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Fuller Heavy Duty Transmissions TRSM0446

1. Transmission Overhaul Procedures Bench Service How to Reassemble the Shift Bar Housing Assembly Special Instructions There are two 2 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes Note their location Be careful when installing the shift bar housing to not damage oil tube with shift yokes Note Forward Shift Bar Housing installation follows the same procedure Special Tools e Typical service tools 1 Shift Bar HSG STD 19 Reverse Light Switch 2 Gasket 20 Plug 3 Breather and Pipe Plug 21 Spring 4 Oil Trough 22 Steel Ball 5 Air Valve Shaft 23 Shift Yoke 6 Capscrew 24 Steel Ball 7 Pipe Plug 25 Shift Block 8 Gasket 26 Lockscrew 9 Plate 27 Interlock Pin 10 Lockwasher 28 Shift Block 11 Capscrew 29 Shift Yoke 12 Gasket 30 Yoke Bar 13 Plug 31 Shift Yoke 14 Neutral Light Switch 32 Yoke Bar 15 Lifting Eye 33 Yoke Bar 16 Capscrew 34 Plunger 17 Pin 35 Spring 18 Gasket 36 Shift Bar HSG STD 140 Transmission Overhaul Procedures Bench Service Procedure 1 If previously removed install the reverse stop plunger in the LO Reverse shift yoke making sure the plunger is fully seat ed in the yoke slot bore 2 Install the spring in the yoke bore and on the plunger shank 29 c c 5 a nv uS 259 lt ae 2 2 2 3 Install the plug and tighten to compress
2. lt REFERENCE TOOL PURPOSE G amp WTOOL NO GREAT LAKES OTC E NUMBER TOOL NO TOOL NO E T12 Bearing Driver To install the auxiliary coun G 200 Kit T 105 Kit ET tershaft tapered bearings T13 Output Seal Remov To remove the output seal in Use 27315 al Tool chassis Can use slide ham hook with 1155 mer slide hammer T14 Auxiliary Section To attach transmission jack G 115 49611 Used Removal Adapter to auxiliary section for auxil with OTC trans Plate jary section removal in chas mission jack P sis N 5019 T15 Mainshaft Hook To assist in lifting of main G 225 T 165 shaft from front section T16 InputBearing Puller To remove input bearing G 38 T 3 7070A Kit T17 Bearing Race Puller remove the auxiliary 7136 puller at countershaft tapered bearing tached to 1155 outer races slide hammer T18 Bearing Race In To install the auxiliary coun 21524 21530 staller tershaft tapered bearing out discs used with er races 27488 handle and 10020 screw Tool ID numbers are referenced in the service procedures Special Tools Table 7 Shop Equipment 20 Ton capacity press To press countershaft gears from countershaft Specialty Tool Manufacturers Below are the addresses and phone numbers of the companies that make tools specifically for Eaton Fuller transmissions G and W Tool Company 1105 E Louisville Broken Arrow OK 74012 5724 Phone 800 247 5882 or 918 258 6
3. How to Remove the Neutral Switch 99 wot efe How to Install the Neutral Switch 100 ortu ER M ec Reverse Switch Operation and Testing 101 e DE How to Remove the Reverse Switch 102 hb tiled How to Install the Reverse Switch 103 How to Remove the Shift Bar Housing 104 How to Install the Shift Bar Housing 105 How to Remove the Oil Seal Mechanical Speedometer 107 How to Install the Oil Seal Mechanical Speedometer 109 How to Remove the Oil Seal Magnetic Speedometer 110 How to Install the Oil Seal Magnetic Speedometer 113 How to Remove the Output Yoke Companion Flange and NUT ehe 115 How to Install the Output Yoke Companion Flange and Nut 117 How to Remove the Auxiliary Section in Chassis 119 How to Install the Auxiliary Section in Chassis 121 How to Disassemble the Range Cylinder Assembly 124 How to Assemble the Range Cylinder Assembly 126 How to Disassemble the Gear Shift Lever 129 How to Assemble the Gear Shift Lever 131 PEE How to Remove the Shift Bar Housing 133 Bi AIC How to Install the Shift Bar Housing 135 How to Disassemble the Shift Bar Housing Assembly 137 How to Reassemble the Shift Bar Housing Assembly 140 How to Remove the Input Shaft Assembly without main case disassembly 144 How to Install the Input Shaft Assembly without main
4. N Procedure 1 Install the countershaft support tools on the auxiliary section countershafts to center and hold the countershafts in posi tion Install a 3 8 16 X 2 1 2 long capscrew into counter shaft center 2 f removed slide the output yoke over the output shaft Lightly oil the threads and install the output nut on the out put shaft Torque the nut to 450 500 Ib ft 610 12 677 91 Nem Note To prevent the output shaft from rotating while install ing 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 3 Usecrocus cloth or a wire wheel to clean rust and paint from the dowel pins before installing them A CAUTION 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 121 In Vehicle Service Procedures 122 11 12 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 ear Clean all rust and paint from
5. 189 Ain How to Remove the Countershaft Assemblies 190 How to Disassemble the Countershaft Assemblies 192 How to Remove the Input Shaft and Main Drive Gear 194 How to Prepare the Main Case for Assembly 197 onde How to Disassemble the Mainshaft Assembly 198 How to Assemble the Mainshaft Assembly with Selective Adjustable Thickness Tolerance Washers 200 How to Assemble the Mainshaft Assembly with Non Se lective Non Adjustable Tolerance Washers 206 How to Assemble the Countershaft Assemblies 209 How to Assemble the Lower Reverse Idler Gear Assembly 211 Mise How to Install Countershaft Assemblies 214 How to Install the Lower Countershaft Bearings 215 How to Install the Input Shaft and Main Drive Gear 217 t How to Install the Mainshaft Assembly 219 How to Install the Upper Countershaft Bearings 221 How to Assemble the Upper Reverse Idler Gear Assembly 224 How to Install the Auxiliary Drive Gear Assembly 227 How to Install the Clutch Housing 229 How to Disassemble the Integral Oil Pump without Auxil jary Tb tte 230 How to Assemble the Integral Oil Pump without Auxiliary OIE TUBB eo eret 233 toe c dde How to Remove the Integral Oil Pump 236 How to Install the Integral Oil Pump 238 How to Disassemble the Integral Oil Pump with Auxiliary Oil TUDB eerte eee te 240 How
6. RANGE CYLINDER AIR FILTER REGULATOR 34 Air System Range System Operation The range shift air system consists of the air filter regulator slave valve a range control valve or master control valve range cyl inder fittings and connecting air lines Constant air from the air filter regulator is supplied to the S or supply port of slave valve and passed through to the inlet or S port of control valve While in LO range the control valve is open and air is returned to slave valve at the P or end port This signals the valve to supply air in line between the LO range or L port of slave valve and the LO range port of range cylinder housing Air received at this port moves the range piston to the rear and causes the auxiliary LO range gear to become engaged While in HI range the control valve is closed and no air is returned to the slave valve This signals the slave valve to supply air in line between the HI range or H port of valve and the HI range port of range cylinder cover Air received at this port moves the range piston forward to engage the auxiliary drive gear with sliding clutch and bypass the LO range gear set Range shifts can be made only when the gearshift lever is in or passing through neutral Thus the range desired can be prese lected while the shift lever is in a gear position As the lever is moved through neutral the actuating plunger in the shift bar housing releases the slave valve allowi
7. 1 2 Transmission Overhaul Procedures Bench Service 7 Install the spacer washer over the input shaft With the bear ing external snap ring to the outside position the bearing on the input shaft 8 Install the input shaft bearing 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 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 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 main shaft installation 218 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 large hook or 3 piece of rope Procedure 1 Block the upper countershaft forward and as close to the case wall
8. The shim procedure can be done in the horizontal or vertical position The procedure is done the same A CAUTION Use genuine Eaton replacement gaskets for the auxiliary housing and countershaft bearing cover Do not omit the gaskets Bearing 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 Y rJ 1 a 1 rJ co rJ e Typical service tools e Shims and Feeler gauge Procedure 1 The auxiliary countershaft bearing covers or countershaft straps and shims should be removed Make sure all old gas ket material is cleaned from the gasket mounting surfaces on the countershaft bearing covers and the auxiliary hous ing 2 Verify that the auxiliary section is in gear When the output shaft is rotated the coun
9. lt ae 2 2 2 s 6 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 Capscrew 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 225 Transmission Overhaul Procedures Bench Service 3 Asthe idler 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 resis tance is felt 5 Install the flat washer over the shaft threaded portion 6 Inspectthe reverse idler nut nylon locking material Replace the capscrew if necessary Install the capscrew 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 226 Transmission Overhaul Procedures Bench Service How to Install 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 Procedure 1 Install the snap ring and splined was
10. 2 Place the 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 dam aged 193 Yy 1 a 1 3 Q rr Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft and Main Drive Gear Special Instructions None Special Tools e Tool Information see Table 6 e item T16 Bearing puller e bar and maul Procedure 1 From the front bearing cover remove the six 6 retaining capscrews and cover Remove any remaining gasket mate rial from the case and cover 2 If present remove and discard the rubber seal ring on the in put shaft The ring is used only to seal the transmission dur ing shipment 3 From the input shaft groove remove the bearing retaining snap ring 194 Transmission Overhaul Procedures Bench Service 4 Use a soft bar and maul to drive the input shaft toward the case rear as far as possible Pull the input shaft forward 5 Install the bearing puller tool and remove the input bearing fro
11. 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 T e tem T4 Tension Spring Driver see Table 6 2 E 2 8 uE 8 PE 2 2 F 3 10 11 lt 2 2 4 P sy 12 1 971 5 wi y DA x J 6 r anf 13 lt 8 8 E 14 2 9 1 8 Capscrew 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 131 Transmission Overhaul Procedures Bench Service Procedure 132 1 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 With dished side up install the washer over the ball Use a tension spring driver T4 to install the tension spring under the housing lugs Remo
12. 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 3 3 S E E Possible Causes e Incorrect air line hook up e Insufficient air supply to transmission e Damaged or defective air filter regulator assembly e Damaged or defective shift knob master valve e Damaged or defective slave valve e Damaged 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 14 No or Slow Range Shift into Low PROCEDURE RESULT WHAT TO DO NEXT Step A Place the shift lever in neutral Constant air leak is detected Go to the other corresponding symp Check for constant air leakage at the shift tom first See beginning of Air System knob slave v
13. The transmission must not be operated consistently at temperatures above 250 F Operation at temperatures above 250 F 121 C causes loaded gear tooth temperatures to exceed 350 F 177 C 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 ca pacity of the existing cooling system increased The following conditions in any combination can cause operating temperatures of over 250 F 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 D S r 9 E D Lubrication Oil Cooler Chart Table 4 TRANSMISSION OIL COOLERS ARE Recommended With engines of 350 and above Required With engines 399 and above and GCW s over 90 000 Ibs e With engines 399 H P and above and 1400 lb 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 supplied oil to water cooler or approved equivalent With engines 450 H P and above Tool Specifications Some repair proce
14. 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 Step 3 Once the origin of the leak is identified repair the oil leak using proper repair procedures from the designated model service manual Step 4 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 17 Power Flow Power Flow Diagrams An understanding of the engine s power flow through a transmission in each particular gear will assist the technician in trouble shooting and servicing a transmission The Eaton Fuller Roadranger 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 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 np Cross Sectio
15. 112 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 How to Install the Oil Seal Magnetic Speedometer Special Instructions To prevent oil leaks do not touch the seal lip and make sure the seal driver is clean Special Tools e Tool Information see Table 8 e Oil seal driver e seal slinger driver Procedure 1 Place a seal on the oil seal driver and 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 us ing a slinger driver 3 f previously removed install the o ring over the output shaft Note To avoid creating oil leaks make sure the speedome ter rotor seal sleeve is free from contaminants 113 Install 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 Inspect the output shaft nut for dam
16. COVER CAPSCREWS CAPSCREWS 35 45 Lbs Ft 50 65 Lbs Ft 7 16 14 Threads 3 16 Threads Secure with Lockwire Apply Loctite 242 to Threads 1 OIL FILL PLUG 4 HAND HOLE COVER CAPSCREWS 60 75 Lbs Ft 114 Pipe Threads 20 25 Lbs Ft 5 16 18 Threads 2 REVERSE IDLER SHAFT NUTS 2 COUNTERSHAFT FRONT BEARING 50 60 Lbs Ft 5 s 18 Threads RETAINER CAPSCREWS 90 120 Lbs Ft 5 s 18 Threads 4 CLUTCH HOUSING CAPSCREWS 90 100 70 75 Lbs Ft 2 13 Threads Use Lockwashers With Aluminum Clutch Housing Cut 7190 K 11 87 13 Torque Specifications Auxiliary Sections 14 AUXILIARY SECTIONS 2 AIR FILTER REGULATOR MOUNTING CAPSCREWS 8 12 Lbs Ft 1 4 20 Threads Apply Loctite 242 to Threads 1 RANGE CYLINDER SHIFT BAR NUT 70 85 Lbs Ft 5 18 Threads 2 RANGE SHIFT YOKE CAPSCREWS 50 65 Lbs Ft 1 20 Threads Secure with Lockwire th Ai cm Ur meg FE N Z S 2 LLLA N TP 1 CAPSCREW REAR AUXILIARY RETAING NUT 90 120 Lbs Ft 5 g 18 Threads 1 SPLITTER SHIFT YOKE LOCKSCREW 35 45 Lbs Ft 716 20 Threads Secure with Lockwire 19 AUXILIARY HOUSING CAPSCREWS 35 45 Lbs Ft 3 s 16 Threads Apply Loctite 242 to Threads 1 OUTPUT SHAFT NUT 450 500 Lbs Ft 2 16 Threads Oiled at Vehicle Installation Cut 7191 Q 11 87 6 MAINSHAFT REAR BEARING COVER CAPSCREWS 35 45 Lbs Ft 3 16 Threads Apply L
17. Check for failed or damaged range pis ton 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 syn chronizer sliding clutch or mating gear Check for excessively worn range syn chronizer friction material Grinding Noise on Range Shift 50 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 Air System Air System Troubleshooting A WARNING Use care when removing air lines or checking for air flow from disconnected 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 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 pressure build to governor cutoff After the pressure reaches
18. Cover 20 Old Style Shift Knob 38 Air System Shift Knob 9 Speed This shift knob contains one switch e range selector lever on the front of the knob is moved down to select low range When the range selector lever is moved up high range is selected D 2 mz D D Component Nomenclature and Auxiliary Countershaft Sectional View 1 Medallion 7 Retainer 2 Spring 8 O Ring 3 Lever 4 Cover 5 Screw 6 Ball 5 32 39 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 8 7 Component Nomenclature and Auxiliary Countershaft Sectional View 1 End Cap 4 Housing 2 O Rings 5 Capscrews 3 Filter Element 6 Air Regulator 40 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 om lave Valv js Slave Valve c 1 rJ a 7 1 Z 17 MES Sleeve amp Plunger Pin Slave Valve Assembly Spring 0 Gasket Poppet Type Component Nomenclature 11 Gasket and Auxiliary Count
19. 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 discon The gauge reads 0 PSI Go to step F nected 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 orhigher for proper range operation than 63 PSI The gauge reads between 58 Go to step E 63 PSI Step E Confirm that shift lever is still in neutral Pressure rapidly changes be Air system appears to be operating Have an assistant move the range selec tween 58 63 PSI and O atthe satisfactory Go to step tor up and down between low and high gauge 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 discon 1 Confirm that the air lines are con At the shift knob move the range selec nected line nected to the correct ports at the shift tion lever up to select high range knob At the
20. amp 13 Speed Shift Patterns 9 Speed Transmissions Shift Lever Patterns and Shifting Controls RT Direct Models Roadranger Valve A 5010 UP for HI RANGE Range Preselection wel 8 DOWN for LO Range Shift LO 1 2 3 4 in LO Range Range shift And shift 5 6 7 8 in HI Range 32 Transmission Shift Patterns 13 Speed Overdrive Models Shift Lever Patterns and Shifting Controls RTO Overdrive Models With Splitter Control But ton in DIR REARWARD position Shift LO 1 2 3 4 in LOW RANGE Range shift And shift 5 6 7 8 in HIGH RANGE Direct c 1 rJ a 7 1 Z 17 WHILE IN HIGH RANGE ONLY Ratios can be split by moving Splitter Control Button to the O D FORWARD position to gain OVERDRIVE 5 6 7 8 Roadranger Valve A 4900 FORWARD REARWARD for for OVERDRIVE DIRECT UP for HIGH RANGE Range Preselection Lever DOWN for LOW RANGE SPLITTER CONTROL BUTTON 33 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
21. case disassembly 146 How to Remove the Auxiliary Section with Tapered Bear IDEE 148 How to Remove the Auxiliary Countershaft Assemblies w Tapered Bearings 150 How to Remove the Countershaft Assemblies w Ball Bearings A Series 153 How to Remove the Splitter Cylinder Assembly 155 How to Remove the Splitter 157 How to Disassemble the Range Cylinder Assembly 158 How to Disassemble the Output Shaft Assembly 160 How to Disassemble the Synchronizer Assembly 163 Reti How to Assemble the Synchronizer Assembly 164 How to Assemble the Output Shaft Assembly 166 How to Install the Splitter 169 How to Assemble the Range Cylinder Assembly 170 How to Install Splitter Cylinder Assembly 173 How to Install the Countershaft Assemblies w Tapered B dringS pete Ee tete 175 How to Install the Countershaft Assemblies w Ball Bear ings A Series used 178 How to Remove the Clutch Housing 181 How to Remove the Auxiliary Drive Gear Assembly 183 How to Disassemble the Upper Reverse Idler Gear Assem lys ecc meia s 185 How to Remove the Upper and Lower Countershaft Bear i ene i tee ees 187 How to Remove the Mainshaft Assembly
22. gear assembly 183 Transmission Overhaul Procedures Bench Service 4 Remove six capscrews from the auxiliary bearing retainer ring Insert three puller screws in the specially tapped holes of retainer ring Tighten screws evenly to pull the front aux iliary drive gear assembly from case bore 5 Remove front auxiliary drive gear from mainshaft 6 Remove the splined washer from the mainshaft also remove the front auxiliary drive gear retaining snap ring from the mainshaft 184 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 Typical service tools e Jaw pullers or impact puller e Soft bar and maul Procedure UOISSIUSULIL 1 Remove retaining bolt from the Idler Shaft v wo E Note If Idler Shaft spins in case bore slightly heat bolt with torch to release loctite adhesive 2 The mainshaft reverse gear must be moved in order to re move the upper reverse idler gear Remove reverse gear snap ring
23. rJ c 1 rJ Make sure use an auxiliary drive gear retaining bolt with thread sealant material Special Tools e Typical service tools e Auxiliary countershaft retaining straps Toolmaker s dye 175 Transmission Overhaul Procedures Bench Service 176 Procedure 1 Place the countershaft assembly vertical on a clean flat sur face If previously removed use the proper driver and maul to install the countershaft bearings Mark each countershaft for correct timing Locate the O stamped on the countershaft and mark the tooth with highly visible toolmaker s dye or paint Install the synchronizer assembly on output shaft front Place the thrust washer the rear auxiliary drive gear the thrust washer the retainer and the 15 16 capscrew on the output shaft assembly Finger tighten the capscrew 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 Align the output shaft between the countershafts match the timing marks With range yoke offset side facing down install into the syn chronizer sliding slot Transmission Overhaul Procedures Bench Service 8 Placethe auxiliary housing over the countershaft assemblies and the output shaft assemble 9 Heatthe rear output bearing cone and install the bearing ta pered side down on the shaft 10 Position a
24. 1 Remove the two screws holding the bottom cover to the valve and slide the cover down the gearshift lever to expose the air line fittings Disconnect the air lines 2 Loosen the 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 the two screws in the side of the valve housing to separate the housing 6 Removethe range selection lever from the left housing along with the position balls and guide 7 lf necessary remove the spring and O ring from the bores in the left housing D e GJ N D a e 2 8 If necessary remove the springs O ring and sleeve from the bores in the right housing 75 In Vehicle Service Procedure How to Assemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft 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 76 In Vehicle Service Procedure Procedure 1 Refertothe drawing for proper reassembly Use a very small amount of silicone lubricant on the O rings to avoid
25. 28 Shift Block 29 Shift Yoke 30 Yoke Bar 31 Shift Yoke 32 Yoke Bar 33 Yoke Bar 34 Plunger 35 Spring 36 Shift Bar HSG STD 137 Transmission Overhaul Procedures Bench Service Procedure 1 Secure the assembly in a vise with the plunger side up The front of the housing will be to the left For models so equipped cut the lockwire and turn out the retaining cap screws to remove the oil trough from the housing Note Start with the upper shift bar move all bars to the right and out the rear boss bore Cut the lockwire and re move the lockscrews from each bar just before their removal 2 Move the 3rd 4th speed shift bar to the housing rear remov ing the yoke and block from the bar 3 Move the 1st 2nd speed shift bar to the housing rear re moving the yoke and block from the bar As the neutral notch in the bar clears the rear boss remove the small inter lock pin from the bore 4 Remove the actuating plunger from the center boss bore 138 5 Transmission Overhaul Procedures Bench Service Move the short LO Reverse speed shift bar to the housing rear remove the yoke from the bar As the shift bar is re moved from the housing two 3 4 interlock balls will drop from the rear boss bottom bore If necessary remove the plug spring and reverse stop plunger from the LO Reverse speed shift yoke bore 139 Y 1 a wo ow x
26. 5 T 2 14 2 9 1 8 Capscrew 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 ESSTTESITATI v rJ 1 2 o 1 rJ N 1 rJ 57 129 Transmission Overhaul Procedures Bench Service 130 Procedure 1 On a non isolated shift lever remove the Roadranger valve using the How to Remove the Roadranger valve instruc tions in In Vehicle Service Procedures If the shift lever is equipped with a lever isolator remove the snap ring bush ing and cross pin to disconnect and remove the upper lever Slide the rubber boot 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 hous ing 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 Transmission Overhaul Procedures Bench Service How to Assemble the Gear Shift Lever Special Instructions Inspect tension spring and washer for wear
27. 7 N rJ 5 7 v a rJ a In Vehicle Service Procedures How to Disassemble the Range Cylinder Assembly Special Instructions None Special Tools e Typical service tools 1 Yoke Bar 8 Nut 2 Gasket 9 Gasket 3 Range Cylinder Assembly 10 Cover 4 O Ring 11 Capscrew 5 Piston 6 O Ring 7 O Ring 124 1 From the range cylinder cover remove the capscrews cov er 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 From the cylinder housing bore remove the range piston 5 Inspect the range piston O rings remove if damaged 6 Remove the capscrews 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 125 SOINP IOAg 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 1 7 O Ring 2 Gasket 8 Nut 3 Range Cylinder Assembly 9 Gasket 4 O Ring 10 Cover 5 Piston 11 Capscrew 6 O Ring 126 In Vehicle
28. 8 Remove the gasket and clean all mounting surfaces of gas ket material 9 If the three 3 sets of tension springs and balls from the housing top bores are loose tilt the assembly and remove them Transmission Overhaul Procedures Bench Service How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of capscrews The 1 1 2 capscrews 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 capscrew 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 Placethe shift bar housing and shift blocks in the neutral po sition 2 Place the mainshaft sliding clutches in the neutral position 29 c c 5 a nv uS 259 lt ae 2 2 2 3 Position 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 Fuller amp Sealant 71205 or equivalent t
29. 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 LAT PET Te y a i 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 counter shaft key long hub against 1st speed gear and press the gear on the countershaft 209 Transmission Overhaul Procedures Bench Service 4 Align 3rd smallest diameter gear keyway with the counter shaft key long hub to countershaft front and press 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 Use a flanged driver or the press to install the bearing inner race on the countershaft front against the drive gea
30. Service 2 Position the gear in the case The gear s long hub is posi tioned forward 3 Place the rear thrust washer on the idler shaft y Z 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 resis tance is felt 7 Install the flat washer over the shaft threaded portion 8 Apply Eaton Fuller Sealant 71205 or equivalent Install capscrew and torque to 67 75 lb 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 easily into the case bore if they are not cocked 213 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 p
31. The gauge should show rapid pressure change The gauge responds slowly The gauge rapidly moves be tween 58 63 PSI and 0 PSI 1 Check for a restricted line between the shift knob and slave valve 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 S port on the shift knob 6 If all are good replace the shift knob Go to step Step I If possible leave air lines attached to slave valve Unbolt the slave valve from transmission side Check for free move ment 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 Actuating plunger pin does not move freely Actuating plunger pin moves freely 1 Remove actuating plunger pin and check for damage 2 Check for missing or broken spring Repair or replace slave valve and check for proper range operation 59 3 3 5 E 3 E Air System Table 14 No or Slow Rang
32. Troubleshooting 51 Timing 66 How to Remove Oil Filter Adapter 68 How to Assemble Oil Filter Adapter 69 How to Disassemble Roadranger Valve A 5010 70 How to Assemble Roadranger Valve A 5010 72 How to Disassemble Roadranger Valve A 4900 74 How to Assemble Roadranger Valve A 4900 76 How to Install the Air Lines and Hoses 78 How to Remove Compression Type Fittings 80 How to Remove the Air Lines and Hoses 81 How to Install Compression Type Fittings 83 How to Remove Push To Connect Type Fittings 84 How to Install Push To Connect Type Fittings 85 MET How to Remove Rubber 1 4 Air Hoses 86 How to Remove the Air Filter Regulator 87 How to Install the Air Filter Regulator 88 How to Remove a Roadranger Valve 89 een ere How to Install a Roadranger Valve 90 PME How to Install Rubber 1 4 Air Hoses 91 How to Remove a Slave Valve 92 m How to Install a Slave Valve 93 How to Remove the Gear Shift Lever Remote Shift Control 94 How to Install the Gear Shift Lever Remote Shift Control 95 How to Adjust the Remote Shift Control LRC Type 96 Neutral Switch Operation and Testing 98
33. b The countershaft support tool center capscrew should be snug to level the countershafts c The dowel pins and auxiliary housing mating holes should be clean and well oiled d The internal gearing on the auxiliary section must have been properly timed during reassembly Apply Eaton thread sealant 71205 or equivalent to the all the retaining capscrew threads Install the capscrews to se cure the auxiliary section to the main case torque to 40 45 lb ft 54 23 61 01 Nem 13 15 16 If the countershaft countershaft bearings or auxiliary hous ing have been replaced or if the countershafts bearings or shims were not marked and reassembled in the same loca tion the bearing endplay must be checked and set by shim ming 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 gasket and countershaft bearing cover Secure the bearing covers with the capscrews Install sealer Apply Loctite 242 to capscrew threads and torque to 40 45 Ib ft 54 23 61 01 Nem Connect all removed air hoses and lines Use Eaton Full er thread sealant 71205 or equivalent as necessary Connect the driveshaft and U joint and refill the transmis sion with the recommended lubricant For lubrication in structions refer to the Lubrication and Maintenance section In Vehicle Service Procedures 123 1 e 5
34. bearing inside diameter is in stalled towards the shaft Use a bearing driver that contacts both the bearing inner race and outer race In the countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torqued Note Make sure the rear snap ring is in place 223 n a D e e 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 e Tool Information see Table 6 e item T18 Bearing race installer Previous Design 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shaft 4 Nut and Washer 8 Plug 224 Transmission Overhaul Procedures Bench Service The capscrew 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 capscrew design main case which does not have the oil feed hole the reverse idler bearing will fail Current Design 29 os nv uS 259
35. cover and the housing Torque the capscrews 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 16 Repeat this procedure for the remaining countershaft Note Make sure the input shaft rotates 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 Red 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 Tan 252 Transmission Overhaul Procedures Bench Service Shim Table Continued FEELER GAUGE SHIM STANDARD SHIM OIL PUMP SHIM COLOR AVERAGE GAP THICKNESS PART NUMBER PART NUMBER CODE 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 253 Copyright Eaton Corporation 2012 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 chan
36. cyl inder Repair as necessary 55 3 wo 5 E 3 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 e Leak past insert valve external o rings e Leak past splitter cylinder piston Table 13 Air Leak at Splitter Cylinder Cover Exhaust Port valve bore in the splitter cylinder cover for contami nation or damage which would result in leakage past the insert valve o rings No contamination or damage found PROCEDURE RESULT WHAT TO DO NEXT Step A old Remove insert valve Check for contamination dam Contamination or damage Repair or replace as neces style aged seals or sticky movement Check the insert found sary Go to Step B Step B Remove the splitter cylinder cover and piston Check the piston bore for contamination or damage Check the piston seals for damage Note Farly production transmissions used a paper gasket to seal the splitter cover to cylinder if neces sary replace this configuration with the spool valve design which uses an o ring Contamination or damage found Repair or replace as neces sary 56 Air System Procedure 5 Symptom No or Slow Range Shift into Low
37. freely e Check capscrews for proper torque 180 Transmission Overhaul Procedures Bench Service How to Remove the Clutch Housing Special Instructions Removal of the clutch housing is done 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 wash ers 2 From inside the clutch housing remove the bolts 29 os nv uS 259 lt ae 2 2 2 s 3 Jarclutch housing to break gasket seal 4 Pull the clutch housing from the studs and transmission case 181 Transmission Overhaul Procedures Bench Service 5 Remove the gasket and clean all mounting surfaces of gas ket material 182 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 Procedure 1 Cutlockwire from auxiliary bearing retainer ring capscrews 29 c c 5 a nv uS 259 lt ae 2 2 2 2 Remove snap from mainshaft rear groove 3 Remove the splined washer from inside front auxiliary drive
38. is selected torque flows from the auxiliary splitter clutch to the auxiliary drive gear From the auxiliary drive gear torque flows to both coun tershafts and then to the splitter gear Torque then flows into the range sliding clutch and output shaft 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 m 3 m oo Ly 2 La Le wees Gases uses bbb cats Obb bs 5th 9 13 speed Split Low 5th 9 13 speed Split High 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 3 Sliding Clutch forward 24 Power Flow 9 Speed r ES J 3 lees ees ge ses LO Gear 1st Gear 1 Sliding Clutch forward 1 Sliding Clutch rearward 2 Sliding Clutch rearward 2 Sliding Clutch rearward d 3 Sliding Clutch rearward 3 Sliding Clutch rearward 5 amp eee wae LO KR LO 8 T Veb Veb OSE Oe 2nd Gear 3rd Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch rearward 3 Sliding Clutch rearward 25 Power Flow L4 c2 RTO
39. 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 be Go to step tween 58 63 PSI and 0 PSI Step If possible leave air lines attached to Actuating plunger pin does 1 Remove actuating plunger pin and not move freely Actuating plunger pin moves freely check for damage 2 Check for missing or broken spring Repair or replace slave valve and check for proper range operation 63 3 3 5 E 3 E 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 sec tion must be removed to inspect for me chanical problem Remove auxiliary section and inspect for Binding of range yoke bar or piston e Damaged or defective range yoke Damaged or defective range synchro nizer Cracked c s weld resulting in gear turn ing on shaft Damaged or defective range sliding clutch Auxiliary section gearing out of time 64 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 g
40. section hanger bracket 7 Slide the auxiliary section the rest of the way into position 8 Apply Eaton Fuller amp Sealant 71205 or equivalent to the retaining capscrews 9 Install the retaining capscrews torque to 35 45 Ib ft 47 45 61 01 Nem 10 To finish installation see The Shimming Procedure for Ta pered Bearings 248 Transmission Overhaul Procedures Bench Service 1 10 Procedure To 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 Position a new gasket on the transmission mounting sur face Install a steel bar through the yoke Attach a lifting chain to the steel bar Position the auxiliary section over the two 2 dowel pins Slide the auxiliary section down the dowels Y 1 a ow Apply Fuller amp Sealant 71205 or equivalent to the retaining capscrews Install the retaining capscrews torque to 35 45 Ib ft 47 45 61 01 Nem Remove the steel bar and chain To finish installation see The Shimming Procedure for Ta pered Bearings Note Make sure the input shaft rotates 249 Transmission Overhaul Procedures Bench Service Shim Procedure without a Shim Tool for Tapered Bearings Special Instructions
41. 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 tol erance 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 design 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 jneysaAg UOISSIUSULIL a a rJ E ow 1 rJ ce 1 rJ Gear tolerance washers internally splined and locked to the mainshaft by the key Gear spacers externally splined 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 toler ance a thicker tolerance washer should be installed This will decrease the axial clearance between the gears If necessary
42. technique Driver contacting the clutch brake during shifts 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 mecha nism 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 49 2 General Troubleshooting General Troubleshooting Chart cont Complaint Shift Lever Slipout Transmission comes out of gear under torque Internal transmission problem Corrective Action Check for excessively worn or damaged sliding clutches or shift yokes Transmission goes to neutral Shift lever doesn t move No range shift or slow range shift Also see Air System Troubleshooting Low air pressure Check air regulator pressure Internal transmission problem Transmission air system problem Check for excessively worn or damaged range sliding clutch or yoke Preform air system troubleshooting pro cedure Check for proper air signal from master valve Check air module test ports for proper air delivery Range cylinder problem
43. the spring left Back the plug out 1 1 5 turns and stake the plug through the small hole in the yoke right 4 Secure the shift bar housing in a vise and hold the notched end of the short LO Reverse speed shift bar Install the bar in the lower bore of the shift bar housing bosses Install the yoke lockscrew tighten and wire securely Note Start with the lower shift bore of the rear boss and move to the left front of the housing Keep bars in the neutral position during installation Do not exceed the recommended torque ratings for the yoke lock screws as over tightening may distort the shift bars 141 Transmission Overhaul Procedures Bench Service 142 5 While holding the plunger shank install the actuating plung er in the center boss bore Install one 3 4 interlock ball in the rear boss top bore This ball rides between LO Reverse and 1st 2nd speed shift bars While holding the notched end of the bar install the 1st 2nd speed shift bar in the housing boss middle bore Position the shift block on the bar between the center and rear bosses and the yoke on the bar between the front and center bosses long hub to the housing front Just before inserting the notched end of the rear boss bar install the small interlock pin vertically in the neutral notch bore Install the block and yoke lockscrews tighten and lockwire securely Note It is necessary that the interlock pin remain in a verti cal position du
44. 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 Shift the 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 continu ity The ohm meter should read open or infinity when the ball is depressed Look into 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 If not remove the shift bar housing and check the air valve and shift rails for excessive wear Also check the slave valve plunger and spring for free movement How to Remove the Neutral Switch Special Instructions None Special Tools e Typical service tools Procedure 1 Remove 2 screws retaining wire terminals 2 Remove the switch using a 7 8 deep well socket or box end wrench In Vehicle Service Procedure 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft 99 7 lt D 2 GJ N D Er a e In Vehicle Service Procedure How to Install 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 Va
45. to Disassemble the Integral Oil Pump without Auxiliary Oil Tube Special Instructions None Special Tools e Typical service tools e 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 pump drive shaft remove the drive gear 4 From the drive shaft keyway remove the key 230 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 29 c 5 a nv a 259 lt ae 2 2 2 7 From the drive shaft keyways remove the two 2 keys 8 From the integral oil pump housing remove the drive shaft 9 f damaged from the drive shaft remove the rear drive gear retention snap ring 231 Transmission Overhaul Procedures Bench Service 232 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 k
46. you or damage equipment To prevent injury or equipment damage the vehicle air tanks must be exhausted Special Tools e Typical service tools Procedure ail 1 Record or mark air line locations Retaining Capscrews 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 rear of transmission Remove slave valve with air hos es still attached 3 Remove the retaining capscrews around valve perimeter 4 Remove slave valve and gasket Plunger 5 From the transmission case remove the sleeve spring and o Mid plunger pin 886 qe Sleeves ae Air Line Fittings P 6 Inspect the air fittings replace if damaged 92 How to Install a Slave Valve Special Instructions None Special Tools e Typical service tools 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 capscrews 6 Install the retaining capscrews torque to 8 12 Ib ft 10 85 16 30 Nem Note Make sure the retaining capscrews are properly torqued In Vehicle Service Procedure Air Line Fittings Plunger Retaining Capscrews 93 aunpardid SETET EIU ET MIT In Vehicle Service Procedure How to Remov
47. 2 capscrews through the adapter to hold the gasket in place z lt 1 e 5 ow 2 1 2 Install the filter adapter and torque all capscrews to 8 12 Ib ft 10 85 16 30 Nem 3 Install a new oil filter Eaton Part 4304827 or equivalent 69 In Vehicle Service Procedure How to Disassemble Roadranger Valve A 5010 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft 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 70 In Vehicle Service Procedure Procedure 1 Remove the two screws holding the bottom cover to the valve and slide the cover down the gearshift lever to expose air line fittings Disconnect the air lines Loosen the jam nut and turn the Roadranger valve from the gear shift lever Pry the medallion from the recess in the top cover Turn out the two screws to remove the top cover from the valve housing Turn out the two screws in the side of the valve housing to separate the housing Remove the range selection lever from the left housing along with the position balls and guide If necessary remove the spring and O ring from the bores in the left housing If necessary remove the springs O ring and sleeve from the bores in the right housing 71 1 5
48. 5000 Slave Valve Air System D mz D D Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly SP Air to Housing Air from Vehicle Source 43 Air System RTLC 1X909 Range Hl 44 Slave Valve A 5010 Roadranger Identification Valve A 5000 Valve THOT U p o QJ P P S A 5000 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly Breather Air from 7 Vehicle Y Source WSS Cover Port RTLO 1X913 LO Range A 4900 Roadranger m Slave Valve Identification pie Q A 5000 Valve Rearward u ee ges TE i e lox oL e HLP S SP A 5000 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly SP Air to Housing Air from Vehicle Source Air System 45 1 rJ y i 1 Z 17 Air System HI Range L A 4900 Roadranger Valve Slave Valve Identification Up A 5000 Valve Rearward TROIS gt em H A 5000 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly A
49. 59 lt ae 2 2 2 2 If present remove and discard the rubber seal ring on the in put shaft The ring is used only to seal the transmission dur ing shipment 3 From the input shaft groove remove the bearing retaining snap ring 144 Transmission Overhaul Procedures Bench Service 145 4 Usea soft bar and maul to drive the input shaft toward the case rear as far as possible Pull the input shaft forward 5 Install the bearing puller tool and remove the input bearing from the case and input shaft or use pry bars or screwdriv ers to complete removal of the bearing 6 From the drive gear front remove drive gear spacer 7 Remove the drive gear internal snap ring 8 Pullthe input shaft forward and out of the drive gear 9 Inspectthe bushing in the input shaft pocket replace if dam aged Transmission Overhaul Procedures Bench Service How to Install the Input Shaft Assembly without main case disassembly Special Instructions None Special Tools e See Tool Information see Table 6 e item T12 Input bearing driver e Toolmaker s dye Procedure 1 f 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 29 c c 5 a nv uS 259 lt ae 2 2 2 Note The current design input shaft spline teeth have no ticeable clearance
50. 7 1 rJ 7 y rJ 1 57 In Vehicle Service Procedure How to Assemble Roadranger Valve A 5010 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft 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 72 In Vehicle Service Procedure 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 Reinstall Roadranger valve on gear shift lever and tighten the jam nut 3 Attach the air lines and reinstall the bottom cover z lt 2 wo ce 5 7 y 2 73 In Vehicle Service Procedure How to Disassemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft 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 74 In Vehicle Service Procedure Procedure
51. 881 Great Lakes Tool 8530 M 89 Richland MI 49083 Phone 800 877 9618 or 269 629 9628 655 Eisenhower Dr Owatonna MN 55060 117 Phone 800 533 6127 or 507 455 7000 The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user Detailed Fuller Transmission Tool Prints are available upon request by writing to Eaton Corporation Truck Components Operations Technical Service Box 4013 Kalamazoo Michigan 49003 11 Recommended Tools 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 Table 8 TOOL PURPOSE EATON PART NUMBER 5 32 Air Line Release Tool To remove 5 32 air lines from push to connect fittings P N 4301157 included in kit K 2394 Air Line Cutting Tool To cut plastic air lines smoothly and squarely P N 4301158 included in kit K 2394 Output Seal Driver To install output seal For 7 series Eaton P N 5564501 driver For 9 series Use Eaton P N 5564509 adapter with 5564501 driver Both parts included in complete Eaton seal kit P N TCMT0912 Output Seal Slinger Driver To install output seal slinger For 7 series Eaton P N 71223 For 9 series Eaton P N 4303829 Torque Specifications Transmission Torque Specifications Correct torque application is
52. B valve exhaust port Step B Move range selector down to select low Air is flowing from high range sup Remove range cylinder cover and range ply port on range cylinder repair leaking range piston or pis Remove the 1 4 1 0 rubber air line at ton seal After repair check for the high range supply port on the range proper range operation 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 No air flow from high range port Repair or replace slave valve 54 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 Step A Listen for the air leak with the trans Leak is only in low range Remove range cylinder and inspect for mission shifted to both low and damaged range yoke bar yoke bar o high range ring or range cylinder Repair as neces sary Leak is in both low and Remove splitter cylinder Inspect for high range damaged splitter yoke bar o ring or
53. Pumps Internal An internal lubrication pump is located in the lower front of the transmission and is driven off the upper coun tershaft Transmissions rated PTO Driven A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear Lubrication Lubrication Specifications IMPORTANT Transmission filters should be changed during regular lube intervals Inspection of the transmission filter should be conduct ed during preventive maintenance checks for damage or corrosion Replace as necessary Note For a list of Eaton Approved Synthetic Lubricants see TCMT0021 or call 1 800 826 HELP 4357 Note The use of lubricants not meeting these requirements will affect warranty coverage Note Additives and friction modifiers must not be introduced Never mix engine oils and gear oils in the same transmission Buy from a reputable dealer For a complete list of approved and reputable dealers write to Eaton Corporation Worldwide Marketing Services P O Box 4013 Kalamazoo MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication will occur The operating angle is the transmis sion 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
54. R wob levee zs 4th Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch rearward m ji 5 RTO wees uses Oba we 6th Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward 26 C Ms cscs w b Obg 5th Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward 4 EE eed ad Hee Hee 7th Gear 1 Sliding Clutch forward 2 Sliding Clutch rearward 3 Sliding Clutch forward Power Flow 9 Speed Non Top 2 Models 8th Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward 9 Speed Top 2 Models ce 1 E rJ a 7 1 Z 17 8th Low Split Gear 8th 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 27 Power Flow 13 Speed Power Flow by Gear U fF woe 5 veg 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 E Pes Gases sues eee wae Lo 5 __ timus les Wee ves 2nd Gear 3rd Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Slidi
55. Service Manual Fuller Heavy Duty Transmissions TRSMOA446 January 2010 ETN Powering Business Worldwide BACKED BY ranger SUPPORT Warnings and Precautions Warnings and Precautions AWARNIN 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 this service publication are current at the time of printing Eaton Corporation 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 saf
56. Service Procedures Procedure 1 If previously removed in the cylinder housing bore install the small O ring 2 If previously removed on the piston 1 0 and O D install the piston O rings lt c e N v E 3 Position a new gasket on the range cylinder housing mount ing surface 4 Install the cylinder housing 5 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 6 Install the capscrews tighten to 20 25 Lbeft of torque 7 Lean auxiliary section back with range cylinder upward 8 Insert the piston and push it in as far as it will go 9 Secure the piston with the retaining nut tighten to 70 85 Lbeft of torque 127 In Vehicle Service Procedures 128 10 Position a new gasket on the cylinder housing cover mount ing surface 11 Over the gasket position the range cylinder cover 12 Apply Eaton Fuller sealant 771205 or equivalent to the re taining capscrews 13 Install the capscrews tighten to 20 25 Lbeft of torque 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 10 11 SD si 2 2 4 u g y D 1 2 1 NS 5 LI den E J 6 4 13 f 8
57. Special Tools e Brass drift e Output yoke puller e T15 Slide hammer 10 m J a i NN 2 1 ET 1 Rear Bearing Cover 6 Oil Seal 2 Sensor Retaining Capscrew 7 Slinger 3 O Ring 8 O Ring 4 Speedometer Sensor 9 Speedometer Spacer Assembly 5 Capscrew 10 Slinger 110 In Vehicle Service Procedures Procedure 1 Disconnect the driveshaft and U joint from the output yoke according to the OEM or driveshaft manufacturer s instruc tions 2 Shiftthe transmission into 1st gear or low gear Low Range to prevent the output yoke from turning when you loosen the output yoke nut 3 Removethe output yoke nut using a 70 mm or2 3 4 socket 4 Remove the output yoke If necessary use an output yoke puller See How to Remove the Output Yoke Companion Flange lt 1 e 1 v 1 a o 5 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 capscrew and pull the sensor out of the bore 6 Remove the speedometer rotor seal sleeve and the o ring 7 Pry the seal out using a large screwdriver or prybar in the metal groove of the seal Note The seal will be damaged during removal and must be replaced 111 In Vehicle Service Procedures
58. 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 capscrew If necessary 3 capscrews 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 capscrew in evenly to prevent damage to the auxiliary housing A CAUTION The weight of the auxiliary section must be supported dur ing removal to avoid damage to internal transmission parts Support the weight of the auxiliary section with a lifting de vice or support jack and move the auxiliary section rearward until it is free from the front section of the transmission In Vehicle Service Procedures How to Install the Auxiliary Section in Chassis Special Instructions None Special Tools e Tool Information see Table 6 e T3 Countershaft support tools e item T14 Auxiliary section removal adapter plate A hoist with lifting chain 1 2 wo wo v rJ a
59. 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 Be tween the gear hub and mainshaft spacer insert 0 006 feel er gauge and 0 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer 11 With the missing internal splines 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 202 Y 1 a ow Transmission Overhaul Procedures Bench Service 203 15 16 17 18 19 20 With clutching teeth down position the next gear on the mainshaft engaging with spacer external splines With clutching teeth up install the next gear on shaft against the previously positioned gear Position another spacer against the previously positioned gear engaging the spacer external splines with gear clutch ing teeth With washer flat side down position the tolerance washer against the spacer Rotate the washer un
60. age and wear If the ny lon locking material is damaged or excessively worn use a new output nut Note The nylon locking material must be in good condition so the nut does not loosen when the vehicle is in use Lightly oil the output shaft threads and output nut threads and install the nut Torque the nut to 450 500 Ib ft 610 12 677 91 Nem Connect the driveshaft and U joint according to the OEM or driveshaft manufacturer s instructions In Vehicle Service Procedures 114 z lt x Q v o 2 In Vehicle Service Procedures How to Remove the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TRSM0912 Rear Seal Maintenance Guide 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 See Tool Information see Table 6 Special Tools large breaker bar or air impact wrench z lt 1 e 1 v 1 a o Procedure 1 Engage two 2 mainshaft sliding clutches into two 2 main shaft gears to lock the transmission or use a yoke holding tool if available 115 In Vehicle Service Procedures 116 2 Usea large breaker bar or ai
61. aging the front auxiliary drive gear HI Range overdrive SIGNAL LINE FROM CONTROL VALVE SP PORT RETAINING NUT INSERT VALVE 11 87 SUPPLY PORT LOW RANGE AND HIGH RANGE DIRECT OVERDRIVE NO AIR ON SIGN AIR APPLIED THROUGH SIGNAL LINE SIGNAL LINE PUSHES INSERT VALVE PISTON DOWN 1 1 gt EXHAUST THIS SECTION FROM CONSTANT AIR TO BACK SIDE OF AT THIS POINT BACK SIDE SEALED OFF PISTON YOKE BAR OF PISTON AT THIS POINT FORWARD TO FRONT SIDE OF PISTON YOKE BAR FORWARD TO FRONT SIDE OF PISTON YOKE BAR Cut 7450E 11 87 CONSTANT AIR Cut 7450F 11 87 37 N 5 e D c Air System Shift Knob 13 Speed The shift knob contains two switches e range selector lever on the front of the knob is moved down to select low range When the range selector lever is moved up high range is selected e splitter button or the button on the side of the shift knob is moved rearward to select LO split and forward for HI split of each lever position When in LO range a mechanical interlock prevents moving the splitter button to HI Component Nomenclature and Auxiliary Countershaft 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
62. al with Slinger 2 Rear Bearing Cover Assembly 6 O Ring 3 Capscrew 7 Speedometer Spacer Assembly 4 Speedometer Drive Gear Procedure 1 Disconnect the driveshaft and U joint from the output yoke according to the OEM or driveshaft manufacturer s instruc tions 2 Shiftthe transmission into 1st gear or low gear Low Range to prevent the output yoke from turning when you loosen the output yoke nut 107 In Vehicle Service Procedures 108 Remove the output yoke nut using a 70 mm or 2 3 4 socket See How to Remove Output Yoke Companion Flange Remove the output yoke If necessary use an output yoke puller Remove the seal sleeve Use a slide hammer with a hook 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 A CAUTION To prevent oil leaks do not touch the seal lip and make sure the seal driver is clean Special Tools 109 See Tool Information see Table 8 Oil seal driver Oi
63. alve and transmission case Troubleshooting section breather when both low and high range have been selected No constant leak is detected Go to Step B Step B Place shift lever in neutral Air flows from the low range Remove range cylinder cover and re Move range selector up to high range port pair leaking range piston or piston seal position At the rear of the transmission 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 Go to step C port Step C Check for air flow from the disconnected Air flows from disconnected Go to step F air line air line No air flow from disconnect Go to step D ed line 57 Air System Table 14 No or Slow Range Shift into Low Continued PROCEDURE RESULT WHAT TO DO NEXT Step D Install a 100 PSI air gauge in the discon The gauge read 0 PSI Go to step F nected 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 orhigher for proper range operation than 63 PSI The gauge reads between 58 Go to step E 63 PSI Step E Confirm that shift lever is still in neutral Pressure rapidly changes be Air system appears to be operating Have an assistant move the range selec tween 58 63 PSI and 0 at the s
64. amaged air fittings Air Line Fitting Types 1 1 8 tube 1 8 NPTF 2 Push to connect 3 5 32 tube 1 8 NPTF 78 In Vehicle Service Procedure 2 Connect the air lines from the slave valve to the range cylin der 3 Connect all removed air lines and hoses 4 Make sure the fittings are tight and the lines are not kinked z 1 e y is 2 1 79 In Vehicle Service Procedure How to Remove Compression Type Fittings Special Instructions A 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 Before removing the air lines and hoses label or record their location Special Tools e Typical service tools Procedure 1 Exhaust the vehicle air tanks before continuing 2 Loosenthenuton the fitting and slide it back out of the way 3 Pull the air line and attached collet from the fitting 4 Inspect the fitting air line collet and nut for damage or 1 Connector 2 Collet wear Replace as necessary 3 Nut 4 Air Line 80 In Vehicle Service Procedure How to Remove the Air Lines and Hoses Special Instructio
65. and slide reverse gear forward over clutch 3 Remove the loosened bolt and remove washer Reinstall bolt 3 4 threads 185 Transmission Overhaul Procedures Bench Service 4 Install an impact puller 1 2 13 threaded end and remove the shaft from case bore 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 186 Transmission Overhaul Procedures Bench Service How to Remove the Upper and Lower Countershaft Bearings Special Instructions The following instructions are used 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 bar and maul e T8 Countershaft Pusher e T9 Bearing Puller Procedure 1 keep the mainshaft pilot from falling out of the input shaft pocket temporarily install the auxiliary drive gear on the mainshaft D 5 77 ae 259 lt 2 2 2 Fromeach countershaft rear groove remove the snap ring 3 Remove six capscrews from front be
66. ansmission is still installed in the vehicle Transmission Overhaul Procedures contain procedures that are performed after the transmission has been removed from the vehicle The procedure sections are laid out with a general heading at the 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 link age 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 Le ver 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 Assemhlies e When disassemb
67. aring cover and remove front bearing cover A 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 187 Transmission Overhaul Procedures Bench Service 188 From the front of each countershaft remove the capscrew 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 bear ings Return to the case rear and drive each countershaft forward as far as possible This exposes the external snap ring Use the appropriate bearing puller T9 or prybars to remove the countershaft front bearings Transmission Overhaul Procedures Bench Service How to Remove the Mainshaft Assembly Special Instructions None Special Tools e See Tool Information see Table 6 e item T15 Mainshaft hook Procedure 1 Secure the upper countershaft to the side and away from the mainshaft Optional Insert prybar between upper counter shaft and main drive gear as shown 2 _Insertthe mainshaft hook tool or rope aroundthe mainshaft Note Keep the upper countershaft forward against the case front wall A WARNING Be careful when removing the mainshaft assembly The slid ing clutch on the front and the reverse gear on the back can slip off the shaft 3 Pull the mains
68. ary housing gasket surface Measure and record the gap at both capscrew locations 8 Average the two feeler gauge measurements by adding the measurements together and dividing by 2 as shown in Ex ample Shim Chart 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 the shim chart at the end of this selection 9 Locate the feeler gauge average measurement in the shim chart to determine the required shim and color code 251 Transmission Overhaul Procedures Bench Service 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 10 Remove the countershaft rear bearing cover and gauging shim 11 Place the selected shim on the rear countershaft bearing race 12 Position a new gasket on countershaft rear bearing cover mounting surface 29 c c 5 a nv uS 259 lt ae 2 2 2 s 13 Position the countershaft rear bearing cover over the new gasket 14 Apply Eaton Fuller amp thread sealant 71205 or equivalent to the auxiliary countershaft rear bearing cover capscrews and auxiliary countershaft rear bearing cover 15 Install the auxiliary countershaft rear bearing cover and se cure it with the capscrews Make sure the shim is in the proper location and is not pinched between the
69. as possible 2 With reverse gear forward against the next speed gear and mainshaft pilot end over the integral oil pump gear lower the mainshaft assembly while pulling the shaft rear through the case bore LAT PET Te y a ix 3 Pullthe input shaft forward until the drive gear is against the Case 4 After the mainshaft drops into the case slide the counter shaft back and the mainshaft should fall down between the countershafts 5 Move the mainshaft pilot end into the input shaft pilot bush ing Mesh the mainshaft gears with the corresponding coun tershaft 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 How to Install the Upper Countershaft Bearings 219 Transmission Overhaul Procedures Bench Service 7 Mesh the reverse gear teeth with the reverse idler gear teeth and move the reverse gear to the rear as far as possible 8 Align the reverse gear spacer external splines with the re verse gear and move the spacer into the reverse gear 9 Install the reverse gear 1 0 snap ring and move the reverse gear forward on the mainshaft and against the reverse gear limit washer 10 Push the input shaft bearing back into the case bore 11 Position a new ga
70. asket on the cylinder housing mounting sur face 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 Install the splitter piston Install the splitter yoke retaining bolt and lockwire Tighten to specification Install the Auxiliary case Use How to Install the Auxiliary Section procedure Position a new gasket or O ring new design aluminum cov er on the 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 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews Install and tighten the retaining capscrews to 20 25 Lbeft of torque Refill transmission with lube to the proper level Note Make sure the retaining nut and capscrews are tight ened to the proper torque Note Make sure gaskets are used at appropriate positions Transmission Overhaul Procedures Bench Service How to Install the Countershaft Assemblies w Tapered Bearings Special Instructions For A Series go to A Series Section To make auxiliary section assembly easier you can make an auxiliary section fixture out of a 2 x 12 lt gt PEREN 2 2 10 74 gt a x rJ 1 a ow 1
71. ass jaws or wood blocks 2 If previously removed install the roll pin in keyway 3 With mainshaft pilot end down install offset washer flat surface up Rotate the washer until the washer splines and mainshaft splines align 4 Start at the mainshaft bottom and install a plastic line in the marked keyway to lock the washer in place 5 With clutching teeth down position the proper gear on the mainshaft Refer to the illustrated parts list for correct gear 6 Install the flat washer Rotate the washer until the washer splines and mainshaft splines align 206 Transmission Overhaul Procedures Bench Service 10 11 12 13 14 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 main shaft 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 y a Position the next 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 next proper gear on the mainshaft Position the flat
72. ated between the filter regulator and the range cylinder cover Special Tools e Typical service tools Procedure 1 Position the air filter regulator 2 Apply Eaton Fuller Sealant 771205 or equivalent to the two 2 retaining capscrews 3 Install the two 2 retaining capscrews tighten to 8 12 Lbeft of torque 4 Install the 1 4 1 0 air hoses between the slave valve and both the air filter regulator and range cylinder assembly 5 Install the 1 4 I D air line between splitter cylinder and air filter regulator 88 In Vehicle Service Procedure How to Remove a Roadranger Valve Special Instructions 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 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 Inspect the 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 89 In Vehicle Service Procedure How to Install a Roadranger Valve Special Instructions To position the Roadranger valve the range lever must be to the front o
73. atisfactory Go to step R tor up and down between low and high gauge 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 discon 1 Confirm that the air lines are con At the shift knob move the range selec nected line nected to the correct ports at the shift tion lever up to select high range 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 If the lines are correct replace the shift knob No air flow from the discon Go to step G nected line Step G Check for air flow from the P port on Air flows from this port Replace the slave valve the slave valve No air flow from this port Go to step H 58 Table 14 No or Slow Range Shift into Low Continued Air System PROCEDURE RESULT WHAT TO DO NEXT Step H Place the shift lever in neutral Install a 100 PSI pressure gauge in line with the P line Move the range selector back and forth from low to high range
74. b No leak found Go to Step B Step B Check air lines to make sure all lines Air lines are not connected to the Connect lines properly are connected to the proper ports proper ports the shift knob A Reversal of S and lines will Air lines are connected to the proper Go to Step C result in a constant leak from the ex ports haust 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 down Constant air flow from the E port Replace knob 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 P Repair or replace the shift knob range Disconnect the 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 disconnect 1 Verify that the air line is connected ed air line 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 92 Table 10 Air Leak at Shift Knob Continued Air System PROCEDURE RESULT WHAT TO DO NEXT Step E Reattach the air line to the P port Move the range selector down to low range and move the
75. ce How to Remove the Integral Oil Pump Special Instructions None Special Tools e Typical service tools 236 Procedure 1 Remove the capscrews 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 Transmission Overhaul Procedures Bench Service 4 Removethree 3 allen head capscrews and washers that re tain 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 f 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 237 n a D wo e Transmission Overhaul Procedures Bench Service How to Install the Integral Oil Pump Special Instructions Lubricate the case front plug o ring with Eaton Fuller lubricant 71206 or equivalent Special Tools e Typical service tools Procedure 1 If removed replace the front case pump plug o ring lubri cate the grove of the plug install the o ring onto the plug and then lubricate the outer diameter of the o ring 2 Seatthe front case pump plug in the case bore by
76. 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 z lt 2 wo ce 5 7 y 2 77 In Vehicle Service Procedure 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 771209 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 ma terial 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 To install the air lines and hoses the air filter regulator must be in position If you are unsure of the air lines and hose location 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 p gt 1 Replace d
77. cover Button FORWARD SP Port Opened 36 Air System Insert Valve Equipped with Roadranger Valve A 4900 The insert valve is a self contained 1 3 16 valve assembly located in the splitter cylinder cover It cannot be disassembled except for the three O rings on the outer diameter The O rings provide a stationary seal and do not move in the cylinder When installing the insert valve in the bottom edge of the cover apply Fuller 71206 silicone lubricant or its equivalent to the O rings and cylinder walls Install the valve in the bore with the flat surface to the outside When installing the special valve retaining nut apply Fuller 71204 adhesive sealant or its equivalent to the threads and tighten See torque specifications Travel of the small insert valve piston is only 3 16 As shown in the illustrations below when no air is applied to the top side of valve piston constant air supplied from the regulator passes to the front side of cylinder piston moving the yoke bar backward to engage the rear auxiliary drive gear LO Range DIRECT and HI Range DIRECT The piston moves up to cut off air to the back side of the cylinder piston This air is exhausted out the cylinder cover as the piston moves rearward When air is applied to top side of valve piston through the signal line the piston moves down passing air through the bottom of the insert valve to the front and backside of the cylinder piston moving the yoke bar forward eng
78. ctions None Special Tools e Typical service tools 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 102 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 Procedure How to Install the Reverse Switch Special Instructions None Special Tools e Typical service tools Procedure 1 Insert the reverse pin in the reverse switch bore 7 lt 1 rA 7 N 1 m rJ 7 v rJ ow 2 57 2 Install new gasket on switch 3 Install the reverse switch torque to 15 20 Ib ft 20 34 27 12 Nem 4 Connect the wiring to the switch AM e e 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 103 In Vehicle Service Procedures How to Remove the Shift Bar Housing Special Instructions CAUTION Always wear eye protection when using compressed air Special Tools e Typical service tools Procedure 1 Use compressed air to clean any loose dirt or debris from transmission top 2 Remove the four capscrews from the shift control and se cure to the side or remove completely It may be necessary to label and disconnect the small air lines from the slave valve 1 v a 1 3 Label and disconnect all wiring for reverse and neutral switches 4 Remo
79. dures pictured in this manual show the use of specialized tools Their actual use is recommended as they make Recommended Tools transmission repair easier faster 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 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 prybars General Tools The following tools are available from several tool manufacturers such as Snap On Mac Craftsman OTC and many others Table 5 General Tools TOOL PURPOSE 0 100 Ib ft 1 2 drive Torque Wrench General torquing of fasteners Typically 15 80 Ib ft 20 34 108 47 Nem 0 600 Ib ft 3 4 or 1 drive Torque Wrench Torquing of output nut to 500 Ib ft 677 91 Nem 0 50 Ib in 3 8 drive Torque Wrench General torquing of fasteners 0 30 Ib in 1 4 drive Torque Wrench Torquing of capscrews to 7 Ib in 0 79 Nem during auxiliary coun tershaft bearing endplay setting procedure 70 MM or 2 2 4 Socket Standard Depth To remove the output yoke nut Large Brass Drift Used to protect shafts and bearings during removal Large Dead Blow Hamme
80. e Idle Gear Rattle Excess engine torsional vibration at idle Check for low engine RPM Check for uneven engine cylinder perfor mance Check for proper clutch damper opera tion Noise High Pitched Whine 48 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 work ing angles Check for damaged or worn gearing General Troubleshooting Chart cont Complaint Hard Lever Shifting Shift lever is hard to gear into or out of gear Shift Lever Jumpout Shift lever comes out of gear on rough roads Master clutch dragging General Troubleshooting What to do next Check master clutch for proper disen gagement Check master clutch for proper adjust ment 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 dam age or excessive wear Driver technique Loose or worn engine mounts Driver not familiar or skilled with proper double clutching
81. e Shift into Low Continued PROCEDURE RESULT WHAT TO DO NEXT Step R If air system has been tested and found to operate satisfactory the auxiliary sec tion must be removed to inspect for me chanical problem Remove auxiliary section and inspect for Binding of range yoke bar or piston Damaged or defective range yoke Damaged or defective range synchro nizer Cracked c s weld resulting in gear turn ing on shaft Damaged or defective range sliding clutch Auxiliary section gearing out of time 60 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 E 3 E 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 e Incorrect air line hook up e Insufficient air supply to tran
82. e larger chamfer on the bearing inside diameter is in stalled towards the shaft Use a bearing driver that contacts both the bearing inner race and outer race 12 In the countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torqued Note Make sure the rear snap ring is in place 216 Transmission Overhaul Procedures Bench Service How to Install the Input Shaft and Main Drive Gear Special Instructions None Special Tools e See Tool Information see Table 6 e item T10 Input bearing driver e Toolmaker s dye Procedure 1 Use a highly visible toolmaker s dye and mark the main drive gear for timing purposes To mark the gear paint toolmak er s die on any two adjacent teeth and then paint the two ad jacent teeth directly opposite the first two teeth If necessary install the bushing in the back of the input shaft Temporarily position the upper countershaft up and away from the transmission center From inside the case mesh the lower countershaft drive gear marked tooth with either set of main drive gear marked teeth From the front engage the input shaft spline teeth into the main drive gear Note The current design input shaft spline teeth have no ticeable clearance to the main drive gear internal spline teeth This is normal Install the snap ring in the main drive gear inside groove 217 Y se a
83. e 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 Special Tools e Typical service tools Procedure 1 From the gear shift lever base shift control housing remove the four 4 retaining capscrews 1 Housing 2 Capscrew 3 Gasket 2 To break the gasket seal lightly jar the gear shift shift con trol housing 3 Remove the gear shift lever housing A CAUTION Make sure the detent springs do not fall into the transmis sion 4 Remove detent springs as needed 5 Remove the gasket and clean the area the replacement gas ket will contact 94 In Vehicle Service Procedure 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 Procedure 1 Thoroughly clean mounting surface 2 Position a ne
84. ear on the drive shaft 15 Install the outer drive gear retention snap ring in drive shaft groove 246 Y 1 a ow Transmission Overhaul Procedures Bench Service 16 Install the outer integral oil pump element over the inner el ement 247 Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Section with Tapered Bearings Special Instructions There are different capscrew 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 See Tool Information see Table 6 e T2 Auxiliary section hanger bracket for horizontal removal e Asteel bar longer than the width of the output yoke for vertical removal e A hoist with a lifting chain Procedure 1 To install the auxiliary section in the horizontal position Position a new gasket on the transmission mounting sur face 2 Attach an auxiliary section hanger bracket to the auxiliary section top 3 Attach a lifting chain to the auxiliary section hanger bracket 4 Position the auxiliary section on the two 2 dowel pins 5 Slide the auxiliary section on until the hanger bracket con tacts the front section back 6 Remove the auxiliary
85. ear position but the shift will not occur until the shift lever is moved to neutral Possible Causes e Worn or missing actuating pin or air valve shaft e 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 Con firm 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 65 3 3 5 E 3 E Timing 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 auxiliar
86. eat 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 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 275xF 136xC 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 e Tool Information see Table 6 e dye e Heat lamp or hot plate and oil e seal installation tool Procedure 1 Usetoolmaker s dye and mark the LO range gear for timing purposes 2 Markany two 2 adjacent teeth on the LO range gear Re peat the procedure for the two 2 adjacent teeth directly op posite the first set marked 3 With splined washer facing up place the washer on the out put shaft shoulder 166 Transmission Overhaul Procedures Bench Service 4 With LO range gear clutching teeth down position LO range gear on the output shaft engage the washer splines 5 With chamfer side up positio
87. elease 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 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 Re place 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 3 3 5 E 3 E e Check all gray iron parts for cracks and breaks Replace parts found to be damaged 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 d
88. ershaft 12 Seal Sectional View 13 O Ring 1 Slave Valve Housing 14 Piston 2 U Seal 15 U Seal 3 Washer 16 Cap 4 Spring 17 O Ring 5 Plug 18 Seal 6 Snap Ring 19 Spring 7 O Rings 8 Plate 9 Capscrew 10 Cap 41 Air System Slave Valve Preselection 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 6 Component Nomenclature and Auxiliary Countershaft Sectional View 1 Actuation Spring 4 Shift Bar Housing 2 Actuating Pin 5 Slave Valve 3 Air Valve Shaft 6 Alignment Sleeve Refer to the drawing for disassembly and reassembly of the piston type slave valve assemblies Should the poppet type slave valve assembly prove to be defective replace the complete assembly as it is non serviceable The actuating components used with these valve assemblies are non interchangeable Failure to use the correct plunger pin spring and alignment sleeve during instal lation on the transmission will cause hard shifting in LO Range gears 42 RTLC 1X909 2 Speed Auxiliary Range LO A 4900 Roadranger Valve Slave Valve Identification Down A 5000 Valve o o o Ot OJ o Rearward A
89. estroyed 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 e Check yokes for correct alignment Replace sprung yokes e Check lockscrew in yoke and blocks Tighten and rewire those found loose e If 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 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 trans m
90. ety of the service technican or vehicle operator Warning Failure to follow indicated procedures creates a high risk of personal injury to the service technician Caution Failure to follow indicated procedures may cause component damage or malfunction Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the service of this unit Always use genuine Eaton replacement parts Warnings and Precautions rJ 5 7 im 5 7 Table of Contents General Information In Vehicle Service Procedures Transmission Overhaul Procedures Bench Service Warnings and Precautions Transmission Overview Purpose and Scope of Manual Serial Tag Information and Model Nomenclature Lubrication Specifications Tool Specifications erarinta Transmission Torque Specifications 13 Preventative Maintenance Check Points 15 Power Flow Diagrams 18 9 amp 13 Speed Shift Patterns 32 Air System 34 General Troubleshooting Chart 48 Air System
91. 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 gears shafts and or bearings Use a torque wrench whenever possible to attain recommended Lbseft ratings Do not torque capscrews dry FRONT SECTION ALL MODELS 1 MAIN DRIVE GEAR BEARING NUT 1 NEUTRAL SIGNAL SWITCH PLUG 250 300 Lbs Ft Apply 35 50 Lbs Ft 34 16 Threads Loctite Grade 277 Sealant and 5 SHIFT BLOCK AND YOKE LOCKSCREWS Stake to Input Shaft 35 45 Lbs Ft 7 16 20 Threads Secure 6 FRONT BEARING COVER CAPSCREWS with Lockwire 35 45 Lbs Ft 3 16 Threads 16 SHIFT BAR HOUSING AND 4 SHIFT Apply Loctite 242 to Threads LEVER HOUSING CAPSCREWS 35 45 Lbs Ft 6 CLUTCH HOUSING NUTS 3 s 16 Threads Apply Loctite 242 to Threads 180 190 170 175 Lbs Ft 1 REVERSE SIGNAL SWITCH PLUG 5 g 18 Threads Use Lockwashers 35 50 Lbs Ft 916 18 Threads 4 SLAVE AIR VALVE CAPSCREWS 2 SUPPORT STUD NUTS 8 12 Lbs Ft 14 20 Threads 170 185 Lbs Ft 5 s 18 Threads Apply Loctite 242 to Threads 4 Use Lockwashers N D lt 5 e 0 D D 6 SMALL PT O COVER CAPSCREWS 1 OIL DRAIN PLUG 35 45 Lbs Ft 3 16 Threads 45 55 Lbs Ft 34 Pipe Threads Apply Loctite 242 to Threads 69 MAINSHAFT REAR BEARING RETAINER 8 LARGE
92. ey in the square keyway Special Tools e with brass jaws or wood blocks Procedure 1 Install the relief valve in the integral oil pump housing Y 1 a ow 2 Install the relief valve spring in oil pump housing 3 Secure the oil pump housing in a vice 4 Depress the relief valve spring and drive the relief valve re tention roll pin into the roll pin bore 233 Transmission Overhaul Procedures Bench Service 234 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 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 LAT PET Te UOISSIWSULIL n a D 3 e ow E N e 13 Install the outer integral oil pump element over the inner el ement 235 Transmission Overhaul Procedures Bench Servi
93. g Note Do not overtighten the nut Overtightening can com press the collet too much and cause an air line restric tion 3 Install the air line collet and nut If installing a new fitting f place the collet in the fitting and loosely install the nut Do not tighten the nut yet Insert the air line through the nut and into the collet Tighten the nut as usual Enable the vehicle air system Allow the air tanks to pressur ize and check for leaks Repair as necessary b i M T 1 1 Connector 2 Collet 3 Nut 4 Air Line 83 z 1 a i 1 Z In Vehicle Service Procedure How to Remove Push To Connect Type Fittings Special Instructions A 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 A 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 dam age to fittings Before removing the air lines and hose label or record their location Special Tools 84 See Tool Information see Table 8 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 Exhaust the vehicle air tanks before continuing 1 Cutter 2 Release Tool 2 Use the air line
94. 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 coun tershaft 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 aux iliary splitter clutch Geo see a GS Front Section Power Flow 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 20 Power Flow Front Section Power Flow Direct Gear In direct gear the front sliding clutch is moved forward and engages 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 yp D lt 5 e D c RTO RT uses wD ES Front Section Power Flow Direct Gear 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 21 Power Flow Front Section Power Flow Reverse Gear Torque will flow from the countershafts to the reverse idler gears Torque will then flow f
95. ger iliary section in the horizon tal position T3 Auxiliary Counter To hold the auxiliary coun G 250 T 311 5062 shaft Support and tershafts in position while in Shim Tool stalling the auxiliary section in the horizontal position Also to simplify the checking and setting of the auxiliary countershaft bearing end play T4 Shift Lever Spring To install the shift tower ten G 116 T 170 Installation Tool sion spring Tension Spring Driver T5 Slide Hammer To remove the output seal G 70 T 150 1155 Slide and reverse idler shafts Re Hammer 8007 quires 1 2 13 threads Op 1 2 13 Adapt tional idler shaft can be er driven out from front T6 Bearing Puller To remove front section G 10 or G 15 T 1 and T 2 7070A Kit countershaft bearings for 9 Series T7 Bearing Driver To install front section coun G200 Kit T 101 Kit tershaft bearings 3 97 OD 1 78 ID T8 Bearing Driver To install the front counter G200 Kit T 101 Kit shaft rear bearings 3 5 OD 1 6 ID T9 Countershaft Sup support and locate the G 50 G 51 G 58 1455 7109 port Tools 2 front section countershafts during bearing removal and installation T10 InputBearing Driver To install input bearing on G 35 T 120 5066 2 shaft input shaft T11 Bearing Puller To remove the auxiliary 4332 4232 1123 927 countershaft tapered bear ings Table 6 Special Tools Continued Recommended Tools
96. ges 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 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 Corporation 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
97. h sides of the HI range synchronizer and pull 4 Fromthe synchronizer ring LO range pins remove the slid ing clutch 163 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 y 26 rJ 1 a 1 rJ co rJ 5 7 Sliding Clutch Procedure 1 On the bench place the larger LO range synchronizer ring face down with pins up 2 With the sliding clutch recessed side up place the sliding clutch on the LO range synchronizer pins 164 Transmission Overhaul Procedures Bench Service 165 In the HI range synchronizer bores install the three 3 springs Place the HI range synchronizer ring over the LO range syn chronizer ring Rotate the HI range synchronizer until the springs are seated against the pins Cover the assembly with a shop rag Apply downward pressure to the HI range synchronizer ring while twisting counterclockwise This compresses the springs to fully s
98. haft 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 189 Y 1 a 1 3 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 Typical service tools 190 Procedure 1 Mark the countershafts as UPPER or LOWER as you remove them Note The mainshaft and main drive gear must be removed before removing the countershaft assemblies Remove the rear snap ring from the rear upper countershaft bearing From inside 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 remov al Itis strongly recommended that this bearing is dis carded Remove the capscrew and the retainer from the upper coun tershaft front Slide the lower countershaft forward This will move the front bearing forward to expose the external snap ring Transmission Overhaul Procedures Bench Service 6 Usethe appropriate bearing puller Tool ID T6 or two pr
99. 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 out side diameter must be used with maincase machined after April 1995 If an older oil pump assembly is in stalled into a new case P N 20510 retainer plate will not seat properly in the spot face machined in the case wall Y 1 a ow 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 238 Transmission Overhaul Procedures Bench Service 5 Install three 3 allen head capscrews 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 9 Position the oil tube in the case bottom through the interme diate wall 10 Apply Loctite 242 to capscrew threads Torque capscrews to 35 45 Ib ft 47 45 61 01 Nem Note Make sure the integral oil pump drive gear can turn 239 Transmission Overhaul Procedures Bench Service How to Disassemble the Integral Oil Pump with Auxiliary Oil Tube S
100. her on the mainshaft 29 c c 5 a nv uS 259 lt ae 2 2 2 s 2 Reinstall the front auxiliary drive gear assembly on rear of mainshaft Use a flanged end driver and maul to set bearing in case bore 3 Align the six capscrew holes in retainer with the tapped holes in case and install capscrews Tighten to recommend ed torque ratings and lockwire the capscrews in groups of three 227 Transmission Overhaul Procedures Bench Service 4 Install splined washer on mainshaft splines behind auxiliary drive gear 5 Install the snap ring in groove at end of mainshaft 228 Transmission Overhaul Procedures Bench Service How to Install the Clutch Housing Special Instructions Installation of the clutch housing is done in the horizontal position Special Tools e Typical service tools Procedure 1 Position a new gasket on the housing mounting surface with beads toward case 29 os nv uS 259 lt ae 2 2 2 s 2 Install the clutch housing on the front box pilot it on the six studs and drive gear bearing cover 3 Install the nuts with washers or lock washers on the studs tighten to 180 190 Lbeft of torque 4 Install the capscrews with lock washers tighten to 90 100 Lbeft of torque Note Make sure the capscrews are properly torqued 229 Transmission Overhaul Procedures Bench Service How
101. in damage to the mainshaft rear bearing A 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 and Specifications Serial Tag Information and Model Nomenclature Transmission model designation and other transmission identification information are stamped on the transmission tag To iden tify 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 RTL CvF 16 6 09 E Roadranger Ratio Set Twin Countershaft Low Inertia Forward Speeds 6 Multi Mesh Gearing 7 Helical Auxiliary Gearing and F Forward Opening Shift Housing Multi Mesh Front Section Gearing 9 Improved Seal System C Convertible ce 1 rJ a 7 1 Z 17 This x 100 Nominal Torque Capacity PTO Code Eaton Fuller gay Transmissions Eaton Corporation AC cz Kalamazos Mi 40023 Do not remove or destroy the transmission identification tag The model number gives basic information about the transmission Use this number when calling for service assistance or re placement parts Serial Number The serial number is the sequential identification number of the transmission Before calling for service assistance write
102. ission during assembly Dirt is an abrasive and can damage polished surfaces of bearings and washers Use certain precau tions as listed below during assembly Axial Clearances e Maintain original axial clearances of 0 006 0 015 in for mainshaft gears Bearings e Use a flange end bearing driver for 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 us ing a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races Capscrews e prevent oil leakage and loosening use Fuller sealant 471205 on all capscrews Gaskets e Use new 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 450 500 Ib ft 610 12 677 91 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
103. ith Check No 9 9 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 trans mission e Check the tension spring and washer for set and wear e Check the 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 10 Universal Joint Companion Flange or Yoke Nut e Check for tightness Tighten to recommended torque 11 Output Shaft Not Shown e upward against output shaft to check radial clearance in mainshaft rear bearing Preventive Maintenance 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 12 Splines on Output Shaft Not Shown e Check for wear from movement and chucking action of the universal joint companion flange or yoke 13 Mainshaft Rear Bearing Cover Not Shown e Check oil seal for wear 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 dirt adhered to the contaminated area Rear Seal Leak Extremely wet or dripping of oil in the con
104. ket position the range cylinder cover 12 Apply Eaton Fuller sealant 771205 or equivalent to the re taining capscrews 13 Install the capscrews tighten to 20 25 Lbeft of torque 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 771213 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 Auxiliary case is installed after the splitter piston and housing Special Tools e Typical service tools e Vise with brass jaws or wood blocks 19 1 Shift Yoke 11 Insert Valve 2 Lockscrew 12 Reducer Bushing 3 Gasket 13 Capscrew 4 Splitter Cylinder 14 O Ring 5 O Ring 16 O Ring 6 Yoke Bar 17 O Ring 7 O Ring 18 Breather 8 Gasket 19 Splitter Valve Kit 9 Plug 21 Capscrew 10 Cover 173 v rJ 1 Qa 1 rJ 1 rJ 57 Transmission Overhaul Procedures Bench Service 174 Procedure 1 10 11 12 13 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 g
105. l Instructions None Special Tools e See Tool Information see Table 6 e T2 Auxiliary section hanger e item T14 Auxiliary section removal adapter plate A hoist with lifting chain z 1 e 1 v 1 a o Procedure 1 Drain the transmission oil 2 Disconnectthe driveshaft and U joint from the output yoke 3 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 4 Disconnect the vehicle air supply line from the filter regula tor assembly 5 Markthe locations and disconnect the large rubber air lines Move the lines aside 6 Label and remove the small air lines 7 Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 8 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use and air gun Tighten by hand until the cap screws are snug 9 Drive the two dowel pins forward and remove them 119 In Vehicle Service Procedures 120 10 Remove all but one capscrew that secure the auxiliary sec tion to the main section Leave one capscrew to secure the housing until it is ready to be removed Note Capscrews are different lengths Note their locations for reassembly purposes A
106. l seal slinger driver Procedure 1 The seal will be damaged during removal and must be re placed Place a seal on the oil seal driver and drive the new seal into the rear bearing cover Install the new slinger on the output yoke using a slinger driver 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 Inspect the output shaft nut for damage and wear If the ny lon locking material is damaged or excessively worn use a new output nut Note The nylon locking material must in good condition so that nut does not loosen when the vehicle is in use Lightly oil the output shaft threads and the output nut threads Install the nut torque to 450 500 Ib ft 610 12 677 91 Nem Connect the driveshaft and U joint according to the OEM or driveshaft manufacturer s instructions 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 For additional information on rear seal service refer to the Rear Seal Maintenance Service Brochure TRSM0912 Special Tools e Tool Information see Table 6
107. ling 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 Bearings 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 3 3 5 E 3 E 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 recom mended Inspection Precautions Before assembli
108. ll the adjustments 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 Loosen the capscrew B see figure A and remove the shift arm from the inner shift shaft Do not disconnect the selec tion lever from the shift arm Turn the shift arm until it is at a right angle 90 to the se lection lever as viewed from the side see figure B Note Ideally the shift arm should be adjusted 90 to the se lection lever as described but in some chassis config urations 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 position as com pared to neutral and a rearward lever position 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 ad justed later Tighten the capscrew B see figure A on the shift arm Connect the pivot link assembly ball joint to the selection le ver 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 c
109. lve Shaft 100 Procedure 1 Install a new gasket 2 Install the neutral switch torque to 15 20 Ib ft 20 34 27 12 Nem 3 Connect the wiring to the switch In Vehicle Service Procedure 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 Volt Ohm meter Procedure lt D 2 GJ N D a e D 1 Disconnect the wiring from the switch 2 Connect an ohm meter to check for continuity 3 Place the transmission shift lever in any position except re verse 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 4 Place the transmission shift lever in the reverse position If the switch is working properly the ohm meter should regis ter 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 101 In Vehicle Service Procedure How to Remove the Reverse Switch Special Instru
110. m the case and input shaft or use pry bars or screwdriv ers to complete removal of the bearing 6 From the drive gear front remove drive gear spacer 7 Remove the drive gear internal snap ring 195 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 dam aged 196 Transmission Overhaul Procedures Bench Service How to Prepare the Main Case for Assembly Thoroughly clean case of metal particles Remove the gasket material from flange surfaces Inspect flange surfaces for damage Inspect bearing bores for damage or excessive wear Replace 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 UOISSIUSULIL im rJ bd wo rJ rJ 5 7 197 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 facilita
111. n the LO range gear rear wash er on the output shaft against the LO range gear y Z 6 With tapered side up use heat or appropriate driver and in stall the output shaft rear bearing 7 On the output shaft position the bearing inner spacer Set aside i 167 Transmission Overhaul Procedures Bench Service 8 Lay the auxiliary housing front face down on a clean flat sur face Install the bearing race in the bearing bore 168 Transmission Overhaul Procedures Bench Service How to Install the Splitter Gear Special Instructions Make sure to use an splitter gear retaining bolt with thread sealant material 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 1 Lay the output assembly on its side 2 Submerge synchronizer in motor oil 3 Install the synchronizer assembly 9 o zi os 2 uS oS 5 ae 2 1 4 Install the splitter gear 5 Install the splitter gear retainer and 15 16 capscrew 6 Tighten the splitter gear retainer bolt to 190 210 Lbeft of torque Note Make sure the splitter gea
112. nal View 1 Front Section 2 Front Section 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 Transmission Components 1 Input Shaft 2 Main Drive Gear 3 Sliding Clutch 4 Countershaft 5 Mainshaft Gear 6 Auxiliary Splitter Clutch slides on front section mainshaft 12 N D 2 lt 5 e D c 7 Auxiliary Countershaft 8 Range Sliding Clutch 9 Auxiliary Mainshaft Reduction Gear 10 Output Shaft Auxiliary Mainshaft 11 Splitter Gear 12 Auxiliary Drive Gear 19 Power Flow Front Section Power Flow Note The heavy lines in the figure below outline the power flow description For help in understanding the transmission compo nents 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 The main drive gear meshes with both countershaft driven gears and the torque is split between both countershafts Beg pe Because the countershaft gears are in constant mesh with the mainshaft gears all the front section gearing rotates How ever only the engaged or selected mainshaft
113. new gasket on the rear bearing cover mounting surface 29 c c 5 a nv uS 259 lt ae 2 2 2 1 Position the rear bearing cover 12 Apply Eaton Fuller Sealant 771205 or equivalent to the re taining capscrews 13 Install the five 5 retaining capscrews in the non chamfered hole tighten to 35 45 Ib ft of torque 14 Install the nylon collar and brass washer in the chamfered hole tighten to 35 45 Ib ft of torque 15 Install each auxiliary countershaft retaining strap with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews WARNING Do not use an air gun Tighten by hand until the capscrews are snug 177 Transmission Overhaul Procedures Bench Service How to Install the Countershaft Assemblies w Ball Bearings A Series Special Instructions For ease of assembly mount the auxiliary section in a vise When Installing the countershaft assemblies into the countershaft bearings keep the countershaft assemblies straight Do not cock the countershafts If when the countershaft bearing cover is removed and you can not see the snap ring groove install the cover and drive the coun tershaft further until you can see the groove Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks e Bearing driver and a maul e Toolmaker s dye e Large snap ring pliers Procedure 1 Place the countershaft assembly vertical on a clean flat s
114. ng Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch rearward 28 Power Flow 2 abe eae oeg Cae 4th Gear 5th Low Split 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 D 2 lt 5 e D c N wob ges bs 5th High Split Gear 6th Low Split Gear 1 Sliding Clutch rearward 1 Sliding Clutch forward 2 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward 3 Sliding Clutch forward 29 Power Flow Ses auc peg ode 6th High Split Gear 7th Low Split Gear 1 Sliding Clutch forward 1 Sliding Clutch forward 2 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward 3 Sliding Clutch forward Le ee a ee eee whe wae es Oot 7th High Split Gear 8th Low Split Gear 1 Sliding Clutch forward 1 Sliding Clutch rearward 2 Sliding Clutch rearward 2 Sliding Clutch forward 3 Sliding Clutch forward 3 Sliding Clutch forward 30 Power Flow L 1 3 9 M 2 RTO wees re 8th High Split Gear 1 Sliding Clutch rearward 2 Sliding Clutch rearward 3 Sliding Clutch forward D mz D D 31 Transmission Shift Patterns 9
115. ng it to move to the selected range position 35 ce 1 a i 1 2 17 Air System Splitter System Operation In addition to the various components of the range shift air system the splitter shift air system utilizes a splitter cylinder and the Roadranger valve A 4900 Constant air from the air filter regulator assembly is supplied to the splitter cylinder at the port on right side of cylinder cover The insert valve installed in the cover provides the proper air flow needed to move the splitter piston in the cylinder rearward to engage rear auxiliary drive gear for operation in direct forward to engage the front auxiliary drive gear for operation in overdrive While in HI or LO range air needed to make the splitter selection and complete the shift is supplied to the Roadranger valve from the tee fitting at the HI range or H port of the slave valve When the overdrive selection is made the air passes through the Roadranger valve and is supplied to the left port of cylinder cover With splitter control button in the DIRECT REARWARD position the SP port of the Roadranger valve is closed and no air is supplied to the left port of the splitter cylinder cover Button REARWARD SP Port Closed While in HI range the button can be moved forward to operate in overdrive The SP port of valve is opened when overdrive is selected supplying air to the left port of the splitter cylinder
116. ng 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 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 Re place 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 R
117. ns Before 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 z e 1 z lt 1 y is 2 1 Procedure 1 Disconnect all air lines and hoses 2 Inspect the air lines and hoses 81 82 In Vehicle Service Procedure 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 Procedure How to Install Compression Type Fittings Special Instructions A 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 Checkthe threads of the fitting for thread sealant If no seal ant is present apply Eaton thread sealant 71205 or equiva lent 2 Install the fittin
118. o the retaining capscrew threads 135 Transmission Overhaul Procedures Bench Service 6 Install interlock parts pin spring and sleeve 7 Install slave valve and tighten to specifications 136 Transmission Overhaul Procedures Bench Service How to Disassemble the Shift Bar Housing Assembly Special Instructions Before removing the shift bar housing the air lines must be disconnected There are two 2 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes Note their location Be careful when removing shift bar housing to not damage oil tube with shift yokes For models equipped with an Oil Pump and or Cooler Assemblies make sure to disconnect the lube line at the fitting on the shift bar housing before doing the following instructions Note Forward Shift Bar Housing removal follows the same procedure Special Tools e Typical service tools UOISSIUSULIL a i rJ E ow 1 rJ ce 1 rJ 1 Shift Bar HSG STD 2 Gasket 3 Breather and Pipe Plug 4 Oil Trough 5 Air Valve Shaft 6 Capscrew 7 Pipe Plug 8 Gasket 9 Plate 10 Lockwasher 11 Capscrew 12 Gasket 13 Plug 14 Neutral Light Switch 15 Lifting Eye 16 Capscrew 17 Pin 18 Gasket 19 Reverse Light Switch 20 Plug 21 Spring 22 Steel Ball 23 Shift Yoke 24 Steel Ball 25 Shift Block 26 Lockscrew 27 Interlock Pin
119. octite 242 to Threads 4 RANGE CYLINDER MOUNTING CAPSCREWS 35 45 Lbs Ft 3 16 Th Apply Loctite 242 to Threads 4 RANGE CYLINDER COVER CAPSCREWS 35 45 Lbs Ft 35 16 Threads Apply Loctite 242 to Threads 1 RETAINING NUT PLUG 40 50 Lbs Ft 5 18 Threads 4 SPLITTER CYLINDER COVER CAPSCREWS 20 25 Lbs Ft 56 18 Threads Apply Loctite 242 to Threads 8 COUNTERSHAFT REAR BEARING COVER CAPSCREWS 35 45 Lbs Ft 3 a 16 Threads Apply Loctite 242 to Threads 1 SPEEDOMETER HOUSING PLUG 35 50 Lbs Ft 13 16 20 Threads Apply Loctite 242 to Threads Preventive Maintenance Preventative Maintenance Check Points 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 A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmis sion 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 breakd
120. ountershaft retaining strap 4 Usea soft bar and maul to drive the output shaft forward far enough to partially unseat the bearing Y 1 a ow 5 Supportthe auxiliary countershaft while removing the auxil iary countershaft retaining strap 6 Remove the auxiliary countershaft 7 Remove the auxiliary countershaft bearing race from bore 151 Transmission Overhaul Procedures Bench Service 8 If necessary secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing separator and jaw pullers 152 Transmission Overhaul Procedures Bench Service How to Remove the Countershaft Assemblies w Ball Bearings A Series Special Instructions For ease of disassembly mount the auxiliary section upright in a vise Both countershafts are removed the same When driving that countershaft to the rear be careful not to damage the bearing inner race As the rear bearing is removed the countershaft will fall Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks e Bearing puller e bar and a maul Procedure 29 c c 5 a nv uS 259 lt ae 2 2 2 1 From the countershaft rear bearing cover remove the cap screws cover and gasket 2 Clean the gasket mounting surface of gasket mate
121. ountershaft to the rear and insert the countershaft support tool to center shaft in rear case bore 221 Transmission Overhaul Procedures Bench Service 4 Obtain a spare inner countershaft race 5 Temporarily install a spare countershaft inner race inside the front roller bearing for installation 6 Use a flanged end driver to start the front bearing in case bore 7 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 8 Move the countershaft forward into the bearing 9 Use a flanged end 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 tem porary race with the driver The temporary race should fall out when installation is complete 10 Onthe countershaft front position the retainer plate with roll pin in hole at shaft end 11 Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller amp thread sealant 71205 or equivalent Torque the capscrew to 90 120 lb 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 222 Transmission Overhaul Procedures Bench Service 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
122. ousing bore remove the 15 16 nut 4 From the cylinder housing bore remove the range piston 5 Inspect the range piston O rings remove if damaged 6 Remove the capscrews 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 159 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 Capscrew 5 Rear Bearing Cover Assembly 6 Gasket 7 Capscrew 8 Capscrew 9 Cover 10 Gasket 11 Shim Kit 12 Gasket mz a Er E D 4 s 13 Rear Housing 15 Lifting Eye 16 Capscrew 19 Speedo Drive Gear 20 Speedo Spacer Assembly 21 Oil Seal w Slinger 22 Capscrew 23 Speed Sensor Kit 24 Bushing 25 O Ring 26 Rear Bearing Cover Assembly 160 Transmission Overhaul Procedures Bench Service 161 Procedure 1 Useasoft bar and maul to drive the output shaft forward and th
123. ove the countershaft to the rear and insert the countershaft support tool to center shaft in rear case bore Y 1 a ow 1 2 Obtain a spare inner countershaft race 3 Temporarily install the spare countershaft inner race inside the front roller bearing for installation 215 Transmission Overhaul Procedures Bench Service 4 Use a flanged end driver to start the front bearing in case bore 5 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 6 Move the countershaft forward into the bearing 7 Use a flanged end 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 tem porary race with the driver The temporary race should fall out when installation is complete 8 On the countershaft front position the retainer plate with roll pin in hole at shaft end 9 Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller amp thread sealant 71205 or equivalent Torque the capscrew 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 10 From the rear remove the countershaft support tool 11 Install the rear countershaft bearing Position the bearing so that th
124. own 1 v a 5 7 Note Transmission appearance may differ however the procedure is the same 15 Preventive Maintenance 1 Air System and Connections e Check for leaks worn air lines loose connections and capscrews 2 Clutch Housing Mounting e Check all capscrews 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 e Change at specified service intervals e only the types and grades as recommended See Recommended Lubrication Chart see Table 2 6 Filler and Drain Plugs e Remove filler plugs and check level of lubricant at specified intervals Tighten fill and drain plugs securely 7 Capscrews and Gaskets e For applicable models check all capscrews especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage e Check PTO opening and rear bearing covers for oil leakage due to faulty gasket 8 Gear Shift Lever e Check for looseness and free play in housing If lever is loose in housing proceed w
125. pecial Instructions None Special Tools e A vise with brass jaws or wood blocks Procedure 1 From the assembly remove the outer oil pump element Y 1 a ow 2 From the drive shaft remove the drive gear retaining snap ring 3 From the pump drive shaft remove the drive gear 4 From the drive shaft keyway remove the key 240 Transmission Overhaul Procedures Bench Service 241 5 From the drive shaft remove the element snap ring 6 Fromthe drive shaft removethe internal oil pump element 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 Transmission Overhaul Procedures Bench Service 11 Loosen the retaining nut 12 Remove the retaining nut spring and ball Y 1 a ow 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 242 Transmission Overhaul Procedures Bench Service 15 Remove the valve cover 16 Inspect all parts for damage replace damaged parts 243 Transmission Overha
126. pline with the mainshaft key and install the front sliding clutch Engage the sliding clutch external splines with the gear clutching teeth errer 204 y Z Transmission Overhaul Procedures Bench Service 205 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 14714 0 263 0 265 Purple 14715 0 268 0 270 Yellow 14716 0 273 0 275 Black Washers for 3 Sided Key PART SIZE COLOR 4300830 0 244 Blue Light Blue 4300382 0 249 White Light Blue 4300383 0 254 Green Light Blue 4300384 0 259 Orange Light Blue 4300385 0 264 Purple Light Blue 4300386 0 269 Yellow Light Blue 4300387 0 274 Black Light Blue 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 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with br
127. r Note Make sure all gears are pressed into place Note Make sure the bearing inner race is installed 210 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 See Tool Information see Table 6 e tem T18 Bearing race installer Previous Design 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shaft 4 Nut and Washer 6 Plug 211 Transmission Overhaul Procedures Bench Service The capscrew 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 capscrew design where main case does not have the oil feed hole the reverse idler bearing will fail Current Design A CJ y _ 6 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 Capscrew Procedure 1 Position the reverse idler bearing and inner race into the re verse idler gear 212 Transmission Overhaul Procedures Bench
128. r impact wrench to remove the output shaft nut 3 Remove the output yoke Use the output yoke puller Tool ref ID T1 In Vehicle Service Procedures How to Install the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TCSM0912 Seal Maintenance Guide Special Tools e Torque wrench with 0 600 Ib ft 0 813 49 Nem capacity Procedure z 1 e 1 a rJ 1 a o 1 Engage two 2 mainshaft sliding clutches into two 2 main shaft 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 If the slinger on the yoke is damaged replace using a Sling er Seal kit 117 In Vehicle Service Procedures 118 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 Install the output shaft nut tighten to 450 500 Ib ft 610 12 677 91 Nem of torque Make sure the output shaft nut is properly torqued and un lock the transmission or remove the yoke holding tool In Vehicle Service Procedures How to Remove the Auxiliary Section in Chassis Specia
129. r or Maul To provide force for shaft and bearing removal Snap Ring Pliers Large Standard External To remove the snap rings at the auxiliary drive gear input shaft bearing and countershaft bearings Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing endplay Rolling Head Crow s Foot Prybar 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 Universal Bushing Driver To remove and install clutch housing bushings Bushing OD 1 125 in ID 1 000 in 3 3 5 E 3 E Recommended Tools The following special tools are designed for this Fuller transmission The addresses and phone numbers of the tool suppliers are listed after the table This list is provided as a convenience to our customers These tools are manufactured by independent com panies with no relationship to Eaton Eaton does not warrant the fit or function of the listed tools To obtain the tools contact the tool supplier directly Table 6 Special Tools REFERENCE TOOL PURPOSE G amp WTOOL NO GREAT LAKES OTC NUMBER TOOL NO TOOL NO 1 Output Yoke Puller May be required to remove SP 450 7075 rusted output yoke T2 Auxiliary Section To support or hang the aux 6 40 T 125 5061 Han
130. r retainer bolt is properly torqued 169 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 1 Yoke Bar 2 Gasket 3 Range Cylinder Assembly 4 O Ring 5 Piston 6 O Ring 7 O Ring 170 8 Nut 9 Gasket 10 Cover 11 Capscrew 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 1 0 and O D install the piston O rings 29 c c 5 a nv uS 259 lt ae 2 2 2 3 Position a new gasket the range cylinder housing mount ing surface 4 Install the cylinder housing 5 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 6 Install the capscrews tighten to 20 25 Lbeft of torque 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 tighten to 70 85 of torque 171 Transmission Overhaul Procedures Bench Service 172 10 Position a new gasket on the cylinder housing cover mount ing surface 11 Over the gas
131. r the splitter button to the left when facing forward Special Tools e Typical service tools Procedure 1 Make sure the nut valve cover air lines sheathing and o rings are in position on the lever shaft 2 P2 y a a 2 f previously removed replace the air fittings and torque to 84 120 Ib in 9 49 13 56 Nem 3 Place the Roadranger valve on the lever shaft and rotate so the range selector faces the vehicle front 4 From the Roadranger valve bottom torque the jam nut to 35 45 lb ft 47 45 61 01 Nem 5 Connect the air lines to the air fittings 6 Slide the cover into position on the Roadranger valve 7 Install the Roadranger valve cover mounting screws Note Make sure the air lines are seated fully 90 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 Procedure 1 If necessary apply Eaton thread sealant 71205 or equiva lent to threads 2 Install and tighten fixed end first then install and tighten swivel end 3 Replace all air line brackets and ties In Vehicle Service Procedure 91 e ow z lt y fs a 1 In Vehicle Service Procedure How to Remove a Slave Valve Special Instructions A sudden release of air pressure can injure
132. 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 200 Transmission Overhaul Procedures Bench Service 201 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 the washer flat side up position a gear tolerance wash er white in the mainshaft 1st or bottom groove Rotate the washer until the washer splines and mainshaft splines align Start at the mainshaft bottom and install a 1 8 or 5 32 di ameter 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 Against the 4th speed gear washer position a spacer washer against the tolerance washer With clutching teeth down and engaged with the spacer ex ternal splines position the proper gear on the mainshaft If necessary refer to the illustrated parts list to determine gear order With clutching teeth up and against this gear install the next gear and spacer washer Transmission Overhaul Procedures Bench Service 8 With the washer flat side down position a tolerance washer
133. release tool from kit K 2394 to press the re lease sleeve down while pulling the air line from the fitting 3 Inspect the fitting for damage or wear Remove and replace as necessary In Vehicle Service Procedure How to Install Push To Connect Type Fittings Special Instructions A 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 A 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 dam age to fittings z 1 a 7 i 1 17 Special Tools e 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 tub ing cutter Procedure 1 Check the threads of the fitting for thread sealant If no seal ant is present apply Eaton thread sealant 71205 or equiv alent 2 Install the fitting Inspect the air line for burrs or deformed areas Trim the air line if necessary using a sharp razor blade or the air line cut ting 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 in serted 4 Pushtheair line into the fitting It should insert approximate l
134. rial 3 From the countershaft rear remove the snap ring 153 Transmission Overhaul Procedures Bench Service 4 Usea sort bar and maul to drive the countershaft forward far enough to partially unseat the bearing 5 Useasoft bar and maul to drive the countershaft to the rear This exposes the bearing snap ring 6 Use a bearing puller and remove the countershaft bearing and countershaft 7 Inspect the countershaft bearing inner race remove if nec essary 154 Transmission Overhaul Procedures Bench Service How to Remove the Splitter Cylinder Assembly Special Instructions When removing the splitter cylinder cover insert valve note the direction the insert valve was positioned nipple in or out Auxiliary section must be removed to remove the splitter piston and splitter cylinder Special Tools e Typical service tools N 1 Shift Yoke 2 Lockscrew 3 Gasket 4 Splitter Cylinder 5 O Ring 6 Yoke Bar 7 O Ring 8 Gasket 9 Plug 10 Cover atest pesig D os 7 JE 259 5 lt o gt 2 2 ocam ot 11 Insert Valve 12 Reducer Bushing 13 Capscrew 14 O Ring 16 O Ring 17 O Ring 18 Breather 19 Splitter Valve Kit 21 Capscrew 155 Transmission Overhaul Procedures Bench Service 156 Procedure 1 Drain lube 2 Remove the auxiliary case Use How to remove the Auxiliary sec
135. ring reassembly as rotation of the bar causes the pin to jam in the tension spring bores Install the other 3 4 interlock ball in the rear boss top bore This ball rides between the 1st 2nd and the 3rd 4th speed shift bars Transmission Overhaul Procedures Bench Service 9 While holding notched end of the bar install the 3rd 4th speed shift bar in the housing boss upper bore Position the shift block on the bar between the front and center bosses long hub to the housing rear Install the block and yoke lock screws tighten and lockwire securely 10 For models so equipped install the oil trough on the hous ing Tighten the capscrews and lockwire securely 11 Remove the assembly from the vise Install the three tension balls one in each bore on the housing top 12 Install the three tension springs one over each ball in the housing bores 143 Y 1 a wo ow Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft Assembly without main case disassembly Special Instructions None Special Tools e Tool Information see Table 6 e Item T21 Bearing puller e bar and maul Procedure 1 From the front bearing cover remove the six 6 retaining capscrews and cover Remove any remaining gasket mate rial from the case and cover 29 c c 5 a nv uS 2
136. rom the reverse idler gears to the main shaft 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 4 L m M 3 1 2 L ee Reverse LO 9 13 speed Reverse HI 9 13 speed 1 Sliding Clutch rearward 1 Sliding Clutch rearward 2 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward 3 Sliding Clutch forward 22 Power Flow Auxiliary Section Power Flow Low Range 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 N V 3 Gases LO 9 13 Speed 1 Sliding Clutch forward 2 Sliding Clutch forward 3 Sliding Clutch rearward D mz D D 23 Power Flow Auxiliary Section Power Flow High Range 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
137. rough the rear bearing assembly 2 Fromthe auxiliary housing rear remove the rear bearing re taining capscrews cover and gasket 3 Clean the gasket mounting surface of gasket material 4 Inspect the rear bearing cover oil seal for damage remove if damaged 5 Fromthe auxiliary housing rear remove the bearing cup and spacer Transmission Overhaul Procedures Bench Service 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 Use the output shaft assemble gear front face as a base press the output shaft through the bearing and gear DDR 162 Transmission Overhaul Procedures Bench Service How to Disassemble the Synchronizer Assembly Special Instructions Place the synchronizer 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 10 Synchronizer jNeys9AQ UOISSIUSULIL a x rJ 1 a E ow 1 rJ c 1 rJ Procedure 1 Placethe larger LO range synchronizer ring on the bench 2 Cover the synchronizer with a shop rag to contain the springs 3 Grab bot
138. shaft as sembly LO range gear stamped with the Follow the assembly procedures in the Auxiliary Section Marking the helical auxiliary countershafts Mark any two teeth on the LO range gear Then mark two teeth located di rectly opposite the first marked Prior to placing each auxiliary countershaft assembly into housing mark the tooth on each auxiliary countershaft as sembly LO range gear stamped with the two O s Repeat the procedure on each auxiliary countershaft reduction gear Follow the assembly procedures in the Auxiliary Section Timing 67 In Vehicle Service Procedure 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 2 From the oil filter adapter remove the 5 3 16 allen head capscrews 3 Remove the gasket and clean all mounting surfaces 68 In Vehicle Service Procedure How to Assemble Oil Filter Adapter Special Instructions None Special Tools e Typical service tools Procedure 1 Position the new gasket on the adapter mounting surface with
139. side to clear the pin Do not install and tighten the capscrews to draw the housing down transmission damage will occur 105 In Vehicle Service Procedures 106 10 11 Apply sealer to capscrews and install the capscrews in their specific location Tighten to 35 45 Lb ft Make sure the longer capscrews are used with the lifting eyes Install a new gasket for the shift control Install the shift control Make sure the shift control finger properly enters the shift yoke and block notches Apply sealer to the capscrews and install Tighten to 35 45 Lb ft Connect the wiring for the reverse and neutral switches Connect the small air lines to the previously marked loca tions 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 See Tool Information see Table 5 and 6 e Brass drift Output yoke puller lt 1 2 1 5 7 v o e item T15 Slide hammer 7 6 A 27 1 Bushing 5 Oil Se
140. sket on the bearing cover mounting sur face make sure to align the gasket oil return hole with case oil return hole 12 Position the front bearing cover make sure to align the cov er oil return hole with case oil return hole 13 Secure the front bearing cover with six 6 capscrews torque to 35 45 Ib ft 47 45 61 01 Nem Note Make sure the drive gear is timed with the both coun tershafts Note Make sure the front bearing cover capscrews are tighten properly 220 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 See Tool Information see Table 6 e T7 Flanged end bearing driver e T8 Bearing driver e item T9 Countershaft support tool jNeys9AQ UOISSIUSULIL Procedure Y 1 a 1 3 5 7 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 re maining main drive gear marked teeth 3 Movethe c
141. slave valve remove the air line from the P port should be black line Check for air flow from the disconnected line 2 If the lines are correct replace the shift knob No air flow from the discon Go to step G nected 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 62 Table 15 No or Slow Range Shift into High Continued Air System 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 If desired the slave valve can be actuat ed and tested while unbolted from the transmission case The air lines of course must remain attached PROCEDURE RESULT WHAT TO DO NEXT Step H Place the shift lever in neutral Install a 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 P line Move the range selector back and forth from low to high range The 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
142. smission e Plugged filter e Incorrect regulator pressure e Damaged or defective shift knob master valve e Damaged or defective slave valve e Damaged 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 symp Check for constant air leakage at the shift tom first See beginning of Air System knob slave valve and transmission case Troubleshooting section breather when both low and high range have been selected No constant leak is detected Go to Step B Step B Place shift lever in neutral Air flows from the high range Remove range cylinder cover and re Move range selector down to low range port pair leaking range piston or piston seal position After repair check for proper range op At the transmission rear disconnect the eration 1 4 rubber air line from the range cylin der 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 F air line air line No air flow from disconnect Go to step D ed line 61 Air System
143. 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 If the line is properly attached check that the insert valve old style is properly installed stem facing in ward and that the insert valve bore is not defective 3 Replace the insert valve Repair or replace the shift knob 53 3 3 S E E Air System Procedure 2 Symptom Air Leak at Slave Valve Normal Operation A momentary exhaust of air at the slave valve occurs during a range shift The air from the low 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 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 ex Airis leaking from fitting or airline Repair or replace fitting or air line haust port on the slave valve and not a fitting or air line Air is definitely leaking from slave Go to Step
144. ssembly SP No Air Air from Vehicle Source Air to Cover Port HI 46 Air System RTLO 1X913 HI Range H HI Range H A 4900 Roadranger Valve Slave Valve Identification Up By A 5000 Valve Forward EN n4 i 1 HEP 9 6P a rJ wo 5000 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly SP No Air LO Air from 9 Vehicle Source Air to Cover Port HI 47 General Troubleshooting 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 Complaint 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 par ticular vehicle speed Corrective Action 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 damp ing Transmission bearing or gear failure Noise may be most pronounced under hard pull or coast high torque Check transmission oil for excessive metal particles Noise Growl Rumble at Idl
145. t damage place transmission in the vertical position clutch housing down 2 Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim Clean the gasket surface area 3 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews 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 capscrews that attach the front box to the auxiliary section 5 Install a steel bar through the yoke 6 Attach a lifting chain to the steel bar 7 Lift assembly from the front section Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Countershaft Assemblies w Tapered Bearings 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 150 See Tool Information see Table 6 Vise with brass jaws or wood blocks Item T11 Bearing Puller Soft bar and maul Procedure 1 To hold the auxiliary countershafts from turning place a shop rag or equivalent between the splitter gear and one countershaft From the output shaft loosen the 15 16 capscrew and re tainer Do not remove the capscrew Transmission Overhaul Procedures Bench Service 3 Install c
146. t yoke for vertical removal e Aboist with a lifting chain e Auxiliary countershaft retaining straps Y 1 a ow Procedure 1 Toremove the auxiliary section in the horizontal position Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 2 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap screws are snug 148 Transmission Overhaul Procedures Bench Service 149 3 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary sec tion 4 Insert the two 2 longest capscrews 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 capscrews from the tapped holes 6 Attach an auxiliary section hanger 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 gas ket material Procedure 1 To remove the auxiliary section in the vertical position With blocks under the clutch housing to prevent input shaf
147. taminated area ce 1 rJ a 7 1 Z 17 1 Clean suspected oil weep area with a clean dry cloth or mild soluble degreaser 2 Ensure lube is to proper level 3 Notify the customer that it is only a weep and it is not considered to be detrimental to the life of the transmission 4 Repair is complete 1 Do not repair Rear seal is designed to allow minimal seepage refer to Roadranger TCSM 0912 Seal Maintance Guide 2 Ensure lube is to proper level 1 Determine the origin of the leak path 2 If origin of leak is obvious skip to Step 3 3 If the origin of the oil leak is not obvious then use either of the two following steps to determine the oil leak Note Do not use a high pressure spray washer to clean the area Use of a high pressure spray may force contamination into the area of concern and 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 Step 2 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
148. te 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 3 Remove snap ring if applicable 4 Remove key washer and reverse gear Mark keyway loca tion 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 198 y Z Transmission Overhaul Procedures Bench Service 199 6 T 10 11 12 Remove the offset washer and 1st gear Remove the flat washer and 2nd gear Remove the offset washer and sliding clutch Remove the offset washer and 3rd gear Remove the flat washer Remove the 4th or overdrive gear Remove the offset washer 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 Three 3
149. tershafts 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 in stalled Be sure the countershaft rear bearing races are seat ed in the bearing bores 4 Install two 2 clean 3 8 1 capscrews without washers di rectly across from each other in each bearing cover Tapped 250 Transmission Overhaul Procedures Bench Service holes in auxiliary case must be free of thread adhesive 5 Evenly torque the capscrews 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 capscrews If the capscrews aretootight the bearing cover will become distorted 6 Rotate the output shaft 4 times clockwise and 4 times coun terclockwise The rotation will seat and align the rollers in each tapered bearing Re torque the capscrews to 7 Ib in 0 79 Nem If the countershafts do not rotate the range slid ing clutch or deep reduction sliding clutch is in neutral Ap ply shop compressed air to shift cylinders to shift the sliding clutches into gear 7 Use a feeler gauge as close to each capscrew location as possible and measure the gap between the countershaft rear bearing cover and the auxili
150. the dowel pin holes in the aux iliary section housing and lightly grease the dowel pins on the main case and the dowel pin holes on the auxiliary sec tion housing 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 Position the gasket onto the main case mounting surface Mount the auxiliary section on the lifting device or jack Tighten the center capscrew on the countershaft support tools to draw the countershafts into a level position Do not overtighten the capscrews The output yoke and shaft must be able to rotate Position the auxiliary section in line with the main case and slide the housing onto the dowel pins Mesh the counter shafts with the auxiliary drive gear Rotate the output yoke and shaft slightly to help the gears mesh and slide the auxil iary section forward until it is flush with the main section A CAUTION The auxiliary section should slide into place fairly easily DO NOT force it on or pull it into place with the capscrews Excessive force may damage the transmission If exces sive force is necessary the gearing is likely out of time If the auxiliary section does not install fully slide it back and check the following a Theoutput yoke and nut should be installed to pull back and center the auxiliary mainshaft assembly
151. 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 A IMPORTANT Use the following air system troubleshooting procedures for part replacement only if the symptom can duplicated If the problem is intermittent parts that are not defective could be replaced Instructions 1 Start at Procedures for Step A 2 Based on the Result of the procedure go to the corresponding What To Do Next 51 3 5 Air System Procedure 1 Symptom Air Leak at Shift Knob Normal Operation 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 A burst of air 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 Possible Causes e Incorrectly attached air lines e Internal leak in slave valve e 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 fitting or air line Check for leaking fitting at the shift kno
152. the num ber 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 Model Designations and Specifications Model Options Torque Rating The torque rating of the transmission specified in the model number is the input torque capacity inLbeft Various torque ratings are available For more information call your Eaton Fuller 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 Power Take Off PTO Usage PTOs can be mounted in the 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
153. til the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft Insert two large screwdrivers between the two gears Apply slight downward pressure to spread the gears evenly Be tween the gear hub and mainshaft spacer insert 0 006 feel er gauge and 0 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer Refer to informa tion before stepped procedures for further information 21 22 23 24 25 26 27 28 Transmission Overhaul Procedures Bench Service 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 At this 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 s
154. tion procedure 3 Remove wire from splitter yoke retaining bolt and remove bolt 4 From the splitter cylinder cover remove the retaining cap Screws 5 Remove the cover and gasket or O ring new design alumi num cover 6 Remove the splitter cylinder from the housing 7 From the auxiliary rear remove the splitter cylinder housing 8 If necessary turn out the insert valve retaining nut and re move insert valve from bore only present on 13 Speed 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 capscrew and re tainer bolt 2 From the output shaft remove the splitter gear 157 Y 1 a wo ow Transmission Overhaul Procedures Bench Service How to Disassemble the Range Cylinder Assembly Special Instructions None Special Tools e Typical service tools 1 Yoke Bar 2 Gasket 3 Range Cylinder Assembly 4 O Ring 5 Piston 6 O Ring 7 O Ring 158 8 Nut 9 Gasket 10 Cover 11 Capscrew Transmission Overhaul Procedures Bench Service Procedure 1 From the range cylinder cover remove the capscrews cov er and gasket 2 Clean the gasket mounting surfaces of all gasket material 3 From the range cylinder h
155. to Assemble the Integral Oil Pump with Auxiliary Oil UDG oett ertet een ets 244 How to Install the Auxiliary Section with Tapered Bearings 248 Shim Procedure without a Shim Tool for Tapered Bear IS tet i tra ete 250 Table of Contents Table of Contents Introduction Transmission Overview Air System Roadranger Valve Shift Bar Housing Levers Housings amp Isolators Auxiliary Section Range Cylinder Shift Bar Housing Shiftbar Housing Assembly 7_ U Front Section Reverse Idler e x wes ALES a V Au SN 22 FN Auxiliary Section Auxiliary Countershaft Air System Air Filter Regulator Front Section Clutch Housing Case Assembly Auxiliary Section Auxiliary Drive Gear Front Section Mainshaft Ly p ey aes Auxiliary Section OIE e Reduction Cylinder Front Section Input Shaft Drive Gear i g Front Section Countershafts amp Air System Slave Valve 106004 8 94 15 spd trans Introduction 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 Proce dures Bench Service In Vehicle Service Procedures contain procedures that can be performed while the tr
156. to the main drive gear internal spline teeth This is normal 3 Install the snap ring in the main drive gear inside groove 4 Install the spacer washer over the input shaft With the bear ing external snap ring to the outside position the bearing on the input shaft 146 Transmission Overhaul Procedures Bench Service 5 Install the input shaft bearing 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 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 147 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Section with Tapered Bearings Special Instructions There can be different capscrew 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 tem T2 Auxiliary section hanger bracket for horizontal removal e Asteel bar longer than the width of the outpu
157. ul Procedures 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 with brass jaws or wood blocks Procedure 1 Install the valve cover n a D wo e 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 re tention roll pin into the roll pin bore 244 Transmission Overhaul Procedures Bench Service 245 5 Install the ball spring and retaining nut 6 Torque the retaining nut to 40 45 Ib ft 54 23 61 01 Nem 7 lf removed replace the drive shaft snap ring on the pump drive shaft 8 Insert the drive shaft through the pump housing bore 9 Install the two 2 keys on the drive shaft 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 14 Align drive gear keyway with drive shaft key and install the drive g
158. ump 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 O 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 PTO 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 coun tershaft if necessary 3 Place the upper countershaft with the 45 tooth PTO gear into the main case with the shaft seated in the upper coun tershaft case bores 214 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 See Tool Information see Table 6 T7 Flanged end bearing driver e tem T8 Bearing driver e T9 Countershaft support tool Procedure 1 M
159. ur face If previously removed using the proper driver and maul install the countershaft bearing race 2 In the countershaft rear bearing bore using the proper driv er and maul install the countershaft bearing 178 Transmission Overhaul Procedures Bench Service 3 Temporarily install the rear bearing cover use two 2 cap screws and no gasket The cover holds the bearing as the countershaft is driven into the bearing 4 Use toolmaker s dye and mark the smaller LO range gear tooth that aligns with countershaft gear marked with an O 5 Position the countershaft in the auxiliary housing Mesh the countershaft marked tooth with either set of LO range gear marked teeth 6 Usea sort bar and maul and drive the countershaft into the countershaft bearing 179 Transmission Overhaul Procedures Bench Service 7 From the auxiliary housing rear remove the countershaft bearing cover and install the rear countershaft snap ring in the snap ring groove 8 Position a new gasket on the countershaft bearing cover mounting surface 9 Position the countershaft bearing cover over the gasket 10 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 11 Install the capscrews tighten to 35 45 Ib ft of torque 12 Repeat all steps for other countershaft installation Final Check e Check both countershafts for timing the output shaft should rotate
160. urved end of the selection le ver 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 capscrews 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 back ward neutral position of the gear shift lever in the cab Tighten one turnbuckle D capscrew see figure A Move the gear shift lever to the desired position Turn the second turnbuckle D capscrew Check for linkage obstructions in all gear positions In Vehicle Service Procedure Selection Lever L H Thread R H Thread 4 Shift Arm 5 Parallel Figure C 7 lt D 2 GJ N D Er a e 97 In Vehicle Service Procedure 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 98 Typical service tools Volt Ohm meter Procedure Disconnect the wiring from the switch Connect an ohm meter to check for continuity or a small reading Place
161. ve 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 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 capscrews The 1 1 2 capscrews 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 capscrew 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 UOISSIUSULIL 1 From the shift bar housing remove the two shift bar retain ing capscrews securing the oil cooler Remove oil cooler and set aside v a ow x wo 2 Remove slave valve 133 Transmission Overhaul Procedures Bench Service 134 3 Remove interlock parts pin spring and sleeve 4 From the 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
162. ve the capscrews from around the shift bar housing top Note location of the lifting eyes longer capscrews and any studs 5 f necessary use a hammer to break the gasket seal Lift the shift bar housing from the transmission top 104 In Vehicle Service Procedures How to Install the Shift Bar Housing Special Instructions None Special Tools e Typical service tools Procedure 1 Make sure the gasket surfaces are clean and free of burrs or other damage 2 Usea gasket adhesive to attach the shift bar housing gasket to the flange surface on the shift bar housing bottom 3 Make sure the sliding clutches in the transmission are cen tered in the neutral position 1 v 1 a 1 4 Position the shift yokes in the neutral position and carefully lower the shift bar housing onto the transmission top Make sure the shift yokes fit into the corresponding sliding clutch es slots 5 Just before the shift bar housing contacts the main case flange surface it is necessary to move the shift bar housing slightly away from the slave valve to clear the slave valve plunger pin Once the housing is flush with the main case it can be repositioned to line up the capscrew holes Note Make sure the shift bar housing sits flush on the main case flange surface If a gap is present the shift bar housing may be caught on the slave valve plunger pin Slide the shift bar housing to the
163. w gear shift lever shift control housing gasket on the gear shift lever mounting surface 3 Install the detent springs 4 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 1 5 Apply Eaton sealant 71205 or equivalent to the retaining capscrews 2 6 Install the retaining capscrews torque to 35 45 Ib ft 47 45 61 01 Nem 3 Note Make sure the capscrews are properly torqued Note Make sure you can shift the transmission Hong Capscrew 3 Gasket 95 gt c c N e rJ o rJ In Vehicle Service Procedure 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 the OEM Chassis Service Manual be consulted first Special Tools e Typical service tools Figure A 1 Reach Rod 5 Shift Arm 2 Turnbuckle 6 Pivot Link Assembly 3 Selection Lever 7 Inner Shift Shaft 4 Inner Shift Finger Figure B 1 Selection Lever 2 Shift Arm 96 7 Procedure 1 5 Move the gear shift lever forward or backward to the neutral position 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 a
164. washer against the gear Rotate the washer until the washer splines and mainshaft splines align 207 Transmission Overhaul Procedures Bench Service 15 With clutching teeth up install next 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 main shaft splines align 17 Push the air line up to lock the washer on the mainshaft 18 With the missing internal splines aligned with the plastic line install the reverse sliding clutch 19 Install the reverse gear offset washer in the last groove 20 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 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 22 From the rear install the reverse gear over the sliding clutch teeth 23 nstall the snap ring in the mainshaft groove Note Some models do not use a snap ring at this position 24 Remove the mainshaft from the vise and lay on its side 25 Install the front sliding clutch into position 208 Transmission Overhaul Procedures Bench Service How to
165. y 3 4 If it does not insert far enough or is difficult to insert the fitting may be damaged and should be replaced After in serting give the air line a slight tug to make sure the line stays in place If line does not stay in place replace the fit ting 5 Enable the vehicle air system Allow the air tanks to pressur ize and check for leaks 85 In Vehicle Service Procedure How to Remove 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 Procedure 1 Remove all air line brackets and ties 2 Remove swivel end 3 Remove fixed end 86 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 Disconnect and remove the 1 4 1 0 air line between the splitter cylinder and air filter regulator ce 1 E rJ a 1 2 17 2 Disconnect and remove the 1 4 1 0 air hoses between the slave valve and both the air filter regulator and range cylin der assembly 3 Turn out the two capscrews and remove the air filter regula tor assembly 87 In Vehicle Service Procedures How to Install the Air Filter Regulator Special Instructions The air filter regulator has two 2 O rings loc
166. y 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 tooth is stamped with an O to aid identification Figure 2 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 v 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 in Figure 3 stalled to complete installation of the countershaft assem blies 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 66 Procedure Auxiliary Section 1 Marking the standard auxiliary countershafts Mark any two teeth on the LO range gear Then mark two teeth located directly opposite the first marked Prior to placing each auxiliary countershaft assembly into housing mark the tooth on each auxiliary counter
167. yb ars to remove the lower front bearing from its bore 7 Move the upper countershaft to the rear until the front bear ing journal clears the front case bore 8 Swing the front of the countershaft to the center of the case and lift out the countershaft assembly Note A large hook or piece of rope may help support the countershaft Note Follow the same procedure for lower countershaft re moval 29 c 5 a nv a 259 lt ae 2 2 2 191 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 left and right countershaft assemblies are identical and disassembled in the same manner Special Tools e See Tool Information see Table 6 e Snap ring pliers e Press 10364 11 96 CS RT 1 Snap Ring 8 Gear 2 Bearing 9 Gear 3 Countershaft with Re 10 PTO Gear verse and LO 11 Drive Gear 4 Key 12 Snap Ring 5 Roll Pin 13 Bearing 6 Key 14 Retainer Kit 7 Gear 15 Capscrew 192 Transmission Overhaul Procedures Bench Service Procedure A CAUTION NEVER USE THE PTO GEAR AS A PRESSING BASE The narrow face width of this gear makes it very susceptible to breakage 1 Remove the front countershaft snap ring

Fuller Heavy Duty Transmissions TRSM0446

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