gauge reads between Go to step E 58 63 PSI Step E Confirm that Shift Lever is still in Neutral Pressure rapidly changes Air System appears to be operating Have an assistant move the Range between 58 63 PSI and Oat satisfa
43. the Lever Shaft If previously removed replace the Air Fittings and torque to 84 120 Ib in 9 49 13 56 Nem Place the Roadranger Valve on the Lever Shaft and rotate so the Range Selector faces the vehicle front From the Roadranger Valve bottom torque the Jam Nut to 35 45 lb ft 47 45 61 01 Nem Connect the Air Lines to the Air Fittings 6 Slide the cover into position on the Roadranger Valve Install the Roadranger Valve Cover mounting screws Note Make sure the Air Lines are seated fully In Vehicle Service Procedures How to Remove a Slave Valve Special Instructions WARNING A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the Vehicle Air Tanks must be exhausted Special Tools e Typical Service Tools Procedure 1 Record or mark Air Line locations Retaining Capscrews rH a ix a o 2 Remove all Air Lines Note Remove three 1 4 ID air Hoses at swivel fitting at Range Cylinder location Remove Air Line Bracket at t rear of Transmission Remove Slave Valve with air Hoses still attached 3 Remove the Retaining Cap Screws around Valve perimeter 4 Remove Slave Valve and Gasket 5 From the Transmission Case remove the Sleeve Spring and Plunger Pin Plunger Pin mum Spr ff Sleeve iis 6 Inspect the Air Fittings repl
44. the OEM Chassis Service Manual be consulted first Special Tools e Typical Service Tools Procedure Figure A 1 Move the Gear Shift Lever forward or backward to the Neutral position 2 Move the Gear Shift Lever sideways toward Reverse until you feel resistance from the Reverse Plunger Spring DO NOT shift to Reverse The Shift Finger must remain in this position while you are making all the adjustments 1 e 5 7 sz rJ 5 7 v rJ a N 3 Remove the Cotter Pin Castle Nut and Ball Joint A see figure A from the Selection Lever Do not remove the Ball Joint from the Pivot Link 4 Loosen the Cap Screw B see figure A and remove the Shift Arm from the inner Shift Shaft Do not disconnect the Selection Lever from the Shift Arm 1 Reach Rod 5 Shift Arm 2 Turnbuckle 6 Pivot Link Assembly T 3 Selection Lever 7 Inner Shift Shaft 4 Inner Shift Finger 5 Turn the Shift Arm until it is at a right angle 90 to the Figure B Selection Lever as viewed from the side see figure B Note Ideally the Shift Arm should be adjusted 90 to the Selection Lever as described but in some Chassis configurations it may be necessary to index the Shift Arm in the vertical position Indexing the Shift Lever is done to prevent Shift Lever jump out This type of adjustment will cause an unequal amount of Gear Shift Lever travel between Neutral and a forward lever p
45. the two screws in the side of the Valve Housing to separate the Housing 6 Remove the Range Selection Lever from the Left Housing along with the Position Balls and Guide 7 If necessary remove the Springs and O Ring from the Bores in the Left Housing 8 If necessary remove the Springs O Ring and Sleeve from the Bores in the Right Housing 68 How to Assemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical Service Tools In Vehicle Service Procedures Component Nomenclature and Roadranger Valve Sectional View 1 Medallion 6 Washer 2 Spring 7 O Ring 3 Retainer 8 Range Selector 4 Housing 9 Pin 5 Spring 10 Cover 11 Screw 12 0 0 13 Spring 14 5 32 Ball 15 Spring 3 lt 7 11 N 3 rJ 11 9 rJ 17 N 16 Ball 17 Seal 18 Detent 19 Splitter Button 20 Old Style Shift Knob 69 In Vehicle Service Procedures Procedure 1 Refertothe drawing for proper reassembly Use a very small amount of Silicone Lubricant on the O Rings to avoid clogging the ports A small amount of grease on the Position Springs and Balls will help to hold them in place during reassembly 2 Install the Control Valve on the Gear Shift Lever and tighten the Jam Nut 3 Attach the Air Lines and install the Bottom Cover 70 In Vehicle Service Procedures How to Remove the Air Lines and Hoses Special Instructions Befor
46. to Disassemble the Mainshaft Assembly 202 How to Disassemble the Mainshaft Assembly with Low Force Gearing 204 How to Assemble the Mainshaft Assembly with Selective Adjustable Thickness Tolerance Washers 206 How to Assemble the Mainshaft Assembly with Non Selective Non Adjustable Tolerance Washers 212 How to Assemble the Mainshaft Assembly with Low Force 215 How to Prepare the Main Case for Assembly 218 How to Assemble the Countershaft Assemblies 219 How to Assemble the Lower Reverse Idler Gear 221 How to Install Countershaft Assemblies 225 How to Remove the Integral Oil Pump 226 How to Install the Lower Countershaft Bearings 228 How to Install the Input Shaft and Main Drive Gear 230 How to Install the Mainshaft Assembly 232 How to Install the Upper Countershaft Bearings 234 How to Assemble the Upper Reverse Idler Gear Assembly ente ides 237 How to Install the Auxiliary Drive Gear Assembly 240 How to Install the Clutch Housing with Internal Oil 241 How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube 244 How to
47. to internal Transmission parts Support the weight of the Auxiliary Section with a Lifting Device or Support Jack and move the Auxiliary Section rearward until it is free from the Front Section of the Transmission In Vehicle Service Procedures lt e 1 wo v 1 a o 115 In Vehicle Service Procedures How to Install the Auxiliary Section in Chassis Special Instructions None Special Tools 116 e RR1002TR Auxiliary Countershaft Support Straps Procedure 1 Install the RR1002TR Auxiliary Countershaft Support Straps to center and hold the Countershafts in position Install a 3 8 16 X 2 1 2 long Cap Screw into Countershaft center Install the Output Yoke and Nut torque the Nut to 650 700 Ib ft 881 28 949 07 Nem Note To prevent the Output Shaft from rotating while installing the Nut place a clean shop rag in the gear mesh Note Due to Chassis interference it may not be possible to install the Yoke at this step However the Output Shaft must be drawn fully into position to prevent it from sagging when the Auxiliary Section is installed in the Chassis If the Chassis causes interference the Yoke can be temporarily installed to draw up the Output Shaft and then removed before the Auxiliary Section is installed Use Crocus Cloth or a Wire Wheel to clean rust and paint from the Dowel Pins before installing them CAUT
48. until it is flush with the Main Section CAUTION The Auxiliary Section should slide into place fairly easily DO NOT force it on or pull it into place with the Cap Screws Excessive force may damage the Transmission If excessive force is necessary the gearing is likely out of time 11 Ifthe Auxiliary Section does not install fully slide it back and check the following a The Output Yoke and Nut should be installed to pull back and center the Auxiliary Mainshaft Assembly b The Countershaft Support Tool center Cap Screw should be snug to level the Countershafts c The Dowel Pins and Auxiliary Housing mating holes should be clean and well oiled d Theinternal gearing on the Auxiliary Section must have been properly timed during reassembly 117 In Vehicle Service Procedures 118 12 13 14 15 16 Apply Eaton Thread Sealant 71205 or equivalent to all the Retaining Cap Screw threads Install the Cap Screws to secure the Auxiliary Section to the Main Case torque to 40 45 Ib ft 54 23 61 01 Nem If the Countershaft Countershaft Bearings or Auxiliary Housing have been replaced or if the Countershafts Bearings or Shims were not marked and reassembled in the same location the Bearing endplay must be checked and set by shimming Shim the Countershaft Bearings using Shim Procedure without a Shim Tool If shimming is not required remove the Support Tools and install the proper Shim Gask
49. 6 Ball 5 32 9 Old Style Shift Knob 65 In Vehicle Service Procedures Procedure 1 Referto the drawing for proper reassembly Use a very small amount of Silicone Lubricant on the O Rings to avoid clogging the ports A small amount of grease on the Position Springs and Balls will help to hold them in place during reassembly 2 Reinstall Roadranger Valve on Gear Shift Lever and tighten the Jam Nut 3 Attach the Air Lines and reinstall the Bottom Cover 66 In Vehicle Service Procedures How to Disassemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical Service Tools wo o N rJ v T rJ wo a wo nan Component Nomenclature and Roadranger Valve Sectional View 1 Medallion 11 Screw 2 Spring 12 O Ring 3 Retainer 13 Spring 4 Housing 14 5 32 Ball 5 Spring 15 Spring 6 Washer 16 Ball 7 O Ring 17 Seal 8 Range Selector 18 Detent 9 Pin 19 Splitter Button 10 Cover 20 Old Style Shift Knob 67 In Vehicle Service Procedures Procedure 1 Remove the two screws holding the Bottom Cover to the Valve and slide the Cover down the Gear Shift Lever to expose the Air Line Fittings Disconnect the Air Lines 2 Loosenthe Jam Nut and turn the Control Valve from the Gear Shift Lever 3 Prythe Medallion from the recess in the Top Cover 4 Turn out the two screws to remove the Top Cover from the Valve Housing 5 Turn out
50. 8 O Ring 2 Gasket 12 0 0 3 Splitter Cylinder 13 O Ring 4 O Ring 14 Breather 5 Piston 15 Splitter Valve Replacement Kit 6 O Ring 18 Cap Screw 7 Nut 156 Transmission Overhaul Procedures Bench Service Procedure 1 Drain lube 2 From the Splitter Cylinder Cover remove the Retaining Cap Screws Remove the Cover and Gasket or O Ring new design aluminum cover Remove the 3 4 nut on the Splitter Yoke Bar From the Auxiliary rear remove the Splitter Cylinder Housing If necessary turn out the Insert Valve Retaining Nut and remove Insert Valve from Bore only present on old style 13 18 Speed If Spool Valve needs to be replaced it must be done as an entire unit which is part of the Splitter Cover Note New 13 18 Speeds Splitter Covers contain a Spool Valve that is replaced as a unit 157 gt a a o LI Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Countershaft Assembly Special Instructions For ease of disassembly mount the Auxiliary Section upright in a Vise Both Countershafts are removed the same As the Countershaft Strap is removed the Countershaft can fall Special Tools e RR1019TR Hand Maul e RR1020TR Soft Bar 158 Transmission Overhaul Procedures Bench Service Procedure 1 To hold the Auxiliary Countershafts from t
51. An understanding of the engine s Power Flow through a Transmission in each particular gear will assist the Technician in troubleshooting and servicing a Transmission The Fuller Transmission can be thought of as two separate Transmissions combined into one unit The first Transmission or Front Section contains six Gear Sets which are shifted with the Gear Shift Lever The second Transmission called the Auxiliary Section contains three Gear Sets and is shifted with air pressure lt 5 5 5 3 gt Note This Transmission is referred to as a Constant Mesh Type Transmission When in operation all gears are turning even though only some of them are transferring power Cross Sectional View 1 Front Section 2 Auxiliary Section 17 Power Flow The Transmission components in the figure below shows the Transmission with the main components called out Note that the Transmission is in the Neutral position because the Sliding Clutches are all in their center positions and not engaged in any gears 12 Transmissions Components 7 Auxiliary Countershaft 1 Input Shaft 8 Range Sliding Clutch 2 Main Drive Gear 9 Auxiliary Mainshaft Reduction Gear 3 Sliding Clutch 10 Output Shaft Auxiliary Mainshaft 4 Countershaft 11 Splitter Gear 5 Mainshaft Gear 12 Auxiliary Drive Gear 6 Auxiliary Splitter Clutch slides on Front Section Mainshaft Power Flow Front Section Power Flow Note Th
52. Bearings 193 Transmission Overhaul Procedures Bench Service How to Remove the Mainshaft Assembly Special Instructions None Special Tools e RR1004TR Mainshaft Lifting Hook e RR1022TR Countershaft Support Tool Procedure 1 With the Upper Countershaft Bearings removed support the Countershaft Assembly with a RR1022TR Support Tool 2 Insert the RR1004TR Mainshaft Hook around the Mainshaft Assembly Note Keep the Upper Countershaft forward against the Case front wall WARNING Be careful when removing the Mainshaft Assembly The Sliding Clutch on the front and the Reverse Gear on the back can slip off the shaft 3 Pull the Mainshaft to the rear to free the pilot from the Input Shaft pocket 4 Tilt the Mainshaft front up and lift the Assembly from the Case 194 Transmission Overhaul Procedures Bench Service How to Remove the Countershaft Assemblies Special Instructions Except for the PTO gears the Upper and Lower Countershaft Assemblies are the same Mark the Countershafts as UPPER or LOWER as you remove them The Mainshaft and Main Drive Gear must be removed before removing the Countershaft Assemblies Special Tools e RR1012TR Countershaft Bearing Puller e RR1019TR Hand Maul e RR1020TR Soft Bar Procedure 1 Remove the Rear Snap Ring from the Rear Upper Countershaft Bearing y e 9 5 i
53. Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch rearward 27 Power Flow Li RTO R add ad as 4th Gear 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch rearward La RTO RTX weds Obb os 5th High Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward 28 V seres o Epis 5th Low Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward RTO SERES Oba Ode 6th Low Split Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch forward m e uis uS ES ges ae 6th High Split Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 1 RTO Y eed peram 7th High Split Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward Power Flow lt 5 5 5 3 gt BI 8 RTO Y RT Y oes SERES o gs sts 7th Low Split Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch forward 4 2 RTO es gerer 8th Low Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward 29 30 Power Flow 1 2
54. Cylinder Repair as necessary Remove Splitter Cylinder Inspect for damaged Splitter Yoke Bar O Ring or Cylinder Repair as necessary 48 Air System Procedure 4 Symptom Air Leak at Splitter Cylinder Cover Exhaust Port Normal Operation A burst of air will exhaust from this port when shifting into Low split the Splitter Button is moved rearward while in Low Range Possible Causes e Damaged defective Insert Valve 3 3 5 5 E gt e Leak past Insert Valve external O Rings e past Splitter Cylinder Piston Table 13 Air Leak at Splitter Cylinder Cover Exhaust Port Procedure Result What to Do Next Step A Remove Insert Valve Check for contamination Contamination or damage Repair or replace as old style damaged seals or sticky movement Check the found necessary Insert Valve Bore in the Splitter Cylinder Cover for contamination or damage which would result in leakage past the Insert Valve O Rings No contamination or damage Go to Step B found Step B Remove the Splitter Cylinder Cover and piston Contamination or damage Repair or replace as Check the piston Bore for contamination or damage found necessary Check the piston seals for damage Note Early production Transmissions used a Paper Gasket to seal the Splitter Cover to Cylinder if necessary replace this configuration with the Spool Valve design which uses an O Ring
55. Gear Clutch Hub and Sliding Clutch 3 Remove the Snap Ring and Key Mark Keyway location 204 Transmission Overhaul Procedures Bench Service 4 Remove the Offset Washer and 1st Gear 5 Remove the Flat Washer and 2nd Gear E e 9 5 5 5 5 o 1 ez 6 Remove the Offset Washer and Sliding Clutch and then remove the Offset Washer and 3rd Gear 7 Remove the Flat Washer remove the 4th or Overdrive Gear and remove the Offset Washer 205 Transmission Overhaul Procedures Bench Service How to Assemble the Mainshaft Assembly with Selective Adjustable Thickness Tolerance Washers Special Instructions There are three distinct Mainshaft Washer and Mainshaft Key designs They are listed from oldest design to newest design a Six 6 sided Mainshaft Key with Selective adjustable Thickness Tolerance Washers b Three 3 sided Mainshaft Key with Selective adjustable Thickness Tolerance Washers c Three 3 sided Mainshaft Key with Non Selective non adjustable Tolerance Washers Note Between 1993 and 1996 some models were produced with a mixture of Selective Thickness Washers and Non Selective Tolerance Washers on the same Mainshaft Note The proper Mainshaft Key must always be used with the proper design Mainshaft Washers If necessary refer to the Parts Manual for your specific model to confirm the proper parts Note Previous desig
56. ION If the Dowel Pins are not installed in the Main Case to the proper depth the Auxiliary Section will not properly align with the Main Case and Bearing or Synchronizer failure may occur In Vehicle Service Procedures 4 Install the Dowel Pins into the Main Case so that 3 8 1 2 of the shoulder is exposed or Pin is flush with front of Case rear 5 Clean all rust and paint from the Dowel Pin holes in the Auxiliary Section Housing and lightly grease the Dowel Pins on the Main Case and the Dowel Pin holes on the Auxiliary Section Housing 6 Make sure the Auxiliary Section is in Low Range If not blow shop air max 100 PSI into the Low Range Supply Port to shift the Range Synchronizer to Low If necessary make sure the Deep Reduction Clutch is engaged into gear 7 Position the Gasket onto the Main Case mounting surface 2 1 wo wo v rJ a o 8 Mountthe Auxiliary Section on the Lifting Device or Jack 9 Tighten the center Cap Screw on the Countershaft Support Tools to draw the Countershafts into a level position Do not overtighten the Cap Screws The Output Yoke and Shaft must be able to rotate 10 Position the Auxiliary Section in line with the Main Case and slide the Housing onto the Dowel Pins Mesh the Countershafts with the Auxiliary Drive Gear Rotate the Output Yoke and Shaft slightly to help the gears mesh and slide the Auxiliary Section forward
57. Overhaul Procedures Bench Service 5 As the Idler Shaft and Idler Plate are removed remove the Thrust Washers and Gear 6 Inspect the Reverse Gear Assembly remove the Inner Race and Needle Bearing if damaged 190 Transmission Overhaul Procedures Bench Service How to Disassemble the Lower Reverse Idler Gear Assembly Special Instructions Before the Lower Reverse Idler Gear Assembly can be removed the Mainshaft and Countershaft Assemblies must be removed While removing the Reverse Idler Shaft the Thrust Washer can drop to the Transmission Case bottom Special Tools e Typical Service Tools e Pullers or Impact Puller Bar and Maul Procedure 1 Remove Retaining Bolt from the Idler Shaft Note If Idler Shaft spins in Case Bore slightly heat bolt with torch to release loctite adhesive 2 Remove the loosened bolt and remove washer Reinstall bolt 3 4 threads v S3 9 5 5 5 5 2o o 1 ez 3 Install an Impact Puller 1 2 13 threaded end and remove the Shaft from Case Bore 4 As the Idler Shaft and Idler Plate are removed remove the Thrust Washers and Gear 5 Inspect the Reverse Gear Assembly remove the Inner Race and Needle Bearing if damaged 191 Transmission Overhaul Procedures Bench Service How to Remove the Upper and Lower Countershaft Bearings Special Instructions The following instructions are use
58. Overhaul Procedures Bench Service With Housing bottom facing up secure the Assembly in a Vise If the Spade Pin is damaged replace and install the Spade Pin in Housing Tower Bore In models so equipped install the Nut and Washer in the Housing Bore If the O Ring is damaged replace lubricate the O Ring with Eaton Fuller amp Lubricant 71206 or equivalent Install the O Ring in the Housing Tower inside groove Align the Lever Ball slot with the Spade Pin and position the Gear Shift Lever in the Housing Tower v e E nn 5 5 22 o oz With dished side up install the Washer over the Ball Using a large Screwdriver or Pry Bar install the Tension Spring under the Housing Lugs Remove the Assembly from the Vise Install a rubber Boot over the Gear Shift Lever and against the Housing Note Make sure the Gear Shift Lever can move 133 Transmission Overhaul Procedures Bench Service How to Remove the Shift Bar Housing Special Instructions Before removing the Shift Bar Housing the Air Lines must be disconnected For models equipped with an Oil Pump and or Cooler Assemblies make sure to disconnect the oil line connected to the Shift Bar Housing There are three 3 sizes of Cap Screws The 1 1 2 Cap Screws are used with the Lifting Eyes The 1 1 4 are used on all other locations except the left front corner at the Roll Pin loc
59. RTO 5 us o5 ag Obb 8th High Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward 18 Speed Power Flow by Gear 10 Low Split Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 1 2 RTO RTX cpa le 1st Low Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch rearward Power Flow lt 5 5 5 3 gt aac eee WS ae LO High Split Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch rearward free 1 RTX i Us Obb OBS 1st High Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 31 Power Flow wees SEES D No 2nd Low Split Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward RTO 3rd Low Split Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 32 L J uf X 3 wees 2nd High Split Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 1 i L4 2 RTO RTX eg ves 3rd High Split Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward
60. Remove the Cap Screws and Range Cylinder Housing 7 Clean the Gasket mounting surfaces of all gasket material 8 Inspect the O Ring inside the Range Cylinder Housing Bore remove if damaged In Vehicle Service Procedures How to Assemble the Range Cylinder Assembly Special Instructions Apply Eaton Lubricant 71214 or equivalent to Shift Cylinder Assembly and Insert Valve O Rings so a film covers the entire surface of each O Ring Special Tools e Typical Service Tools 5 5 1 N 5 rJ ow v T rJ 17 wo N 1 Gasket 8 Piston 2 Shift Yoke 9 O Ring 3 Bolt 10 O Ring 4 Range Cylinder Assembly 11 Nut 5 Cap Screw 12 Gasket 6 O Ring 13 Cover 7 Yoke Bar 127 In Vehicle Service Procedures Procedure 1 If previously removed in the Cylinder Housing Bore install the small O Ring 2 If previously removed on the Piston I D and O D install the Piston O Rings 3 Position a new Gasket on the Range Cylinder Housing mounting surface 4 Install the Cylinder Housing 5 Apply Fuller amp Sealant 71205 or equivalent to the Retaining Cap Screw threads 6 Install the Cap Screws torque to 20 25 Ib ft 27 12 33 90 Nem 7 Lean Auxiliary Section back with Range Cylinder upward 8 Insert the Piston Push it in as far as it will go 9 Secure the Piston with the Retaining Nut torque to 70 85 Ib ft 94 91 115 24 Nem
61. Service Manual Fuller Heavy Duty Transmissions TRSMO670 EN US September 2013 RTLO 12713A RTLO 12913A RTLO 14713A RTLO 14718B RTLO 14913A RTLO 14918B RTLO 14918B T2 RTLO 16713A RTLO 16713A T2 RTLO 16718B RTLO 16913A RTLO 16913A T2 RTLO 16918B RTLO 16918B T2 RTLO 18718B RTLO 18718B T2 RTLO 18913A RTLO 18913A T2 RTLO 18918B RTLO 18918B T2 RTLO 20913A RTLO 20918B RTLO 20918B T2 RTLO 22918B RTLOC 16909A T2 RTLOF 12713A ETN Powering Business Worldwide RTLOF 12913A RTLOF 14713A RTLOF 14718B RTLOF 14913A RTLOF 14918B RTLOF 14918B T2 RTLOF 16713A RTLOF 16713A T2 RTLOF 16718B RTLOF 16913A RTLOF 16913A T2 RTLOF 16918B RTLOF 16918B T2 RTLOF 18718B RTLOF 18913A RTLOF 18913A T2 RTLOF 18918B RTLOF 18918B T2 RTLOF 20913A RTLOF 20918B RTLOF 20918B T2 RTLOF 22918B RTLOFC 16909A T2 BACKED BY Roadranger SUPPORT This Page Intentionally Blank Warnings and Cautions Warnings WARNING Before starting a vehicle always be seated in the Driver s Seat place the Transmission in Neutral set the Parking Brakes and disengage the Clutch Before working on a vehicle place the Transmission in Neutral set the Parking Brakes and block the wheels Before towing the vehicle place the Transmission in Neutral and lift the rear wheels off the ground remove the Axle Shafts or disconnect the Driveline to avoid damage to the Transmission during towing The description and specifications contained in thi
62. Shaft rotates Transmission Overhaul Procedures Bench Service Shim Table Feeler Gauge Shim Standard Shim Oil Pump Shim Color Average Gap Thickness Part Number Part Number Code 0 072 0 075 0 033 0 034 4302345 4302346 Gold 0 69 0 0715 0 036 0 037 21452 21472 0 066 0 0685 0 039 0 040 21453 21473 Pink 0 063 0 0655 0 042 0 043 21454 21474 Brown 0 060 0 0625 0 045 0 046 21455 21475 0 057 0 0595 0 048 0 049 21456 21476 Orange 0 054 0 0565 0 051 0 052 21457 21477 Yellow 0 051 0 0535 0 054 0 055 21458 21478 Green 0 048 0 0505 0 057 0 058 21459 21479 Light Blue 0 045 0 0475 0 060 0 061 21460 21480 Lavender 0 042 0 0445 0 063 0 064 21461 21481 White 0 039 0 0415 0 066 0 067 21684 21686 Black 0 036 0 0385 0 069 0 070 21685 21687 Silver 265 gt a i 1 ow LI 1 rJ 1 5 E 3 o v 5 2 gt D Transmission Overhaul Procedures Bench Service How to Remove the Boosted or Hydraulic Actuator and Adapter Housing Special Instructions The Air Line must be disconnected if removing an air over Hydraulic Boosted Actuator The hydraulic line does not need to be disconnected for the removal and installation of the Actuator and Actuator Housing A WARNING The Air System must be bled prior to removing any Air Lines to prevent possible injury CAUTION Do
63. Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward 21 Power Flow Auxiliary Section Power Flow Low Range Depending on the position of the Splitter Button L or H the Auxiliary Splitter Clutch engages in either the Auxiliary Drive Gear or the Splitter Gear The selected Auxiliary Gear transfers torque to both Auxiliary Countershafts If the Auxiliary Section is in low range the Range Sliding Clutch is rearward and engaged into the Auxiliary Mainshaft Reduction Gear Torque flows from the Auxiliary Countershafts into the Auxiliary Mainshaft Reduction Gear through the Range Sliding Clutch and then into the Output Shaft Auxiliary Mainshaft U T 0 tases wees was DIM ses sts LO 9 13 Speed LO Low Split 18 Speed 0 High Split 18 Speed 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 3 Sliding Clutch rearward 22 Auxiliary Section Power Flow High Range Power Flow If the Auxiliary Section is in high range the Range Sliding Clutch is forward and engaged into the back of the Auxiliary Drive Gear Torque flows through the Auxiliary Section in high range depending on the splitter state selected L or H If splitter L is selected torque flows from the Auxiliary Splitter Clutch to the Auxiliary Drive Gear From the Auxiliary Drive Gear torq
64. Special Instructions The Air Lines must be depressurized Special Tools e Typical Service Tools Procedure 1 Install the two 2 Retaining Cap Screws torque to 35 45 b ft 47 45 61 01 Nem Note Install the Exhaust Breather on the Top 2 Valve if previously removed arrow shows location on the Top 2 Valve 2 Connect the Air Lines to the Air Fittings Note Replace any damaged Air Fittings or Lines 3 Connect the 3 Way Connector to the Harness Note Be sure Connector is free from dirt and debris 88 In Vehicle Service Procedures How to Remove the Gear Shift Lever Remote Shift Control Special Instructions The Air Lines must be disconnected from the Transmission or from the Roadranger Valve Different Detent Springs are available to increase or decrease shifting effort Note and record specific locations for specific springs In some cases a stiffer spring is installed in the top rail position Remote Control Housings are removed the same way as Gear Shift Levers 2 1 wo wo v rJ a o Special Tools e Typical Service Tools Procedure 1 From the Gear Shift Lever Base Shift Control Housing 1 remove the four 4 Retaining Cap Screws 2 3 1 Housing 2 Capscrew 3 Gasket 2 To break the Gasket seal lightly jar the Gear Shift Shift Control Housing 3 Remove the Gear Shift Lever Housing A CAUTION Make sure the Detent Sprin
65. Stamp Position 3 Locate the two stamped O s on the Countershaft Y paint preferably a yellow or white 58 Use a Round File or Bar to properly align from the marked teeth on the Auxiliary Countershaft to the Auxiliary Splitter Gear When the Bar is lined up with the root between the correct teeth you will notice it s parallel with the Auxiliary Countershaft Mark both the teeth with a highly visible paint Example of correct alignment Bar in correct position parallel with the Countershaft and between the marked Splitter gear and Reduction Gear teeth Examples of Left or Right Misalignment Timing 59 E 3 Timing 60 Lay the Splitter Gear on a flat surface and mark it similar to steps 1 and 2 of this procedure Make sure the teeth are painted on both faces of the Splitter Gear front and rear Example showing correct view of Reduction Gear timed to Countershaft Gears on the bench Install the Reduction Gear and Output Shaft Assembly into the Auxiliary Case Then install the Auxiliary Countershafts and Splitter Gear Countershaft Retaining Straps must be used to hold the Auxiliary Countershafts in place until the Auxiliary Section is fully installed Failure to use the straps could result in the Auxiliary Section moving out of time Examples of Splitter Gear timed to the Auxiliary Countershafts To ensure the timing is correct check that the m
66. Start installation of the bottom Shift Bar as the Bar passes the Bosses install the two 2 bottom Shift Yoke Assemblies Install the Shift Yoke Lock Screw torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place the Actuating Plunger in the top center Bore Place one 3 4 Interlock Ball in the Interlock Bore against the bottom Bar Holding the middle Bar notched end start installation As the Bar passes the Rear Boss position the Shift Block As the Bar passes the center Boss position the Shift Yoke on Bar long hub to the Housing front Just prior to inserting notched end of Bar in Rear Boss install the small Interlock Pin vertically in the Neutral Notch Bore Install the Shift Block and Shift Yoke Lock Screws torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place one 3 4 Interlock Ball in the Interlock Bore against the middle Bar Transmission Overhaul Procedures Bench Service 15 Holding the top Bar notched end start installation As the Bar passes the Rear Boss position the Shift Block 16 As the Bar passes the center Boss position the Shift Yoke on the Bar long hub to the Housing rear 17 Install the Shift Block and Shift Yoke Lock Screws torque to 35 45 16 47 45 61 01 Nem Lockwire securely 18 Install the Oil Trough Torque the Retaining Cap Screws to 8 12 lb ft 10 85 16 30 Nem Some models do not have an Oil Trough
67. Worn Shift Rail Procedure If the Range has been confirmed to shift with the Shift Lever in gear unbolt the Slave Valve from the side of the Transmission Confirm that the Actuating Pin is present and that it is the proper P N for the corresponding Slave Valve If correct remove the Shift Bar Housing Assembly and check for a worn or damaged Air Valve Shaft or worn Shift Rails Replace necessary parts 57 Timing Procedures Special Instructions It is essential that both Countershaft Assemblies of the Front and Auxiliary Sections are timed This assures proper tooth contact is made between Mainshaft Gears seeking to center on the Mainshaft during torque transfer and mating Countershaft Gears that distribute the load evenly If not properly timed serious damage to the Transmission is likely to result from unequal tooth contact causing the Mainshaft Gears to climb out of equilibrium Timing is a simple procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh while in the Transmission In the Front Section it is necessary to time only the Drive Gear set And depending on the model only the LO Range Deep Reduction or Splitter Gear Set is timed in the Auxiliary Section Procedure Front Section 1 Marking Countershaft Drive Gear teeth Prior to placing each Countershaft Assembly into the Case clearly mark the tooth located directly over the Drive Gear Keyway as shown This too
68. ace as necessary If necessary replace any damaged or worn Clutch Housing or rear support studs Apply Eaton Fuller Thread Sealant 71205 or equivalent to any replacement studs before installing them Verify the three Magnetic Discs are firmly attached to the bottom of the Main Case If they are not firmly attached apply 3M Scotch Grip or equivalent adhesive to the bottom of the Discs and attach them to the Main Case 218 Transmission Overhaul Procedures Bench Service How to Assemble the Countershaft Assemblies Special Instructions Except for the PTO Gears the Upper and Lower Countershaft Assemblies are the same To avoid confusion during installation mark the Upper Countershaft 45 Tooth PTO Gear with an U The Lower Countershaft has a 47 Tooth PTO Gear Special Tools e Snap Ring Pliers e Press Procedure 1 If previously removed install the Keys in each Countershaft Keyway E e 9 5 i ue 5 5 2 o 1 ez 2 Align smallest diameter gear Keyway with the Countershaft Key long hub to Countershaft front and press the gear on the Countershaft 3 Align 2nd smallest diameter gear Keyway with the Countershaft Key long hub against 1st Speed Gear and press the Gear on the Countershaft 219 Transmission Overhaul Procedures Bench Service 4 Align 3rd smallest diameter gear Keyway with the Countershaft Key long hub to Countershaft front and pr
69. ace if damaged Air Line Fittings 85 In Vehicle Service Procedures How to Install a Slave Valve Special Instructions None Special Tools e Typical Service Tools Air Line Fittings Plunger Pin a 2 gt Sleeves Retaining Capscrews mac 86 Procedure 1 Clean gasket surface and install Air Fittings 2 Lightly lubricate and install plunger Pin Spring and Sleeve into Case 3 Install any necessary air Hoses at this time 4 Install new Gasket 5 Apply Eaton Sealant 71205 or equivalent to the Retaining Cap Screws 6 Install the Retaining Cap Screws torque to 8 12 Ib ft 10 85 16 30 Nem Note Make sure the Retaining Cap Screws are properly torqued In Vehicle Service Procedures How to Remove the Top 2 Valve Assembly Transmissions with Top 2 Option Only Special Instructions The Air Lines must be depressurized Special Tools e Typical Service Tools Procedure 1 From the 3 Way Connector disconnect the Wire Harness 1 e 1 v ix 1 a o 2 From the Air Fittings disconnect the Air Lines 3 From the Top 2 Valve Assembly remove the two 2 Cap Screws Note If necessary remove the Exhaust Breather from the Top 2 Valve arrow indicates location on the Valve 87 In Vehicle Service Procedures How to Install the Top 2 Valve Assembly Transmissions with Top 2 Option Only
70. aining Cap Screws and cover Remove any remaining gasket material from the Case and Cover 2 If present remove and discard the rubber Seal Ring on the Input Shaft The Ring is used only to seal the Transmission during shipment eo From the Input Shaft groove remove the Bearing Retaining Snap Ring 150 Transmission Overhaul Procedures Bench Service 4 UseaSoft Bar and Maul to drive the Input Shaft toward the Case rear as far as possible Pull the Input Shaft forward 5 Install the RR1023TR Input Bearing Puller and remove the Input Bearing from the Case and Input Shaft or use Pry Bars or Screwdrivers to complete removal of the Bearing 6 From the Drive Gear front remove Drive Gear Spacer E e 9 5 i ue 5 5 2 o 1 ez 7 Remove the Drive Gear Internal Snap Ring 8 Pullthe Input Shaft forward and out of the Drive Gear 9 Inspect the bushing in the Input Shaft pocket replace if damaged 151 Transmission Overhaul Procedures Bench Service How to Install the Input Shaft Assembly without Main Case disassembly Special Instructions None Special Tools e RR1023TR Input Bearing Puller e 1019 Hand Maul Procedure 1 If necessary install the bushing in the back of the Input Shaft 2 From the front engage the Input Shaft Spline Teeth into the Main Drive Gear Note The current design Input Shaft Spline Teeth have
71. amaged or defective Range Cylinder e Damaged or defective range Yoke or Yoke Bar e Damaged or defective Range Synchronizer e Damaged or defective gearing in Auxiliary Section of Transmission Table 15 No or Slow Range Shift into High Procedure Result What To Do Next Step A Place the Shift Lever in Neutral Constant air leak is detected Go to the other corresponding Check for constant air leakage at the symptom first See beginning of Air Shift Knob Slave Valve and System Troubleshooting section Transmission Case Breather when both Low and High Range have been selected No constant leak is detected Go to Step Step B Place Shift Lever in Neutral Air flows from the High Remove Range Cylinder Cover and Move Range Selector down to Low Range port repair leaking Range Piston or Piston Range position Seal After repair check for proper Atthe Transmission rear disconnect the range operation 1 4 Rubber Air Line from the Range Cylinder High Range Supply Port Check for air flow from the Cylinder High Range port No air flow from High Range Go to step C port Step C Check for air flow from the disconnected Air flows from disconnected Go to step Air Line Air Line No air flow from Go to step D disconnected line 53 Air System Table 15 No or Slow Range Shift into High Continued Procedure Result What To Do Next Step D Install a 100 PSI air Gauge in the The G
72. and Rear Bearing Covers for oil leakage due to faulty Gasket 9 Gear Shift Lever e Check for looseness and free play in Housing If Lever is loose in Housing proceed with Check No 10 10 Gear Shift Lever Housing Assembly e f present remove Air Lines at Air Valve or Slave Valve Remove the Gear Shift Lever Housing Assembly from the Transmission e Check the Tension Spring and Washer for set and wear e Check Gear Shift Lever Spade Pin and slot for wear e Check bottom end of Gear Shift Lever for wear and check slot of Yokes and Blocks in Shift Bar Housing for wear at contact points with Shift Lever Checks With Drive Line Dropped 11 Universal Joint Companion Flange or Shaft Nut e Check for tightness Tighten to recommended torque 12 Output Shaft Not Shown e Pry upward against Output Shaft to check radial clearance in Mainshaft Rear Bearing Checks With Universal Joint Companion Flange or Yoke Removed Note If necessary use solvent and shop rag to clean sealing surface of Companion Flange or Yoke Do not use Crocus Cloth Emery Paper or other abrasive materials that will mar surface finish 13 Splines on Output Shaft Not Shown e Check for wear from movement and chucking action of the Universal Joint Companion Flange or Yoke 14 Mainshaft Rear Bearing Cover Not Shown e Check Oil Seal for wear Inspection Preventive Maintenance Part to Inspect What to Check For Action to be Done Speedome
73. ar Housing 187 Transmission Overhaul Procedures Bench Service 10 Remove the gasket and clean all mounting surfaces of gasket material a Without Oil Tube channel Old style b With Oil Tube channel New style Note Clutch Housing with Oil Channel can be used on Transmissions without the Oil Tube New Style 188 Transmission Overhaul Procedures Bench Service How to Disassemble the Upper Reverse Idler Gear Assembly Special Instructions Before the upper Reverse Idler Gear Assembly can be removed Mainshaft Reverse Gear must be positioned forward against the next Gear While removing the Reverse Idler Shaft the Thrust Washer can drop to the Transmission case bottom The Mainshaft Reverse Gear must be moved in order to remove the upper Reverse Idler Gear Special Tools e 1010 Slide Hammer Procedure 1 Remove Retaining Bolt from the Idler Shaft Note If Idler Shaft spins in Case Bore slightly heat bolt with torch to release loctite adhesive v 2 eu 9 5 o nn 5 5 22 o 1 ez 2 Mainshaft Reverse Gear must be moved order to remove the Upper Reverse Idler Gear Remove Reverse Gear Snap Ring and slide Reverse Gear forward over Clutch 3 Removethe loosened bolt and remove washer Reinstall bolt 3 4 threads 4 Install an Impact Puller 1 2 13 threaded end and remove the Shaft from Case Bore 189 Transmission
74. ar Housing Special Tools e Typical Service Tools 136 Procedure Place the Shift Bar Housing and Shift Blocks in the Neutral position Place the Mainshaft Sliding Clutches in the Neutral position Position a new Shift Bar Housing Gasket on the Shift Bar Housing mounting surface Note The Slave Valve and Interlock Assembly must remain off until the Shift Bar Housing is installed to avoid damaging the Interlock Pin As you install the Shift Bar Housing make sure the Yokes fit into the corresponding Sliding Clutch slots and the Housing aligns with the Roll Pin Apply Fuller amp Sealant 71205 or equivalent to the Retaining Cap Screw threads Transmission Overhaul Procedures Bench Service 6 Install Interlock parts Pin Spring and Sleeve 7 Install Slave Valve and tighten to specifications Y 3 1 a o LI E o 5 o 137 Transmission Overhaul Procedures Bench Service How to Disassemble the Standard Shift Bar Housing Special Instructions The Shift Bar Housing must be removed from the Transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars Start with the bottom Shift Bar Cut the Lockwire and remove the Lock Screws from each Bar just before th
75. arked tooth on the Splitter Gear is between the two marked teeth on the Auxiliary Countershaft Gears as shown in the illustrations In Vehicle Service Procedures How to Remove Oil Filter Adapter Special Instructions The Oil Filter Adapter must be removed before the Transmission can be set on the table for servicing Failure to do so will make the Transmission unstable and may damage the Filter Adapter If the Transmission is not equipped with an Oil Filter Adapter at the Pump Outlet skip this procedure Special Tools e Typical Service Tools Procedure 1 Remove the Oil Filter by turning it in the counter clockwise direction 1 e 1 v is I5 o 2 From the Oil Filter Adapter remove the 5 3 16 Allen Head Cap Screws 3 Remove the Gasket and clean all mounting surfaces 61 In Vehicle Service Procedures How to Assemble Oil Filter Adapter Special Instructions None Special Tools e Typical Service Tools 62 Procedure 1 Position the new Gasket on the Adapter mounting surface with 2 Cap Screws through the Adapter to hold the Gasket in place 2 Install the Filter Adapter and torque all Cap Screws to 8 12 Ib ft 10 85 16 30 Nem 3 Installa new Oil Filter Eaton Part 4304827 or equivalent In Vehicle Service Procedures How to Disassemble Roadranger Valve A 5010 Special Instructions None Special Tools e Typical Se
76. ary use an Output Yoke Puller Remove the Seal sleeve Use RR1010TR Slide Hammer and RR1011 1 Attachment to remove the Seal Or remove Output Bearing Cover and drive Seal out from front side Note The Seal will be damaged during removal and must be replaced Remove Seal Slinger from the Output Yoke using a Brass Drift and Hammer Inspect all parts of the Seal surface for wear scratches burrs or other damage Note Replace the Seal surface if it is worn or damaged Do not attempt to salvage the Seal mating surface with Crocus Cloth filing etc In Vehicle Service Procedures How to Install the Oil Seal Mechanical Speedometer Special Instructions CAUTION To prevent oil leaks do not touch the seal lip and make sure the Seal Driver is clean Special Tools e RR1001TR 2 Output Seal Driver e RR1001TR 4 Output Seal Slinger Driver Procedure 1 2 wo wo v rJ a N 1 Seal will be damaged during removal and must be replaced 2 Place a Seal on the RR1001TR 2 Output Seal Driver and drive the new Seal into the Rear Bearing Cover 3 Install the new Slinger on the Output Yoke using the RR1001TR 4 Output Seal Slinger Driver 4 Install the Output Yoke over the Output Shaft The Yoke should slide on when the Splines are lined up If it does not clean the Splines with solvent and oil them lightly 5 Install the Output Nut and t
77. ation This Cap Screw is 1 3 4 Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes Special Tools e Typical Service Tools Procedure 1 From the Shift Bar Housing remove the two Shift Bar Retaining Cap Screws securing the Oil Cooler Remove Oil Cooler and set aside 2 Remove Slave Valve 134 Transmission Overhaul Procedures Bench Service 3 Remove Interlock parts Pin Spring and Sleeve 4 Fromthe Shift Bar Housing rim remove the Retaining Cap Screws 5 To break the Gasket seal jar the Shift Bar Housing 6 Remove the Shift Bar Housing 7 Inspect the Roll Pin replace if damaged 8 Remove the Gasket and clean all mounting surfaces of gasket material 9 Ifthe three 3 sets of Tension Springs and Balls from the Housing top Bores are loose tilt the Assembly and remove them 135 Transmission Overhaul Procedures Bench Service How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of Cap Screws The 1 1 2 Cap Screws are used with the Lifting Eyes The 1 1 4 are used on all other locations except the left front corner at the Roll Pin location This Cap Screw is 1 3 4 Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes The Slave Valve and Interlock parts must be removed prior to installing the Shift B
78. auge reads 0 PSI Go to step F disconnected Air Line end With the Shift Lever in Neutral move the Range Selector up to select High Range Observe the Gauge The Gauge reads pressure but Replace the Filter Regulator and check is lower than 58 PSI or higher for proper range operation than 63 PSI The Gauge reads between Go to step E 58 63 PSI Step E Confirm that Shift Lever is still in Neutral Pressure rapidly changes Air System appears to be operating Have an assistant move the Range between 58 63 PSI and Oat satisfactory Go to step Selector up and down between Low and the Gauge High Range Does the pressure measured at the Gauge respond rapidly when going from High to Low Pressure does not change 1 Check for a plugged or dirty filter in rapidly at Gauge the Filter Regulator Assembly 2 Check for a pinched or obstructed 1 4 rubber Air Line between the Filter Regulator and Slave Valve 3 Check for a pinched or obstructed 1 4 Rubber Air Line between the Slave Valve and the Test Gauge 4 If all are satisfactory go to step Step F Place Shift Lever in Neutral Air flows from the 1 Confirm that the Air Lines are At the Shift Knob move the Range disconnected line connected to the correct ports at the Selection Lever up to select High Range Shift Knob At the Slave Valve remove the Air Line from the P port should be black line Check for air flow from the disconnected line 2 f the lines are correct replace the S
79. ause personal injury or damage to equipment To prevent injury or equipment damage exhaust the Vehicle Air Tanks CAUTION Make sure only 5 32 Air Lines are used with Push to Connect Fittings Using sizes other than 5 32 can cause air leaks or damage to Fittings Special Tools e See Tool Information see Table 5 e For Push to Connect Fittings we recommend Eaton Service Tool Kit K 2394 The Kit contains the Release Tool and the Tubing Cutter Procedure 1 Check the threads of the fitting for thread sealant If no sealant is present apply Eaton Thread Sealant 71205 or equivalent 2 Install the fitting 3 Inspect the Air Line for burrs or deformed areas Trim the air line if necessary using a sharp razor blade or the Air Line Cutting Tool from Kit K 2394 The cut must be smooth and square If the tubing end is deformed or burred the internal O Ring in the fitting will be damaged when the Air Line is inserted 4 Pushthe Air Line into the fitting It should insert approximately 3 4 If it does not insert far enough or is difficult to insert the fitting may be damaged and should be replaced After inserting give the Air Line a slight tug to make sure the line stays in place If line does not stay in place replace the fitting 5 Enable the vehicle Air System Allow the Air Tanks to pressurize and check for leaks 78 In Vehicle Service Procedures How to Remove Rubber 1 4 Air Hoses Special Instructions
80. ch on the LO Range Synchronizer Pins 3 Inthe HI Range Synchronizer Bores install the three 3 springs y e ez o 5 5 dE 55 ez 9 4 Place the HI Range Synchronizer Ring over the LO Range Synchronizer Ring Rotate the HI Range Synchronizer until the springs are seated against the pins 5 Cover the Assembly with a shop rag 6 Apply downward pressure to the HI Range Synchronizer Ring while twisting counterclockwise This compresses the springs to fully seat HI Range on the LO Range Synchronizer This should be done with a rapid twist and push motion Note Make sure there are three springs and they are fully compressed Note Make sure you can move the Sliding Clutch from HI to LO Range and back 169 Transmission Overhaul Procedures Bench Service How to Assemble the Output Shaft Assembly Special Instructions Make sure the Magnetic Plugs are installed in the Auxiliary Housing Output shaft stack up should be done on a clean flat surface When heating the bearings do not heat above 275 F 136 C When installing the rear Bearing Race the proper depth is when the Race shoulder is seated on Bearing Bore top Because the collar becomes distorted when compressed do not use an old nylon collar in the Rear Bearing Cover Special Tools Procedure 1 Use Toolmaker s Dye and mark the LO Range Gear for timing purposes 2 Markany two 2 adjacent teeth
81. continued operation of the unit frosted gears heal and do not progress to the pitting stage In most cases gears with light to moderate pitted teeth have considerable gear life remaining and can be reused but gears in the advanced stage of pitting should be replaced e Check for gears with Clutching teeth abnormally worn tapered or reduced in length from clashing during shifting Replace gears found in any of these conditions e Check Axial Clearance of gears Introduction Gear Shift Lever Housing Assembly e Check spring tension on Shift Lever Replace Tension Spring if lever moves too freely e f Housing is disassembled check Gear Shift Lever bottom end and Shift Finger Assembly for wear Replace both gears if excessively worn Gray Iron Parts e Check all gray iron parts for cracks and breaks Replace parts found to be damaged 3 3 5 5 5 3 gt E Oil Return Threads and Seals e Check oil return threads on the Input Shaft If return action of threads has been destroyed replace the Input Shaft e Check Oil Seal in Rear Bearing Cover If sealing action of lip has been destroyed replace Seal O Rings e Check all O Rings for cracks or distortion Replace if worn Reverse Idler Gear Assemblies e Check for excessive wear from action of Roller Bearings Shift Bar Housing Assembly e Check for wear on Shift Yokes and Block at pads and lever slot Replace excessively worn parts
82. ctor 2 Collet and into the Collet Tighten the Nut as usual 3 Nut 4 Air Line 4 Enable the Vehicle Air System Allow the Air Tanks to pressurize and check for leaks Repair as necessary 76 In Vehicle Service Procedures How to Remove Push to Connect Type Fittings Special Instructions WARNING Asudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tank CAUTION Make sure only 5 32 Air Lines are used with Push to Connect Fittings Using sizes other than 5 32 can cause air leaks or damage to Fittings Before removing the Air Lines and Hose label or record their location 1 2 5 7 wo v rJ N Special Tools e Tool Information see Table 8 e For Push to Connect Fittings the Eaton Service Tool Kit K 2394 is recommended The Kit contains the Release Tool and the Tubing Cutter Procedure 1 Exhaustthe Vehicle Air Tanks before continuing 1 Cutter 2 Release Tool 2 Usethe Air Line Release Tool from Kit K 2394 to press the Release Sleeve down while pulling the Air Line from the fitting Inspect the fitting for damage or wear Remove and replace as necessary 77 In Vehicle Service Procedures How to Install Push to Connect Type Fittings Special Instructions WARNING Asudden release of air pressure can c
83. ctory Go to step Selector up and down between Low and the Gauge High Range Does the pressure measured at the Gauge respond rapidly when going from High to Low Pressure does not change 1 Check for a plugged or dirty filter in rapidly at Gauge the Filter Regulator Assembly 2 Check for a pinched or obstructed 1 4 Rubber Air Line between the Filter Regulator and Slave Valve 3 Check for a pinched or obstructed 1 4 Rubber Air Line between the Slave Valve and the Test Gauge 4 f all are satisfactory go to step F Step F Place Shift Lever in Neutral Air flows from the 1 Confirm that the Air Lines are At the Shift Knob move the Range disconnected line connected to the correct ports at the Selection Lever up to select High Range Shift Knob At the Slave Valve remove the Air Line from the P port should be black line Check for air flow from the disconnected line 2 f the lines are correct replace the Shift Knob No air flow from the Go to step G disconnected line Step G Check for air flow from the P portonthe Air flows from this port Replace the Slave Valve Slave Valve No air flow from this port Go to step H Step H Place the Shift Lever in Neutral Installa The Gauge responds slowly 1 Check for a restricted line between 100 PSI Pressure Gauge in line with the P line Move the Range Selector back and forth from Low to High Range The Gauge should show rapid pressure change the Shift Knob a
84. d Bearing Endplay Rolling Head Pry Bar To remove the Auxiliary Drive Gear Bearing 2 Air Pressure Gauges 0 100 PSI 0 1034 kPa To troubleshoot and verify correct operation of Air System To remove and install Clutch Housing Bushings Bushing Universal Bushing Driver OD 1 125 in ID 1 000 in Recommended Tools Special Tools The following Transmission Tools are available directly from K Line Industries To obtain any of these tools listed contact K Line by phone or visiting the online store K Line Industries Inc 315 Garden Avenue Holland MI 49424 1 800 824 KLINE 5546 http www klineind com K Line Part Tool Tool Description Used to install Output Seal Protective Slinger on FR amp RT Series RR1001TR 1 Driver Output Seal Slinger Gen 9 Transmission Output Yokes QUSE Slinger on RT Series Gen 6 amp ng Coon FR amp Ses Ge Tnm n EE De RR1004TR Mainshaft Lifting Hook ien to remove install Mainshaft Assembly into the Transmission ain Case Used to install the Input Bearing on Transmissions with 2 amp 1 75 RR1005TR Driver Input Bearing Input Shafts RR1 RRIOOBTR Auxiliary Section Lifting Bracket Used to lift Transmission Auxiliary Sections RR1007TR FRE an Gauge Auxiliary Used for setting proper Auxiliary Countershaft Bearing clearance on Countershaft 0 100 FR Series and RT Series Gen 7 amp 9 Transmissions RR1011TR 1 Slide Ham
85. d to remove the Upper and Lower Countershaft Bearings To remove the Mainshaft Assembly only the Upper Countershaft Bearings need to be removed Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned The Bearing Inner Race remains pressed on the Countershaft after removal of the Front Bearings Special Tools e RR1019TR Hand Maul e RR1020TR Soft Bar e RR1012TR Bearing Puller Procedure 1 To keep the Mainshaft Pilot from falling out of the Input Shaft pocket temporarily install the Auxiliary Drive Gear on the Mainshaft 2 From each Countershaft Rear Groove remove the Snap Ring 3 Remove six Cap Screws from Front Bearing Cover and remove Front Bearing Cover CAUTION Damage will likely occur to this bearing during removal It is strongly recommended that this bearing is discarded 4 From inside the case use a Soft Bar and Maul to drive the Countershaft Rear Bearings rearward off the shaft 192 Transmission Overhaul Procedures Bench Service From the front of each Countershaft remove the Cap Screw and front Retainer Plate Use the Soft Bar and Maul to drive each Countershaft to the rear as far as possible This partially unseats the Front Bearings Return to the case rear and drive each Countershaft forward as far as possible This exposes the External Snap Ring Use theRR1012TR Bearing Puller to remove the Countershaft Front
86. ding Clutch rearward 3 Sliding Clutch rearward 24 Power Flow lt 5 5 5 3 gt M as oles 4th Gear 5th Gear 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch forward NC RTO RT RTO Y RT eae eee eae Wee ode Hee Hae 6th Gear 7th Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch forward 3 Sliding Clutch forward 25 Power Flow RTO wees wae Obed 8th Low Split Gear Top 2 Models 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward 26 E RTO mI 5 Wed Mae 8th High Split Gear Top 2 Models 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward Power Flow 13 Speed Power Flow by Gear lt 5 5 5 3 gt 1 2 RTO RTX wob LEG SoS wad ess ves ae Wee LO Gear 1st Gear 1 Sliding Clutch forward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch rearward m S wie aug wae LO 8 8 ES e wai ses 2nd Gear 3rd Gear 1 Sliding
87. dler Shaft slides into the Gear insert the Front Thrust Washer into position Continue sliding the Idler Shaft into the Case Support Boss 4 From the rear gently tap the Idler Shaft forward until resistance is felt 5 Install the Flat Washer over the Shaft s threaded portion y e 9 5 54 5 5 ig 55 ez 9 6 Inspect the Reverse Idler Nut nylon locking material Replace the Cap Screw if necessary Install the Cap Screw and torque to 67 75 Ib ft 90 84 101 69 Nem 7 Using a Bearing Race Driver install the Auxiliary Countershaft Bearing Race into the Lower Reverse Idler Bore Note The Bearing Races have a slip fit in their Bores They should slide or rotate easily into the Case Bore if they are not cocked 239 Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Drive Gear Assembly Special Instructions Before installing the Auxiliary Drive Gear the Mainshaft must be completely installed Special Tools 240 co Procedure If removed press the Spacer into the Bearing Slide the Auxiliary Bearing on the Mainshaft up to the Case Bore Use a Brass Maul and carefully seat the bearing in Case Bore Install the Splined Washer on the Mainshaft Align the Retainer Ring Cap Screw holes with the tapped holes Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screw threads Install th
88. e Mainshaft With the missing internal Splines aligned with the plastic line install the Reverse Sliding Clutch Install the Reverse Gear Offset Washer in the last groove From the Mainshaft rear install the Mainshaft Key into the Spline with the Air Line Pull the Air Line from the Spline while installing the Key Install the Reverse Gear Spacer Washer with external Spline teeth over the Mainshaft rear and against the Offset Washer Note Some models the Reverse Gear Offset Washer has a large chamfer machined in the backside This special Offset Washer must be used in this position The large chamfer faces rearward From the rear install the Reverse Gear over the Sliding Clutch teeth Install the Snap Ring in the Mainshaft groove Note Some models do not use a Snap Ring at this position Remove the Mainshaft from the Vise and lay on its side Install the front Sliding Clutch into position How to Assemble the Mainshaft Assembly with Low Force Gearing Transmission Overhaul Procedures Bench Service Special Instructions The design of the Mainshaft with Low Force Gearing is slightly different from the standard Mainshaft It still utilizes Non Selective non adjustable Tolerance Washers but the 1st and Reverse Gears and Sliding Clutch have been redesigned In this configuration the 1st Reverse Sliding Clutch rides on a Clutch Hub and the 1st and Reverse Gears have been redesigned to accommodate this change
89. e Retaining Cap Screws torque to 35 45 Ib ft 47 45 61 01 Nem Install the Auxiliary Drive Gear and Retaining Washer on the Mainshaft Install the Auxiliary Drive Gear Retaining Snap Ring in the Mainshaft Snap Ring groove Transmission Overhaul Procedures Bench Service How to Install the Clutch Housing with Internal Oil Tube Special Instructions Installation of the Clutch Housing is performed in the horizontal position IMPORTANT Some early production models do not have an Oil Tube behind the Clutch Housing For these models skip steps 3 4 and 5 The Oil Tube comes in two different lengths The older units extend 2 3 of the way through the Front Box The new units go into the intermediate wall that separates the Main Case from the Auxiliary Case see step 5 Special Tools e Typical Service Tools Torque wrench Procedure 1 Position a new gasket on the Housing mounting surface Note Ifthe Front Bearing Cover was removed it needs to be installed before the Clutch Housing to ensure correct alignment of the Clutch Housing 2 If Oil Tube is not being replaced follow steps 6 8 Note For additional information on the removal of the Shift Bar Housing and Slave Valve refer to the proper section 3 Inspect O Rings on Oil Tube and replace if damaged 4 Apply Eaton Fuller silicone Lubricant 71203 to O Rings and install Oil Tube in Case 241 y 7 1 a o LI wo rJ co
90. e heavy lines in the figure below outline the Power Flow description For help in understanding the Transmission components refer to the figure Transmission Components on the previous page Power torque from the vehicle s engine is transferred to the Transmission s Input Shaft The Input Shaft rotates the Main Drive Gear through internal Splines in the hub of the Gear lt 5 2 5 5 3 gt The Main Drive Gear meshes with both Countershaft driven gears and the torque is split between both Countershafts geo Das SS Because the Countershaft Gears are in constant mesh with the Mainshaft Gears all the Front Section gearing rotates However only the engaged or selected Mainshaft Gear will have torque External Clutching teeth on the Sliding Clutch will engage internal Clutching teeth on the selected Mainshaft Gear Torque will now be provided from both opposing Countershaft Gears into the engaged Mainshaft Gear and through the Sliding Clutch to the Front Section Mainshaft 5 The rear of the Front Section Mainshaft is splined into the Auxiliary Splitter Clutch and torque is now delivered to the Auxiliary Splitter Clutch 1 2 GS Front Section Power Flow 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 19 Power Flow Front Section Power Flow Direct Gear In direct gear the Front Sliding Clutch is moved forward and engages
91. e most pronounced under hard pull or coast high torque Check Transmission Oil for excessive metal particles Noise Growl Rumble at Idle Idle Gear Rattle Excess engine torsional vibration at idle Check for low Engine RPM Check for uneven Engine Cylinder performance Check for proper Clutch Damper operation Noise High Pitched Whine Gear Noise Isolate as to axle or Transmission noise If Transmission isolate to specific gear or gears Check for worn or defective Shift Lever Isolator Check for direct Cab or Bracket contact with Transmission grounding Check for proper Driveline U joint working angles Check for damaged or worn gearing Hard Lever Shifting Shift lever is hard to gear into or out of gear Master Clutch dragging Check Master Clutch for proper disengagement Check Master Clutch for proper adjustment both Release Bearing travel and Clutch Brake height Shift linkage problem Remote Shifter Check Shift Linkage or cables for proper adjustment binding lubrication or wear Shift Bar Housing problem Check Shift Bar Housing components for binding wear or damage Transmission Mainshaft problem Check Mainshaft for twist Check Sliding Clutches for binding damage or excessive wear Driver technique Driver not familiar or skilled with proper double Clutching technique Driver contacting the Clutch Brake during shifts Shift Lever Jumpout
92. e page 114 for removing Auxiliary Section instructions Special Tools e Typical Service Tools 1 Gasket 2 Shift Yoke 3 Bolt 4 Range Cylinder Assembly 5 Cap Screw 6 O Ring 7 Yoke Bar 162 8 Piston 9 O Ring 10 O Ring 11 Nut 12 Gasket 13 Cover Transmission Overhaul Procedures Bench Service Procedure 1 From the Range Cylinder Cover remove the Cap Screws Cover and Gasket 2 Clean the gasket mounting surfaces of all gasket material 3 From the Range Cylinder Housing Bore remove the 15 16 nut E e 5 Oo 5 5 5 5 2 o 1 ez 4 Fromthe Cylinder Housing Bore remove the Range Piston 5 Inspect the Range Piston O Rings remove if damaged 6 Remove the Cap Screws and Range Cylinder Housing 7 Clean the gasket mounting surfaces of all gasket material 8 Inspectthe O Ring inside the Range Cylinder Housing Bore remove if damaged 163 Transmission Overhaul Procedures Bench Service How to Disassemble the Output Shaft Assembly Special Instructions When using the Soft Bar and Maul on the Output Shaft be careful not to damage the threads When removing the Rear Bearing Cover the Rear Bearing Cone drops from the Housing Bore Special Tools e Vise with brass jaws or wood blocks e Press e Soft Bar and Maul 1 Speedo Rotor Assembly 2 O Ring 3 Oil Seal Kit 4 Cap Screw 5 Rear Bearing Cover Assembl
93. e removing the Air Lines and Hoses label or record their location If you are unsure of their location after you remove the Air Lines and Hoses see the Air System Troubleshooting Guide TRTS0920 Special Tools e Typical Service Tools e For Push to Connect Fittings the Eaton Service Tool Kit K 2394 is recommended The Kit contains the Release Tool and the Tubing Cutter Procedure 1 Disconnect all Air Lines and Hoses 1 e 1 v ix 1 a o 2 Inspect the Air Lines and Hoses 71 72 In Vehicle Service Procedures Air Line Fitting Types 1 1 8 tube 1 8 NPTF 2 Push to connect 3 5 32 tube 1 8 NPTF 3 Inspect Air Fittings and remove if damaged In Vehicle Service Procedures How to Install the Air Lines and Hoses Special Instructions Make sure Air Lines and Hoses are not damaged Install the Air Lines and Hoses at their proper location All externally threaded 1 8 or 5 32 Air Lines and Pipe Fittings that are not coated with pre applied thread sealant must be coated with Eaton Sealing Material 71209 or equivalent for at least 5 complete and consecutive threads All externally threaded 1 4 Air Fittings that are not coated with pre applied thread sealant must be coated with Eaton Sealing Material 71209 or equivalent for at least 3 complete and consecutive threads For the 1 4 I D Air Hoses install the fixed nut end first
94. ear Bearing Cover Gasket and Rear Bearing Shim Clean the gasket surface area 3 Install the RR1002TR Auxiliary Countershaft Support Straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean Cap Screws Note Do not use an Air Gun Tighten by hand until the Cap Screws are snug 4 From the Auxiliary Section Housing remove the Retaining Cap Screws that attach the Front Box to the Auxiliary Section 5 Install a Steel Bar through the Yoke 6 Attach Lifting Chain to the Steel Bar 7 Liftassembly from the Front Section 155 79 a D LI 5 2 2 Transmission Overhaul Procedures Bench Service How to Remove the Splitter Cylinder Assembly Note On 9 Series and Super 10 Transmissions it is necessary to R amp R the Auxiliary Section Prior to Range Cylinder Removal Damage to internal components will result if Auxiliary Section is not properly removed prior to Cylinder Removal Note When replacing just the O Rings in the Splitter Cylinder removal of the Auxiliary Section is not necessary Special Instructions When removing the Splitter Cylinder Cover Insert Valve note the direction the Insert Valve was positioned nipple in or out Special Tools e Typical Service Tools P SEEN C NOS id ol MO o cot S mem S oo 7 18 18 Speed M 12 1 Splitter Yoke Assembly
95. eck Points Note Transmission appearance may differ however the procedure is the same 13 Preventive Maintenance 1 Air System and Connections e Check for leaks worn Air Lines loose connections and Cap Screws 2 Clutch Housing Mounting e Check all Cap Screws of Clutch Housing flange for looseness 3 Clutch Release Bearing Not Shown e Remove Hand Hole Cover and check Radial and Axial Clearance in Release Bearing e Check relative position of thrust surface of Release Bearing with Thrust Sleeve on Push type Clutches 4 Clutch Pedal Shaft and Bores e Pry upward on Shafts to check wear e f excessive movement is found remove Clutch Release Mechanism and check Bushings on Bores and wear on Shafts See OEM literature 5 Lubricant Lubrication Manual TCMT0021 6 Oil Filter e Filter Inspection during vehicle PM schedule Inspect Oil Filter for damage or rust Replace as necessary Inspect Oil Filter Adapter for damage or leakage Replace as necessary e Filter Replacement Replace every 100 000 miles and top off fluid Every Transmission fluid change 7 Filler and Drain Plugs e Remove Filler Plugs and check level of lubricant at specified intervals Tighten fill and Drain Plugs securely 8 Cap Screws and Gaskets e For applicable models check all Cap Screws especially those on PTO Covers and Rear Bearing Covers for looseness which would cause oil leakage e Check PTO opening
96. eir removal Special Tools e Typical Service Tools Procedure 1 If the three 3 sets of Tension Springs and Balls from Housing Bores have not been removed place the Shift Bar Housing on its side to remove them 2 Remove the Oil Trough Retaining Cap Screws and Oil Trough Some models do not have an Oil Trough 3 With the Housing rear to the right lay the Assembly on a flat surface 138 Transmission Overhaul Procedures Bench Service 4 While removing the top Yoke Bar to the right remove the two 2 Shift Blocks 5 From the middle Yoke Bar remove the Shift Yoke and Shift Block As the Neutral Notch in the Bar clears the Rear Boss remove the small Interlock Pin from the Notch Bore E e 5 Oo 5 5 5 5 2 o 1 ez 6 Remove the Actuating Plunger from the top center Boss Bore 7 From the bottom Yoke Bar remove the two 2 Shift Yokes 139 Transmission Overhaul Procedures Bench Service 8 Asthe Shift Bar clears the last Boss two 2 3 4 Interlock Balls drop from the bottom rear Boss Bore 9 If damaged from the 1st and Reverse Shift Yoke remove the Plug Spring and Plunger 10 Inspect the Yoke or Block parts replace the worn parts 140 Transmission Overhaul Procedures Bench Service How to Assemble the Standard Shift Bar Housing Special Instructions Inspect Shift Blocks and Shift Yokes for wear Apply
97. ershaft Rear Groove install the Rear Snap Ring Transmission Overhaul Procedures Bench Service How to Assemble the Upper Reverse Idler Gear Assembly Special Instructions In 1996 Eaton changed the Reverse Idler System design In the Nut design the Reverse Idler Bearing was lubricated through a hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle Special Tools Previous Design gt 090 5 o an i 2 ez 5 zs 25 2 5 2 _ 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shaft 4 Nut and Washer 8 Plug 237 Transmission Overhaul Procedures Bench Service The Cap Screw design eliminates the Case hole and Idler Shaft hole The Reverse Idler Bearing is supplied oil through the use of star design Thrust Washers If the Nut design parts are used with the Cap Screw design Main Case which does not have the oil feed hole the Reverse Idler Bearing will fail Current Design 1 Star Washer 6 Idler Plate 2 Inner Race 7 Bearing 3 Star Washer 8 Reverse Idler Gear 4 Retaining Ring 9 Reverse Idler Shaft 5 Cap Screw 238 Transmission Overhaul Procedures Bench Service Procedure 1 Place the rear Thrust Washer on the Idler Shaft 2 From the rear insert the Idler Shaft through the Main Case Bearing Bore and into the Reverse Idler Gear Bearing 3 As the I
98. ess the Gear on the Countershaft 5 Align PTO Gear Keyway with the Countershaft Key bullet nose of teeth facing up shaft rear Align Drive Gear Keyway with the Countershaft Key long hub against PTO Gear and press both Gears on the Countershaft 6 On each Countershaft front install the Drive Gear Retaining Snap Ring in groove 7 Usea Flanged Driver or the Press to install the Bearing Inner Race onthe Countershaft Frontagainstthe Drive Gear Note Make sure all Gears are pressed into place Note Make sure the Bearing Inner Race is installed 220 Transmission Overhaul Procedures Bench Service How to Assemble the Lower Reverse Idler Gear Assembly Special Instructions In 1996 Eaton changed the Reverse Idler System design In the Nut design the Reverse Idler Bearing was lubricated through a hole in the Main Case Reverse Idler Support Boss and a oil passage through the Idler Shaft middle Special Tools Previous Design 00155180611 ow 5 e 2 5 We 4 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shaft 4 Nut and Washer 8 Plug 221 Transmission Overhaul Procedures Bench Service The Cap Screw design eliminates the Case hole and Idler Shaft hole The Reverse Idler Bearing is supplied oil through the use of star design Thrust Washers If the Nut design parts are u
99. essure build to Governor cutoff After the pressure reaches the Governor cutoff continue testing The pressure is critical if the vehicle is equipped with a Vehicle Air System Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a preset level IMPORTANT Use the following Air System troubleshooting procedures for part replacement only if the symptom can he duplicated If the problem is intermittent parts that are not defective could be replaced Instructions 1 Start at Procedures for Step A 2 Basedon the Result of the procedure go to the corresponding What To Do Next 44 Air System Procedure 1 Symptom Air Leak at Shift Knob Normal Operation e A burst of air will be exhausted from the Shift Knob when moving the Range Selector from Low to High This is the air being exhausted from the P Air Line e Aburstofair will be exhausted from the Shift Knob when moving the Splitter Button rearward shifting to Low split This is the air being exhausted from the SP Air Line 3 3 5 5 5 3 gt Possible Causes e ncorrectly attached Air Lines e Internal leak in Slave Valve Internal leak at Insert Valve e Internal leak at Shift Knob Table 10 Air Leak at Shift Knob Procedure Result What to Do Next Step A Remove lower skirt on Shift Knob Leak found Repair leaking fittin
100. et and Countershaft Bearing Cover Secure the Bearing Covers with the Cap Screws Install sealer Apply Loctite 242 to Cap Screw threads and torque to 40 45 Ib ft 54 23 61 01 Nem Connect all removed air Hoses and lines Use Eaton Fuller amp Thread Sealant 771205 or equivalent as necessary Connect the Driveshaft and U joint and refill the Transmission with the recommended lubricant For lubrication instructions refer to the Lubrication and Maintenance section How to Remove the Splitter Cylinder Assembly Special Instructions Note On 9 Series and Super 10 Transmissions it is necessary to R amp R the Auxiliary Section prior to Range Cylinder removal Damage to internal components will result if Auxiliary Section is not properly removed prior to Cylinder removal Note When replacing just the O Rings in the Splitter Cylinder removal of the Auxiliary Section is not necessary When removing the Splitter Cylinder Cover Insert Valve note the direction the Insert Valve was positioned nipple in or out Special Tools e Typical Service Tools 1 e 5 7 D rJ 5 7 v rJ a N 12 1 Splitter Yoke Assembly 8 O Ring 2 Gasket 12 0 0 3 Splitter Cylinder 13 O Ring 4 O Ring 14 Breather 5 Piston 15 Splitter Valve Replacement Kit 6 O Ring 18 Cap Screw 7 Nut 119 In Vehicle Service Procedures Procedure 1
101. following way 6 or 8 Bolt The 6 or 8 bolt openings are standard with the Transmission The PTO is mounted to the opening and driven from the PTO Gear on the Front Countershaft Thru Shaft The Thru Shaft PTO mounts on the rear of the Transmission It requires a special Auxiliary Housing and Main Case Countershaft with Internal Splines Lubrication Lubrication Specifications IMPORTANT Transmission Filters should be changed during regular lube intervals Inspection of the Transmission Filter should be conducted during preventive maintenance checks for damage or corrosion Replace as necessary e Fora list of Eaton Approved Synthetic Lubricants see TCMT0021 or call 1 800 826 HELP 4357 e The use of lubricants not meeting these requirements will affect warranty coverage D S 5 9 E gt e Additives and friction modifiers must not be introduced Never mix engine oils and gear oils in the same Transmission Transmission Operating Angles If the Transmission operating angle is more than 12 degrees improper lubrication will occur The operating angle is the Transmission mounting angle in the Chassis plus the percent of upgrade expressed in degrees For operating angles over 12 degrees the Transmission must be equipped with an Oil Pump or Cooler kit to insure proper lubrication Operating Temperatures with Oil Coolers The Transmission must not be operated consistently at temperatures abo
102. fraction of the total cost of downtime and labor avoid reusing a questionable part which could lead to additional repairs and expense soon after assembly To aid in determining the reuse or replacement of any Transmission part consideration should also be given to the unit s history mileage application etc Recommended inspection procedures are provided in the following checklist Bearings e Wash all Bearings in clean solvent Check Balls Rollers and Raceways for pitting discoloration and spalled areas Replace Bearings that are pitted discolored spalled or damaged during disassembly e Lubricate Bearings that are not pitted discolored or spalled and check for axial and radial clearances e Replace bearings with excessive clearances e Check bearing fit Bearing Inner Races should be tight to Shaft Outer Races slightly tight to slightly loose in Case Bore If the Bearing spins freely in the Bore the Case should be replaced Bearing Covers e Check Covers for wear from thrust of adjacent Bearing Replace Covers damaged from thrust of Bearing Outer Race e Check Cover Bores for wear Replace those worn or oversized Clutch Release Parts e Check Clutch Release parts Replace Yokes worn at Cam surfaces and Bearing Carrier worn at Contact Pads e Check Pedal Shafts Replace those worn at Bushing surfaces Gears e Check gear teeth for frosting and pitting Frosting of gear teeth faces presents no threat of Transmission failure Often in
103. g Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward 35 Air System Air System Overview Pressurized air from the vehicle s Air System is used to shift the Transmission Low High Range and Low High Split The Low High Range and Low High Split gearing and Shift Mechanisms are located in the Auxiliary Section of the Transmission The vehicle operator controls these shifts with two separate Switches on the Shift Knob Master Control Valve The following components are part of the Air Shift Systems 36 Air System Shift Knob 13 18 Speed The Shift Knob contains two Switches 1 The Range Selector Lever on the front of the Shift Knob is moved down to select Low Range When the Range Selector Lever is moved up High Range is selected 2 The Splitter Button or the button on the side of the Shift Knob is moved rearward to select LO Split and forward for Split of each lever position When in LO Range a Mechanical Interlock prevents moving the Splitter Button to HI lt 5 D 5 5 3 gt Component Nomenclature and Shift Knob Sectional View 1 Medallion 11 Screw 2 Spring 12 0 0 3 Retainer 13 Spring 4 Housing 14 5 32 Ball 5 Spring 15 Spring 6 Washer 16 Ball 7 O Ring 17 Seal 8 Range Selector 18 Detent 9 Pin 19 Splitter Button 10 Cover 20 Old Style Shift Knob
104. g or Air Line Check for leaking fitting at the Shift Knob No leak found Go to Step B Step B Check Air Lines to make sure all Air Lines are not connected to the Connect lines properly lines are connected to the proper proper ports ports on the Shift Knob A Reversal of S and P lines will Air Lines are connected to the Go to Step C result in a constant leak from the proper ports exhaust when High Range is selected B Reversal of the H L and SP lines will result in a constant leak when the Splitter Button is rearward Step C Move the Range Selector Lever Constant air flow from the port Replace Knob down to Low Range Check for constant air flow from the exhaust E port No air flow from E port Go to Step D Step D Move the Range Selector up to High Constant air is leaking from the Repair or replace the Shift Knob Range Disconnectthe small Air Line port or the E port connected to the P port of the Shift Knob Check for air flow from the port and Air Line Air is coming out of the 1 Verify that the Air Line is disconnected Air Line connected to the Slave Valve P port 2 If properly connected replace the Slave Valve Air is not leaking from either port or Go to Step E disconnected Air Line 45 Air System Table 10 Air Leak at Shift Knob Continued Procedure Result What to Do Next Step E Reattach the Air Line to
105. gs do not fall into the Transmission 4 Remove Detent Springs as needed 5 Remove the Gasket and clean the area the Replacement Gasket will contact 89 In Vehicle Service Procedures How to Install the Gear Shift Lever Remote Shift Control Special Instructions Remote Control Housings are installed the same way as Gear Shift Levers For Standard and Forward Shift Bar Housings make sure the Detent Springs and Balls are in the Shift Bar Housing top Bores Make sure the Shift Block and Yoke Notches are aligned in the Neutral position Special Tools e Typical Service Tools L 2 3 1 Housing 2 Capscrew 3 Gasket 90 Procedure 1 2 Thoroughly clean mounting surface Position a new Gear Shift Lever Shift Control Housing Gasket on the Gear Shift Lever mounting surface Install the Detent Springs Install the Shift Lever Shift Control Housing Make sure the tip finger of the Gear Shift Lever fits into the slots in the Shift Block Apply Eaton Sealant 71205 or equivalent to the Retaining Cap Screws Install the Retaining Cap Screws torque to 35 45 Ib ft 47 45 61 01 Nem Note Make sure the Cap Screws are properly torqued Note Make sure you can shift the Transmission In Vehicle Service Procedures How to Adjust the Remote Shift Control LRC Type Special Instructions The following is a typical adjustment procedure for an LRC type slave control It is recommended that
106. haft Support Straps e RR1006TR Auxiliary Section Lifting Bracket Procedure 1 Toremove the Auxiliary Section in the horizontal position Remove the four 4 Cap Screws and the Auxiliary Countershaft Rear Bearing Cover gasket and Rear Bearing shim 2 Install the RR1002TR Auxiliary Countershaft Support Straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean Cap Screws Note Do not use an Air Gun Tighten by hand until the Cap Screws are snug 154 Transmission Overhaul Procedures Bench Service 3 From the Auxiliary Section Housing remove the Retaining Cap Screws that attach the Front Section to the Auxiliary Section 4 Insert the two 2 longest Cap Screws in the Housing flange tapped holes Tighten evenly to move the Auxiliary Section away from the Front Box Go far enough to break the gasket seal 5 Remove the Cap Screws from the tapped holes 6 Attach the RR1006TR Auxiliary Section Lifting Bracket to the Auxiliary Section top 7 Attach a Lifting Chain to the Auxiliary Section Hanger Bracket 8 Move Assembly to the rear until Auxiliary Section is free 9 Remove the Gasket and clean all mounting surfaces of gasket material Procedure 1 To remove the Auxiliary Section in the vertical position With blocks under the Clutch Housing to prevent Input Shaft damage place Transmission in the vertical position Clutch Housing down 2 Remove the four 4 Cap Screws and the Auxiliary Countershaft R
107. he Drive Shaft 15 Install the Outer Drive Gear Retention Snap Ring in Drive Shaft groove Transmission Overhaul Procedures Bench Service 16 Install the Outer Integral Oil Pump Element over the Inner Element E e 9 5 i ue 5 5 o 1 ez 259 Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Section Special Instructions There are different Cap Screw lengths install in the correct location Auxiliary Sections can be installed either with the Transmission in the horizontal position or the vertical position To install in the vertical position the Clutch Housing must be installed Special Tools e RR1006TR Auxiliary Section Lifting Bracket Procedure 1 260 To install the Auxiliary Section in the horizontal position Position a new gasket on the Transmission mounting surface Attach the RR1006TR Auxiliary Section Lifting Bracket to the Auxiliary Section top Attach a Lifting Chain to the Auxiliary Section Hanger Bracket Position the Auxiliary Section on the two 2 Dowel Pins Slide the Auxiliary Section on until the hanger bracket contacts the Transmission Main Case Remove the Auxiliary Section Hanger Bracket Slide the Auxiliary Section the rest of the way into position Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screws Install the Retaining Cap Screws
108. he Mainshaft Assembly while pulling the shaft rear through the Case Bore 3 Pull the Input Shaft forward until the Drive Gear is against the case 4 After the Mainshaft drops into the case slide the Countershaft back and the Mainshaft should fall down between the Countershafts 5 Move the Mainshaft pilot end into the Input Shaft Pilot bushing Mesh the Mainshaft Gears with the corresponding Countershaft Assembly gears 6 Position the upper Reverse Idler Gear in case Note At this time other components of the Front Section must be installed before the Mainshaft installation can be completed see the procedure to Install the Upper Countershaft Bearings 232 10 11 12 Secure the Front Bearing Cover with six 6 Cap Screws Transmission Overhaul Procedures Bench Service Mesh the Reverse Gear teeth with the Reverse Idler Gear teeth and move the Reverse Gear to the rear as far as possible Align the Reverse Gear Spacer external Splines with the Reverse Gear and move the Spacer into the Reverse Gear Install the Reverse Gear 1 0 Snap Ring and move the Reverse Gear forward on the Mainshaft and against the Reverse Gear Limit Washer Push the Input Shaft Bearing back into the Case Bore Position a new gasket on the Bearing Cover mounting surface make sure to align the gasket oil return hole with Case oil return hole Position the Front Bearing Cover make sure to align the Cover oil return
109. hift Knob No air flow from the Go to step G disconnected line Step G Check for air coming out of the Slave Air flows from this port Replace the Slave Valve Valve P port No air flow from this port Go to step H 54 Air System Table 15 No or Slow Range Shift into High Continued Procedure Result What To Do Next wo Step H Place the Shift Lever in Neutral Installa The Gauge responds slowly 1 Check for a restricted line between 100 PSI Pressure Gauge in line with the the Shift Knob and Slave Valve 5 P line Move the Range Selector back and forth from Low to High Range The 8 Gauge should show rapid pressure change 2 Check for a restricted Exhaust Port on the Shift Knob 3 Check for a plugged or dirty filter in the Filter Regulator Assembly 4 Check for a pinched or obstructed 1 4 Rubber Air Line between the Filter Regulator and Slave Valve 5 Check for a pinched or obstructed Air Line between the Slave Valve and the S port on the Shift Knob 6 If all are good replace the Shift Knob The Gauge rapidly moves Go to step between 58 63 PSI and 0 PSI Step If possible leave Air Lines attached to Plunger pin does 1 Remove Actuating Plunger Pin and Slave Valve Unbolt the Slave Valve from move freely check for damage Transmission side Check for free movement of the Plunger Pin protruding from the Case under the Slave Valve The Pi
110. hread Sealant to Cap Screws and then snug each Cap Screw to 35 Ibs ft 47 N m 2 Fully tighten both Retaining Cap Screws to specified torque rating 74 81 Ibs ft 100 110 N m lt 1 2 5 7 5 7 v a N Note This fastening design employs Spiralock threads A conventional metric thread Pitch Tap cannot be used for thread restoration on this product A WARNING Use only Eaton Fuller 71205 Liquid Thread Sealant or liquid equivalent on the Yoke Retaining Cap Screws Do not use any type of thread locking tape on the End Yoke Retaining Cap Screws This may cause the Cap Screws threads to strip and cause the End Yoke to loosen 3 Reinstall Driveshaft per OEM guidelines 113 In Vehicle Service Procedures How to Remove the Auxiliary Section in Chassis Special Instructions None Special Tools e RR1002TR Auxiliary Countershaft Support Straps e RR1006TR Auxiliary Section Lifting Bracket 114 Procedure Drain the Transmission Oil Disconnect the Driveshaft and U joint from the Output Yoke If the Auxiliary Section is to be disassembled remove the Output Nut To prevent the Output Shaft from rotating while removing the Nut shift the Transmission into 1st Gear Disconnect the vehicle air supply line from the Filter Regulator Assembly Mark the locations and disconnect the large rubber Air Lines Move the lines aside Label and rem
111. ied in the Model Number is the Input Torque Capacity in Ib ft Various torque ratings are available For more information call your Eaton Regional Sales and Service Office at 1 800 826 HELP 4357 Shift Bar Housings Two types of Shift Bar Housings are available for this Transmission Both are described and shown below Standard The standard Shift Bar Housing has a Gear Shift Lever opening that is located toward the rear of the Transmission Forward The forward Shift Bar Housing has a Gear Shift Lever opening located three inches closer to the Transmission front than the standard opening This forward design allows greater flexibility in mounting the Transmission and is indicated by an F in the Model Number standard Opening Forward Opening Lubrication Pumps Three types of Lubrication Pumps are available for use on this Transmission and are described below Internal An internal Lubrication Pump is located in the lower front of the Transmission and is driven off the Upper Countershaft 13 Speed Transmissions rated 1550 Ib ft and above include the Internal Pump standard All 18 Speed Transmissions contain the Internal Lube Pump Auxiliary Countershaft An Auxiliary Countershaft Pump is mounted on the rear of the Transmission and driven off the Auxiliary Countershaft PTO Driven A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO Gear Power Take Off PTO Usage PTOs can be mounted in the
112. ifiCations ci theses 9 How to Adjust the Remote Shift Control LRC Type 91 Transmission Torque Specifications 12 Neutral Switch Operation and Testing 93 Preventive Maintenance Inspection 13 How to Remove the Neutral Switch 94 Power Flow Diagrams e 17 How to Install the Neutral Switch sss 95 Air System 36 Reverse Switch Operation and Testing 96 General Troubleshooting Chart 42 How to Remove the Reverse Switch 97 Air System Troubleshooting 44 How to Install the Reverse Switch 222222222222 98 Timing Procedures 57 How to Remove the Shift Bar Housing 99 How to Install the Shift Bar Housing 101 In Vehicle Service Procedures How to Remove the Oil Seal Mechanical How to Remove Oil Filter Adapter 61 Speedometer 2 22 103 How to Assemble Oil Filter Adapter 62 How to Install the Oil Seal Mechanical How to Disassemble Roadranger Valve A 5010 63 Speedometer 105 How to Assemble Roadranger Valve A 5010 65 How to Remove the Oil Seal Magnetic Howe
113. ing endplay is influenced by the compressed thickness of the gasket 0 011 0 012 or 0 28 0 30 mm The bearing endplay must be checked and adjusted any time a Countershaft Bearing or Housing is replaced If during reassembly the same Countershaft Bearings Housing and Shims are reused and kept in the same location it is not necessary to reset Bearing endplay The following procedure is used to adjust the endplay for the Auxiliary Countershaft Tapered Bearings By correctly following this procedure each Countershaft will have 0 001 0 005 0 03 0 12 mm endplay Shims must be aligned properly or else the Rear Bearing Cover may be damaged when final torque is applied Special Tools e Typical Service Tools e Shims Feeler Gauge Procedure 1 The Auxiliary Countershaft Bearing Covers or Countershaft straps and shims should be removed Make sure all old gasket material is cleaned from the gasket mounting surfaces on the Countershaft Bearing Covers and the Auxiliary Housing 2 Verify that the Auxiliary Section is in gear When the Output Shaft is rotated the Countershafts must also rotate If not shift the Auxiliary into gear by applying shop air to the high range air port on Range Cylinder to shift into gear 3 Make sure a 0 100 Countershaft Rear Bearing Shim is installed Be sure the Countershaft Rear Bearing Races are seated in the bearing Bores 4 Install two 2 clean 3 8 x 1 Cap Screws without washers di
114. ing inside diameter is installed towards the Shaft Use the RR1012TR 4 Bearing Driver and a Hand Maul to completely seat the Bearing Inthe Countershaft Rear Groove install the Rear Snap Ring 229 Transmission Overhaul Procedures Bench Service How to Install the Input Shaft and Main Drive Gear Special Instructions None Special Tools e RR1005TR Input Bearing Driver e 1019 Hand Maul e RR1020TR Soft Bar Procedure 1 Usea highly visible Toolmaker s Dye and mark the Main Drive Gear for timing purposes To mark the Gear paint Toolmaker s Dye on any two adjacent teeth and then paint the two adjacent teeth directly opposite the first two teeth 2 f necessary install the bushing in the back of the Input Shaft 3 Temporarily position the Upper Countershaft up and away from the Transmission center 4 From inside the case mesh the Lower Countershaft Drive Gear marked tooth with either set of Main Drive Gear marked teeth 5 From the front engage the Input Shaft Spline Teeth into the Main Drive Gear Note The current design Input Shaft Spline Teeth have noticeable clearance to the Main Drive Gear internal Spline Teeth This is normal 6 Install the Snap Ring in the Main Drive Gear inside groove 230 Transmission Overhaul Procedures Bench Service 7 Install the Spacer Washer over the Input Shaft With the Bearing Externa
115. ings e Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use Remove bearings planned to be reused with pullers designed for this purpose Cleanliness e Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Dirt is an abrasive and can damage bearings It is always a good practice to clean the outside of the unit before starting the planned disassembly Input Shaft e Input Shaft can be removed from the Transmission without removing the Countershafts Mainshaft or Main Drive Gear Special procedures are required and provided in this manual Introduction Snap Rings e Remove Snap Rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose When Using Tools to Move Parts e Always apply force to Shafts Housings etc with restraint Movement of some parts is restricted Never apply force to driven parts after they stop solidly The use of soft Hammers Soft Bars and Mauls for all disassembly work is recommended Inspection Precautions Before assembling the Transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Fuller Transmission parts to assure continued performance and extended life from your unit Since the cost of a new part is generally a small
116. into the back of the Main Drive Gear Torque will flow from the Input Shaft to the Main Drive Gear Main Drive Gear to Sliding Clutch Sliding Clutch straight into the Front Section Mainshaft which delivers the torque to the Auxiliary Splitter Clutch See figure below Note All Countershaft and Mainshaft Gears will rotate but the gears will not be loaded 1 RTO RT wee Eats Front Section Power Flow Direct Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 20 Power Flow Front Section Power Flow Reverse Gear Torque will flow from the Countershafts to the Reverse Idler Gears Torque will then flow from the Reverse Idler Gears to the Mainshaft Reverse Gear Torque will now travel through the Mainshaft Reverse Gear the Sliding Clutch in the Reverse position and then to the Mainshaft and Auxiliary Splitter Clutch See figures below Note The Idler Gears cause the reversal of rotation lt 5 5 5 3 gt Reverse 0 9 13 speed Reverse LO Low Split 18 speed Reverse LO High Split 18 Speed 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 3 Sliding Clutch rearward Reverse 9 13 speed Reverse HI Low Split 18 Speed Reverse HI High Split 18 Speed 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2
117. ith Auxiliary Oil Tube Special Instructions None Special Tools e A Vise with brass jaws or wood blocks Procedure 1 Fromthe assembly remove the Outer Oil Pump Element 2 From the Drive Shaft remove the Drive Gear Retaining Snap Ring 3 From the Pump Drive Shaft remove the Drive Gear 4 Fromthe Drive Shaft Keyway remove the Key 252 Transmission Overhaul Procedures Bench Service 5 From the Drive Shaft remove the Element Snap Ring 6 Fromthe Drive Shaft removethe Internal Oil Pump Element vu 5 9 2 5 an 11502 o 25 9 a rJ 1 7 From the Drive Shaft Keyways remove the two 2 Keys 8 Remove the Transfer Tube 9 Fromthe Integral Oil Pump Housing remove the Drive Shaft 10 If damaged from the Drive Shaft remove the Rear Drive Gear Retention Snap Ring 253 Transmission Overhaul Procedures Bench Service 254 11 Loosen the Retaining Nut 12 Remove the Retaining Nut Spring and Ball 13 From the Pump Housing remove the Relief Valve Roll Pin 14 From the Relief Valve Housing Bore remove the Relief Spring and Relief Valve Transmission Overhaul Procedures Bench Service 15 Remove the Valve Cover 16 Inspect all parts for damage replace damaged parts E e 9 5 i ue 5 5 2 o 1 ez 255 Transmission Overhaul Procedu
118. itions In Vehicle Service Procedures Neutral Switch Operation and Testing Special Instructions The Neutral Switch is a normally closed switch An electrical current flows through it when the Transmission Shifter is in the Neutral position When the Transmission Shifter is in gear the Switch is open and no current flows through it Likewise the Switch is open when the Ball is depressed The Switch is actuated by the Air Valve Shaft Special Tools e Typical Service Tools 4 Volt Ohm Meter Procedure 1 Disconnect the wiring from the Switch 1 ce 1 gt BS o rJ 1 ow 2 Connect an Ohm Meter to check for continuity small reading 3 Place the Transmission Shift Lever in the Neutral position The Ohm Meter should register continuity or a small reading If it does go to the next step If it does not remove the Switch and replace it 4 Shiftthe Transmission into all gear positions The Ohm Meter should read Open or Infinity If it does not remove the Switch Then depress the Switch ball and check for continuity The Ohm Meter should read Open or Infinity when the Ball is depressed 5 Lookinto the Neutral Switch hole and verify that the Air Valve Shaft moves as the Transmission is shifted from Neutral into gear a If it does replace the Switch b If not remove the Shift Bar Housing and check the Air Valve and Shift Rails for excessive wear Al
119. l Snap Ring to the outside position the bearing on the Input Shaft 8 Install the Input Shaft Bearing over the Input Shaft Use the RR1005TR Input Bearing Driver and a Hand Maul to drive the Bearing until it contacts the front wall of the Main Case 9 Temporarily install the Front Bearing Cover with two Cap Screws 10 From inside the Main Case drive the Input Shaft forward until it is fully seated Oo n a an a e o ez rJ 1 11 Install the Input Shaft Retaining Snap Ring Note Do not replace the small rubber Lip Seal It is used only to prevent leakage during shipping 12 Do not reinstall the Input Bearing Cover atthis time Instead pull the Input Shaft and Bearing forward to allow for Mainshaft installation 231 Transmission Overhaul Procedures Bench Service How to Install the Mainshaft Assembly Special Instructions The Lower Countershaft Bearings and the Input Shaft must be installed but for higher torque ratings do not install the Front Bearing Cover Check to make sure the Lower Countershaft Drive Gear marked tooth is in time with Main Drive Gear set of marked teeth Special Tools e RR1004TR Mainshaft Lifting Hook Procedure 1 Block the Upper Countershaft forward and as close to the case wall as possible 2 With Reverse Gear forward against the next speed Gear and Mainshaft pilot end over the Integral Oil Pump gear lower t
120. ls from the Housing top Bores are loose tilt the Assembly and remove them 100 In Vehicle Service Procedures How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of Cap Screws The 1 1 2 Cap Screws are used with the Lifting Eyes The 1 1 4 are used on all other locations except the left front corner at the Roll Pin This Cap Screw is 1 3 4 Be careful when removing the Shift Bar Housing to prevent damaging the Oil Tube with the Shift Yokes The Slave Valve and Interlock parts must be removed prior to installing the Shift Bar Housing Special Tools e Typical Service Tools Procedure 1 Place the Shift Bar Housing and Shift Blocks in the Neutral position 1 e 1 lt v 1 a o 2 Placethe Mainshaft Sliding Clutches in the Neutral position 3 Position a new Shift Bar Housing gasket on the Shift Bar Housing mounting surface Note The Slave Valve and Interlock Assembly must remain off until the Shift Bar Housing is installed to avoid damaging the Interlock Pin 4 Asyouinstall the Shift Bar Housing make sure the Yokes fit into the corresponding Sliding Clutch slots and the Housing aligns with the Roll Pin 5 Apply Eaton Sealant 71205 or equivalent to the Retaining Cap Screws Torque the Cap Screws to 35 45 b ft 47 45 61 01 Nem 101 In Vehicle Service Procedures 6 Install Interlock parts Pin
121. m E e 9 5 5 5 5 o 1 ez 2 5 2 Remove the Trough Retaining Cap Screws and Oil Trough Some models do not have an Oil Trough 3 With the Housing rear to the right lay the Assembly on a flat surface 147 Transmission Overhaul Procedures Bench Service 4 While removing the top Yoke Bar to the right remove the two 2 Shift Blocks e From the middle Yoke Bar remove the Shift Yoke and Shift Block As the Neutral Notch in the Bar clears the Rear Boss remove the small Interlock Pin from the Notch Bore 6 Remove the Actuating Plunger from the center top Boss Bore 7 Fromthe Bottom Yoke Bar remove the two 2 Shift Yokes 148 Transmission Overhaul Procedures Bench Service 8 Asthe Shift Bar clears the last Boss two 2 3 4 Interlock Balls drop from the bottom Rear Boss Bore 9 If damaged from the 1st and Reverse Shift Yoke remove the Plug Spring and Plunger E e 9 5 i ue 5 5 2 o 1 ez 10 Inspect the Yoke or Block parts replace the worn parts 149 Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft Assembly without Main Case disassembly Special Instructions None Special Tools e RR1023TR Input Bearing Puller e RR1019TR Hand Maul Procedure 1 From the Front Bearing Cover remove the six 6 Ret
122. mer Attachment Used for removing Output Seals RR1011TR 2 Slide Hammer Attachment Used for removing Bearing Races from the Transmission Case RR1011TR 3 Slide Hammer attachment Used for removing Bearing Races from the Transmission Case Used to install Front Countershaft Bearings on RT Series RR1012TR 2 Driver Countershaft Front Bearings Transmissions Used to remove Front Countershaft Bearings on RT Series RR1012TR 3 Puller Countershaft Front Bearings Transmissions RR1012TR 4 Driver Countershaft Rear Bearings Used to install Rear Countershaft Bearings RT Series Transmissions RR1012TR 5 Driver Auxiliary Countershaft Used to install Auxiliary Countershaft Bearings on FR amp RT Series Bearings Transmissions with Auxiliary Section helical gearing RR1012TR 6 Driver Auxiliary Countershaft Used to install Auxiliary Countershaft Bearings on RT Series Bearings Transmissions with Auxiliary Section spur gearing Used to support the Upper Countershaft during Main Box assembly on RR1013TR Timing Block RT Series Countershaft HT Series Transmissions Recommended Tools K Line Part Tool Tool Description 1015 Driver Countershaft Front Rear Used to install Front and Rear Countershaft Bearings on FR Series bearings Transmissions Used to push the Countershaft Assembly rearward to create clearance Pusher Countershaft for Bearing Puller on FR amp RT Series Transmissions RR1019TR Hand
123. n Motor Oil Install the Synchronizer Assembly Install the Splitter Gear Install the Splitter Gear Retainer and 15 16 Cap Screw Torque the Splitter Gear Retainer Bolt to 190 210 Ib ft 257 61 284 72 Nem Note Make sure the Splitter Gear Retainer Bolt is properly torqued Transmission Overhaul Procedures Bench Service How to Assemble the Range Cylinder Assembly Special Instructions Apply Eaton Lubricant 71214 or equivalent to Shift Cylinder Assembly and Insert Valve O Rings so a film covers the entire surface of each O Ring Special Tools e Typical Service Tools a o 5 o an 1 5 25 9 2 1 Gasket 8 Piston 2 Shift Yoke 9 0 0 3 Bolt 10 O Ring 4 Range Cylinder Assembly 11 Nut 5 Cap Screw 12 Gasket 6 O Ring 13 Cover 7 Yoke Bar 173 Transmission Overhaul Procedures Bench Service Procedure 1 If previously removed in the Cylinder Housing Bore install the small O Ring 2 If previously removed on the piston I D and O D install the Piston O Rings 3 Position a new gasket on the Range Cylinder Housing mounting surface 4 Install the Cylinder Housing 5 Apply Fuller amp Sealant 71205 or equivalent to the Retaining Cap Screws 6 Install the Cap Screws torque to 20 25 Ib ft 27 12 33 90 Nem 7 Lean Auxiliary Section back with Range Cylinder upward 8 Insert the Piston
124. n levels can be updated to the current design Each Mainshaft Gear must have its inside Snap Ring installed before placement on the Mainshaft Do not install Reverse Gear Inside Snap Ring at this time Gear Tolerance Washers are internally splined and locked to the Mainshaft by the Key Gear Spacers are externally splined to engage with Gear Hub Clutching teeth There is one Tolerance Washer and one Spacer for each Mainshaft Gear Axial Clearance end play limits are 0 006 0 015 for all Mainshaft Gears If the Axial Clearance is less than the minimum 0 006 tolerance the Tolerance Washer should be replaced with a thinner Tolerance Washer This will increase the Axial Clearance between the gears If the Axial Clearance is greater than the maximum 0 015 tolerance a thicker Tolerance Washer should be installed This will decrease the Axial Clearance between the gears If necessary refer to the Parts Manual for your specific Transmission model to determine the correct position of each Mainshaft Gear The Mainshaft you are using may have 3 grooves in certain gear positions The middle groove is not used with the Selective Washer design Special Tools e A piece of 5 32 Air Line 1 long e Vise with brass jaws 206 Transmission Overhaul Procedures Bench Service Procedure 1 With Mainshaft pilot end down secure the Mainshaft in a Vise equipped with brass jaws or wood blocks 2 If previously removed install the Roll Pin in Ke
125. n should extract when the Transmission is shifted into gear and retract when shifted into Neutral If desired the Slave Valve can be actuated and tested while unbolted from the Transmission Case The Air Lines of course must remain attached 2 Check for missing or broken Spring Actuating Plunger Pin moves Repair or replace Slave Valve and freely check for proper range operation 55 Air System Table 15 No or Slow Range Shift into High Continued Procedure Result What To Do Next Step R If Air System has been tested and found to operate satisfactory the Auxiliary Section must be removed to inspect for mechanical problem Remove Auxiliary Section and inspect for Binding of Range Yoke Bar or Piston Damaged or defective range Yoke Damaged or defective Range Synchronizer Cracked c s weld resulting in gear turning on shaft Damaged or defective Range Sliding Clutch Auxiliary Section gearing out of time 56 Air System Procedure 7 Symptom Range Shifts with Shift Lever in Gear Normal Operation Range shift should only occur when the Shift Lever is in Neutral The Range Selector can be moved up or down while the Shift Lever is in a gear position but the shift will not occur until the Shift Lever is moved to Neutral Possible Causes 3 3 5 5 5 3 gt e Worn or missing Actuating Pin or Air Valve Shaft e
126. nd Slave Valve 51 lt 5 3 5 5 5 3 gt E Air System Table 14 No or Slow Range Shift into Low Continued Procedure Result What to Do Next 2 f the lines are correct replace the Shift Knob 3 Check for a plugged or dirty filter in the Filter Regulator Assembly 4 Check for a pinched or obstructed 1 4 Rubber Air Line between the Filter Regulator and Slave Valve 5 Check for a pinched or obstructed Air Line between the Slave Valve and the 5 Port on the Shift Knob 6 If all are good replace the Shift Knob The Gauge rapidly moves Go to step between 58 63 PSI and 0 PSI Step If possible leave Air Lines attached to Slave Valve Unbolt the Slave Valve from Transmission side Check for free movement of the Plunger Pin protruding from the Case under the Slave Valve The Pin should extract when the Transmission is shifted into gear and retract when shifted into Neutral Note If desired the Slave Valve can be actuated and tested while unbolted from the Transmission Case The Air Lines of course must remain attached 1 Remove Actuating Plunger Pin and check for damage Actuating Plunger Pin does not move freely 2 Check for missing or broken Spring Actuating Plunger Pin moves Repair or replace Slave Valve and freely check for proper range operation Step R If Air System has been tested and found t
127. ng Spacer 5 Remove the Bearing 6 Remove the Front Bearing Race using the proper Driver 7 If damaged remove the Bearing Sleeve 182 Transmission Overhaul Procedures Bench Service How to Assemble the Splitter Gear Bearing Assembly Special Instructions Make sure to use the proper Drivers for the Bearing and Sleeve When installing the Inner Bearing Sleeve it must be flush with the Bearing The Splitter Gear Cups and Cones are matched do not mix Special Tools e 3 30 Diameter Bearing Driver Procedure 1 If removed install the Bearing Sleeve 2 Install the Front Bearing Race E e 9 5 5 5 5 o 1 ez 3 Turn the Splitter Gear over and position the Bearing against the Front Bearing Race 4 Install the Bearing Spacer 5 Install the Rear Bearing Race using the proper Bearing Driver 6 Install the Splined Washer 7 Install the Internal Snap Ring 183 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Drive Gear Assembly Special Instructions Before removing the Auxiliary Drive Gear the Auxiliary Section must be removed Special Tools e Large pair of Snap Ring Pliers e Brass Maul e Crow s Foot Procedure 1 Remove the Mainshaft rear groove Snap Ring 2 Remove the Auxiliary Drive Gear and Washer from the Mainshaft 3 Remove the Auxiliary Bearing Retainer Ring Ca
128. not press or disengage Clutch Pedal when removing Slave Cylinder or Clutch Servo Special Tools e Typical Service Tools Procedure 1 If system is an air over hydraulic the Air Line must be disconnected from the Boosted Actuator prior to removing the assembly Note It is not necessary to remove the hydraulic line Removing the hydraulic line will allow air to enter the system requiring the system to be bleed 2 Remove the four Cap Screws from the Boosted or Hydraulic Actuator 3 Apply force to remove the Actuator Rod from the Clutch Slave Fork 266 Transmission Overhaul Procedures Bench Service 4 Pullthe Boosted or Hydraulic Actuator back and remove it Boosted Air over Hydraulic Actuator from the Actuator Housing f Hydraulic Actuator v e E nn 5 5 22 o oz 5 Remove the four Cap Screws holding the Actuator Housing to the Clutch Housing 6 Lower the Actuator Housing and remove it from the Clutch Housing 267 Transmission Overhaul Procedures Bench Service How to Install the Boosted or Hydraulic Actuator and Adapter Housing Special Instructions The Air Line should remain disconnected until the Boosted Actuator and Boosted Actuator Housing are assembled CAUTION Do not press or disengage Clutch Pedal when Slave Cylinder or Clutch Servo is removed Special Tools e Typical Service To
129. o operate satisfactory the Auxiliary Section must be removed to inspect for mechanical problem Remove Auxiliary Section and inspect for Binding of Range Yoke Bar or Piston Damaged or defective Range Yoke Damaged or defective Range Synchronizer Cracked c s weld resulting in gear turning on shaft Damaged or defective Range Sliding Clutch Auxiliary Section gearing out of time 92 Air System Procedure 6 Symptom No or Slow Range Shift into High Normal Operation When the Range Selector on the Shift Knob is moved down to select Low Range air pressure will flow through the Shift Knob to the P port on the Slave Valve The Slave Valve will direct air pressure through the Low Range 1 4 Rubber Supply Hose to the Range Cylinder to shift the range There will be a brief burst of air at the Slave Valve as the High Range side of the Range Piston exhausts 3 3 5 5 5 3 gt E Likewise when High Range is selected the air pressure in the will be exhausted at the Shift Knob This will cause the Slave Valve to direct air to the rear side of the Range Cylinder Piston The air pressure on the Low Range side will be exhausted at the Slave Valve Possible Causes e Incorrect Air Line hook up e Insufficient air supply to Transmission e Plugged Filter e Incorrect Regulator pressure e Damaged or defective Shift Knob Master Valve e Damaged or defective Slave Valve e D
130. o two 2 Mainshaft Gears to lock the Transmission or use a Yoke Holding Tool if available 2 Install the Speedometer Drive Gear Rotor or Replacement Spacer on the Output Shaft inside the Rear Bearing Cover 3 Ifthe Slinger on the Yoke is damaged replace using a Slinger Seal Kit 4 Install the Output Yoke over the Output Shaft The Yoke should slide on and stop before contacting the Speedometer Rotor As the Output Shaft Nut is installed the Output Yoke will contact the Speedometer Rotor 5 Install the Output Shaft Nut tighten to 650 700 Ib ft 881 28 949 07 Nem of torque 6 Make sure the Output Shaft Nut is properly torqued and unlock the Transmission or remove the Yoke Holding Tool 111 e 1 v 1 a o In Vehicle Service Procedures How to Remove the Output Yoke Flange and Retaining Cap Screws Special Instructions None Special Tools e Typical Service Tools Procedure 1 Remove Drive Shaft from the Transmission Reference OEM removal guidelines 2 Remove the End Yoke Retaining Cap Screws and Washer from Auxiliary Mainshaft 3 Remove the End Yoke Flange 112 In Vehicle Service Procedures How to Install the Output Yoke Flange and Retaining Cap Screws Special Instructions Special Tools e Typical Service Tools Procedure 1 Install End Yoke Retaining Washer and Cap Screws Apply Eaton Fuller 71205 Liquid T
131. ols Procedure 4 1 Lift Boosted or Hydraulic Actuator Housing up through the Clutch Housing opening 2 Torque the four Cap Screws for the Actuator Housing to 72 80 Ib ft 97 62 108 47 Nem 268 Transmission Overhaul Procedures Bench Service 3 Slide Boosted or Hydraulic Actuator into the back of the Actuator Housing and snap the Push Rod into the Clutch Release Fork Boosted Air over Hydraulic Actuator mm Hydraulic Actuator v e eu E nn 5 5 22 o oz 4 Install the four Screws holding the Boosted or Hydraulic Actuator to the Actuator Housing and torque to 14 Ib ft 18 98 Nem 5 Install the Air Line if it is Boosted Actuator 269 Copyright Eaton 2013 Eaton hereby grant their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness
132. on the LO Range Gear Repeat the procedure for the two 2 adjacent teeth directly opposite the first set marked 3 With Splined Washer facing up place the washer on the Output Shaft shoulder 170 Transmission Overhaul Procedures Bench Service With LO Range Gear Clutching teeth down position LO Range Gear on the Output Shaft engage the Washer Splines With chamfer side up position the LO Range Gear rear washer on the Output Shaft against the LO Range Gear With tapered side up use heat or appropriate driver and install the Output Shaft Rear Bearing On the Output Shaft position the Bearing Inner Spacer Set aside Lay the Auxiliary Housing front face down on a clean flat surface Install the Bearing Race in the Bearing Bore v e 9 5 i ue 5 5 22 o 1 ez 171 Transmission Overhaul Procedures Bench Service How to Install the Splitter Gear Special Instructions Make sure to use a Splitter Gear Retaining Bolt with thread locking compound Loctite 242 The Output Shaft Assembly will need to be placed in a Vise in order to tighten the Retaining Bolt to proper torque Applying oil to Synchronizer material will ease the installation of the Auxiliary Section to the Main Case Special Tools e Vise with brass jaws or wood blocks Procedure 172 1 2 Lay the Output Shaft Assembly on its side Submerge Synchronizer i
133. orque to 650 700 Ib ft 881 28 949 07 Nem 6 Connectthe Driveshaft and U joint according to the OEM or Driveshaft Manufacturer s instructions 105 In Vehicle Service Procedures How to Remove the Oil Seal Magnetic Speedometer Special Instructions Prior to replacing the Seal carefully inspect the Transmission to make sure the oil leakage is coming from the Seal Pay particular attention to the Speedometer parts the Rear Bearing Cover gasket surfaces Rear Countershaft Bearing Covers and Shift Bar Housing Special Tools 9 WE 1 N 1 Rear Bearing Cover 6 Oil Seal 2 Sensor Retaining Cap Screw 7 Slinger 3 O Ring 8 O Ring 4 Speedometer Sensor 9 Speedometer Spacer Assembly 5 Cap Screw 106 Procedure 1 Disconnect the Driveshaft and U joint from the Output Yoke according to the OEM or Driveshaft Manufacturer s Instructions Shift the Transmission into 1st Gear or Low Gear Low Range to prevent the Output Yoke from turning when you loosen the Output Shaft Nut Remove the Output Shaft Nut using a 70 mm or 2 3 4 socket Remove the Output Yoke If necessary use an Output Yoke Puller See How to Remove the Output Yoke Companion Flange Remove the Speedometer Sensors from the Rear Bearing Cover Note If the Sensor is a thread in type note the number of threads expose so the Sensor can be reinstalled to the same depth If the Sensor is a push in type remove the hold down Cap Screw and
134. osition as compared to Neutral and a rearward lever position 6 Install the Shift Arm on the Splines of the inner Shift Shaft You may have to move the Shift Arm 4 or 5 to align the Splines of the two parts Disregard any movement of the Gear Shift Lever at this point The Gear Shift Lever will be 1 Selection Leve adjusted later 91 In Vehicle Service Procedures 92 Figure C 1 Selection Lever 2 L H Thread 3 R H Thread 4 Shift Arm 5 Parallel 10 11 12 13 14 15 16 17 18 19 Tighten the Cap Screw B see figure on the Shift Arm Connect the Pivot Link assembly Ball Joint to the Selection Lever Secure it with the Castle Nut and Cotter Pin Loosen the Jam Nuts C see figure C on the Pivot Link Check to be sure the inner Shift Finger is still in place Rotate the Pivot Link until the curved end of the Selection Lever is parallel with the Shift Arm as viewed from the rear see figure C Tighten the Pivot Link Jam Nuts C see figure C Loosen both Cap Screws on the Turnbuckle D see figure A Check to be sure inner Shift Finger is still in place Rotate the Turnbuckle to obtain the proper forward backward Neutral position of the Gear Shift Lever in the cab Tighten one Turnbuckle D Cap Screw see figure A Move the Gear Shift Lever to the desired position Turn the second Turnbuckle D Cap Screw Check for linkage obstructions in all gear pos
135. ove the small Air Lines Remove the four 4 Cap Screws and the Auxiliary Countershaft Rear Bearing Cover Gasket and Rear Bearing Shim Install RR1002TR Auxiliary Countershaft Support Straps Note Do not use and Air Gun Tighten by hand until the Cap Screws are snug Drive the two Dowel Pins forward and remove them 10 Remove all but one Cap Screw that secure the Auxiliary Section to the Main Section Leave one Cap Screw to secure the Housing until it is ready to be removed Note Cap Screws are different lengths Note their locations for reassembly purposes WARNING Use the proper equipment with safety chains attached to remove the Auxiliary Section The Auxiliary Section can slide rearward and could fall causing you serious injury and or damage to the Auxiliary Section Attach a Chain and Lifting Device to the Auxiliary Section Hanger figure A or attach the Support Jack to the Auxiliary Section figure B With the Support Device in position remove the remaining Cap Screw If necessary 3 Cap Screws can be installed into the three threaded holes in the Auxiliary Section Flange When threaded in they will push the Auxiliary Section rearward Clean the holes of rust paint and other debris by threading a 3 8 16 Tap into each hole Thread each Cap Screw in evenly to prevent damage to the Auxiliary Housing CAUTION The weight of the Auxiliary Section must be supported during removal to avoid damage
136. p Drive Shaft remove the Drive Gear 4 Fromthe Drive Shaft Keyway remove the Key 244 Transmission Overhaul Procedures Bench Service 5 From the Drive Shaft remove the Element Snap Ring 6 From the Drive Shaft remove the Internal Oil Pump Element 7 From the Drive Shaft Keyways remove the two 2 Keys 8 Fromthe Integral Oil Pump Housing remove the Drive Shaft 9 Ifdamaged from the Drive Shaft remove the rear Drive Gear Retention Snap Ring 245 Transmission Overhaul Procedures Bench Service 246 10 From the Pump Housing remove the Relief Valve Roll Pin 11 From the Relief Valve Housing Bore remove the Relief Valve Spring 12 From the Housing Bore remove the Relief Valve 13 Inspect all parts for damage replace damaged parts Transmission Overhaul Procedures Bench Service How to Assemble the Integral Oil Pump without Auxiliary Oil Tube Special Instructions When installing the Drive Shaft Keys the round Key goes in the round Keyway and the square Key in the square Keyway Special Tools e A Vise with brass jaws or wood blocks Procedure 1 Install the Relief Valve in the Integral Oil Pump Housing v e 9 5 i ue 5 5 o 1 ez 2 Install the Relief Valve Spring in Oil Pump Housing 3 Secure the Oil Pump Housing in a Vice 4
137. p Screws and Bearing Retainer Ring 4 From the Mainshaft remove the Splined Washer 5 From inside the Case carefully tap the Auxiliary Bearing rearward 184 Transmission Overhaul Procedures Bench Service Use a Crow s Foot and work the Bearing out of the Bore Inspect the Bearing and Spacer If the parts have been damaged press the Spacer out of the Bearing and replace the parts E e 9 5 i ue 5 5 o 1 ez 185 Transmission Overhaul Procedures Bench Service How to Remove the Clutch Housing with Internal Oil Tube Special Instructions Removal of the Clutch Housing is performed in the horizontal position The Clutch Release Mechanism must be removed Some early production models do not have an Oil Tube behind the Clutch Housing For these models skip step 5 Special Tools e Typical Service Tools Procedure 1 From inside the Clutch Housing remove the Nuts and Washers 2 Frominside the Clutch Housing remove the Cap Screws 3 Jar Clutch Housing to break Gasket seal 4 Pullthe Clutch Housing from the studs and Transmission Case 5 f Oil Tube is not being removed skip to step 10 6 Remove Oil Tube 186 Transmission Overhaul Procedures Bench Service 7 Remove Slave Valve 8 Remove Interlock parts Pin Spring and Sleeve 21 29 9 Remove Shift B
138. plines aligned with the plastic line install a Sliding Clutch 12 With the washer flat side up position Tolerance Washer white in the next available groove Rotate the washer until the Washer Splines and Mainshaft Splines align 13 Push the Air Line up to lock the washer on the Mainshaft 14 Install a Gear Spacer 208 Transmission Overhaul Procedures Bench Service 15 With Clutching teeth down position the next Gear on the Mainshaft engaging with Spacer external Splines 16 With Clutching teeth up install the next Gear on Shaft against the previously positioned gear E e 9 5 i ue 5 5 2 o 1 ez 17 Position another Spacer against the previously positioned gear engaging the Spacer External Splines with Gear Clutching teeth 18 With washer flat side down position the Tolerance Washer I MITT mmm against the Spacer Rotate the washer until the Washer d M Splines and Mainshaft Splines align an 19 Push the Air Line up to lock the washer on the Mainshaft 20 Insert two large Screwdrivers between the two gears Apply slight downward pressure to spread the gears evenly Between the Gear Hub and Mainshaft Spacer insert 0 006 Feeler Gauge and 0 015 Feeler Gauge If out of tolerance change the washer against the Mainshaft Spacer Refer to information before stepped procedures for further information 209 Transmission Ove
139. pray washer to is only a weep and it is not clean the area Use of a high pressure spray may considered to be detrimental force contamination into the area of concern and the life of the transmission temporarily disrupt the leak path i Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level OR ii Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level Repair is complete Operate vehicle to normal transmission operating temperature and inspect the area for oil leak s visually or if tracer dye was introduced use an UVL Ultraviolet Light to detect the tracer dye s point of origin Note When inspecting for the origin of the leak s make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine shift tower shift bar housing top mounted oil cooler etc Once the origin of the leak is identified repair the oil leak using proper repair procedures from the designated model service manual After the repair is completed verify the leak is repaired and operate the vehicle to normal transmission operating temperature Inspect repaired area to ensure oil leak has been eliminated If the leak s still occurs repeat steps or contact the Roadranger Call Center at 1 800 826 4357 16 Power Flow Power Flow Diagrams
140. pull the Sensor out of the Bore Remove the Speedometer Rotor Seal Sleeve andthe O Ring Pry the Seal out using a large Screwdriver or Pry Bar in the metal groove of the Seal Note The Seal will be damaged during removal and must be replaced Remove Seal Slinger from the Speedometer Rotor Seal Sleeve using a Brass Drift and Hammer Inspect all parts of the Seal surface for wear scratches burrs or other damage Note Replace the Seal surface if it is worn or damaged Do not attempt to salvage the Seal mating surface with Crocus Cloth filing etc In Vehicle Service Procedures 107 3 lt 1 N 3 7 79 X ce a In Vehicle Service Procedures How to Install the Oil Seal Magnetic Speedometer Special Instructions Special Tools e 1001 2 Output Seal Driver e RR1001TR 8 Seal Driver Insert e RR1001TR 1 Seal Slinger Driver Procedure 1 Using the RR1001TR 2 Seal Driver and RR1001TR 8 Seal Driver Insert drive the new Seal into the Rear Bearing Cover The Seal is fully installed when the Flange on the Seal is flush with the shoulder in the Bore 2 Install the new Slinger on Speedometer Rotor Seal Sleeve using the RR1001TR 1 Slinger Driver 3 previously removed install the O Ring over the Output Shaft Note To avoid creating oil leaks make sure the Speedometer Rotor Seal Sleeve is free from contaminants 108 Ins
141. r e RR1013TR Timing Block e RR1019TR Hand Maul Procedure 1 Move the Countershaft to the rear and insert the RR1013TR Timing Block to center Shaft in rear Case Bore 2 Obtain a spare Inner Countershaft Race 3 Temporarily install the spare Countershaft Inner Race inside the Front Roller Bearing for installation 228 Transmission Overhaul Procedures Bench Service Use the RR1012TR 2 Bearing Driver to start the Front Bearing in Case Bore Use a Screwdriver inserted in the Countershaft Cap Screw Bore to help center the Countershaft Move the Countershaft forward into the bearing Use the RR1012TR 2 Bearing Driver and Maul to completely seat the Front Bearing in the Case Bore Note Make sure to contact only the Bearing and not the Temporary Race with the Driver The Temporary Race should fall out when installation is complete On the Countershaft front position the Retainer Plate with Roll Pin in hole at Shaft end Install the Front Bearing Retainer Plate and Cap Screw If the Cap Screw is being reused apply Eaton Fuller amp Thread Sealant 771205 or equivalent Torque the Cap Screw to 90 120 Ib ft 122 02 162 70 Nem Note Earlier models may have a Roll Pin in the Retainer This Roll Pin is not required and was removed on units built after 1994 From the rear remove the Countershaft Support Tool Install the Rear Countershaft Bearing Position the Bearing so that the larger chamfer on the Bear
142. r Assembly on a clean flat surface Cover the Synchronizer Assembly with a shop rag to prevent losing the three 3 springs under pressure from the HI Range Synchronizer Pin locations Special Tools e Typical Service Tools Synchronizer Synchronizer Hox v e E io Sa og o oz ep Procedure 1 Place the larger LO Range Synchronizer Ring on the bench 2 Cover the Synchronizer with a shop rag to contain the springs 3 Grab both sides of the HI Range Synchronizer and pull 4 From the Synchronizer Ring LO Range pins remove the Sliding Clutch 167 Transmission Overhaul Procedures Bench Service How to Assemble the Synchronizer Assembly Special Instructions Assembly should be done on a clean flat surface slightly lower than your waist Pins on the LO Range Synchronizer must line up with the chamfered holes on the Sliding Clutch bottom When compressing the HI Range Synchronizer springs cover with a shop rag In the event compression is not achieved the first time this prevents the springs from leaving the bench area Special Tools e Typical Service Tools synchronizer synchronizer HEN Sliding Clutch 168 Transmission Overhaul Procedures Bench Service Procedure 1 Onthe bench place the larger LO Range Synchronizer Ring face down with pins up 2 With the Sliding Clutch recessed side up place the Sliding Clut
143. r bearing installation These special drivers apply equal force to both Bearing Races preventing damage to Balls Rollers and Races while maintaining correct Bearing alignment with Bore and Shaft Avoid using a Tubular or Sleeve Type Driver whenever possible as force is applied to only one of the Bearing Races Cap Screws e prevent oil leakage and loosening use Fuller Sealant 71205 on all Cap Screws Gaskets e Usenew Gaskets throughout the Transmission as it is being rebuilt Make sure all Gaskets are installed An omission of any Gasket can result in oil leakage or misalignment of Bearing Covers Initial Lubrication e Coat all Limit Washers and Shaft Splines with Lubricant during assembly to prevent scoring and galling of such parts O Rings e Lubricate all O Rings with silicon lubricant Universal Joint Companion Flange or Yoke e Pull the Companion Flange or Yoke tightly into place with the Output Shaft Nut using 650 700 Ib ft 881 28 949 07 Nem of torque Make sure the Speedometer Drive Gear or a Replacement Spacer of the same width has been installed Failure to pull the Companion Flange or Yoke tightly into place can result in damage to the Mainshaft Rear Bearing IMPORTANT See the appropriate Illustrated Parts Lists specified by model series to ensure that proper parts are used during assembly of the Transmission Model Designations Serial Tag Information and Model Nomenclature Transmission model designa
144. r failed or damaged Range Piston Piston Bar or Cylinder Check for failed or loose Range Piston Snap Ring Range Yoke Assembly problem Check for failed or damaged Range Yoke Check for failed or loose Range Yoke Snap Rings Check for excessively long fastener installed in rear support hole Check for binding between Range Yoke Bar and Range Alignment Lock Cover Range Synchronizer problem Check for failed or damaged Range Synchronizer Sliding Clutch or Mating Gear Check for excessively worn Range Synchronizer Friction Material Grinding Noise on Range Shift Driver not preselecting range shift Instruct driver to preselect range shifts Range Synchronizer worn or defective Check Range Synchronizer and mating parts for excessive wear or damage 43 7 wo 5 5 3 gt E Air System Air System Troubleshooting WARNING Use care when removing Air Lines or checking for air flow from disconnected Air Lines High pressure air may exhaust suddenly Wear Safety Glasses Exhaust all air pressure from system before removing Air Filter Regulator or Combination Cylinder Cover VALVE RANGE CYLINDER AIR FILTER REGULATOR Note During all testing the vehicle air pressure must be greater than 90 PSI 620 kPa If during testing the pressure falls below 90 PSI 620 kPa make sure the Transmission is in Neutral start the engine and let the pr
145. re Countershaft Inner Race inside the Front Roller Bearing for installation 6 Use the RR1012TR 2 Bearing Driver to start the Front Bearing in Case Bore 7 Use a Screwdriver inserted in the Countershaft Cap Screw Bore to help center the Countershaft 8 Move the Countershaft forward into the Bearing 9 Usethe RR1012TR 2 Bearing Driver and Maul to completely seat the Front Bearing in the Case Bore Note Make sure to contact only the bearing and not the Temporary Race with the driver The Temporary Race should fall out when installation is complete 10 On the Countershaft front position the Retainer Plate with Roll Pin in hole at shaft end 11 Install the Front Bearing Retainer Plate and Cap Screw If the Cap Screw is being reused apply Eaton Fuller Thread Sealant 71205 or equivalent Torque the Cap Screw to 90 120 Ib ft 122 02 162 70 Nem Note Earlier models may have a Roll Pin in the Retainer This Roll Pin is not required and was removed on units built after 1994 235 Transmission Overhaul Procedures Bench Service 236 12 13 14 From the rear remove the Countershaft Support Tool Install the Rear Countershaft Bearing Position the Bearing so that the larger chamfer on the Bearing inside diameter is installed towards the Shaft Use the RR1012TR 4 Bearing Driver and a Hand Maul to completely seat the Bearing In the Count
146. rectly across from each other in each Bearing Cover Tapped holes in Auxiliary Case must be free of thread adhesive 262 5 9 Transmission Overhaul Procedures Bench Service Evenly torque the Cap Screws to 7 Ib in 0 79 Nem Do not install the Countershaft Rear Bearing Cover gasket The gap between the Bearing Cover and the Housing surface should be even from side to side Note 7 Ib in 0 79 Nem is slightly more than finger tight Do not overtighten the Cap Screws If the Cap Screws are too tight the Bearing Cover will become distorted Rotate the Output Shaft 4 times clockwise and 4 times counterclockwise The rotation will seat and align the rollers in each tapered bearing Re torque the Cap Screws to 7 Ib in 0 79 Nem If the Countershafts do not rotate the Range Sliding Clutch or Deep Reduction Sliding Clutch is in Neutral Apply shop compressed air to Shift Cylinders to shift the Sliding Clutches into gear Use a Feeler Gauge as close to each Cap Screw location as possible and measure the gap between the Countershaft Rear Bearing Cover and the Auxiliary Housing Gasket surface Measure and record the gap at both Cap Screw locations Average the two Feeler Gauge measurements by adding the measurements together and dividing by 2 as shown in the following Example Example Shim Selection Gap 1 0 060 Gap 2 0 050 Total Gap 0 060 0 050 0 110 Average 110 2 0 055 Select yellow shim as indicated in
147. res Bench Service How to Assemble the Integral Oil Pump with Auxiliary Oil Tube Special Instructions When installing the Drive Shaft Keys the round Key goes in the round Keyway and the square Key in the square Keyway Special Tools e A Vise with brass jaws or wood blocks Procedure 1 Install the Valve Cover 2 Install the Relief Valve and Relief Valve Spring in the Integral Oil Pump Housing 3 Secure the Oil Pump Housing in a Vice 4 Depress the Relief Valve Spring and drive the Relief Valve Retention Roll Pin into the Roll Pin Bore 256 Transmission Overhaul Procedures Bench Service 5 Install the Ball Spring and Retaining Nut 6 Torquethe Retaining Nut to 40 45 Ib ft 54 23 61 01 Nem 7 If removed replace the Drive Shaft Snap Ring on the Pump Drive Shaft y e 9 5 i ue z se 55 25 9 8 Insert the Drive Shaft through the Pump Housing Bore 9 Install the two 2 Keys on the Drive Shaft 257 258 Transmission Overhaul Procedures Bench Service 10 Install the Transfer Tube 11 Align the Inner Element Keyways with the Drive Shaft Keys and install the Integral Oil Pump Inner Element 12 Install the Inner Element Retention Snap Ring in Drive Shaft Snap Ring groove 13 Install Drive Gear Key in Drive Shaft Keyway 4 Align Drive Gear Keyway with Drive Shaft Key and install the Drive Gear on t
148. rews are tightened to proper torque Note Make sure gaskets were used at appropriate positions Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Countershaft Assembly Special Instructions To make Auxiliary Section Assembly easier you can make an Auxiliary Section fixture out of a 2 x 12 piece of wood This fixture is designed to ease the assembly of the Auxiliary gearing Set the Auxiliary Countershaft Rear Bearings in the 3 holes an an o E gt Set the assembled Auxiliary Mainshaft between the Countershafts with the timing marks aligned gt a a 1 i wo Special Tools e RR1002TR Auxiliary Countershaft Support Straps 179 Transmission Overhaul Procedures Bench Service 180 Procedure 1 Place the Countershaft Assembly vertical on a clean flat surface If previously removed use the proper Driver and Maul to install the Countershaft Bearings Mark each Countershaft for correct timing Locate the O s stamped on the Countershaft and mark the teeth with highly visible Toolmaker s Dye or paint Place the Countershafts in the fixture or on a flat surface for reassembly Turn the Countershafts so that the two teeth marked on each LO Range Gear are towards the middle Refer to Timing Procedure on page 57 Align the Output Shaft between the Co
149. rhaul Procedures Bench Service 2 LI ah n 23 Y 210 21 24 25 27 28 Align the Sliding Clutch missing internal Spline with the Mainshaft Key and install the Reverse Speed Sliding Clutch With the flat side up place a washer blue or white in the next available groove Rotate the washer until the Washer Splines and Mainshaft Splines align Push the Air Line up to lock the washer on the Mainshaft Against the Tolerance Washer position Reverse Speed Gear Spacer Install Reverse Gear on the Mainshaft Engage the Gear Clutching teeth with Spacer External Splines and Sliding Clutch Move the Reverse Gear down against the 1st Speed Gear Atthis time remove the Air Line and insert the Mainshaft Key Be careful not to move the gears while doing this procedure the Tolerance Washers are unlocked and can rotate which would cause the gears to drop Remove the Mainshaft from the Vise On the shaft front align the Sliding Clutch missing internal Spline with the Mainshaft Key and install the front Sliding Clutch Engage the Sliding Clutch external Splines with the gear Clutching teeth Transmission Overhaul Procedures Bench Service 29 Washers for 6 Sided Key Part Size Color 14711 0 248 0 250 White 14712 0 253 0 255 Green 14713 0 258 0 260 Orange
150. rvice Tools 3 lt 7 11 N 3 rJ 11 9 rJ 17 gt N Component Nomenclature and Roadranger Valve Sectional View 1 Medallion 7 Retainer 2 Spring 8 O Ring 3 Lever 9 Old Style Shift Knob 4 Cover 5 Screw 6 Ball 5 32 63 In Vehicle Service Procedures Procedure 1 Remove the two screws holding the Bottom Cover to the Valve and slide the Cover down the Gear Shift Lever to expose Air Line Fittings Disconnect the Air Lines 2 Loosen the Jam Nut and turn the Roadranger Valve from the Gear Shift Lever 3 Prythe Medallion from the recess in the Top Cover 4 Turn out the two screws to remove the Top Cover from the Valve Housing 5 Turn out the two screws in the side of the Valve Housing to separate the Housing 6 Remove the Range Selection Lever from the Left Housing along with the Position Balls and Guide 7 If necessary remove the Springs and O Ring from the Bores in the Left Housing 8 If necessary remove the Springs O Ring and Sleeves from the Bores in the Right Housing 64 In Vehicle Service Procedures How to Assemble Roadranger Valve A 5010 Special Instructions None Special Tools e Typical Service Tools 1 gt c gt i rJ 1 ow Component Nomenclature and Roadranger Valve Sectional View 1 Medallion 4 Cover 7 Retainer 2 Spring 5 Screw 8 O Ring 3 Lever
151. ry Section Introduction Transmission Overview Air System Roadranger Valve Shift Bar Housing Levers Housings amp Isolators Auxiliary Section Range Cylinder Shift Bar Housing Shiftbar Housing Assembly U Front Section Reverse Idler e x om wes ALES gt W Aut SN Auxiliary Section Auxiliary Countershaft Air System Air Filter Regulator Front Section Clutch Housing Case Assembly Auxiliary Section Auxiliary Drive Gear Front Section Mainshaft Ly ey aes Auxiliary Section e Reduction Cylinder Front Section Input Shaft Drive Gear i P Front Section Countershafts amp Air System Slave Valve 106004 8 94 15 spd trans Table of Contents General Information In Vehicle Service Procedures cont d Warnings and Cautions How to Install the Top 2 Valve Assembly Transmission Overview Transmissions with Top 2 Option Only 88 How to Remove the Gear Shift Lever Remote Purpose and Scope of Manual 1 Shift GoOntrol cete eee 89 Serial Tag Information and Model Nomenclature 5 i IU NEM How to Install the Gear Shift Lever Remote Lubrication Specifications 7 Shift Control 90 Tool Spec
152. s Shafts and or Bearings Use a Torque Wrench whenever possible to attain recommended Ib ft ratings Do not torque Cap Screws dry 2 Support Stud Nuts 170 185 Ib ft 230 49 250 93 Nm 5 18 Threads Use Lockwashers 1 Output Nut 650 700 Ib ft 881 949 Nm Intall output nut onto a clean oil free shaft Note DO NOT reuse output nut replace with new if removed from shaft 1 Oil Drain Plug 45 55 Ib ft 61 01 74 57 Nm 34 Pipe Threads 1 Oil Fill Plug 35 50 Ib ft 47 68 Nm 1 Pipe Threads 12 Preventive Maintenance Preventive Maintenance Inspection Everyday there are countless vehicles operating over the highways with Transmissions in such a neglected mechanical condition they can be referred to as failures looking for a place to break down They lack a proper and organized preventive maintenance program Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost short of removing and repairing the unit 5 2 5 5 Q 3 gt A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed Transmission Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost If the Transmission is not cared for it will breakdown Preventative Maintenance Ch
153. s Service Publication are current at the time of printing Eaton reserves the right to discontinue or modify its models and or procedures and to change specifications at any time without notice Any reference to Brand Name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents may be used This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator Always use genuine Eaton replacement parts WARNING Failure to follow indicated procedures creates a high risk of personal injury to the servicing technician CAUTION Failure to follow indicated procedures may cause component damage or malfunction IMPORTANT Highly recommended procedures for proper service of this unit Note Additional service information not covered in the service procedures Tip Helpful removaland installation procedures to aid in the service of this unit CAUTION Conversion of a 13 Speed to an 18 Speed by simply changing the Air System will invalidate the User s Warranty and will cause major internal damage to the Auxilia
154. sed with the Cap Screw design where Main Case does not have the oil feed hole the Reverse Idler Bearing will fail Current Design 1 Star Washer 6 Idler Plate 2 Inner Race 7 Bearing 3 Star Washer 8 Reverse Idler Gear 4 Retaining Ring 9 Reverse Idler Shaft 5 Cap Screw 222 Transmission Overhaul Procedures Bench Service Procedure 1 Position the Reverse Idler Bearing and Inner Race into the Reverse Idler Gear 2 Position the gear in the Case The Gear s long hub is positioned forward y e ez o 5 5 E dE 55 ez 9 3 Place the Rear Thrust Washer the Idler Shaft 4 From the Case rear insert the Idler Shaft through the Main Case Bearing Bore and into the Reverse Idler Gear Bearing 5 Asthe Idler Shaft slides into the gear insert the Front Thrust Washer into position Continue sliding the Idler Shaft into the Case Support Boss 6 From the rear gently tap the Idler Shaft forward until resistance is felt 223 Transmission Overhaul Procedures Bench Service 7 Install the Flat Washer over the Shaft s threaded portion 8 Apply Eaton Fuller Sealant 71205 or equivalent Install Cap Screw and torque to 67 75 Ib ft 90 84 101 69 Nem 9 Using a Bearing Race Driver install the Auxiliary Countershaft Bearing Race into the Lower Reverse Idler Bore Note The Bearing Races have a slip fit in their Bores They should slide or rotate
155. side e nstallthe Spring into the Bore over the Plunger Shank e Install the Plug and tighten to compress the Spring e After Plug bottoms out back the Plug out 1 to 1 1 2 turns e Complete the Block Assembly process by staking the Plug through the small hole in Block With the Housing rear to the right lay the Assembly on a flat surface Start installation of the bottom Shift Bar as the Bar passes the Bosses install the two 2 bottom Shift Yoke Assemblies Install the Shift Yoke Lock Screw torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place the Actuating Plunger in the top center Bore Place one 3 4 Interlock Ball in the Interlock Bore against the bottom Bar Holding the middle Bar notched end start installation As the Bar passes the Rear Boss position the Shift Block As the Bar passes the center Boss position the Shift Yoke on Bar long hub to the Housing front Just prior to inserting notched end of Bar in Rear Boss install the small Interlock Pin vertically in the Neutral Notch Bore Install the Shift Block and Shift Yoke Lock Screws torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place one 3 4 Interlock Ball in the Interlock Bore against the middle Bar 145 gt a a o LI Transmission Overhaul Procedures Bench Service 146 15 Holding the
156. so check the Slave Valve Plunger and Spring for free movement 93 In Vehicle Service Procedures How to Remove the Neutral Switch Special Instructions None Special Tools e Typical Service Tools 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft 94 Procedure 1 2 Remove 2 screws retaining Wire Terminals Remove the Switch using a 7 8 Deep Well Socket or Box End Wrench In Vehicle Service Procedures How to Install the Neutral Switch Special Instructions None Special Tools e Typical Service Tools Procedure ff 7 UAR 42 1 Install a new Gasket 2 Install the Neutral Switch torque to 15 20 20 34 27 12 Nem 1 2 5 7 wo v rJ a N Connect the wiring to the Switch 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft 95 In Vehicle Service Procedures Reverse Switch Operation and Testing Special Instructions The Reverse Switch is a normally open Ball Switch When the Transmission is shifted into Reverse a Ramp on the Reverse Yoke Bar contacts and raises a Pin The Pin depresses the Ball on the Switch which closes the Switch Contact allowing current to flow through the Switch and light up the vehicle s backup lights Special Tools e Typical Service Tools e Volt Ohm Meter Procedure 1
157. ster and prevent costly damage to critical parts For the most part ordinary Mechanic s Tools such as Socket Wrenches Screwdrivers etc and other standard shop items such as a Press Mauls and Soft Bars are the only tools needed to successfully disassemble and reassemble any Fuller Transmission 3 3 5 5 E gt E The following tables list and describe the typical tools required to properly service this model Transmission above and beyond the necessary basic Wrenches Sockets Screwdrivers and Pry Bars General Tools The following tools are available from several Tool Manufacturers such as Snap On Mac Craftsman OTC and many others Tool Purpose General torquing of fasteners Typically 15 80 Ib ft 0 100 Ib ft 1 2 drive Torque Wrench 20 34 108 47 0 700 Ib ft 3 4 or 1 drive Torque Wrench Torquing of Output Nut to 650 700 Ib ft 881 28 949 07 Nem 0 50 Ib in 3 8 drive Torque Wrench General torquing of fasteners Torquing of Cap Screws to 7 Ib in 0 79 Nem during Auxiliary Countershaft 0 30 Ib in 1 4 drive Torque Wrench Bearing endplay setting procedure 70 MM or 2 2 4 Socket Standard Depth To remove the Output Shaft Nut To remove the Snap Rings at the Auxiliary Drive Gear Input Shaft Bearing Snap Ring Pliers Large Standard External and Countershaft Bearings Feeler Gauges To set Mainshaft Washer Endplay and Auxiliary Tapere
158. t up and off the Shift Lever Shaft With Housing bottom facing up secure the Assembly in a Vise Use large Screwdriver to twist between the Spring and Housing forcing the Spring from under the Housing Lugs one coil at a time From inside the Housing Tower remove the Tension Spring washer and Gear Shift Lever In models so equipped from the Housing Bore remove the Nut and Washer From the Housing Tower Spade Pin Bore remove and inspect the Spade Pin discard if damaged From the Housing Tower inside groove inspect the O Ring discard if damaged v e 9 5 i ue 5 5 o 1 ez 131 Transmission Overhaul Procedures Bench Service How to Assemble the Gear Shift Lever Special Instructions Inspect Tension Spring and Washer for wear Apply Eaton rust preventative Lubricant 71212 or equivalent to the Shift Lever Pivot Ball A rust preventative lubricant film should cover all surfaces between and including the Pivot Ball Seat the Tension Spring one coil at a time Special Tools e Vise with brass jaws or wood blocks 1 Pin 2 Bushing 3 Upper Lever 4 Snap Ring 5 Rubber Boot 6 Spade Pin 7 Housing 132 10 6 gt 4 a 4 _ 12 5 j 7 4 13 208 14 209 8 Screw 9 Gasket 10 O Ring 11 Washer 12 Lower Lever 13 Stepped Washer 14 Tension Spring Procedure 1 Transmission
159. tall the Speedometer Rotor Seal Sleeve over the Output Shaft and install the Speedometer Sensors Install the Output Yoke over the Output Shaft The Yoke should slide on an stop before contacting the Speedometer Rotor As the Output Shaft Nut is installed the Output Yoke will contact the Speedometer Rotor Install the Output Nut and torque to 650 700 Ib ft 881 28 949 07 Nem Connect the Driveshaft and U joint according to the OEM or Driveshaft Manufacturer s instructions In Vehicle Service Procedures 109 5 o N wo g rJ 9 T rJ 17 1 a In Vehicle Service Procedures How to Remove the Output Yoke Companion Flange and Nut Special Instructions After removal of the Output Yoke Companion Flange temporarily replace the Output Shaft Nut to protect the Output Shaft threads during Auxiliary Section disassembly Special Tools e large Breaker Bar or Air Impact Wrench Procedure 1 Engage two 2 Mainshaft Sliding Clutches into two 2 Mainshaft Gears to lock the Transmission or use a Yoke Holding Tool if available 2 Usealarge Breaker Bar or Air Impact Wrench to remove the Output Shaft Nut 3 Remove the Output Yoke 110 In Vehicle Service Procedures How to Install the Output Yoke Companion Flange and Nut Special Instructions Special Tools e Torque Wrench with 0 700 Ib ft capacity Procedure 1 Engage two 2 Mainshaft Sliding Clutches int
160. tate the washer until the Washer Splines and Mainshaft Splines align With the missing internal Splines aligned with the plastic Position the next Offset Washer in the next available groove Push the Air Line up to lock the washer on the Mainshaft With Clutching teeth down position the next proper gear on Position the Flat Washer against the gear Rotate the washer Transmission Overhaul Procedures Bench Service With Clutching teeth up and against the spacer install the next Gear Position the Offset Washer flat surface down against the gear Rotate the washer until the Washer Splines and Mainshaft Splines align Push the Air Line up to lock the washers on the Mainshaft line install the proper Sliding Clutch Rotate the washer until the Washer Splines and Mainshaft Splines align the Mainshaft until the Washer Splines and Mainshaft Splines align 213 Y 2 is a o LI 1 5 e ow 2 E E a 2 Em lt Transmission Overhaul Procedures Bench Service 214 15 16 17 18 19 22 23 24 25 With Clutching teeth up install next Gear on the Shaft against previously installed Gear Position the Offset Washer flat surface down against the Gear Rotate the Washer until the Washer Splines and Mainshaft Splines align Push the Air Line up to lock the Washer on th
161. ter Connections Speedometer Cables should not be loose Applied hydraulic Thread Sealant 71208 to threads torque Speedometer Sleeve to 35 50 Ib ft 47 45 67 79 Nem Should be an O Ring or gasket between the mating Speedometer Sleeve and the Rear Bearing Cover Replace the O Ring gasket if damaged or missing Rear Bearing Cover Cap Screws Gasket and Nylon Collar Check Retaining Cap Screws for tightness Apply Eaton Sealant 71205 to the Cap Screw threads torque to 35 45 Ib ft 47 45 61 01 Nem Verify Nylon Collar and Gasket are installed at the chamfered hole aligned near the mechanical Speedometer opening Use new parts if need to replace Apply Eaton Sealant 71205 to the Cap Screw threads torque to 35 45 Ib ft 47 45 61 01 Nem Verify that a Rear Bearing Cover gasket is in place Install a new Gasket if Rear Bearing Cover was removed Check the Output Shaft Nut for Torque the Output Shaft Nut to 650 700 Ib ft Output Shaft Nut tightness 881 28 949 07 Nem Do not over torque the Output Nut Apply Eaton Sealant 71205 to the Cap Screw PTO Covers and Openings Check the Cap Screws for tightness threads Torque 6 bolt PTO Cap Screws to 35 45 Ib ft 47 45 61 01 Nem 8 bolt Cap Screws to 50 65 Ib ft 67 79 88 13 Nem Gray Iron Parts Check Front Bearing Cover Front Case Shift Bar Housing Rear Bearing Cover and Clutch Housing for cracks or breaks Replace par
162. th is stamped with an O to aid identification 2 Marking Main Drive Gear teeth Mark any two adjacent teeth on the Main Drive Gear Mark the two adjacent teeth located directly opposite the first set marked on the Main Drive Gear As shown to the left there should be an equal number of unmarked gear teeth on each side between the marked sets 3 Meshing marked Countershaft Drive Gear teeth with marked Main Drive Gear teeth After placing the Mainshaft Assembly into the Case the Countershaft Bearings are installed to complete installation of the Countershaft Assemblies When installing the bearings on the left Countershaft mesh the Countershaft Drive Gear marked tooth with either set of Main Drive Gear two marked teeth Repeat the procedure when installing the Bearings on the Right Countershaft make use of the remaining set of Main Drive Gear two marked teeth to time assembly Timing D S 5 9 E gt Figure 2 Figure 3 97 Timing Procedure Time the RT Auxiliary Section 1 Marka tooth on the Reduction Gear with a highly visible paint preferably a yellow or white 2 Marka second tooth 180 degrees away from the first Ensure the marks are in the correct position by counting the teeth between them You should have exactly the same number of teeth on the Reduction Gear between the marked teeth Reduction Gears and mark both teeth with a highly visible FR and RT
163. the port Move the Range Selector down to Low Range and move the Splitter Button rearward Disconnect line from the SP port Check for air flowing from the SP port on the Shift Knob Air is flowing from the SP line Air is not flowing from the line 1 Check to make sure the SP line is connected to the Splitter Cylinder Cover 2 f the line is properly attached check that the Insert Valve old style is properly installed stem facing inward and that the Insert Valve Bore is not defective 3 Replace the Insert Valve Repair or replace the Shift Knob 46 Air System Procedure 2 Symptom Air Leak at Slave Valve Normal Operation A momentary exhaust of air the Slave Valve occurs during a range shift The air from the Low Range side of the Range Cylinder is exhausted as air pressure is applied to the High Range side Likewise air from the High Range side of the Piston is exhausted as air pressure is applied to the Low Range side The Exhaust Port is located at the Slave Valve to Transmission mounting interface Possible Causes 3 3 5 5 5 3 gt E e Internal leak in Range Cylinder e Internal leak in Slave Valve Table 11 Air Leak at Slave Valve Procedure Result What to Do Next Step A Confirm that air is leaking from the Air is leaking from fitting or Repair or replace Fitting or Exhaust Port on the Slave Valve and not Air Line
164. the Shim Table at the end of this selection Locate the Feeler Gauge average measurement in the Shim Table to determine the required Shim and Color Code Note The Oil Pump Shim is used when an Auxiliary Oil Pump or PTO is mounted on the Countershaft The Oil Pump Shims have a smaller outside diameter 263 Y a is a o LI 1 rJ 1 S ow E gt z Ll 5 2 lt ow Transmission Overhaul Procedures Bench Service 264 10 11 12 13 14 15 16 Remove the Countershaft Rear Bearing Cover and Gauging Shim Place the selected Shim on the Rear Countershaft Bearing Race Position a new gasket on Countershaft Rear Bearing Cover mounting surface Position the Countershaft Rear Bearing Cover over the new gasket Apply Eaton Fuller amp Thread Sealant 71205 or equivalent to the Auxiliary Countershaft Rear Bearing Cover Cap Screws and Auxiliary Countershaft Rear Bearing Cover Install the Auxiliary Countershaft Rear Bearing Cover and secure it with the Cap Screws Make sure the Shim is in the proper location and is not pinched between the Cover and the Housing Torque the Cap Screws to 40 45 Ib ft 54 23 61 01 Nem Note Use a thick grease to hold the Shim in position when installing the Cover Repeat this procedure for the remaining Countershaft Note Make sure the Input
165. tion and other Transmission identification information are stamped on the Transmission Tag To identify the Transmission model designation and Serial Number locate the Tag on the Transmission and then locate the numbers as shown When calling for service assistance or parts have the Model and Serial Numbers handy Do not remove or destroy the Transmission Identification Tag FTO Code Eaton Fuller Transmissions Eaton Corporati Kalumazps RTL 0 C F 167 18 2 2 Roadranger Multi Torque Twin Countershaft Ratio Set Low Inertia Forward Speeds _ 6 Multi Mesh Gearing 0 Overdrive w Direct Shift Pattern 7 Helical Auxiliary Gearing and C Convertible Multi Mesh Front Section Gearing 9 Improved Seal System F Forward Opening Shift Housing This x 100 Nominal Torque Capacity The Model Number gives basic information about the Transmission Use this number when calling for service assistance or replacement parts Serial Number The Serial Number is the sequential identification number of the Transmission Before calling for service assistance write the number down It may be needed Bill of Material or Customer Number This number may be located below the Model and Serial Numbers It is a reference number used by Eaton gt 3 gt Model Designations Model Options Torque Rating The torque rating of the Transmission specif
166. top Bar notched end start installation As the Bar passes the Rear Boss position the Shift Block 16 Asthe Bar passes the center Boss position the Shift Yoke 17 18 19 on Bar long hub to the Housing rear Install the Shift Block and Shift Yoke Lock Screws torque to 35 45 lb ft 47 45 61 01 Nem Lockwire securely Install the Oil Trough torque the Retaining Cap Screws to 8 12 Ib ft 10 85 16 30 Nem Some models do not have an Oil Trough Install the three 3 Tension Balls one in each Housing top Bore Install the three 3 Detent Springs one over each Tension Ball Note Make sure Interlocking System is working should not shift into 2 gears at the same time Note Make sure all Lock Screws are lockwired Transmission Overhaul Procedures Bench Service How to Disassemble the Forward Shift Bar Housing Special Instructions The Shift Bar Housing must be removed from the Transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift Bars not being removed must be kept in the Neutral position or the interlocking parts lock the Bars Start with the bottom Shift Bar Cut the Lockwire and remove the Lock Screws from each Bar just before their removal Special Tools e Typical Service Tools Procedure 1 If the three 3 sets of Tension Springs and Balls from Housing Bores have not been removed place the Shift Bar Housing on its side to remove the
167. top outside edge of each page followed by more specific headings and the procedures To find the information you need in these sections first go to the section that contains the procedure you need Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the Transmission Note In some instances the Transmission appearance may be different from the illustrations but the procedure is the same Disassemble Precautions It is assumed in the detailed assembly instructions that the lubricant has been drained from the Transmission the necessary linkage and vehicle Air Lines disconnected and the Transmission has been removed from vehicle Chassis Removal of the Gear Shift Lever Housing Assembly or Remote Control Assembly is included in the detailed instructions How to Remove the Gear Shift Lever This Assembly MUST be detached from the Shift Bar Housing before the Transmission can be removed Follow closely each procedure in the detailed instructions make use of the text illustrations and photographs provided Assemblies e When disassembling the various Assemblies such as the Mainshaft Countershafts and Shift Bar Housing lay all parts on a clean bench in the same sequence as removed This procedure will simplify assembly and reduce the possibility of losing parts Bear
168. ts found to be damaged Front Bearing Cover Check return threads for damage If threads damaged replace the Input Shaft Check the Cap Screws for tightness Torque the Cap Screws to 35 45 47 45 61 01 Nem Oil Cooler and Oil Filter Check all connectors Fittings Hoses and Filter Element for tightness Tighten any loose Fittings Oil Drain Plug Oil Fill Plug Check the Oil Drain Plug and the Oil Fill Plug for leakage Torque the Oil Drain Plug to 45 55 Ib ft 61 01 74 57 Nem Oil Fill Plug to 60 70 Ib ft 81 35 94 91 Nem 15 3 3 5 5 5 3 gt E Preventive Maintenance Oil Leak Inspection Process Inspect for Oil Leak Determine if it is a Weep or a Leak Weep Stained damp no drips light oil film Leak Fxtremely wet or dripping of oil in the dirt adhered to the contaminated area contaminated area Clean suspected oil weep 1 Do not repair Rear seal is 1 Determine the origin of the leak path area with a clean dry cloth designed to allow minimal or mild soluble degreaser seepage 2 If origin of leak is obvious skip to Step 3 Rear Seal 3 Ifthe origin of the leak is not obvious then Ensure lube is to proper 2 Ensure lube is to proper use either of the two following steps to determine BE level the oil leak Notify the customer that it Note Do not use a high pressure s
169. tthe Front Case Pump Plug in the Case Bore by hand Do not install the Pump Plug using any type of Impact Tool i e Hammer Maul etc Note P N 4303107 Retainer Plate which has a smaller outside diameter must be used with Main Cases machined after April 1995 If an older Oil Pump Assembly is installed into a new case P N 20510 Retainer Plate will not seat properly in the Spot Face machined in the case wall 3 With the Retainer Bore facing the case rear install the Integral Oil Pump over the Alignment Pin inside the case 4 Align Oil Pump with Retainer and Alignment Pin and install the Integral Oil Pump Assembly 250 Transmission Overhaul Procedures Bench Service 5 Install three 3 Allen Head Cap Screws and washers through the Case Front and into the Pump Housing Torque the Cap Screws to 8 12 Ib ft 10 85 16 30 Nem 6 Replace the O Ring on the Suction Tube 7 Install the Tube under the Case Rib and into the Integral Oil Pump 8 Bend the Suction Tube Lock over the Case Rib v e 9 5 5 5 5 o 1 ez 9 Position the Oil Tube the case bottom through the intermediate wall 10 Apply Loctite 242 to Cap Screw threads Torque Cap Screws to 35 45 Ib ft 47 45 61 01 Nem Note Make sure the Integral Oil Pump Drive Gear can turn 251 Transmission Overhaul Procedures Bench Service How to Disassemble the Integral Oil Pump w
170. ue z se 55 25 9 2 Frominside the case use a long Soft Bar to drive the Upper Countershaft Rear Bearing rearward off the Shaft Note Damage will likely occur to this bearing during removal It is strongly recommended that this bearing is discarded 3 Remove the Cap Screw and the Retainer from the Upper Countershaft front 4 Slide the Lower Countershaft forward This will move the Front Bearing forward to expose the External Snap Ring 195 Transmission Overhaul Procedures Bench Service 5 Usethe RR1012TR Countershaft Bearing Puller to remove the Lower Front Bearing from its Bore 6 Move the Upper Countershaft to the rear until the Front Bearing Journal clears the Front Case Bore 7 Swingthe front of the Countershaft to the center of the Case and lift out the Countershaft Assembly Note Follow the same procedure for Lower Countershaft removal 196 Transmission Overhaul Procedures Bench Service How to Disassemble the Countershaft Assemblies Special Instructions As you disassemble the Countershafts mark each part as belonging to the Upper or Lower Countershaft and mark the gears for front or back orientation Except for the PTO Gears the Upper and Lower Countershaft Assemblies are identical and disassembled in the same manner Special Tools 10364 11 96 CS RT 1 Snap Ring 2 Bearing 3 Countershaft with Reverse and LO 4 Key 5 Roll Pin 6
171. ue flows to both Countershafts and then to the Splitter Gear Torque then flows into the Range Sliding Clutch and Output Shaft See Figure 1st 13 Speed 1st Low Split 18 Speed If splitter H is selected torque flows directly through the Auxiliary Section Torque flows from the Auxiliary Splitter Clutch to the Auxiliary Reduction Gear to the Range Sliding Clutch to the Output Shaft The Auxiliary gearing still turns but the gear teeth will not be loaded See Figure 1st High Split 18 Speed gt s L4 i RTO Gunes les 5th 9 13 18 speed Low Split 1 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward Gu oba 555 Hee 5th 9 13 18 speed High Split 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward 23 lt 5 D 5 5 3 gt Power Flow 9 Speed NE X pm L1 2 RTO RTX wob LEG SoS wad ess ves 10 Gear 1st Gear 1 Sliding Clutch forward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch rearward NE qe WE hon wees GRECE eee ro d a C92 8 191 C628 veb CES Me 2nd Gear 3rd Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sli
172. untershafts match the timing marks With Range Yoke offset side facing down install into the Synchronizer Sliding Slot Place the Auxiliary Housing over the Countershaft Assemblies and the Output Shaft Assembly Transmission Overhaul Procedures Bench Service 7T Make sure the Output Shaft Bearing Spacer is on the Output Shaft 8 Heatthe rear Output Bearing Cone and install the Bearing tapered side down on the Shaft 9 Position a new gasket on the Rear Bearing Cover mounting surface 10 Position the Rear Bearing Cover 11 Apply Eaton Fuller Sealant 71205 or equivalent to the Retaining Cap Screws 12 Install the six 6 Retaining Cap Screws in the non chamfered hole torque to 35 45 Ib ft 47 45 61 01 Nem 13 Install the Bearing Races 14 Install each Auxiliary Countershaft Retaining Strap with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean Cap Screws Note Do not use an Air Gun Tighten by hand until the Cap Screws are snug 181 Transmission Overhaul Procedures Bench Service How to Disassemble the Splitter Gear Bearing Assembly Special Instructions Make sure to use the proper Drivers for the Bearing and Sleeve Special Tools e 3 30 diameter Bearing Driver Procedure Remove the Internal Snap Ring 2 Remove the Splined Washer 3 Remove the Rear Bearing Race using he proper Bearing Driver 4 Remove the Beari
173. urning place a shop rag or equivalent between the Splitter Gear and one Countershaft 2 From the Output Shaft loosen the 15 16 Cap Screw and Retainer Do not remove the Cap Screw 3 Use a Soft Bar and to drive the Output Shaft forward far enough to partially unseat the Bearing 4 Support the Auxiliary Countershaft while removing the Auxiliary Countershaft Retaining Strap 5 Remove the Auxiliary Countershaft 6 Remove the Auxiliary Countershaft Bearing Race from Bore 159 Transmission Overhaul Procedures Bench Service 7 necessary secure the Countershaft Assemblies in a Vise and remove both the Front and Rear Bearings with a Bearing Separator and Jaw Pullers 160 Transmission Overhaul Procedures Bench Service How to Remove the Splitter Gear Special Instructions None Special Tools e Typical Service Tools Procedure 1 From the Output Shaft remove the 15 16 Cap Screw and Retainer Bolt 2 From the Output Shaft remove the Splitter Gear 161 Y a o LI wo 5 1 S E E a 2 ml lt gt Transmission Overhaul Procedures Bench Service How to Disassemble the Range Cylinder Assembly Special Instructions For RTLO XX9XX 9 Series remove the Auxiliary Section before disassembling the Range Cylinder Se
174. ve 250 F Operation at temperatures above 250 F 121 causes loaded gear tooth temperatures to exceed 350 F 177 which will ultimately destroy the heat treatment of the gears If the elevated temperature is associated with an unusual operating condition that will reoccur a Cooler should be added or the capacity of the existing cooling system increased The following conditions in any combination can cause operating temperatures of over 250 121 C e Operating consistently at slow speed e High ambient temperatures e Restricted air flow around Transmission e Use of engine retarder e High horsepower operation Note Transmission Coolers must be used to reduce the operating temperatures when the above conditions are encountered Lubrication Oil Cooler Chart Table 4 Transmission Oil Coolers are Recommended With engines of 350 and above Required With engines 399 H P and above and GCW s over 90 000 Ibs With engines 399 H P and above and 1400 Ib ft 1898 15 Nem or greater torque With engines 1500 Ib ft 2033 73 Nem and above 18 speed AutoShift Transmissions require use of an Eaton supplied Oil to Water Cooler or approved equivalent With engines 450 H P and above Recommended Tools Tool Specifications Some repair procedures pictured in this Manual show the use of specialized tools Their actual use is recommended as they make Transmission repair easier fa
175. y 6 Gasket 7 Cap Screw 8 Cap Screw 9 Cover 10 Gasket 11 Shim Kit 12 Gasket 164 13 Rear Housing 15 Lifting Eye 16 Cap Screw 19 Speedo Drive Gear 20 Speedo Spacer Assembly 21 Oil Seal w Slinger 22 Cap Screw 23 Speed Sensor Kit 24 Bushing 25 O Ring 26 Rear Bearing Cover Assembly Transmission Overhaul Procedures Bench Service Procedure 1 Use a Soft Bar and Maul to drive the Output Shaft forward and through the Rear Bearing Assembly 2 From the Auxiliary Housing rear remove the Rear Bearing Retaining Cap Screws Cover and Gasket 3 Clean the gasket mounting surface of gasket material y e ez o 5 5 dE 55 ez 9 4 Inspect the Rear Bearing Cover Oil Seal for damage remove if damaged 5 From the Auxiliary Housing rear remove the Bearing Cup and Spacer 165 Transmission Overhaul Procedures Bench Service 166 6 From the Auxiliary Housing front remove the remaining Bearing Cup 7 Some models have a one piece Bearing Race Remove it from the Bearing Bore 8 From the Output Shaft remove the Bearing Inner Spacer 9 Usethe Output Shaft Assemble Gear front face as base press the Output Shaft through the Bearing and Gear Transmission Overhaul Procedures Bench Service How to Disassemble the Synchronizer Assembly Special Instructions Place the Synchronize
176. yway 3 With the washer flat side up position a gear Tolerance Washer white in the Mainshaft 1st or bottom groove Rotate the washer until the Washer Splines and Mainshaft Splines align 4 Start at the Mainshaft bottom and install a 1 8 or 5 32 diameter plastic line in the Keyway to lock the washer in place As Limit Washers and Gears are installed continue to push the plastic line up E e 5 Oo 5 5 5 5 2 o 1 ez 5 Against the 4th Speed Gear Washer position a Spacer Washer against the Tolerance Washer 6 With Clutching teeth down and engaged with the Spacer external Splines position the proper Gear on the Mainshaft If necessary refer to the illustrated parts list to determine Gear order 7 With Clutching teeth up and against this gear install the next Gear and Spacer Washer 207 Transmission Overhaul Procedures Bench Service 8 With the washer flat side down position a Tolerance Washer against the Spacer Rotate the washer until the Washer Splines and Mainshaft Splines align 9 Push the Air Line up to lock the washer on the Mainshaft 10 Insert two large Screwdrivers between the two gears Apply slight downward pressure to spread the gears evenly Between the Gear Hub and Mainshaft Spacer insert 0 006 Feeler Gauge and 0 015 Feeler Gauge If out of tolerance change the washer against the Mainshaft Spacer 11 With the missing Internal S

Fuller® Heavy-Duty Transmissions TRSM0670 EN-US

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Fuller&reg; Heavy-Duty Transmissions TRSM0670 EN-US

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Fuller® Heavy-Duty Transmissions TRSM0670 EN-US