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Fuller Heavy Duty Transmissions TRSM0430

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1. Range Cylinder Assembly Air Filter Regulator oplitter Cylinder Assembly Assembly Air from Vehicle Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature RT amp RTOO XX613 and XX813 Models Range HI Splitter Underdrive or Overdrive Slave Valve Identification A 3546 Range Valve A 4900 Roadranger Selector Valve Valve U D O D A 4688 Valve ON LO A 5000 Valve O 19470 Valve H 121 ea 19470 or A 5000 Slave Valve A 4688 Slave Valve H L Range Cylinder Assembly Air Filter Regulator oplitter Cylinder Assembly Assembly Air from Vehicle Source Air to Cover Port DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS AIR SYSTEM ROADRANGER VALVE SHEATHING jj O RING A 5010 2 PORT GEAR SHIFT CONNECTORS toj NES LEVER HOUSING BAR HOUSING jf RANGE CYLINDER ROADRANGER AIR LINES e a i me VALVE A 5015 4 PORT CONNECTORS A 4900 4 PORT AIR FILTER loi ae RANGE VALVE A 3546 2 PORT CONNECTORS
2. Air Filter Regulator Assembly Deep Reduction Valve Air from CO pur 9 Vehicle Source x o Reduction Cylinder Assembly Constant Air Range Cylinder Assembly Air to Housing Port RT RTO amp RTX XX607LL XX608LL and XX615 Models Range LO Slave Valve Identification A 3546 Range A 5010 Roadranger Valve Valve A 4688 Valve ON Q3 Down zee A 5000 Valve O Outlet 19470 Valve 19470 5000 Slave Valve Schematic For all questions concerning removal and replacement refer to Eaton Air to Service and Parts S ia Housing Literature Port Air Filter Regulator Deep Reduction Valve Range Cylinder Assembly Assembly Q neue lt SHIFT ONLY WHEN IN LOW T range N Air from CO pur CO R y ource Reduction Cylinder Assembly 5 4 222 Constant Air Schematic For all questions concerning removal and replacement refer to Eaton service and Parts Literature
3. Fuller Heavy Duty Transmissions TRSM0430 July 2010 RT 8608L RTF 8608L RTO 11608LL RTO 14608LL RTOF 11608LL RTOF 14608LL RTX 11608LL RTX 11609A RTX 11609B RTX 11609P RTX 11609R RTX 12609A RTX 12609B RTX 12609P RTX 12609R RTX 13609A RTX 13609B RTX 13609P ETN RTX 13609R RTX 14608LL RTX 14609A RTX 14609B RTX 14609P RTX 14609R RTXF 11608LL RTXF 11609A RTXF 11609B RTXF 11609P RTXF 11609R RTXF 12609A RTXF 12609B RTXF 12609P RTXF 12609R RTXF 13609A RTXF 13609B RTXF 13609P Powering Business Worldwide RTXF 13609R RTXF 14608LL RTXF 14609A RTXF 14609B RTXF 14609P RIXF 14609R BACKED BY Roadranger SUPPORT TABLE OF CONTENTS FOREWORD MODEL DESIGNATIONS AND SPECIFICATIONS LUBRICATION OPERATION 8 SPEED LL MODELS 9 SPEED AND 8608L MODEL 13 SPEED MODELS POWER FLOW TIMING TORQUE RECOMMENDATIONS TOOL REFERENCE PREVENTIVE MAINTENANCE PRECAUTIONS DISASSEMBLY INSPECTION REASSEMBLY CHANGING INPUT SHAFT AIR SYSTEM RANGE SHIFT SYSTEM DEEP REDUCTION AIR SYSTEM 8 SPEED LL MODELS SPLITTER SHIFT AIR SYSTEM 13 SPEED MODELS AIR SYSTEM SCHEMATICS DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS AIR SYSTEM GEAR SHIFT LEVER HOUSING ASSEMBLY SHIFT BAR HOUSING ASSEMBLY REMOVALDCOMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING DISASSEMBLYDAUXILIARY SECTION 8 SPEED LL MODELS REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS DISASSEMBLYDAUXILIARY SECTION 9 SPEED MODELS AND
4. 11 f i bl uds Em 8 Using the front face of deep reduction gear as base press the output shaft through the bearing and gear This will free the bearing gear washer and for models so equipped the spacer or oil re tention ring DO NOT DAMAGE MAINSHAFT REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS AUXILIARY SECTION 8 SPEED LL A Reassembly and Installation of Range Mainshaft Assembly 3 Install the bearings in front bore of range main shaft Use a small flanged end driver to properly 1 Secure the output shaft in a vise with mainshaft seat bearing in bore on mainshaft quill quill up 4 Install the C ring in groove of mainshaft quill to retain bearing 2 If necessary press the bushing in rear bore of range mainshaft inset and install the mainshaft in position on quill REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS B Reassembly and Installation of Output Shaft and Rear Bearing Assemblies 3 IMPORTANT Mark any two adjacent teeth on deep reduction gear and repeat the procedure for the two adjacent teeth directly opposite the first set marked A highly visible color of toolmakersO dye is recommended for making timing marks 1 Remount the output shaft in vise with threaded end up and secure on range mainshaft For models so equipped install the stepped washer on shaft large diameter step down 2 Ins
5. WASHER WASHER SPACER MAINSHAFT WASHER SLIDING CLUTCH WASHER Cut 6324B 4 84 E Removal and Disassembly of Mainshaft Assembly 2 Remove the 3rd 4th speed sliding clutch from front of mainshaft 1 Block the right countershaft assembly against case wall and pull the mainshaft assembly to the rear to free pilot from pocket of input shaft Tilt front of mainshaft up and lift the assembly from case inset Use caution as the reverse gear is free and can fall from shaft DISASSEMBLY FRONT SECTION 3 Remove the snap ring from groove at rear of mainshaft 5 From rear of mainshaft pull the key from main shaft keyway NOTE When removing limit washers spacers and gears note their location on mainshaft to fa cilitate reassembly Keep the internal splined washers and external splined spacers with the gear from which they were removed There is ONLY one limit washer and one spacer belonging to each gear 4 Remove the reverse gear and spacer from rear of mainshaft 6 Turn the reverse gear limit washer to align its splines with those of mainshaft and remove washer DISASSEMBLY FRONT SECTION 7 Remove the LO Reverse speed sliding clutch from mainshaft 9 Pull the LO speed gear from rear of mainshaft to remove limit washer spacer and gear If neces sary remove the snap ring from I D of gear in set 10 Remove each remaining gear limit washer spacer and sliding clu
6. LOW LIMIT WASHER 380 SPEED OR OVERDRIVE 2ND SPEED LOW LIMIT WASHER 157 SPEED LO SPEED 5 te Ze ATEM Ms nem 1 AED REVERSE Cut 6324C 4 84 FRONT SECTION REASSEMBLY 14 Install the LO speed gear on shaft against 1st speed gear clutching teeth up 13 Install the 1st speed gear on mainshaft clutching teeth down and engaged with external splines of 15 Install the spacer in LO speed gear engaging the spacer external splines of spacer with clutching teeth of gear REASSEMBLY FRONT SECTION 17 Check axial clearance and make adjustments if necessary between the LO and 1st speed gears as described 16 Remove the key from keyway and install the LO speed gear limit washer on mainshaft flat side of washer down and against spacer Rotate washer in the 4th groove of mainshaft to align the splines of washer with those of the mainshaft and rein sert key in keyway to lock washer in place inset REASSEMBLY FRONT SECTION ATH nm Lg P T 18 Install the LO Reverse speed sliding clutch align 20 Install the spacer on shaft against washer ing the missing internal spline of sliding clutch with key in mainshaft 19 Remove the key from keyway and install the re E m verse gear limit washer on mainshaft flat side of washer up Rotate washer in the sth groove of 21 Install the snap ring in 6th groove of
7. RT RTO amp RTX XX607LL XX608LL and XX615 Models Range HI A 3546 Range A 5010 Roadranger Valve Valve Outlet N P S 19470 or A 5000 Slave Valve A 4688 Slave Valve Slave Valve Identification A 4688 Valve ON AQ A 5000 Valve O 19470 Valve Air Filter Regulator Assembly Deep Reduction Valve Air from CO pouor 9 Vehicle Source Reduction Cylinder Assembly NN Constant Air LLL Range Cylinder Assembly TL 8 9 and 10 Speed 2 Speed Auxiliary Range LO A 3546 Range A 5010 Roadranger Slave Valve Valve Valve Identification Down Al Outlet N P 5 A 4688 Valve HEA D L z A9 A 5000 Valve 19470 Valve fo 7 10 C o _ 19470 or A 5000 Slave Valve Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature Air Filter Regulator Range Cylinder Assembly Assembly Air from Vehicle Source Constant Air Schematic For all questions concerning removal and replacement refer to Eaton
8. 6 If previously removed install the insert valve in bottom bore of cylinder cover flat end to the in side left Install the valve retaining nut in ex haust port of cover and tighten to recommended torque ratings right NOTE Prior to installation of insert valve make sure the three O rings on valve O D are not defec tive Replace if necessary 1 Install the snap ring in groove of range mainshaft inset Install the coupler on range mainshaft against snap ring clutching teeth to the rear REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 2 Spread the countershaft assemblies with splitter 4 Install the key keyway of range mainshaft in gear set remaining in time and install the low serting the thick end of key in keyway of toler range gear on shaft against coupler clutching ance washer to lock low range gear on shaft teeth to the front NOTE To spread countershaft far enough to in F Reassembly and Installation of stall low range gear move the splitter clutch to the forward position Synchronizer Assembly 1 Place the larger low range synchronizer ring on l bench and install the sliding clutch on blocker 3 Install the splined tolerance washer on mainshaft pins recessed side up and in hub of low range gear Rotate the washer in groove of mainshaft to engage external splines with clutching teeth of gear and align the keyway of washer with keyway of mainshaft IMPORTANT This
9. 1 Mark any two adjacent teeth on the mainshaft gear of set to be timed Then mark the two ad jacent teeth located directly opposite the first set marked as shown in lllustration B 2 Prior to placing each auxiliary countershaft as sembly into housing mark the tooth stamped with an O on gear to mate with timed main shaft gear as shown in Illustration A 3 Install the mainshaft gear in position on range mainshaft OR output shaft 4 Place the auxiliary countershaft assemblies into position and mesh the marked teeth of mating countershaft gears with the marked teeth of mainshaft gear as shown in Illustration C 9 Fully seat the rear bearings on each counter shaft to complete installation TORQUE RECOMMENDATIONS Correct torque application is extremely important to assure long transmission life and dependable performance Over tightening or under tightening can result a loose installation and in many instance eventually cause damage to transmission gears shafts and or bearings Use a torque wrench whenever possible to attain recommended lbs ft ratings Tighten clutch housing fasteners in a cross pattern to help insure even clamp distribution FRONT SECTION ALL MODELS 1 MAIN DRIVE GEAR BEARING NUT 1 NEUTRAL SIGNAL SWITCH PLUG bere Apoplate D LTT Sete mede 5 SHIFT BLOCK AND YOKE LOCKSCREWS 6 FRONT BEARING COVER CAPSCREWS 35 45 Lbs Ft 7116 20 Threads Secure 35 45 Lbs Ft
10. 3 Install the retaining capscrews in housing flange and tighten to secure the assembly to shift bar housing 1 Check the shift bar housing assembly to make sure shift block and yoke notches are aligned in the neutral position 2 Install the new gear shift lever housing gasket in position on shift bar housing and install the gear shift lever housing assembly on shift bar hous ing fitting the lever into shift bar and yoke notches INSTALLATION SHIFTING CONTROLS AIR SYSTEM A Installation of Slave Valve 3 Install the hat type alignment sleeve in bore of slave valve 1 If previously removed install the air line fittings on slave valve 4 Position the corresponding new gasket on valve mounting surface and install the slave valve on case inserting the end of actuating pin into align ment sleeve Secure the valve to case with four 2 Install the spring on shank of actuating pin and retaining capscrews tightened evenly insert in bore of transmission case B Installation of Air Lines See Air System Schematics on pages 40 47 Tapered Roller Bearing Shimming Procedure Note The auxiliary section may be shimmed in either the vertical or horizontal position Vertical shimming is performed with the transmission removed from the truck while horizontal shimming takes place with the transmission still in the truck Before installing the auxiliary section install countershaft straps on each cou
11. E B 5 Install the washer on shaft 11609 12609 models if flat side of washer facing up 14609 models flat T Install the bearing inner spacer on output shaft side of washer facing down e i b 4 8 Install the front bearing cup in bore of auxiliary plate taper to the inside Use a soft bar to start 6 Heat the front bearing cone and install on shaft cup into bore against washer bearing taper up NOTE DO NOT HEAT BEARING ABOVE 2759F 136 C If possible use heat lamps as source REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS pix Install the auxiliary plate over end of output shaft assembly Heat the rear bearing cone and install on shaft taper down and inside bearing cup NOTE DO NOT HEAT BEARING ABOVE 275 F 136 C 11 9 Place the bearing outer spacer against cup and use a soft bar or flanged end driver to move both parts evenly into bore eT ll 12 If previously removed install the oil seal in rear bearing cover with a flanged driver inset Seal should be installed so the spring is to the front of transmission 10 Place the rear bearing cup against spacer Use a flanged end driver to move all three parts evenly into bore until lip of rear bearing cup seats on auxiliary plate REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 13 Remount the assembly upright in vise and secure 2 Install the three spr
12. If previously removed in stall the O ring in tower groove F E mea lt gt a l zi r y i 4 Remove the spade pin from bore in housing tower If necessary remove the O ring from groove inside tower 2 Position the gear shift lever in housing with spade pin in lever ball slot and install the tension spring washer over ball dished side up DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 3 Install the tension spring under lugs in housing 4 Remove the assembly from vise and install the seating one coil at a time Use of a spring driving rubber boot over gear shift lever and against tool is recommended housing DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS SHIFT BAR HOUSING ASSEMBLY m plug STEELBALL SPRING LOCKWASHER M GASKET E COVER o GASKET EE PIPE PLUG ag E m CAPSCREW _ MU RIT V A35 Qm BREATHER REDUCER d PIPE FLUG SHIFT BAR HOUSING X GASKET LIFTING EYE b l7 ae PIPE PL pp S de REDUCEH Am VEM us sg wet yrs AIA VALVE mant SHAFT GASKET NOTE Use Lockwire al Miel positions during reassembly 52001 1 009 Removal and Disassembly NOTE For models equipped with an Oil Pump and or Cooler Assemblies make sure to discon nect the lube line at fitting on shift bar housing prior to proceeding with the following instruc tions 1 Turn out the retaining capscrews j
13. Leak at gasket B results in a steady flow of air to atmosphere while in HIGH RANGE C Leak at O ring C results in a slow shift to LOW RANGE pressurizing of transmission case HOUSING LOW RANGE AIR PORT IS Wo SS HIGH lt lt RANGE 8 AIR PORT r COVER SS d nsn 2 ik PISTON A NS Cut 7420 4 84 Range Cylinder Assembly All Models AIR SYSTEM AIR FILTER REGULATOR ASSEMBLY END CAP PLUG FILTER ELEMENT HOUSING AIR REGULATOR Cut 6141 3 86 The air filter contains a replaceable filter element which can be removed by turning out the end cap This ele ment should be cleaned at each oil change or more often under high humidity conditions Replace if necessary SLAVE VALVES PISTON TYPE PISTON TYPE POPPET TYPE SLAVE VALVE PLUNGER PIN ASSEMBLY SLEEVE SPRING PLUNGER PIN GASKET GASKET HOUSING SPRING O RING PLUG CAP SPRING 2 C PSCREWS S CAP SLAVE VALVE cAPscREw GASKET ASSEMBLY RING PISTON Cut 6160C 4 84 Cut 6162A 12 84 Cut 6090G 8 84 Refer to the drawing for disassembly and reassembly of the piston type slave valve assemblies Should the pop pet 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 installation
14. PISTON CONSTANT AIR HOUSING From Air Filter Regulator Cut 7441 4 84 REDUCTION CYLINDER ASSEMBLY Models equipped with Master Control A 5015 ONLY 4 Insert Valve See page 37 Any constant flow of air from exhaust port of cyl inder cover usually indicates a faulty insert valve Exhaust should occur ONLY BRIEFLY when Deep Reduction Button is moved FORWARD WHILE IN LOW RANGE A faulty insert valve leaking at the O rings of valve O D or from inner seals will result in shift failure Two indications of defective O rings or seals are A CONSTANT AIR flowing from exhaust port of cylinder cover B CONSTANT AIR flowing from exhaust port E of control valve WHILE DEEP REDUC TION BUTTON IS REARWARD providing the control valve is operating properly The three O rings in position on valve O D can be replaced However if an inner seal is damaged the complete assembly MUST be replaced AIR SYSTEM ROADRANGER VALVE A 5015 HOUSING SPRING RETAINER LEVER MEDALLION ACTUATOR pec DETENT 5 32 BALL SPRING RING F HOUSING NOTE This valve provides BOTH range deep s Ns reduction selection replacing the need for separate units Range Control Valve A 3546 or Roadranger Valve A 5010 with dash mounted Deep Reduction Valve Cut 6147A 11 83 Removal and Disassembly 1 Remove two screws holding bottom cover to valve and slide cover down gearshift lever t
15. Removal of Countershaft Bearings NOTE In the following instructions the front and rear bearings from BOTH countershaft are re moved For removal of the mainshaft assembly from case it is necessary to remove the bearings from right countershaft ONLY 2 From inside the case use a soft punch and maul to drive the countershaft rear bearings to the rear and from case bores NOTE This procedure will damage the bearings and should not be attempted unless replacement of the bearings is planned 1 Remove the snap ring from groove at rear of each countershaft DISASSEMBLY FRONT SECTION 3 Turn out the capscrew and remove the front 5 From the rear of case use a soft bar and maul to bearing retainer plate from each countershaft drive each countershaft forward to unseat the front bearings from case bores and expose the bearing snap rings 4 Use a soft bar and maul to drive each counter shaft to the rear as far as possible This will par E 2 tially unseat the front bearings 6 Use a bearing puller or pry bars to remove the NOTE The soft bar used should have a flattened countershaft front bearings end that is large enough so as not to damage NOTE The bearing inner race of models holes for roll pin and capscrew equipped with roller type front bearings will re main pressed on countershaft DISASSEMBLY FRONT SECTION SLIDING CLUTCH REVERSE SLIDING ROLL PIN CLUTCH SPACER HASHES SPACER
16. preventing damage to balls rollers and races while maintaining correct bearing align ment with bore and shaft Avoid using a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races See TOOL REFERENCE UNIVERSAL JOINT COMPANION FLANGE OR YOKE Pull the companion flange or yoke tightly into place with the output shaft nut using 450 500 foot pounds of torque Make sure the speedome ter drive gear or a replacement spacer of the same width has been installed Failure to pull the com panion flange or yoke tightly into place will permit the output shaft to move axially with resultant damage to the rear bearing IMPORTANT REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST SPECI FIED BY MODEL SERIES TO ENSURE THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION CHANGING INPUT SHAFT Special Procedure In some cases it may become necessary to replace the input shaft due to excessive clutch wear on the splines Except for removal of the shift bar housing assembly the input shaft can be removed without further disas sembly of the transmission Removal of the clutch housing is optional NOTE The following illustration and instructions pertain to changing the input shaft ONLY To change the main drive gear disassembly of the front section is required SNAP RING SNAP RING GASKET OIL BEARING SLEEVE FRONT BEARING COVER PUSH TYPE FRONT BEARING COVER PULL
17. turn out the insert valve retaining nut of covers so equipped and remove insert valve from bore F EE E i F k i 1 E a 1 Turn out the capscrews and remove the deep re duction cylinder cover and gasket DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS F Removal and Disassembly of Range Mainshaft Assembly NOTE Refer to the illustration provided at Part D of this section 3 Cut lockwire and remove the lockscrew from shift yoke dam 1 Remove snap ring from range mainshaft 4 Pull the yoke bar from cylinder housing and re move shift yoke If necessary remove the O ring from piston O D inset 2 Remove deep reduction sliding clutch Y 5 22 4 5 Remove the deep reduction cylinder housing and gasket from auxiliary housing If necessary re move the small O ring from bore in cylinder hous ing DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 5 Remove the front bearing from bore in range mainshaft If necessary press the bushing from mainshaft bore inset 3 Remove the C ring from groove at front of main shaft quill 4 Insert jaws of puller behind range mainshaft and pull from quill DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS PLUG ELECTRONIC SPEEDO PLUG ELECTRONIC SPEEDO CAPSCREW MIT PLUG OPTIONAL F HOSE CLAMP MECHANICAL CAPSCREW BEARING SOM OIL SEAL SPACER SPEEDO A
18. 1 1 Fa 4 Remove the hat type alignment sleeve from bore in slave valve DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS a eee A Removal and Disassembly LEVER GRIP CAPSCREW BOOT LU 100 NUT SPADE PIN O RING Lock 1 Turn out the four retaining capscrews jar lightly WASHER to break gasket seal and remove the gear shift lever housing and gasket from shift bar housing NOTE Remote control housings are removed from shift bar housing in the same manner For disassembly and reassembly of LRC Assemblies see Illustrated Parts List No P 541 For disas STUD sembly and reassembly of SRC Assemblies see Illustrated Parts List No P 515 I n HOUSING GASKET ae LEVER j 2 Remove the boot from gear shift lever and secure assembly in vise with bottom of housing up Use a large screwdriver to twist between the spring and housing forcing the spring from under the lugs in housing Do one coil at a time Cut 7288A 11 84 Sa M DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS B Reassembly of Gear Shift Lever Housing Assembly bu e rl i ie L F E j E A 3 Remove the tension spring washer and gear shift lever from housing 1 With the gear shift lever housing secured in vise as during disassembly install the spade pin in bore of housing tower
19. 130 7 81 C Removal and Disassembly of Synchronizer Assembly 3 Remove the sliding clutch from pins of low range synchronizer ring 1 Pull the synchronizer assembly from the splines of range mainshaft 2 Place the larger low range synchronizer ring on bench and pull the high range synchronizer from blocker pins However before doing so cover the assembly with a shop rag to prevent losing the three springs released from high range synchroni zer at pin locations DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS SNAP RING s xz WASHER WASHER BEARING COUPLER WASHER Cut 6590A 4 84 x Ma ss 2 Turn the washer located in the hub at low range gear so that the splines of washer align with the 1 Remove the key from keyway of range splines of mainshaft DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 3 Pull the low range gear and washer from splines 4 Remove the coupler from splines of range main of range mainshaft shaft NOTE If desired Removal and Disassembly of Range Mainshaft Assembly may be performed prior to Removal and Disassembly of Deep Re duction Cylinder Assembly DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS AUXILIARY 2 CYLINDER YOKE BAR AND PISTON GASKET Note Use lock wire at Cut 6443 12 83 this position E Removal and Disassembly of Deep Reduction Cylinder Assembly 2 If necessary
20. A CONSTANT AIR flowing from exhaust port of cylinder cover B CONSTANT AIR flowing from Exhaust Port E of control valve WHILE SPLITTER CON TROL BUTTON IS REARWARD providing the control valve is operating properly The three O rings in position on valve O D can be replaced However if an inner seal is damaged the complete assembly MUST be replaced C COVER NS Air ONLY when Splitter Control Button is FORWARD AND PISTON CONSTANT AIR SPLITTER CYLINDER ASSEMBLY 13 Speed Splitter Models ONLY AIR SYSTEM INSERT VALVE 8 SPEED LL MODELS EQUIPPED WITH ROADRANGER VALVE A 5015 AND 13 SPEED SPLITTER MODELS The insert valve is a self contained 1 3 16 valve as sembly located in the reduction or splitter cylinder cover It CANNOT be disassembled except for the three O rings on outer diameter The O rings provide a stationary seal and do not move in cylinder COVER QUU m E di MSS NS CENTER PORT SIGNAL LINE FROM CONTROL VALVE SP PORT ISSN SHIA AB INSERT VALVE N RETAINING NUT BOTTOM EXHAUST PORT Cut 7450 4 84 LOW RANGE AND HIGH RANGE OR DIRECT NO AIR ON SIGNAL LINE AIR TO BACK SIDE OF PISTON YOKE BAR FORWARD 1 Cut 7450A 4 84 When installing the insert valve in bottom edge of cover apply Fuller 71206 silicone lubricant or its equivalent to O r
21. MODELS 5 Remove range yoke from sliding clutch of syn chronizer assembly 4 Pull yoke bar from bore of cylinder housing 6 Remove the range piston from cylinder bore If necessary remove the O rings from piston I D and O D inset DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 7 Turn out the capscrews and remove the range inder housing and gasket If necessary remove the small O ring from groove in housing bore in set DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS BEARING BEARING SNAP RING COUNTERSHAFT ASSEMBLY B Removal of Auxiliary Countershaft Rear Bearings 1 Turn out the capscrews and remove both counter 2 Remove the snap ring from groove at rear of each shaft rear bearing covers countershaft NOTE For removal and disassembly of models equipped with an Auxiliary Oil Pump Assembly on rear of countershaft see OPTIONS DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 3 Use a soft bar and maul to drive the counter 5 Use a puller to remove the countershaft rear shaft forward far enough to partially unseat rear bearings NOTE The auxiliary countershaft assemably CAN NOT be removed from housing until splitter shift yoke is removed 4 Using caution so as not to damage the bearing in ner race on front of each countershaft drive the shafts to the rear to expose the bearing snap rings DISASSEMBLY AUXILIARY SECTION 13
22. TYPE Cut 6390B 8 84 OIL SEAL NUT Disassembly 5 Using a flanged end driver install the drive gear bearing on shaft and into case bore When apply ing force to driver use caution so as not to dam age bearing shield Suggestion Engaging the sliding clutch into main drive gear and blocking it forward will hold 2 Remove the front bearing cover and gasket If nec the input shaft forward essary remove the oil seal from cover of models 6 When drive gear bearing nut is used degrease 1 Remove the gear shift lever housing assembly or remote control assembly from shift bar housing if necessary and the shift bar housing assembly from transmission case SOC equippee the threads of input shaft and new nut DO NOT 3 Remove the drive gear bearing nut left hand REUSE OLD NUT When snap ring is used install threads or snap ring from input shaft the snap ring in groove of input shaft and pro Suggestion For removal of nut ONLY engage Iwo ceed to 10 mainshaft sliding clutches into gear to prevent the mainshaft from rotating 7 Apply Fuller Transmission adhesive sealant 71204 or equivalent to the cleaned threads of in 4 Move the main drive gear assembly as far forward put shaft and nut using caution so as not to con as possible and remove the drive gear bearing taminate bearing with sealant 5 Remove the spacer from input shaft 8 Engage two mainshaft sliding clutches into gear to prevent the mainshaft from
23. With the Deep Reduction Button in the REAR WARD position the SP Port of control valve is CLOSED and NO AIR is supplied to the Center Port of cylinder cover Button REARWARD SPY Port CLOSED WHILE IN THE LO SPEED GEAR POSITION the button can be moved FORWARD to operate in LO LO The SP Port of valve is OPENED when deep reduc tion selection is made supplying AIR to the Center Port of cylinder cover Button FORWARD SPY Port OPENED NOTE WHILE IN HIGH RANGE the mechanical in terlock of Master Control Valve prevents movement of Deep Reduction Button to the FORWARD position Trouble Shooting If the transmission fails to shift or shifts too slowly to or from LO LO the fault may be in the Deep Re duction Air System or related components of the Range Shift Air System To locate the trouble the following checks should be made with normal vehicle air pressure supplied to the system but with the engine off See CAUTION Page 25 NOTE It is assumed that correct PSI readings were obtained from the air filter regulator and all air lines have been checked for leaks For Models Equipped with the Deep Reduction Valve 1 Air Supply See Air System Schematics With the gear shift lever in neutral loosen the connection at the INLET End Port of Deep Re duction Valve until it can be determined that CONSTANT AIR is supplied to valve Reconnect air line If there is NO AIR check for a restricti
24. actuator button from valve housing and the spring retainer springs seal and detent parts from actuator and or valve housing Turn out the two screws inside of valve housing to separate the housing Remove the Range Preelection Lever from left housing and the position balls and guide from lever If necessary remove the spring and O ring from bores in left housing d MEDALLION Le SCREW TOP COVER ACTUATOR BALL we O RING HOUSING 9 If necessary remove the springs O ring and re tainer from bores in right housing Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly Reinstall control valve on gear shift lever and tighten jam nut Attach air lines and reinstall bottom cover Schematic For all questions concerning removal and replacement refer to Eaton service and Parts Literature RT RTO amp RTX XX607LL XX608LL and XX615 Models Deep Reduction A 3546 Range A 5010 Roadranger Valve Valve Down Outlet 19470 or A 5000 Slave Valve Slave Valve Identification A 4688 Valve ON O A 5000 Valve O 19470 Valve rpg
25. air pressure readings replace the complete as sembly as the air regulator is nonserviceable 4 CONTROL VALVE See Pages 28 and 29 With the gear shift lever in neutral select HIGH RANGE and disconnect the 1 8 O D air line at the OUTLET or P Port of control valve AIR SYSTEM A When LOW RANGE is selected a steady blast of air will flow from opened port Select HIGH RANGE to shut off air flow This indicates the control valve is operating properly Reconnect air line B If control valve does not operate properly check for restrictions and air leaks Leaks in dicate defective or worn O rings 5 HIGH RANGE OPERATION With the gear shift lever in neutral select LOW RANGE and disconnect the 4 I D air line at the port of range cylinder cover Make sure this line leads from the High Range or H Port of slave valve A When HIGH RANGE is selected a steady blast of air should flow from disconnected line Select LOW RANGE to shut off air flow B Move the shift lever to a gear position and se lect HIGH RANGE There should be NO AIR flowing from disconnected line Return the gear shift lever to the neutral position There should now be a steady flow of air from dis connected line Select LOW RANGE to shut off air flow and reconnect air line C If the air system does not operate accord ingly the slave valve or actuating components of the shift bar housing assembly are defec tive IMPORTANT RANGE P
26. ball grip 4 Attach the air lines AIR SYSTEM RANGE VALVE A 501 O ROADRANGER VALVE ASSEMBLY MEDALLION HOUSING Removal and Disassembly 1 Remove two screws holding bottom cover to valve and slide cover down gearshift lever to expose air line fittings Disconnect air lines Loosen jam nut and turn control valve from gear shift lever Pry medallion from recess in top cover Turn out the two screws to remove the top cover from valve housing Turn out the two screws in side of valve housing to separate the housing Remove the Range Preelection Lever from left housing and the position balls and guide from lever If necessary remove spring and O ring from bores in left housing If necessary remove springs O ring and sleeve from bores in right housing SPRING O RING E HOUSING Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Reinstall control valve on gear shift lever and tighten jam nut 3 Attach air lines and reinstall bottom cover AIR SYSTEM DEEP REDUCTION AIR SYSTEM 8 SPEED LL MODELS ONLY Operation In addition to the various components of the Range Shift Air System the Deep Reduction Air System uti lizes a reduction cylind
27. cS QE lt a B E D PLUG 9 7 1 Tj i 5 zs all i a a Y 7 J 4 ra A TE 1 e Si D el c T ea a O i y CAPSCREW s pe RI 5 4 se Op gt PTO COVER FRONT BEARING amp WP GSS gt BUSHING COVER 3 Nue a PUSH GASKET 12 7 CLUTCH HOUSING CAPSCREW M HAND HOLE COVER CAPSCREW y O es CAPSCREW FRONT BEARING Cut 6191 5 83 COVER PULL A Removal of Universal Joint Companion Flange or Yoke 2 Pull the companion flange or yoke from splines of output shaft Remove the speedometer drive gear or replacement spacer from hub of flange 1 Lock the transmission by engaging two main yoke or from inside rear bearing cover remaining shaft gears with sliding clutches inset Use a on output shaft inset For some models it is large breaker bar to turn the nut from output shaft necessary to remove the snap ring in groove of and remove washer if so equipped output shaft PRIOR to removal of the speedome ter gear or spacer REMOVAL COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING B Removal of Auxiliary Section 3 Remove puller screws and attach a chain hoist to auxiliary section Move the assembly to the rear 1 Turn out the retaining capscrews in auxiliary until free of front section and remove gasket housing flange 2 Insert three puller screws in the tapped holes of housing flange Tighten evenly to m
28. control that provides range se lection UP and DOWN A f there is a steady leak from the exhaust port of control valve O rings and or related parts of the control valve are defective B If there is a steady leak from breather of slave valve an O ring in valve is defective or there is a leak past O rings of range cylinder piston C If transmission fails to shift into LOW RANGE or is slow to make the range shift and the case is pressurized see Check No 7 of this section D Tighten all loose connections and replace de fective O rings and parts 3 AIR FILTER REGULATOR See illustration Page 27 With the gear shift lever in neutral check the breather of air filter regulator assembly There should be NO AIR leaking from this port The complete assembly should be replaced if a steady leak is found Cut off the vehicle air supply to the air filter regulator assembly disconnect the air line at fit ting in Supply OUTLET and install an air gage in opened port Bring the vehicle air pressure to nor mal Regulated air pressure should be 57 5 to 62 5 PSI DO NOT ADJUST SCREW AT BOTTOM OF REGU LATOR TO OBTAIN CORRECT READINGS The air regulator has been PREADJUSTED within the correct operating limits Any deviation from these limits especially with regulators that have been in operation for some time is likely to be caused by dirt or worn parts If replacement or cleaning of the filter element does nothing to correct the
29. flat side of washer up Rotate washer in the 1st or bottom groove of mainshaft to align the splines of washer with those of the mainshaft in stall the key in mainshaft keyway to lock washer in place REASSEMBLY FRONT SECTION 6 Install the 2nd speed gear on shaft against 3rd speed or Overdrive gear clutching teeth up 8 Remove the key from keyway and install the 2nd speed gear limit washer on mainshaft flat side of washer down and against spacer Rotate washer in the 2nd groove of mainshaft to align the splnes of washer with those of the mainshaft and reinsert key in keyway to lock washer in place inset T Install the spacer in 2nd speed gear engaging the external splines of spacer with clutching teeth of gear REASSEMBLY B 9 Insert two large screwdrivers between the 2nd and 3rd speed or Overdrive gears to check axial clearances Apply slight downward pressure on screwdriver handles to spread gears evenly Mak ing sure the gear hubs are parallel insert a feeler gage between hubs Correct axial clearance should be from 005 to 012 If the clearance is less than the minimum 005 tolerance the limit washer in the 2nd speed gear should be replaced by a thinner limit washer This will increase the axial clearance between the gears If the clear ance checked is greater than the maximum 012 tolerance a thicker limit washer should be in staled in the 2nd speed gear This would de crease th
30. gear teeth 1 Prior to placing each countershaft assembly into case clearly mark the tooth located directly over the keyway of drive gear as shown This tooth is stamped with an O to aid identification A TOOTH MARKED ON EACH COUNTERSHAFT DRIVE GEAR FOR TIMING PURPOSES cut 7300 B Marking main drive gear teeth 1 Mark any two adjacent teeth on the main drive gear 2 Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear As shown below there should be an equal number of unmarked gear teeth on each side between the marked sets B TEETH MARKED ON MAIN DRIVE GEAR FOR TIMING PURPOSES Cut 7300A C Meshing marked countershaft drive gear teeth with marked main drive gear teeth After placing the mainshaft assembly into case the countershaft bearings are installed to cornz plete installation of the countershaft assemblies 1 When installing the bearings on left counter shaft mesh the marked tooth of countershaft drive gear with either set of two marked teeth on the main drive gear 2 Repeat the procedure when installing the bearings on right countershaft making use of the remaining set of two marked teeth on the main drive gear to time assembly C DRIVE GEAR SET PROPERLY TIMED Cut 7300B Auxiliary Section A Timing the deep reduction gear set of 8 speed LL models the low range gear set of 9 speed models or the splitter gear set of 13 speed models
31. h CAPSCREW GASKET COLLAR RING OIL DEFLECTOR 14608LL MODELS D CAPSCREW GASKET GASKET REAR HOUSING Cut 6527 3 85 G Removal and Disassembly of Output Shaft and Rear Bearing Assemblies NOTE In addition to the above refer to the illus tration provided at Part D of this section 2 If not previously done so remove the snap ring and speedometer drive gear or replacement spa cer from output shaft of models so equipped 1 Turn out the capscrews and remove the rear bearing cover and gasket If necessary remove the oil seal from cover inset DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 3 Temporarily reinstall rear bearing cover in posi tion on housing ONLY to catch rear bearing cone released from bore in the following procedure 6 Remove the two bearing cups and outer spacer from bore in auxiliary housing 4 Use a soft bar and maul to drive the output shaft forward and through rear bearing assembly This will cause the rear bearing cone to be released from bore in auxiliary housing NOTE When applying force to rear of output shaft DO NOT AMAGE THREADS Support front of shaft to avoid damaging the mainshaft quill once output shaft is free of bearing DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 7T Remove the bearing inner spacer from output shaft 9 If necessary remove the snap ring from D of deep reduction gear of models so equipped
32. lever slot Replace excessively worn parts 2 Check yokes for correct alignment Replace sprung yokes 3 Check lockscrews in yokes and blocks Tighten and rewire those found loose 4 If housing has been disassembled check neutral notches of shift bars for wear from in terlock balls GEAR SHIFT LEVER HOUSING ASSEMBLY 1 Check spring tension on shift lever Replace tension spring and washer if lever moves too freely 2 If housing is disassembled check spade pin and corresponding slot in lever for wear Re place both parts if excessively worn BEARING COVERS 1 Check covers for wear from thrust of adjacent bearing Replace covers damaged from thrust of bearing outer race 2 Check bores of covers for wear Replace those worn oversize OIL RETURN THREADS AND SEALS 1 Check oil return threads in front bearing cover If sealing action of threads has been destroyed by contact with input shaft replace bearing cover 2 Check oil seal in rear bearing cover If sealing action of lip has been destroyed replace seal SLIDING CLUTCHES 1 Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat 2 Check engaging teeth of sliding clutches for partial engagement pattern SYNCHRONIZER ASSEMBLY 1 Check synchronizer for burrs uneven and ex cessive wear at contact surface and metal particles 2 Check blocker pins for excessive wear or looseness 3
33. mainshaft to mainshaft to align the splines of washer with retain key in keyway those of the mainshaft and reinsert key in keyway to lock washer in place REASSEMBLY FRONT SECTION eai i mam 22 Install the snap ring in hub of reverse gear ONLY TO CHECK AXIAL CLEARANCE END PLAY LIMITS Tm Tm 24 Install the auxiliary drive gear assembly its proper position on rear of mainshaft gt Bum s he 7 23 Install the reverse gear on mainshaft clutching teeth down and engaged with external splines of spacer REASSEMBLY FRONT SECTION 25 Force both the reverse gear and auxiliary drive gear downward on the shaft to flatten their re spective snap rings Making sure the gear hubs are parallel insert a feeler gage between the hubs of the reverse gear and auxiliary drive gear Correct axial clearance should be from 005 to 012 If clearance is less than the minimum 005 tolerance the reverse gear limit washer should be replaced by a thinner limit washer This will in crease the axial clearance between the gears If the clearance checked is greater than the max imum 012 tolerance a thicker limit washer should be installed in teh reverse gear This would decrease the axial clearance between the gears NOTE THIS CHECK IS MADE WITHOUT SPREADING THE GEARS WITH SCREW DRIVERS 1 26 Wi
34. mm Mg ter 14 69 815 289 8 13 6 15 33 853 4 314 1 13 6 RT 8608L Series Transmissions Relative Speed 1 2 3 PTO Gear Gear Ratios To Input RPM Length dn i Cap 0 In 5 ints Model Spas Righi mm Ko Liters 734 0 299 7 12 69 CHART NOTES 1 Lengths measured from face of clutch housing to front bottoming surface of companion flange or yoke 2 Weight Listed weights are without clutch housing Weights include standard controls which consist of gear shift lever housing gear shift lever range and splitter controls and attaching lines Weight of standard controls is approximately 10 lbs 4 5 kg All weights are approximate 3 Oil Capacities are approximate depending on inclination of engine and transmission Always fill transmis sion with proper grade and type of lubricant to level of filler opening See LUBRICATION MODEL DESIGNATIONS AND SPECIFICATIONS Speed Transmissions Relative Speed 3 i PTO Gear Oil Ca Gear Ratios To Input R P M Pas No RT 11609A 12 65 8 38 6 22 4 57 3 40 2 46 1 83 1 34 3 89 13 22 28 590 734 265 5 12 59 RTO 11609A 9 41 6 23 4 62 3 40 2 53 1 83 1 36 2 89 9 83 28 9 590 734 265 5 12 69 0 11609 12 86 3 82 3 43 13 14 28 9 590 27 734 5 12 69 RT 12609A 12 65 8 38 6 22 3 40 2 46 1 83 1 34 1 00 3 89 13 22 28 9 27 734 370 12 69 0 12609 6 23 4 62 3 40 1 83 1 36 1 00 2 89 9 83 28
35. on the transmission will cause hard shifting in Low Range gears AIR SYSTEM RANGE VALVE A 3546 NOTE This valve provides range selection ONLY When equipped on 15 Speed Models the dash mounted Deep Reduction Valve is required to provide deep reduction selections 2 POSITION SPRINGS Qu HOUSING FRONT O RING HOUSING OUTLET BLACK AIR LINE Cut 6155 1 84 Removal and Disassembly CONTROL 2 FELT SEALS HOUSING REAR SPRING SEAL O RING INSERT VALVE WHITE AIR LINE Reassembly and Installation 1 Disconnect the air lines and loosen clamp se 1 Refer to the drawing for proper reassembly Use a curing the valve to gear shift lever Remove valve 2 Remove the four screws to separate the front and rear housings and remove the slide and two sets of position springs and balls 3 Remove the seal insert valve O ring and spring from rear housing 4 If necessary remove the two felt seals Punch out the roll pin to remove the control knob from slide VERY SMALL amount of silicone lubricant on the O rings to avoid clogging ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Install the air lines with their sheathing and O rings on the gear shift lever 3 Secure the valve on gear shift lever with mounting clamp The control knob should face to the front and be approximately 6 below the centerline of
36. or Yoke Nut a Check for tightness Tighten to recom mended torque 11 Output Shaft Not Shown a Pry upward against output shaft to check radial clearance in mainshaft rear bearing CHECKS WITH UNIVERSAL JOINT COMPANION FLANGE OR YOKE REMOVED NOTE If necessary use solvent and shop rag to clean sealing surface of companion flange or yoke DO NOT USE CROCUS CLOTH EMERY PAPER OR OTHER ABRASIVE MATERIALS THAT WILL MAR SURFACE FINISH 12 Splines on Output Shaft Not Shown a Check for wear from movement and chuck ing action of the universal joint companion flange or yoke 13 Mainshaft Rear Bearing Cover a Check oil seal for wear PRECAUTIONS Disassembly It is assumed in the detailed assembly instructions that the lubricant has been drained from transmission the necessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis Re moval of the gear shift lever housing assembly or remote control assembly is included in the detailed instruc tions Disassembly and Reassembly Shifting Controls however this assembly MUST be detached from shift bar housing before transmission can be removed FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS MAKING USE OF THE TEXT ILLUS TRATIONS AND PHOTOGRAPHS PROVIDED 1 BEARINGS Carefully wash and relubricate all tershafts mainshaft or main drive gear Special reusable bearings as removed and protectively procedures
37. rotating and install 6 From the front of transmission remove the snap the new drive gear bearing nut left hand threads ning Trom 0 9 307 main ative gear Using wo small on input shaft Tighten nut with 250 300 Lbs Ft screwdrivers If mainshaft was previously locked of torque in two gears it may become necessary to place Suggestion To avoid damaging the O D of nut sliding clutches in the neutral position to rotate use the tool specifically designed for this pur input shaft for removal of snap ring pose See TOOL REFERENCE T Pull the input shaft forward and from splines of 9 With a punch and maul peen the nut into the two drive gear milled slots of input shaft using caution so as not to distort O D of nut Reassembly 10 To facilitate proper reinstallation of the shift bar 1 If necessary install bushing in pocket of input housing assembly on case make sure mainshaft shait sliding clutches are placed in the neutral posi 2 Install new input shaft into splines of main drive tion gear just far enough to expose snap ring groove 11 Reinstall the shift bar housing assembly the in 1 0 of drive gear front bearing cover and all other parts and as 3 Install snap ring in groove of drive gear semblies previously removed making sure to re place the gaskets used 4 install spacer on input shaft AIR SYSTEM MASTER CONTROL VALVE O RINGS O D AIR LINES SHEATHING RANGE CYLINDER AIR FILTER REGULAT
38. so equipped turn out the two mounting screws in valve cover 6 Loosen the jam nut and turn the Valve and nut from gear shift lever Remove the valve cover air lines sheathing and O rings from lever DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS B Removal of Air Filter Regulator Assembly 3 Turn out the two capscrews and remove the air fil ter regulator assembly NOTE For disassembly and reassembly of Air Fil ter Regulator Assembly see Page 27 1 Disconnect and remove the 1 4 1 0 air hose be tween the slave valve and air filter regulator assembly C Removal of Slave Valve oS 2 For 8 Speed LL 13 Speed Models also discon 1 Disconnect and remove the 1 4 1 0 air hose be nect the 1 4 1 0 air hose between the filter tween the slave valve and Low Range Port in hous regulator assembly and reduction splitter cylinder ing of range cylinder DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 2 Disconnect and remove the 1 4 I D air hose be 5 Remove the spring and plunger pin from bore in tween the slave valve and High Range Port in transmission case Remove slave valve gasket cover of range cylinder EM 3 Turn out the four retaining capscrews and remove 6 If necessary remove the air hose fittings from slave valve from transmission case slave valve NOTE For disassembly and reassembly of piston type Slave Valve Assembly ONLY see Page 27 7 we
39. the 1 st speed gear on shaft long hub of gear to the front of countershaft B Reassembly of Countershaft Assemblies NOTE Except for the PTO gears the left and right countershaft assemblies are identical and reassembled in the same manner 3 Press the 2nd speed gear on countershaft long hub of gear against 1st speed gear hub 1 If previously removed install the roll pin and key in keyway of countershaft REASSEMBLY FRONT SECTION 6 To avoid confusion during installation mark the end of left countershaft with an L the end of right countershaft with an R 4 Press the 3rd speed or Overdrive gear on coun tershaft long hub of gear to the front of shaft T Install the drive gear retaining snap ring in groove on front of each countershaft 5 Start the PTO gear onto countershaft bullet nose side of teeth facing up and toward rear of shaft Align keyway of drive gear with key in coun tershaft and press BOTH gears onto shaft long hub of drive gear against PTO gear NOTE The left countershaft assembly has a 47 tooth PTO gear the right countershaft assembly has a 45 tooth PTO gear REASSEMBLY FRONT SECTION C Partial Installation of Countershaft Assemblies 1 Place the left countershaft assembly into posi tion in case making sure that the L marked as sembly has the larger 47 tooth PTO gear 8 For models equipped with roller type front bearings use a rubber mall
40. 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 A BACKED BY E TeN Roadranger Powering Business Worldwide SUPPORT
41. washer is available in varying thicknesses Use the splined tolerance washer that provides a snug fit in gear hub REASSEMBLY AUXILIARY SECTION 1 3 SPEED MODELS 2 Install the three springs in bores of high range 4 Apply downward pressure to the high range syn synchronizer ring chronizer ring WHILE TWISTING COUNTER CLOCKWISE to compress the springs and fully seat ring on blocker pins of low range synchroni 3 Place the high range synchronizer ring over blocker pins of low range synchronizer seating the springs against pins 5 Spread the countershaft assemblies with splitter gear set remaining in time and install the syn chronizer assembly on splines of range main shaft low range ring in recess of low range gear REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS G Installation of Auxiliary Countershaft Rear Bearings NOTE The splitter gear set MUST remain in time during the installation of rear bearings 1 Center the rear of either countershaft assembly in bearing bore and use a soft bar to start rear bearing in bore Complete installation with a flanged end bearing driver and maul Repeat the procedure with other auxiliary countershaft as sembly making sure the splitter gear set has re mained in time NOTE Check the synchronizer assembly for springs that may have been released from bores in high range ring during bearing installation 2 Install the snap ring in groove at rear of e
42. washer on shaft flat side down 4 If previously removed install the snap ring in 2 Install the splined spacer and output shaft splitter gear inset Install the gear on output against washer shoulder up shaft snap ring up and clutching teeth engaged with splines of spacer REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 5 Install the stepped washer on shaft against gear 7 Install the bearing inner spacer on output shaft flat side up melt ue E i DT m 8 Place the front bearing cup in housing bore taper 6 Heat the front bearing cone and install on output to the inside and use a soft bar to start cup into shaft against washer bearing taper up bore NOTE DO NOT HEAT BEARING ABOVE 275 F 136 C If possible use heat lamps as source REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 9 Stack the bearing outer spacer and rear bearing 11 Heat the rear bearing cone and install on shaft cup on top of front bearing cup in proper se taper down and inside cup Make sure the lip of quence Use a flanged end driver to move all rear bearing cup is fully seated on housing with three parts evenly into bore until lip of rear bearing installed bearing cup seats on housing ERES DO NOT HEAT BEARING ABOVE 275 F 0 10 Install the auxiliary housing over end of output shaft assembly seating the front bearing cone on shaft in cup 12 If previously removed install the
43. yoke bar flat side to the rear Secure with nut tightened to recommended torque ratings inset 4 Install the two yoke lockscrews tighten and wire securely T Position the corresponding new gasket on cover mounting surface and install teh range cylinder cover on housing open port to the upper left Tighten capscrews to secure cover to housing 5 If previously removed instll the O rings in th e I D and O D of range piston DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS AUXILIARY SECTION 9 SPEED MODELS CAPSCREW CAPSCREW AUXILIARY CYLINDER PISTON CYLINDER COVER SHIFT YOKE 1 YOKE BAR NOTE Use lockwire at these Cut 6427 5 83 positions during reassembly A Removal and Disassembly of Range Cylinder Assembly 2 Remove nut from end of yoke bar 1 For ease of disassembly mount the auxiliary sec tion upright in a vise Turn out the capscrews and remove the range cylinder cover and gasket DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS j 5 Remove range yoke from sliding clutch of syn chronizer assembly 3 Cut lockwire and remove two yoke lockscrews 6 Remove the range piston from cylinder bore If necessary remove the O rings from piston l D and O D inset 4 Pull yoke bar from bore of cylinder housing DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 7 Turn out the capscrew
44. 00 2 89 11 06 29 5 749 3 2772 12 69 13 Speed Transmissions Relative Speed PTO Gear Gear Ratios To Input R P M RT 11613 13 112 56 8 32 6 18 4 54 3 38 2 86 2 46 2 12 1 83 1 56 1 34 1 16 11 00 3 89 13 13 85 8 52 RT 14613 13 112 56 8 32 6 18 4 54 3 38 2 86 2 46 2 121 1 83 1 56 1 34 1 16 1 00 3 89 13 13 32 4 pe EDS CREDE M 823 299 2 13 6 RT 15613 13 112 56 8 32 6 18 4 54 3 38 2 86 2 46 2 12 1 83 1 56 1 34 1 16 1 00 3 89 13 13 32 4 685 29 823 308 2 13 6 500 7o sm fs 0 J 0 11613 13 12 56 8 32 6 18 4 54 3 38 2 46 2 15 1 83 1 60 1 34 1 17 1 00 87 3 89 13 13 32 1 653 28 815 293 8 13 2 00 11613 13 12 12 7 21 5 09 3 69 2 70 1 95 1 66 1 38 1 17 1 00 85 73 62 3 43 12 68 788 788 32 1 653 28 815 293 8 13 2 RT0 14613 13 112 56 8 32 6 18 4 54 3 38 2 46 2 15 1 83 1 60 1 34 1 17 1 00 87 3 89 13 13 32 4 665 29 823 299 2 13 6 00 14613 13 142 13 7 21 5 09 3 69 2 70 1 95 1 66 1 38 1 17 1 00 85 73 62 3 43 12 68 788 788 32 4 665 29 823 299 2 13 6 RT0 15613 13 112 56 8 32 6 18 4 54 3 38 2 46 2 15 1 83 1 60 1 34 1 17 1 00 87 3 89 13 13 32 4 823 308 6 13 6 LUBRICATION Proper Lubrication the Key to long transmission l
45. 3 8 16 Threads with Lockwire Apply Loctite 242 to Threads 16 SHIFT BAR HOUSING AND 4 SHIFT 6 CLUTCH HOUSING NUTS LEVER HOUSING CAPSCREWS 35 45 LbsJFt 35Lbs Ft 47 N m 90 CW rotation or 16 Threads Apply Loctite 242 to Threads 1 REVERSE SIGNAL SWITCH PLUG 35 50 Lbs Ft 916 18 Threads 2 SUPPORT STUD NUTS 170 185 Lbs Ft 58 18 Threads Use Lockwashers AUXILIARY SECTION Speed Models 175 Lbs ft 237 N m 4 SLAVE AIR VALVE CAPSCREWS 8 12 Lbs ft 1 4 20 Threads Apply Loctite 242 to Threads L p y il Bi JH E te M SENI AUXILIARY SECTION SLL amp 13 Speed Models 6 SMALL P T O Cover Capscrews 20 25 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads 8 LARGE P T O COVER CAPSCREWS 50 65 Lbs Ft 7 16 14 Threads 1 OIL DRAIN PLUG 45 55 Lbs Ft 3 4 Pipe Threads 6 MAINSHAFT REAR BEARING RETAINER CAPSCREWS 35 45 Lbs Ft 3la 16 Threads Secure with Lockwire Apply Loctite 242 to Threads 1 OIL FILL PLUG 4 HAND HOLE COVER CAPSCREWS B VERLA MUT EL pud Threads 20 25 Lbs Ft 5 16 18 Threads 2 COUNTERSHAFT FRONT BEARING RETAINER 50 60 LbsJFt 51 18 Threads CAPSCREWS 90 120 LBS Ft 5 8 18 Threads 4 or 6 CLUTCH HOUSING CAPSCREWS 115 Lbs Ft 156 N m Dd 7190 1184 TORQUE RECOMMENDATIONS AUXILIARY SECTIONS 2 AIR FILTER REGULATOR MOUNTING 6 MAIN
46. 8608L REASSEMBLY AUXILIARY SECTION 9 SPEED MODELS AND 8608L DISASSEMBLYDAUXILIARY SECTION 13 SPEED MODELS REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS DISASSEMBLY FRONT SECTION REASSEMBLY FRONT SECTION INSTALLATION COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING INSTALLATION SHIFTING CONTROLS SHIFT BAR HOUSING GEAR SHIFT LEVER HOUSING ASSEMBLY AIR SYSTEM APPENDIX TAPERED ROLLER BEARING SHIMMING PROCEDURE FOREWORD This manual is designed to provide detailed infor mation necessary to service and repair the Fuller Transmission listed on the cover As outlined in the Table of Contents the manual is divided into 3 main sections a Technical information and reference b Removal disassembly reassembly and installation Options The format of the manual is designed to be fol lowed in its entirety if complete disassembly and reassembly of the transmission is necessary But if only one component of the transmission needs to be repaired refer to the Table of Contents for the page numbers showing that component For exam ple if you need to work on the Shifting Controls you will find instructions for removal disassembly and reassembly on page 48 Instructions for instal lation are on page 174 Service Manuals Illustrated Parts Lists Drivers Instructions and other forms of product service information for these and other Fuller Transmissions are available upon request A Technical Literature Order Form may b
47. 9 602 27 734 270 12 69 RTO 12609B 12 56 7 47 5 28 195 138 t 00 73 3 43 13 14 28 9 602 27 734 270 12 69 RT 13609A 12 65 8 38 6 22 246 1 83 1 34 100 3 89 13 22 28 9 679 27 734 308 13 RTX 13609A 9 41 6 23 4 62 1 36 1 00 2 89 9 83 28 9 679 27 734 308 13 RTX 13609B 12 56 7 47 528 3 82 100 73 343 13 14 28 9 679 27 734 308 13 RT 14609A 12 65 838 622 457 2 46 183 1 34 100 3 89 13 22 29 5 616 27 749 277 2 12 69 RTO 14609A 9 41 623 462 340 253 1 83 136 1 00 74 2 89 9 83 935 935 29 5 616 27 749 21 2 AGES RTO 14609B 12 56 528 3 82 279 195 138 1 00 73 3 43 13 14 29 5 749 291 2 12 69 M Relative Speed PTO Gear Gear Ratios To Input R M RTX 11609P 10 58 7 55 5 39 3 83 2 71 1 97 1 41 1 00 83 2 89 11 06 54 455 5 i 59 RTX 12609P 10 58 7 595 5 39 3 83 2 77 1 97 1 00 83 2 89 11 06 28 9 734 290 ad RTX 14609P 10 58 7 55 5 39 3 83 2 80 2 01 1 41 1 00 83 2 89 11 06 7 3 em 2 42 Eg RTX 11609R 10 58 7 55 5 39 3 83 2 77 1 97 1 41 1 00 2 89 11 06 aay 285 5 Eg RTX 12609R 10 58 7 55 5 39 3 83 2 77 1 97 1 41 1 00 2 89 11 06 28 9 602 734 270 9 o RTX 13609R 10 58 7 55 5 39 3 83 277 1 97 141 1 00 2 89 11 06 28 9 679 734 GS iE RTX 14609R 10 58 7 55 5 39 3 83 2 80 2 01 1 41 1
48. ARWARD to shut off air flow and re connect air line B If the preceding conditions did not exist the control valve is defective or there is a restric tion in the air lines 3 Splitter Cylinder Refer to the following illustra tion If any of the seals in the splitter cylinder as sembly are defective the splitter shift will be af fected The degree of air lost will govern the degree of failure from slow shifting to complete shift failure A Leak at O ring A results in a slow shift to engage splitter gearing pressurizing of trans mission case splitter gearing can be dis engaged AIR SYSTEM B Leak at O ring B results in slow shifting or complete failure to engage and disengage splitter gearing steady flow of air from ex haust port of control valve and or cylinder cover when Splitter Control Button is in the FORWARD position C Leak at gasket C results in a slow shift to dis engage splitter gearing steady flow of air to atmosphere SHIFT YOKE Pierre A EXTA fH N N wem p 4 Insert Valve See 37 Any constant flow of air from exhaust port of cyl inder cover usually indicates a faulty insert valve Exhaust should occur ONLY BRIEFLY when Split ter Control Button is moved FORWARD WHILE IN HIGH RANGE A faulty insert valve leaking at the O rings of valve O D or from inner seals will result in shift failure Two indications of defective O rings or seals are
49. ATE THRUST Cut 6382 9 80 WASHER C Removal and Disassembly of Left Reverse Idler Gear Assembly 1 Move the mainshaft reverse gear as far to the rear 2 Move the reverse gear forward and against the as possible and remove the snap ring from 1 0 of LOW speed gear engaging the splines of main gear shaft sliding clutch DISASSEMBLY FRONT SECTION A 3 Using jaw pullers or impace puller remove 5 Remove the pipe plug from rear of idler shaft and the auxiliary countershat front bearing from left use an impact puller 1 2 13 threaded end to re reverse idler gear bore If necessary repeat the move shaft from case bore inset procedure for removing the auxiliary countershaft front bearing from right reverse idler gear bore 6 As the idler shaft and idler plat are moved to the rear remove the thrust washer and gear from case 4 Turn out the stop nut from front of idler shaft and remove washer T If necessary remove the inner race from bearing and press needle bearing from idler gear DISASSEMBLYN FRONT SECTION COUNTERSHAFT COUNTERSHAFT ASSEMBLY BEARING SNAP ASSEMBLY ROLLPIN RTO SERIES R RT SERIES RTX SERIES M i COUNTERSHAFT nc o 2ND 7 m 2 SNAP PIN RING 77 gt ROLL IN RING RETAINER RETAINER DRIVE GEAR CAPSCREW CAPSCREW BEARING DRIVE GEAR Cut 6346 11 85 Cut 6346B 11 85 D
50. ATION AT THIS TIME H Bearing Installation and Timing of Right Countershaft Assembly IMPORTANT The left countershaft assembly MUST remain in time with main drive gear when timing right countershaft assembly EL ie A m ie N T i J Te 1 Remove blocking from right countershaft as sembly and place it parallel to mainshaft as sembly Mesh the marked tooth of right countershaft drive gear with remaining set of two marked teeth on main drive gear REASSEMBLY FRONT SECTION 2 Insert countershaft support tool or blocking in rear bearing bore 3 Install the right countershaft bearings in the same manner described in Part D for left coun tershaft bearings 5 Move the reverse gear to the rear on mainshaft and use a screwdriver to engage sliding clutches with all forward speed gears A sliding clutch that will not engage with a gear indicates the gear set is not in proper mesh The bearings of the right countershaft would then need to be removed and the drive gear set retimed NOTE Do not engage sliding clutches with more than one gear at the same time This will lock the gearing and prevent the mainshaft and countershaft assemblies from rotating 1 Reassembly and Installation of Left Reverse Idler Gear Assembly NOTE Since the left and right reverse idler gear assemblies are identical reassembly and installa tion of the left reverse idler gear assembly should be pe
51. Check synchronizer contact surfaces on the auxiliary drive and low range gears for exces sive wear O RINGS 1 Check all O rings for cracks or distortion Re place if worn PRECAUTIONS Reassembly Make sure that interiors of case and housings are clean It is important that dirt and other foreign materials be kept out of the transmission during reassembly Dirt is an abrasive and can damage polished surfaces of bearings and washers Use certain precautions as listed below during reassembly 6 AXIAL CLEARANCES Maintain original axial 1 GASKETS 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 CAPSCREWS To prevent oil leakage use Loctite 242 thread sealant on all capscrews For torque ratings see TORQUE RECOMMENDATIONS O RINGS Lubricate all O rings with silicon lubri cant ASSEMBLY Refer to the illustrations provided in the detailed disassembly instructions as a guide to reassembly INITIAL LUBRICATION Coat all limit washers and splines of shafts with Lubriplate during reas sembly to prevent scoring and galling of such parts T clearances of 005 to 012 for mainshaft gears BEARINGS Use of flanged end bearing drivers is recommended for the installation of bearings These special drivers apply equal force to both bearing races
52. DO NOT REUSE OLD NUT NOTE For models equipped with a snap ring to retain bearing install the snap ring in groove of input shaft and proceed to No 4 REASSEMBLY FRONT SECTION 2 Engage two mainshaft sliding clutches into gear to prevent transmission from rotating s 4 If previously removed install the oil seal in drive gear bearing cover of models so equipped 3 Install the nut on shaft left hand threads Using a drive gear nut installer tighten to 250 300 Ibs ft of torque Use a punch and maul to peen the nut into the two milled slots of input shaft 5 Install the drive gear bearing cover and gasket making sure to align the oil return hole in case Secure cover on case with retaining capscrews inset INSTALLATION COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING A Installation of Clutch Housing 3 Install the four capscrews and tighten in cross pattern See TORQUE RECOMMENDATIONS 1 Position the corresponsing new gasket on hous ing mounting surface and install the clutch hous 4 For models so equipped install the clutch re ing on front case piloting on the six studs and lease mechanism and or clutch brake assembly drive gear bearing cover See OPTIONS 2 Install the six nuts with washers on studs and tighten in cross pattern See TORQUE RECOMMENDATIONS INSTALLATION COMPANION FLANGE AUXILIARY SECTIO
53. E Some repair procedures pictured in this manual show The specialized tools listed below can be obtained the use of specialized tools Their actual use is rec from a tool supplier or made from dimensions as re ommended as they make transmission repair easier quired by the individual user Detailed Fuller Transmit faster and prevent costly damage to critical parts sion Tool Prints are available upon request by writing But for the most part ordinary mechanic s tools Eaton Corporation such as socket wrenches screwdrivers etc and Transmission Division other standard shop items such as a press mauls and Technical Service Dept soft bars are all that is needed to successfully disas P O Box 4013 semble and reassemble any Fuller Transmission Kalamazoo Michigan 49003 TOOL HOW OBTAINED Mali eas Made lem Made nav UT EE m 167 Made som 77 Made Rope 170 Made ri d Dimensions necessary to determine specific tool number required PREVENTIVE MAINTENANCE 10 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE CHECK CHART CHECKS WITHOUT PARTIAL DISASSEMBLY OF CHASSIS OR CAB 1 Air System and Connections a Check for leaks worn air lines loose con nections and capscrews See AIR SYSTEM Clutch Housing Mounting a Check all capscrews of clutch housing flange for looseness Clutch Release Bearing Not Shown a Remove hand hole cover and check radial and axial clearance i
54. FORE proceeding to Part G 6 Temporarily install the front bearing cover 1 If previously removed install the O rings on ex tended front hub of auxiliary drive gear REASSEMBLY FRONT SECTION 2 Install the retainer ring on auxiliary drive gear 4 Install the snap ring in groove of front gear hub to snap ring groove facing front hub and away from retain bearing gear teeth G Reassembly and Partial Installation of Mainshaft Assembly 1 If previously removed install the corresponding snap rings in 1 0 of mainshaft gears 3 Start the auxiliary drive gear bearing on front hub bearing snap ring facing groove in retainer ring Using both the inner and outer race of bearing as a base press the bearing on gear with snap ring in groove of retainer ring or use a bearing driver inset REASSEMBLY FRONT SECTION 2 Secure the mainshaft in a vise equipped with brass jaws or wood blocks pilot end of shaft down If previously removed install the roll pin in keyway EI 5 Install the 3rd speed or Overdrive gear on main shaft clutching teeth down and engaged with ex ternal splines of spacer NOTE Gear limit washers are internally splined and locked to mainshaft by the key Gear spacers are externally splined to engage with clutching teeth in gear hubs There is one limit washer and one spacer for each gear in the mainshaft as sembly 3 Install the 3rd speed gear limit washer on main shaft
55. MBLY SHIFTING CONTROLS 3 Mount the assembly in a vise with plunger side 5 Move the 1st 2nd speed shift bar to the rear of up and secure on housing flange The front of housing removing the yoke and block from bar housing will be to the left For models so As the neutral notch in bar clears the rear boss equipped cut lockwire and turn out the retaining remove the small interlock pin from bore at capscrews to remove oil trough from housing notch NOTE Starting with the upper shift bar move all bars to the right and out bore of rear boss Cut lockwire and remove lockscrews from each bar just prior to their removal from housing 6 Remove the actuating plunger from bore at top of center boss 4 Move the 3rd 4th speed shift bar to the rear of housing removing the yoke and block from bar DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS B Reassembly of Shift Bar Housing Assembly 7 Move the short LO Reverse speed shift bar to the rear of housing removing the yoke from bar As the shift bar is removed from housing two O in terlock balls will drop from bottom bore of rear boss 1 If previously removed install the reverse stop plunger in LO Reverse shift yoke making sure plunger is fully seated in bore at yoke slot La 8 If necessary remove the plug spring and reverse 4 ie stop plunger from bore in LO Reverse speed shift d yoke 2 Install the spring in bore of yoke and onto shank of
56. MODELS E Reassembly and Installation of Synchronizer Assembly 3 Place the high range synchronizer ring over blocker pins of low range synchronizer seating 1 Place the larger low range synchronizer ring on the springs against pins bench and install the sliding clutch on blocker pins recessed side up 4 Apply downward pressure to the high range syn chronizer ring WHILE TWISTING COUNTER CLOCKWISE to compress the springs and fully seat ring on blocker pins of low range synchronizer 2 Install the three springs in bores of high range synchronizer ring REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 5 Install the synchronizer assembly on splines of range mainshaft low range ring towards rear F Timing and Installation of Auxiliary Countershaft Assemblies 4 LJ end L i BI 8 4 r L 1 If previously removed install the bearing inner race on front of each countershaft 2 IMPORTANT On the low range gear of each aux countershaft assembly locate the O stamped on one tooth Align tooth with O with smaller deep reduction gear tooth and mark with high visible color of toolmakers dye 3 Place countershaft into position in housing meshing the marked tooth of countershaft gear with either set of two marked teeth of mainshaft deep reduction gear inset Center rear of coun tershaft in bearing bore start r
57. N AND CLUTCH HOUSING B Installation of Auxiliary Section NOTE Make sure the bearing inner race is in stalled on front of each auxiliary countershaft BE FORE proceeding with the following 1 Attach a chain hoist to auxiliary Move the as sembly evenly into rear of front case piloting it on the dowel pins As assembly is moved forward the countershaft drive gears will mesh with the auxiliary drive gear IMPORTANT On 8 speed L model auxiliary sections shift the deep reduction sliding clutch into deep reduction before installing auxiliary This will prevent possible timing error 2 Install the retaining capscrews in flange of aux plate housing and tighten to secure the aux iliary section to the front section See TORQUE RECOMMENDATIONS 3 he auxiliary section can also be installed with transmission set in the vertical position Block under the clutch housing to prevent damage to the input shaft position the corresponding new gasket on plate housing mounting surface and lower the assembly onto rear of front case Install the retaining capscrews and tighten securely See TORQUE RECOMMENDATIONS IMPORTANT On 8 speed LL model auxiliary sections shift the deep reduction sliding clutch into deep reduction before installing auxiliary This will prevent possible timing error INSTALLATION COMPANION FLANGE C Installation of Universal Joint Companion Flange or Yoke 1 For models so equip
58. ONLY Ratios can b e split by moving Splitter Control Two Position Splitter Control Valve A 4491 4494 for OVERDRIVE N REARWARD for UP for DIRECT HIGH RANGE III Range Control Knob i C DOWN for LOW RANGE a Range Control Valve A 3546 FORWARD SPLITTER CONTROL BUTTON Button to the O D FORWARD position to gain OVERDRIVE 5 6 7 8 Roadranger Valve A 4900 FORWARD for OVERDRIVE REARWARD for y DIRECT UP for HIGH RANGE Range Preselection Lever DOWN for LOW RANGE SPLITTER CONTROL BUTTON POWER FLOW The transmission must efficiently transfer the engine s power in terms of torque to the vehicle s rear wheels Knowledge of what takes place in the transmission during torque transfer is essential when trouble shooting and making repairs become necessary Front Section Power Flow Auxiliary Section Power Flow All Models LO LO 8 Speed LL Models 1 Power torque from the vehicle s engine is trans 7 The auxiliary drive gear splits torque between the ferred to the transmission s input shaft two auxiliary countershaft drive gears 2 Splines of input shaft engage internal splines in 8 Torque is delivered along both auxiliary counter hub of main drive gear shaft to the mating engaged deep reduction 3 Torque is split between the two countershaft gear on output shaft drive gears 9 Torque is transferred to output shaft through slid 4 Torque is delivered along b
59. OR 0 RN E lt gt op 19 QA SLAVE DEEP REDUCTION 1 D AIR LINES CYLINDER 8 SPEED LL MODELS ONLY SPLITTER CYLINDER 13 SPEED MODELS ONLY AIR SYSTEM RANGE SHIFT AIR SYSTEM ALL MODELS Operation The Range Shift Air System consists of the air filter regulator slave valve a Range Control Valve or Mas ter Control Valve range cylinder fittings and connecting air lines See Air System Schematics CONSTANT AIR from the air filter regulator is sup plied to the S or Supply Port of slave valve and passed through to the INLET or S Port of control valve WHILE IN LOW 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 be tween the Low Range or L Port of slave valve and the Low Range Port of range cylinder housing AIR received at this port moves the range piston to the rear and causes the auxiliary low range gear to be come engaged WHILE IN HIGH 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 be tween the High Range or H Port of valve and the High Range Port of range cylinder cover AIR re ceived at this port moves the range piston forward to engage the auxiliary drive gear with sliding clutch and bypass the low range gear set Range shifts can be made ONLY when the gear shift lever is in or p
60. RESELECTION The plunger pin located in case bore between the slave valve and actuating plunger of shift bar housing prevents the slave valve from operating while the shift lever is in a gear position When the lever is moved to or through the neutral po sition the pin is released and the salve valve be comes operational 6 LOW RANGE OPERATION With the gear shift lever in neutral select HIGH RANGE and disconnect the 1 4 D air line at the fitting on range cylinder housing Make sure this line leads from the Low Range or L Port of slave valve A When LOW RANGE 15 selected a steady blast of air should flow from disconnected line Se lect HIGH RANGE to shut off air flow B Move the shift lever to a gear position and se lect LOW RANGE There should be NO AIR flowing from disconnected line Return the gear shift lever to the neutral position There should now be a steady flow of air from dis connected line Select HIGH RANGE to shut off air flow and reconnect air line C If the air system does not operate accord ingly the slave valve or actuating components of the shift bar housing assembly are defec tive 7 RANGE CYLINDER Refer to the following Illustration If any of the seals in the range cylinder assembly are defective the range shift will be affected A Leak at either O ring A results in complete failure to make a range shift steady flow of air from breather of slave valve in both ranges B
61. SHAFT REAR BEARING COVER CAPSCREWS 8 12 Lbs Ft 1 4 20 Threads CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads Apply Loctite 242 to Threads 1 RANGE CYLINDER SHIFT BAR NUT 4 RANGE CYLINDER MOUNTING 70 85 Lbs Ft 5 s 18 Threads CAPSCREWS 35 45 Lbs Ft 3 s 16 Threads 2 RANGE SHIFT YOKE CAPSCREWS EO ed 50 65 Lbs Ft 1 2 20 Threads 4 RANGE CYLINDER COVER Secure with Lockwire CAPSCREWS 35 45 Lbs Ft 3 s 16 Threads Apply Loctite 242 to Threads pex 1 g 4 4 2 GET PT RI E CLM N8 dy MEE Lo p Bl uem m EM ampli 157 oe fp See NOTE 1 REDUCTION OR SPLITTER SHIFT YOKE LOCKSCREW 4 REDUCTION OR SPLITTER CYLINDER 35 45 Lbs Ft 7 16 20 Threads COVER CAPSCREWS 20 25 Lbs Ft Secure with Lockwire 5he 18 Threads 19 AUXILIARY HOUSING CAPSCREWS APPI POCE ere TO meson 35 45 Lbs Ft 3 e 16 Threads 8 COUNTERSHAFT REAR BEARING Apply Loctite 242 to Threads COVER CAPSCREWS 35 45 Lbs Ft 16 Threads 1 OUTPUT SHAFT NUT 450 500 Lbs Ft Apply Loctite 242 to Threads 2 16 Threads Oiled at 1 SPEEDOMETER HOUSING PLUG Vehicle Installation 35 50 Lbs Ft 13 16 20 Threads Apply Loctite 242 to Threads NOTE If insert valve is used in reduction or splitter cylinder cover 1 RETAINING NUT PLUG 40 50 Lbs Ft 5 s 18 Threads Cut 7191 11 84 TOOL REFERENC
62. SPEED MODELS PIN SYNCHRONIZER LO SYNCHRONIZER HI SPRING SPRING SLIDING CLUTCH PIN i Note Not used in current production or in K 1654 kit Was only used with A 4683 Synchronizer Do not use with A 4388 Synchronizer Cut 6480 B 3 84 Ref Service Bulletin 130 7 81 C Removal and Disassembly of Synchronizer Assembly 1 Spread the countershaft assemblies and pull the synchronizer assembly from splines of rang e mainshaft 2 Place the larger low range synchronizer ring on bench and pull the high range synchronizer from blocker pins However before doing so cover the NOTE To spread countershaft far enough to re assembly with a shop rag to prevent losing the move synchronizer on RTO amp RTOO models l three springs released from high range synchroni move the splitter clutch to the forward position zer at pin locations DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 3 Remove the sliding clutch from pins of low range synchronizer ring REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS WASHER MAINSHAFT SNAP RING BUSHING BEARING h yee d SNAP RING COUPLER 2 ANN i WASHER WASHER EE MAINSHAFT SLIDING CLUTCH SNAP RING Cut 6593A 9 80 D Removal of Low Range Gear 4 1 Remove the key from keyway of range 2 Turn the washer located in the hub of low range gear so that the splines of washer align with the splin
63. Service and Parts Literature TL 8 9 and 10 Speed 2 Speed Auxiliary Range HI A 3546 Range A 5010 Roadranger Valve Up 19470 or A 5000 Slave Valve Air Filter Regulator Range Cylinder Assembly Assembly Air from Vehicle Source Constant Air Slave Valve Identification A 4688 Valve 19470 Valve Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature RT RTO amp 00 XX613 and XX813 Models Range LO A 3546 Range Valve A 4900 Roadranger Selector Valve Valve A 4688 Slave Valve 19470 or A 5000 Slave Valve H L Slave Valve Identification A 4688 Valve 01 09 O A 5000 Valve 19470 Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly Air from Vehicle Air to Housing Source Bi Bs RT RTO amp 613 and XX813 Models Range HI Splitter Dire Slave Valve A 3546 Range Valve A 4900 Roadranger Identification Selector Valve Valve A 4688 Valve Up 01 Rearward A 5000 Valve 19470 Valve Out Tl C o _ eg A 4688 Slave Valve 19470 or A 5000 Slave Valve H L
64. Shift Lever Patterns and Shifting Controls Overdrive Models Roadranger Valve A 5010 Shift 1 2 3 4 in Low Rande HIGH RANGE Range Shift 2 eL And shift 5 6 7 8 ES in High Range DOWN for LOW RANGE OPERATION 13 Speed Underdrive Models Shift Lever Patterns and Shifting Controls With Splitter Control Button 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 i E Neutral L 6 10 a Two Position Range Control Splitter Control Valve A 3546 Valve A 4493 FORWARD REARWARD for UNDERDRIVE for DIRECT UP for HIGH RANGE Range Control Knob DOWN for LOW RANGE SPLITTER CONTROL BUTTON WHILE IN HIGH RANGE ONLY Ratios can be split by moving Splitter Control Button to the U D FORWARD position to gain UNDER DRIVE 5 6 7 8 Roadranger Valve A 4900 FORWARD for UNDERDRIVE REARWARD for DIRECT UP for HIGH RANGE Range Preselection Lever DOWN for LOW RANGE SPLITTER CONTROL BUTTON OPERATION 13 Speed Overdrive Models Shift Lever Patterns and Shifting Controls RTO Overdrive Models RTOX Double Overdrive Models RTOO Double Overdrive Models With Splitter Control But ton in DIR position RANGE Shift LO 1 2 3 4 in LOW Range shift And shift 5 6 7 8 in HIGH RANGE Direct IREARWARD WHILE IN HIGH RANGE
65. TWO POSITION i EE M te in cec REDUCTION SELECTOR 1 MI CYLINDER VALVE i SPEED LL MODELS 2 PORT UE Ua LD AIR HOSES SPLITTER CYLINDER CONNECTORS 74 13 5PEED MODELS A Removal of Air Control NOTE For removal and disassembly of models also equipped with the Countershaft Actuator Valve see OPTIONS 2 For models equipped with the Roadranger Valve A 5015 or A 4900 also disconnect the 1 8 O D air hose line at the L or Low Range Port of slave valve left and the 1 8 O D air line at the Center Port of reduction cylinder splitter cylinder cover right NOTE If desired the gear shift lever housing as sembly can now be removed from shift bar housing 1 Disconnect the two 1 8 O D air line or at the S or Supply Port and the P or End Port of slave valve on transmission case NOTE For models equipped with the A 3546 or Roadranger Valve A 5010 the gear shift lever hous ing assembly can now be removed from shift bar housing DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 1 Disconnect the two 1 8 O D air lines at the Range Valve of models so equipped left Remove the ball grip loosen the valve mounting clamp and remove Hood idu Lu bea sheathing and 5 Slide the cover down shift lever to expose valve rings from gear shift lever right eq NOTE For disaesenibi and reassemble Range ports and disconnect the 1 8 O D air lines Valve see Page 28 4 For models
66. ach countershaft vy 7 E i 3 Position the corresponding new gasket on cover mounting surface and install both rear bearing covers Tighten capscrews to secure covers to auxiliary housing NOTE For reassembly and installation of models equipped with an Auxiliary Oil Pump Assembly on rear of countershaft see OPTIONS REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS H Reassembly and Installation of Range Cylinder Assembly 3 Place the range yoke into position with sliding clutch of synchronizer assembly long hub of yoke to the rear Insert threaded end of yoke bar through yoke and into bore of range cylinder housing aligning the notches in bar with yoke lockscrew holes 1 If previously removed install the O ring in bore of range cylinder housing a R 2 Position the corresponding new gasket on hous uj EM VN ing mounting surface and install the cylinder 4 Install the two yoke lockscrews tighten and wire housing in rear bore of auxiliary housing air fit securely ting to the upper left Tighten capscrews to se cure cylinder housing to auxiliary housing E REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 5 If previously removed install the O rings in the 7 Position the corresponding new gasket on cover I D and O D of range piston mounting surface and install the range cylinder cover on housing open port to the upper left 6 In cylin
67. aft 9 After the correct shim has been selected place the shim on the rear countershaft bearing race install the countershaft rear bearing gasket and cover Check for proper shim alignment If misaligned the bearing cover may be damaged when final torque is applied to cover capscrews Perform the same procedure on the other rear countershaft 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 changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness 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
68. ar to break gasket seal and lift the shift bar housing from case Remove gasket NOTE During disassembly lay all parts on a clean bench in order of removal from housing to facilitate reassembly Shift bars not being re moved MUST be kept in the neutral position or in terlock parts will lock bars For disassembly and reassembly of X and F model assemblies see lllustrated Parts List a Vi STEEL BALL Ik 5HIFT BAR HOUSING LOCK SCREW PLUNGER SPAING 1 PLUG TORE BAR REVERSE 1 STEEL BALL E o YOKE BAR 3RD t d SHIFT TORE IST 2ND s SHIFT YOKE a LO REVERSE I Tg qo FT SCREW SHIFT BLOCK 3RD 4TH ml h Sg n m a PIN 31 4 x it i SCREW T LOCK SCREW SHIFT YOKE JAD 4TH X BAR HOUSING ASSEMBLY PLUG SPRING PLUNGER TORE BAR Jrd REVERSE zi ij T d EM MUT ni WASHER po YOKE a SCREW ACTIVATOR Au ACTIVATOR im PIVOT PIN i Ba p SHIFT YORE said ig 3 d LOCK SCREW SHIFT YOKE neum irl pr SHIFT BLOCK f and i STEEL BALL td BBIFT BLOCK YOKE BAR Jrd D and OD qt STEEL BALL s LOCK SCREW Lock SCREW NOTE Use book wire mi Ehase positions iA m oum 0 2 lilt the assembly and remove the three sets of tension springs and balls from bores in top of housing DISASSEMBLY AND REASSE
69. are required and provided in this man wrap until ready for use Remove bearings planned ual eee ele WINT Pi Nets GERINGE TOF tale Pure CLEANLINESS Provide a clean place to work It pose is important that no dirt or foreign material enters 2 ASSEMBLIES When disassembling the various the unit during repairs Dirt is an abrasive and can assemblies such as the mainshaft countershaft damage bearings It is always good practice to and shift bar housing lay all parts on a clean clean the outside of the unit before starting the bench in the same sequence as removed This pro planned disassembly cedure will simplify reassembly and reduce the WHEN USING TOOLS TO MOVE PARTS Always possibility of losing parts apply force to shafts housings etc with restraint 3 SNAP RINGS Remove snap rings with pliers de Movement of some parts is restricted Never apply signed for this purpose Snap rings removed in this force to the part being driven after it stops solidly manner can be reused if they are not sprung or The use of soft hammers bars and mauls for all loose disassembly work is recommended 4 INPUT SHAFT The input shaft can be removed from transmission without removing the coun Inspection Before reassembling 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 a
70. assembled in the same manner 3 Using the rear face 3rd speed sear as a base press the drive gear PTO gear and 3rd speed or overdrive gear from each countershaft left This will also remove the front bearing inner race from countershaft of models so equipped right IMPORTANT NEVER USE THE PTO GEAR AS A PRESSING BASE The narrow face width of this gear makes it very susceptible to breakage B 1 Move the right countershaft assembly to the rear as far as possible so front of shaft can be re moved from case bore and moved to the center of case Lift the assembly from case and repeat the 2 procedure for left countershaft assembly NOTE The left and right reverse idler gear as semblies are identical and disassembled in the same manner If removal and disassembly of this assembly is necessary refer to Part C of this sec tion a i 4 Using the rear face of 1st speed gear as a base press the 2nd speed and 1st speed gears from each countershaft NOTE Always use caution when pressing a clus ter of gears from countershaft t is necessary to press these gears off in a cluster of three and 2 Remove the drive gear retaining snap ring from then in a cluster of two front of each countershaft DISASSEMBLY FRONT SECTION 5 If necessary remove the keys and roil pin from countershaft REASSEMBLY FRONT SECTION CASE ASSEMBLIES NOTE Before starting reassembly ma
71. assing through neutral Thus the range desired can be PRESELECTED 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 allowing it to move to the selected range position Trouble Shooting If the transmission fails to make a range shift or shifts too slowly the fault may be in the Range Shift Air System or actuating components of the shift bar housing assembly To locate the trouble the following checks should be made with normal vehicle air pressure applied to the system but with the engine off CAUTION NEVER WORK UNDER A VEHICLE WHILE ENGINE IS RUNNING as personal injury may result from the sudden and unintended movement of vehicle under power 1 INCORRECT AIR LINE HOOK UPS See Air System Schematics With the gear shift lever in neutral move the con trol that provides range selection UP and DOWN A If the air lines are crossed between control valve and slave valve there will be CON SIANT AIR flowing from the exhaust port of control valve WHILE IN HIGH RANGE B If the air lines are crossed between the slave valve and range cylinder the transmission gearing will not correspond with the range se lection A LOW RANGE selection will result in a HIGH RANGE engagement and vice versa 2 AIR LEAKS With the gear shift lever in neutral coat all air lines and fittings with soapy water and check for leaks moving the
72. der housing bore install the range piston on yoke bar flat side to the rear Secure with nut tightened to recommended torque ratings inset DISASSEMBLY FRONT SECTION A Removal of Front Bearing Cover and Input Shaft Nut 3 Engage two mainshaft sliding clutches into gear this prevents transmission from rotating Remove nut left hand thread with drive gear nut remov ing tool 1 Turn out the retaining capscrews and remove the drivegear bearing cover and gasket 2 If necessary remove the oil seal from cover of models so equipped DISASSEMBLY FRONT SECTION CASE ASSEMBLIES GEAR AUXILIARY DRIVE RETAINER RING BEARING SNAP RING SNAP RING CAPSCREW NOTE Use lockwire at these Cut 6417 9 80 positions during reassembly B Removal and Disassembly of Auxiliary Drive Gear Assembly 2 Cut lockwire and remove the capscrews from bearing retainer ring tr 1 Remove the snap ring from groove at rear of mainshaft DISASSEMBLY FRONT SECTION 3 Insert three puller screws in the specially tapped holes of retainer ring Tighten screws evenly to 5 Using the rear face of retainer ring as a base press the drive gear through bearing 4 Remove the snap ring from hub of auxiliary drive gear 6 If necessary remove the O rings from hub O D of auxiliary drive gear DISASSEMBLY FRONT SECTION GEAR IDLER IDLER SHAFT BEARING WASHER p 9 C IDLER PL
73. duction Lever Button in the OUT REARWARD position Shift LO 1 2 3 4 in LOW RANGE Range Shift Shift 5 6 7 8 in HIGH RANGE 4 a A 9 t we f eu TTC 14651 Neutral sid adis i swift WHEN IN LOW RANGE p ao eam I Nm de amo a WHILE IN LOW RANGE ONLY and shift lever in LO LO LO can be obtained by mov ing Deep Reduction Lever Button to the IN FORWARD position Range Control Valve Roadranger Valve A 3546 A 5010 Roadranger Valve A 5015 Deep Reduction Button REARWARD for OUT UP for HIGH RANGE gt Range Control Knob Range Preselection Lever Preselection Lever DOWN for Yl LOW RANGE cand Gm LOW RANGE DOWN for LOW RANGE OPERATION 9 Speed and RT 8608L Transmissions Shift Lever Patterns and Shifting Controls RT Direct Models RTX Overdrive Models Range Control Valve 46 UP for HIGH RANGE Range Control Knob DOWN for LOW RANGE Shift LO 1 2 3 4 RTO Overdrive Models in Low Range Range Shift ouo LO 4 And shift 5 6 7 8 in High Range Roadranger Valve A 5010 UP for HIGH RANGE SEM N Range Preselection eL b DOWN for LOW RANGE RTX 11609P and RTX 11609R Transmissions RTX 12609P and RTX 12609R Transmissions RTX 14609P and RTX 14609R Transmissions
74. e axial clearance between the gears FRONT SECTION 10 Install the 1st 2nd speed sliding clutch aligning the missing internal spline of sliding clutch with key in mainshaft 11 Remove the key from keyway and install the 1st speed gear limit washer on mainshaft flat side of washer up Rotate washer in the 2nd groove of mainshaft to align the splines of washer with those of the mainshaft and reinsert key in keyway to lock washer in place REASSEMBLY FRONT SECTION SETTING CORRECT AXIAL CLEARANCES FOR MAINSHAFT GEARS Axial Clearance End Play Limits Are 005 012 for all mainshaft gears Washers are used to obtain the correct limits six thicknesses are available as follows LIMITS INCH COLOR CODE 248 250 WHITE 253 255 GREEN 208 260 ORANGE 263 265 PURPLE 268 270 YELLOW 273 275 BLACK PLUS RED New style limit washers come in a full range of tolerances as corresponding colors listed above olus red Example Orange plus red limit washer has an inch limit thickness of 258 260 Refer to Illustrated Parts Lists for washer part num bers Always use the 248 250 low limit washer White or white plus red in the 1st and 3rd speed gear Do sitions as shown at right IMPORTANT REFER TO THE APPROPRIATE iL LUSTRATED PARTS LIST SPECI FIED BY MODEL SERIES TO ENSURE THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION
75. e found in the back of this manual You may also obtain Service Bulletins detailing information on product improve ments repair procedures and other service related subjects by writing to the following address EATON CORPORATION TRANSMISSION DIVISION Technical Service Department P O Box 4013 Kalamazoo Michigan 49003 616 342 3344 Every effort has been made to ensure the accuracy of all information in this brochure However Eaton Transmission Division makes no expressed or implied warranty or representation based on the enclosed information Any errors or omissions may be reported to Train ing and Publications Eaton Transmission Division P O Box 4013 Kalamazoo MI 49003 MODEL DESIGNATIONS AND SPECIFICATIONS Nomenclature RTOF 11609A Op Ratio Set Roadranger Forward Speeds Twin Countershaft Multi Mesh Gearing Overdrive x 100 Nominal Torque X z Overdrive model with a direct Capacity shift pattern replacing designation RTXF 11609A IMPORTANT All Eaton Fuller Transmissions are Forward position of gear shift lever identified by model and serial number This infor Does not affect shift pattern mation is stamped on the transmission identifica tion tag and affixed to the case DO NOT REMOVE OR DESTROY THE TRANS MISSION IDENTIFICATION TAG 8 Speed LL Series Transmissions Relative Speed 1 Gear Ratios Length Weight Oil Cap 0 In Lbs Pints Models 5205 ig
76. e tooth stamped with an O for timing purposes REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS E 4 Install the snap ring in groove at rear of each countershaft 3 Place one of the assemblies into position in rear plate meshing the marked tooth of countershaft low range gear with either set of two marked teeth of low range gear on output shaft inset Center rear of countershaft in bearing bore start rear bearing in bore and complete installation with a flanged end driver and maul Repeat the procedure with other auxiliary countershaft as sembly making sure the low range gear set re mains in time during bearing installation NOTE Check synchronizer assembly for springs that may have been released from bores in high range ring during bearing installation 5 Position the corresponding new gasket on cover mounting surface and install both rear bearing covers Tighten capscrews to secure covers to auxiliary plate REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS D Reassembly and Installation of Range Cylinder Assembly 3 Place the range yoke into position with sliding clutch of synchronizer assembly long hub of yoke to the front RT 11609 12609 Series long hub of yoke to the rear RT 14609 Series Insert threaded end of yoke bar through yoke and into 1 If previously removed install the O ring in bore o f bore of range cylinder housing aligning the range cylinder
77. ear bearing in bore and complete installation with a flanged end driver and maul Repeat the procedure with other auxiliary countershaft assembly making sure the deep reduction gear set remains in time during bearing installation NOTE Check synchronizer assembly for springs that may be released during bearing installation REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 4 Install the snap ring in groove at rear of each countershaft 1 If previously remvoed install the O ring in bore of range cylinder housing 5 Position the corresponding new gasket on cover mounting surface and install both rear bearin 9 covers Tighten capscrews to secure covers to 2 Position the corresponsding new gasket on hous auxiliary housing ing mounting surface and install the cylinder NOTE For reassembly and installation of models housing in rear bore of auxiliary housing air fit equipped with an Auxiliary Oil Pump Assembl y ting to the upper left Tighten capscraews to se on rear of countershaft see OPTIONS cure cylinder housing to auxiliary housing REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 3 Place the range yoke into position with sliding clutch of synchronizer assembly long hub of yoke to the rear Insert threaded end of yoke bar through yoke and into bore of range cylinder housing aligning the notches in bar with yoke lockscrew holes 6 In cylinder housing bore install the range piston on
78. er and a separate dash mounted Deep Reduction Valve OR the Master Con trol Valve A 5015 CONSTANT AIR from the air filter regulator assem bly is supplied to the reduction cylinder at the port on right side of cylinder cover See Air System Sche matics With the Deep Reduction Lever in the OUT posi tion the valve is OPENED and AIR is supplied to the Center Port of cylinder cover moving the reduction piston forward to disengage deep reduction gearing With the lever moved to the IN position the valve is CLOSED and NO AIR is supplied to the Center Port CONSTANT AIR from the air filter regulator as sembly moves the reduction piston rearward to en gage reduction gearing lt a 27 wuENINLOw O Q RANGE 2 OUT e SHIFT ONLY 72 4 wuEN iN Low O 2 DO NOT PRE SELECT PRE SELECT Lever to IN Valve CLOSED Lever to OUT Valve OPENED For models equipped with the Master Control Valve A 5015 AIR is supplied to the built in deep re duction valve ONLY WHILE IN LOW RANGE from tee fitting at the Low Range or L Port of slave valve The insert valve see page 37 MUST be installed in cylinder cover to provide the proper air flow needed to move the reduction piston in the cylinder See schematic provided on Page 32 NOTE The insert valve is NOT USED in the reduc tion cylinder cover of models equipped with the dash mounted Deep Reduction Valve
79. es If the transmission operating angle is more than 12 degrees improper lubrication can oc cur The operating angle is the transmission mounting angle in the chassis plus the per cent of upgrade expressed in degrees The chart below illustrates the safe percent of upgrade on which the transmission can be used with various chassis mounting angles For example if you have a 4 degree transmis sion mounting angle then 8 degrees or 14 percent of grade is equal to the limit of 12 degrees If you have a O degree mounting angle the transmission can be operated on a 12 degree 21 percent grade Anytime the transmission operating angle of 12 degrees is exceeded for an extended period of time the transmission should be equipped with an oil pump or cooler kit to insure proper lubrication Note on the chart the effect low oil levels can have on safe operating angles Allowing the oil level to fall 1 2 below the filler plug hole reduces the degree of grade by approxi mately 3 degrees 5 5 percent Proper Lubrication Levels are Essential Percent Grade Converted to Dearees Transmission Mounting Angle Dotted line showing 2 Quarts Low is for reference only Not recommended OPERATION 8 Speed LL Series Transmissions Shift Lever Patterns and Shifting Controls RTX Overdrive Models RQ db 3 14651 REDY RTO Overdrive Models WHEN IN LOW RANGE With Deep Re
80. es of mainshaft DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 4 Remove the coupler from splines of range main shaft 3 Spread the countershaft assemblies and pull the NOTE If desired Removal and Disassembly of one gear and washer from splines of main Range Mainshaft Assembly may be performed shatt prior to Removal and Disassembly of Splitter Cyl inder Assembly DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS e CAPSCREW GASKET YOKE BAR amp PISTON AUXLIARY GASKET CYLINDER COVER O RING SHIFT YOKE NOTE Use lock wire at these positions ut 6442 9 80 E Removal and Disassembly of Splitter Cylinder Assembly 1 Cut lockwire and remove the lockscrew from shift 2 Turn out the capscrews and remove the splitter yoke cylinder cover and gasket DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS w 3 If necessary turn out the plug in bottom bore of cover and remove the insert valve 5 Remove the splitter cylinder housing and gasket from auxiliary housing If necessary remove the small O ring from bore in cylinder housing inset 4 Remove the yoke bar from cylinder housing bore If necessary remove the O ring from piston O D inset DISASSEMBLY AUXILIARY SECTION 13 SPEED ied F Removal and Disassembly of Range Mainshaft Assembly 3 Remove both auxiliary countershafts 1 Remove the snap ring from the groove of ran
81. et or flanged end driver to install bearing inner race on shaft shoulder of race against shoulder of coun tershaft 2 Place the right countershaft assembly into posi tion in case making sure that the R marked as sembly has the smaller 45 tooth PTO gear IMPORTANT Mark the countershaft drive gear for timing purposes On the drive gear of each coun tershaft assembly mark the tooth aligned with key way of gear and stamped with an O for easy identification A highly visible color of toolmakers dye is recommended for making timing marks REASSEMBLY FRONT SECTION D Bearing Installation of Left Countershaft Assembly 3 Center the front of left countershaft in bearing and move the assembly forward 1 Move the left countershaft assembly to the rear and insert countershaft support tool or blocking to center shaft in rear case bore 4 Use a flanged end bearing driver to completely seat front bearing or bearing outer race in case bore 2 Use a flanged end bearing driver to start the bearing in case bore NOTE The inner race of roller type front bearing is pressed on front of countershaft REASSEMBLY FRONT SECTION 5 Position the retainer plate on front of left counter shaft roll pin in hole at end of shaft and secure with capscrew tightening to recommended tor que ratings 6 Remove countershaft support tool or blocking from rear case bore and install the left counter shaft rea
82. ge mainshaft 4 Remove the C ring from the groove at front of n mainshaft quill 2 Remove splitter shift yoke and sliding clutch DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS gt 7 Remove bearing inner race from front of counter 5 Remove range mainshaft with jaw puller shaft with jaw puller 6 Remove bearing from front bore of mainshaft If necessary press bushing from mainshaft inset DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS AUXILIARY HOUSING PLUG ASSEMBLY PIPE PLUG MAGNETIC OIL SPEEDO CAPSCREW SEAL P SLINGER PLUG MECHANICAL ELECTRONIC GASKET O RING REAR BEARING COVER MECHANICAL AND GASKET ELECTRONIC SPEEDO CAPSCREW LIFTING EYE Cut6528 1g REAR HOUSING G Removal and Disassembly of Output Shaft and Rear Bearing Assemblies NOTE In addition to the above refer to the illus tration provided at Part D of this section a 1 Use a soft bar to drive the output shaft 2 Remove the bearing inner spacer from output forward and through rear bearing assembly shaft NOTE When applying force to rear of output shaft DO NOT DAMAGE THREADS Support front of shaft to avoid damaging the mainshaft quill once output shaft is free of bearing as sembly DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 5 Remove the two bearing cups and outer spacer from housing bore 3 Using the front face of splitter gear as a base
83. he yoke on bar between tween the front and center bosses long hub to the front and center bosses long hub to the rear the front of housing Just prior to inserting of housing Install the block and yoke lock notched end of bar in rear boss install the small tight 4 interlock pin VERTICALLY in bore at neutral can NN notch Install the block and yoke lockscrews 10 For models so equipped install the oil trough on tighten and wire securely housing Tighten capscrews and wire securely NOTE It is necessary that interlock pin remain in a vertical position during reassembly as rotation of the bar will cause pin to jam in tension spring bores 11 Remove the assembly from vise and install the three tension balls one in each bore on top of housing 8 Install the other 3 4 interlock ball in bore at top of rear boss This ball rides between the 1st 2nd and 3rd 4th speed shift bars DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS D 12 Install the three tension springs one over each ball in housing bores REMOVAL COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING MAGNET NUT DOWEL PLATE d Y fm SELF TAPPING SCREW STUD GASKET PTO COVER CAPSCREW 7 e Um GP AN ERES x x 54 2 T 3 Mu HA i G7 ADU 4 7 i S 2 uve z SUN j an E GUI oat De 2 4 BUSHING 22
84. heck for gears with clutching teeth abnor mally worn tapered or reduced in length from clashing in shifting Replace gears found in any of these conditions PRECAUTIONS Inspection cont d 3 Check axial clearance of gears Where exces sive clearance is found check gear snap ring washer spacer and gear hub for excessive wear Maintain 005 to 012 axial clearance between mainshaft gears SPLINES 1 Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub have worn into the sides of the splines replace the specific shaft affected TOLERANCE LIMIT WASHERS 1 Check surfaces of all limit washers Washers scored or reduced in thickness should be replaced REVERSE IDLER GEAR ASSEMBLIES 1 Check for excessive wear from action of roller bearings GRAY IRON PARTS 1 Check all gray iron parts for cracks and breaks Replace or repair parts found to be damaged Heavy castings may be welded or brazed pro vided the cracks do not extend into bearing bores or bolting surfaces When welding how ever never place the ground so as to allow cur rent to pass through the transmission CLUTCH RELEASE PARTS 1 Check clutch release parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pads 2 Check pedal shafts Replace those worn at bushing surfaces SHIFT BAR HOUSING ASSEMBLY 1 Check for wear on shift yokes and blocks at pads and
85. housing notches in bar with yoke lockscrew holes inset T 4 Install th ke lock igh 2 Position the corresponding new gasket hous 2 two yoke lockscrews tighten and wire ing mounting surface and install the cylinder housing in rear bore of auxiliary plate air fitting to the upper left Secure housing to plate with capscrews tightened to recommended torque rat ings REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 5 If previously removed install the O rings in the 7 Position the corresponding new gasket on cover I D O D of range piston mounting surface and install the range cylinder cover on housing open port to the upper left Tighten capscrews to secure cover to housing 1 E i f 6 In cylinder housing bore install the range piston on yoke bar flat side to the rear Secure with nut tightened to recommended torque ratings inset DISASSEMBLY AUXILIARY SECTION 13 SPEED MODELS AUXILIARY SECTION 13 SPEED SPLITTER MODELS AUXILIARY CYLINDER GASKET CAPSCREW SHIFT YOKE YOKE BAR NOTE Use lockwire at these positions during reassembly it 5426 1078 A Removal and Disassembly of Range Cylinder Assembly ans 2 Remove nut from end of yoke bar 1 For ease of disassembly mount the auxiliary sec tion upright in a vise Turn out the capscrews and remove the range cylinder cover and gasket DISASSEMBLY AUXILIARY SECTION 13 SPEED
86. ife Proper lubrication procedures are the key to a good all around maintenance program If the oil is not doing its job or if the oil level is ignored all the maintenance procedures in the world are not going to keep the transmission running or assure long transmission life Eaton Fuller Transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Thus all parts will be amply lubricated if these procedures are closely followed 1 Maintain oil level Inspect regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy from a reputable dealer Lubrication Change and Inspection Eaton Roadranger CD50 Transmission Fluid HIGHWAY USE First 3 000 to 5 000 miles Factory fill 4827 to 8045 Km Initial drain Every 10 000 miles Check fluid level 16090 Km Check for leaks Every 250 000 miles Change transmission 402336 Km fluid OFF HIGHWAY USE First 30 hours Factory fill Initial drain Every 40 hours Inspect fluid level Check for leaks Every 500 hours Change transmission fluid where severe dirt conditions exist Every 1 000 hours Change transmission fluid Normal off highway use Heavy Duty Engine Lubricant or Mineral Gear Lubricant HIGHWAY USE First 3 000 to 5 000 miles Factory fill 4827 to 8045 Km initial drain Every 10 000 miles Inspect lubricant level 16090 Km Check for
87. ife When the average operating temperature is above 250 F the transmission may require more frequent oil changes or external cooling The following conditions in any combina tion can cause operating temperatures of over 250 F 1 operating consistently at slow speeds 2 high ambient temperatures 3 re stricted air flow around transmission 4 ex haust system too close to transmission 5 high horsepower overdrive operation External oil coolers are available to reduce operating temperatures when the above condi tions are encountered Transmission Oil Coolers are Recommended With engines of 350 H P and above with overdrive transmissions Required With engines 399 H P and above with overdrive transmissions and GCW S over 90 000 Ibs With engines 399 H P and above and 1400 Lbs Ft or greater torque With engines 450 H P and above With EP or Multipurpose Gear Oil Mild EP gear oil and multipurpose gear oil are not recommended when lubricant operating temperatures are above 230 110 C In addi tion transmission oil coolers are not recom mended with these gear oils since the oil cooler materials may be attacked by these gear oils The lower temperature limit and oil cooler restriction with these gear oils gener ally limit their success to milder applications Limitation for Proper Lubrication Percent of Grade Proper Lubrication Levels as Related to Transmission Installation Angl
88. ings and cylinder walls Install valve in bore with flat surface to the inside When install ing the special valve retaining nut apply Fuller 71204 adhesive sealant or its equivalent to threads and tighten See TORQUE RECOMMENDATIONS 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 freely through the insert valve and to the backside of cylin der piston moving the yoke bar forward to disengage deep reduction or splitter gearing LOW RANGE AND HIGH RANGE OR DIRECT When AIR is applied to the top side of valve piston through signal line the piston moves down to cut off air supplied to the backside of cylinder piston This air is exhausted out bottom port of cover when CONSTANT AIR supplied from the regulator is directed to the frontside of cyl inder piston moving the yoke bar rearward to engage deep reduction or splitter gearing LO LO AND UNDERDRIVE OVERDRIVE LO LO OR UNDERDRIVE OVERDRIVE AIR APPLIED THROUGH SIGNAL LINE PUSHES INSERT VALVE PISTON DOWN CONSTANT AIR SEALED OFF AT THIS POINT Cut 7450B 4 84 AIR EXHAUST THROUGH BOTTOM PORT FROM BACK SIDE OF PISTON AIR SYSTEM SELECTOR VALVE Em COVER RTO RTOO SHOWN SEAT DETENT d RETAINER SPRING SG RING RETAINER VALVE BODY NOTE This valve is used as a separate unit with Range Valve to
89. ings in bores of high range on flange of auxiliary plate Position the corre synchronizer ring sponding new gasket on cover mounting surface and install the rear bearing cover Use the nylon collar and brass washer with capscrew at the chamfered hole which intersects speedometer bore inset Tighten the capscrews to secure cover to auxiliary plate NOTE Because the collar becomes distorted when compressed DO NOT RE USE OLD NYLON COLLAR B Reassembly and Installation of Synchronizer Assembly 3 Place the high range synchronizer ring over blocker pins of low range synchronizer seating the springs against pins 1 Place the larger low range synchronizer ring on bench and install the sliding clutch on blocker pins recessed side up REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS C Timing and Installation of Auxiliary Countershaft Assemblies 1 m E T zx 1 Apply downward pressure to the high range syn chronizer ring WHILE TWISTING COUNTER CLOCKWISE to compress the springs and fully seat ring on blocker pins of low range synchroni Zer 1 If previously removed install the bearing inner race on front of each countershaft 5 Install the synchronizer assembly on splines of output shaft low range ring in recess of low range gear 2 IMPORTANT On the low range gear of each aux countershaft assembly use a highly visible color of toolmaker s dye to mark th
90. inst front bearing cone 10 Place the front bearing cup in housing bore taper to the inside and use a soft bar to start cup into bore 7 Place two mainshaft spacers or flat steel stock of equivalent thickness 190 on rear face of deep reduction gear 1809 from each other left Install the auxiliary housing over end of output shaft as sembly allowing the housing to rest on blocking right REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 11 Stack the bearing outer spacer and rear bearing cup on top of the front bearing cup in proper se quence Use a soft bar or a flanged driver to move all three parts evenly into housing bore until lip of rear bearing cup seats on housing 14 Remount assembly upright in vise and secure in stall the deep reduction sliding clutch on output shaft internal splines toward gear and engaged with splines of shaft 12 If not previously done so install the auxiliary housing over end of output shaft assembly Heat the rear bearing cone and install on shaft taper down and inside bearing cup NOTE DO NOT HEAT BEARING ABOVE 2759 136 C 13 For 14608 LL Model install the speedometer 15 Install snap ring in groove of range mainshaft drive gear or replacement spacer on output shaft and retain with snap ring installed in groove of shaft left Remove the blocking two mainshaft spacers or flat steel stock from between the deep reduction gear and auxiliary hou
91. ion Trouble Shooting If the transmission fails to shift or shifts too slowly to or from the split position the fault may be in the Splitter Shift Air System or related components of the Range Shift Air System To locate the trouble the following checks should be made with normal vehicle air pressure supplied to the system but with the engine off See CAUTION Page 25 NOTE It is assumed that correct PSI readings were obtained from the air filter regulator and ail air lines have been checked for leaks 1 Air Supply See Air System Schematics With the gear shift lever in neutral select HIGH RANGE and loosen the connection at the S Port of Splitter Selector Valve or H Port of Mas ter Control Valve until it can be determined that AIR is supplied to valve Reconnect air line If there is NO AIR check for a restriction in the 1 8 O D air line between the control valve and slave valve making sure this line is connected to tee fitting at the High Range or H Port of slave valve 2 Selector or Roadranger Valve See Pages 38 39 and Air System Schematics With the gear shift lever in neutral disconnect the 1 8 O D air line at the Center Port of splitter cylinder cover making sure this line leads from the D Port of Splitter Selector Valve or SP Port of Master Valve A WHILE IN HIGH RANGE move the Splitter Control Button FORWARD There should be AIR flowing from disconnected line Move the button RE
92. ith the gear shift lever in neutral disconnect the 1 8 O D air line at the Center Port of reduc tion cylinder cover making sure this line leads from the SP Port of control valve A WHILE IN LOW RANGE move the Deep Re duction Button FORWARD There should be AIR flowing from disconnected line Move the button REARWARD to shut off air flow and re connect air line B If the preceding conditions did not exist the control valve is defective or there is a restric tion in the air lines 3 Reduction Cylinder Refer to the following illus tration If any of the seals in the reduction cylinder as sembly are defective the deep reduction shift will be affected The degree of air lost will govern the degree of failure from slow shifting to com plete shift failure A Leak at O ring A results in a slow shift to engage deep reduction gearing pressurizing of transmission case deep reduction gearing can be disengaged B Leak at O ring B results in slow shifting or complete failure to engage and disengage deep reduction gearing steady flow of air from exhaust port of control valve and or inder cover when Deep Reduction Button is in the FORWARD position C Leak at gasket C results in a slow shift to dis engage deep reduction gearing steady flow of air to atmosphere Air ONLY when Deep Reduction Button is FORWARD YY Y S DULL E Ra ES VL 1 y Nis e VE z 1 YOKE BAR T SD
93. ke sure the three magnetic discs are solidly in place at bottom of case These can be secured to disc mounting sur faces with Scotch Grip Rubber Adhesive or equiva lent adhesive A Reassembly and Installation of Right Reverse Idler Gear Assembly 3 Install the bearing inner race on idler shaft and in sert shaft into case bore threaded end of shaft to the front As the idler shaft is moved forward in stall the reverse idler gear on shaft long hub to the front and seating on bearing inner race Posi tion the thrust washer on shaft between the gear and support boss in case and continue with movement of idler shaft forward into bore of sup port boss 1 If previously removed thread pipe plug in rear of reverse idler shaft and tighten Install the idler plate on shaft flat side to the front inset 4 Making sure that the reverse idler shaft is seated in bore of support boss and forward as far as pos sible install the washer and stop nut on front of shaft Tighten nut to recommended torque rating 2 If previously removed press the needle bearing into bore of reverse idler gear REASSEMBLY FRONT SECTION 7 S 5 Install the OUTER RACE of auxiliary countershaft front bearing into case bore and against idler plate NOTE The bearing INNER RACE is installed on front of auxiliary countershaft and never with po outer race 2 Align keyway of gear with key in countershaft and press
94. leaks Every 50 000 miles Change transmission 80450 Km lubricant OFF HIGHWAY USE Change transmission lubricant new units First 30 hours Every 40 hours Inspect lubricant level Check for leaks Every 500 hours Change transmission lubricant where severe dirt conditions exist Every 1 000 hours Change transmission lubricant Normal of highway use Recommended Lubricants Fahrenheit Celsius Grade mbien Temperature Type SAE Eaton Roadranger CD50 Transmission Fluid Heavy Duty Engine 011 MIL L 2104B C or D or 50 API SF or API CD 40 Prewous API designations 30 acceptable Above 10 E 12 C Above 10 F 12 C Below 10 12 Mineral Gear Oil with rust 90 and oxidation inhibitor 80W API GL 1 The use of mild EP gear oil or multi pur pose gear oil is not recommended but if these gear oils are used be sure to adhere to the following limitations Do not use mild EP gear oil or multi pur pose gear oil when operating temperatures are above 230 110 C Many of these gear oils particularly 85W140 break down above 230 and coat seals bearings and gears with de posits that may cause premature failures If these deposits are observed especially a coat ing on seal areas causing oil leakage change to Eaton Roadranger CD50 transmission fluid heavy duty engine oil or mineral gear oil to assure maximum component life and to main tain your warranty with Eaton Al
95. lve 3 Place the reduction yoke into position with slid ing clutch lockscrew hole to the front From rear of auxiliary housing insert the yoke bar through cylinder bore and into yoke aligning the notch in bar with yoke lockscrew hole 6 Position the corresponding new gasket on cover mounting surface and install the deep reduction cylinder cover aligning the air channel with chan nel in cylinder housing housing Tighten capscrews to se cure c ver to cylinder housing 4 Install the yoke lockscrew tighten and wire se curely REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS D Installation of Low Range Gear a mE Lm Ne m cte omo 1 3 Install the splined tolerance washer on mainshaft and in hub of low range gear Rotate the washer in groove of mainshaft to engage external splines with clutching teeth of gear and align square in ternal spline with keyway of mainshaft IMPORTANT This washer is available in varying thicknesses Use the splined tolerance washer that provides a snug fit in gear hub 1 Install the coupler on range mainshaft clutching teeth to the rear 2 Install the low range gear on mainshaft against coupler clutching teeth to the front 4 Install the key in keyway of range mainshaft in serting the thick end of key in square internal spline of tolerance washer to lock low range gear on shaft REASSEMBLY AUXILIARY SECTION 8 SPEED LL
96. n release bearing b Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches Clutch Pedal Shaft and Bores a Pry upward on shafts to check wear b If excessive movement is found remove clutch release mechanism and check bush ings in bores and wear on shafts Lubricant a Change at specified service intervals b Use only the types and grades as recom mended See LUBRICATION Filler and Drain Plugs a Remove filler plugs and check level of lubri cant at specified intervals Tighten filler and drain plugs securely Capscrews and Gaskets a Check all capscrews especially those on PIO covers and rear bearing covers for looseness which would cause oil leakage oee TORQUE RECOMMENDATIONS b Check PTO opening and rear bearing covers for oil leakage due to faulty gasket Gear Shift Lever a Check for looseness and free play in hous ing If lever is loose in housing proceed with Check No 9 9 Gear Shift Lever Housing Assembly a Remove air lines at slave valve and remove the gear shift lever housing assembly from transmission b Check tension spring and washer for set and wear c Check the gear shift lever spade pin and slot for wear d 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
97. nd extended life from your unit oince the cost of a new part is generally a small fraction of the total cost of downtime and labor avoid reus ing a questionable part which could lead to additional repairs and expense soon after initial reassembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the un its history mileage application etc Recommended inspection procedures are provided in the following checklist A BEARINGS 1 Wash all bearings in clean solvent Check balls rollers and raceways for pitting discol oration and spalled areas Replace bearings that are pitted discolored or spalled 2 Lubricate bearings that are not pitted discol ored or spalled and check for axial and radial clearances Replace bearings with excessive clearances 3 Check bearing fits Bearing inner races should be tight to shaft outer races slightly tight to slightly loose in case bore If bearing spins freely in bore however the case should be replaced B GEARS 1 Check gear teeth for frosting and pitting Frosting of gear tooth faces present no threat of transmission failure Often in continued operation of the unit frosted gears will heal and not progress to the pitting stage And in most cases gears with light to moderate pit ted teeth have considerable gear life remain ing and can be reused But gears with advanced stage pitting should be replaced 2 C
98. ntershaft Use three 3 3 8 x 1 capscrews for each strap For vertical shimming place the transmission in the vertical position Place 2 wood blocks under the clutch housing to prevent the trans mission from tipping and damaging the input shaft Place the auxiliary housing on the front box Install the auxiliary housing capscrews Tighten to the recom mended torque Remove each countershaft strap Install the 125 gaging shim and the countershaft bearing cover Make sure the shim is properly aligned on the bearing race Use two 2 3 8 x 1 capscrews without lock washers Install the capscrews directly across from each other 7 Tighten to 7 in lbs of torque Do not over torque Incorrect readings will be produced Make sure the countershaft rear bearing cover gaskets have been removed 8 Rotate the output shaft six times in the clockwise direction then six times counterclockwise to properly seat the bearings Use a feeler gauge to measure the clearance between the shim gauge and auxiliary housing surface near each capscrew location Record each measurement and average the two measurements Refer to the Shimming Endplay Chart and select the number in the left column which corresponds to the average measurement which was achieved Follow the column to the right to determine the proper thickness and shim required Note part number and shim color Repeat this procedure for the other countersh
99. o expose air line fittings Disconnect air lines 2 Loosen jam nut and turn control valve from gear shift lever 3 Pry medallion from recess in top cover 4 Turn out the two screws to remove the top cover from valve housing 5 Remove the actuator button from valve housing and the spring retainer springs seal amp detent parts from actuator and or valve housing 6 Turn out the two screws in side of valve housing to separate the housing 7 Remove the Range Preelection Lever from left housing and the position balls and guide from lever 8 If necessary remove springs O ring and retainer from bores in right housing Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Reinstall control valve on gear shift lever and tighten jam nut 3 Attach air lines and reinstall bottom cover AIR SYSTEM SPLITTER SHIFT AIR SYSTEM 13 SPEED SPLITTER MODELS ONLY Operation In addition to the various components of the Range shift Air System the Splitter Shift Air System utilizes a splitter cylinder and a separate lever mounted Split ter Selector Valve OR the Roadranger Control Valve A 4900 See Air System Schematics CONSTANT AIR from the air filter regulator assem bly is supplied to the s
100. oil seal in rear bearing cover Seal should be installed so the spring is to the front of cover inset REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 13 Position the corresponding new gasket on cover mounting surface and install the rear bearing cover on auxiliary housing Use the nylon collar and brass washer with capscrew at the cham fered hole which intersects speedometer bore in set Tighten the capscrews to secure cover to housing NOTE Because the collar becomes distorted when compressed DO NOT REUSE OLD NYLON COLLAR REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS C Timing and Installation of Auxiliary Countershaft Assemblies NOTE The auxiliary countershaft assemblies CANNOT be installed in housing with prior instal lation of the splitter shift yoke L 3 Place the left countershaft assembly into posi tion in housing and mesh the marked tooth of countershaft splitter gear with either set of two marked teeth of splitter gear on output shaft DO NOT INSTALL REAR BEARING AT THIS TIME 1 If previously removed install the bearing inner race on front of each countershaft 4 Repeat the previous procedure with the right countershaft assembly meshing the marked tooth of countershaft splitter gear with the re maining set of two marked teeth of splitter gear on output shaft DO NOT INSTALL REAR 2 On the splitter gear of each assembly use a BEARING AT THIS TIME highly visible col
101. on in line between the Deep Reduction Valve and slave valve making sure this line is connected to tee fitting at the Supply or S Port of slave valve AIR SYSTEM 2 Deep Reduction Valve See Air System Schematics With the gear shift lever in neutral disconnect the air line leads from OUTLET of Deep Reduc tion Valve A WHILE IN LOW RANGE move the Deep Re duction Valve Lever to the IN position There should be NO AIR flowing from discon nected line B Move the valve lever to the OUT position There should now be CONSTANT AIR flowing from disconnected line Return the valve lever to the IN position to shut off air flow and re connect air line 555 HOUSING Cut 7440 4 84 3 Reduction Cylinder Refer to the following illustration If any of the seals in the reduction cylinder as sembly are defective the deep reduction shift will be affected The degree of air lost will govern the degree of failure from slow shifting to com plete shift failure A Leak at O ring A results in a slow shift to engage deep reduction gearing pressurizing of transmission case deep reduction gearing can be disengaged B Leak at O ring B results in slow shifting or complete failure to engage and disengage deep reduction gearing steady flow of air from exhaust port of Deep Reduction Valve when lever is in the IN position C Leak at gasket C results in a slow shift to dis engage deep reduction gearing s
102. or of toolmakers dye to mark the tooth stamped with an O for timing pur poses REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS D Reassembly and Installation of Splitter Cylinder Assembly 3 If previously removed install the O ring in O D groove of yoke bar piston 1 Install the splitter sliding clutch on output shaft internal splines toward gear and engaged with splines of shaft inset Place the splitter shift yoke into position with sliding clutch on output shaft yoke hub to the front of housing 4 From the rear of housing insert the yoke bar through cylinder bore and into shift yoke align ing the notch in bar with lockscrew hole in yoke hub 2 If previously removed install the small O ring in bore of cylinder housing inset Position the cor responding new gasket on housing mounting sur face and install the splitter cylinder housing in rear bore of auxiliary housing air channel to the right REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS 9 Install the yoke lockscrew tighten and wire se 7 Position the corresponding new gasket on cover curely mounting surface and install the splitter cylinder cover on cylinder housing exhaust port down in stall the capscrews in cover and tighten to secure the assembly on auxiliary housing NOTE With the cover installed in this manner the air channel of cover will align with that of cyl inder housing E Installation of Low Range Gear
103. oth countershaft to ing clutch mating countershaft gears of engaged main 10 Output shaft delivers torque to driveline as shaft gear The following cross section views LO LO Figures 2 4 illustrate a 1st 5th speed gear engagement Figure 1 illustrates the engagement of the Lo Speed Gear Internal clutching teeth in hub of engaged main shaft gear transfers torque to mainshaft through sliding clutch Mainshaft transfers torque directly to auxiliary drive gear 3 9 2 10 1 1 PR15 LO LO POWER FLOW POWER FLOW Auxiliary Section Power Flow LOW RANGE All Models 7 The auxiliary drive gear splits torque between the 9 Torque is transferred to range mainshaft or out two auxiliary countershaft drive gears put shaft through sliding clutch 8 Torque is delivered along both countershaft to 10 Torque is delivered to driveline as LOW RANGE engaged low range gear on range mainshaft or 1st output shaft PLIO Figure 2 LOW RANGE POWER FLOW 9 Speed Model Shown Auxiliary Section Power Flow HIGH RANGE All Models 7 The auxiliary drive gear transfers torque 8 Torque is delivered through range mainshaft and directly to the range mainshaft or output or output shaft to driveline as HIGH RANGE 5th shaft through engaged sliding clutch oth direct with 13 speed models 3 4 5 5 7 Figure 3 HIGH RANGE POWER FLOW 9 Speed Model Shown POWER FLOW Auxiliary Sec
104. ove auxiliary section to the rear and just far enough from front section to break gasket seal 4 The auxiliary section can also be removed with transmission set in the vertical position Block under the clutch housing to prevent damage to the input shaft remove the retaining capscrews in housing flange and lift the assembly from front section Remove gasket REMOVAL COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING C Removal of Clutch Housing 1 For models so equipped remove the clutch re lease mechanism and or clutch brake assembly See OPTIONS 2 Turn out the four capscrews and remove the six nuts and lockwashers from studs securing the clutch housing to transmission case 3 Jar clutch housing with a rubber mallet to break gasket seal and pull from transmission case Re move gasket DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS AUXILIARY SECTION 8 SPEED LL MODELS CAPSCREW RING NUT AUXILIARY CYLINDER GASKET SHIFT YOKE YOKE BAR NOTE Use lockwire at these Cut 6426 10 80 positions during reassembly A Removal and Disassembly of Range Cylinder Assembly 1 For ease of disassembly mount the auxiliary sec tion upright in a vise Turn out the capscrews and remove the range cylinder cover and gasket 3 Cut lockwire and remove two yoke lockscrews DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 6 Remove the rance piston f
105. ped install the speedometer drive gear or replacement spacer in position on hub of companion flange or yoke Install the com panion flange or yoke on splines of output shaft and move into rear bearing cover NOTE For 14608LL models the speedometer drive gear or replacement spacer is installed on output shaft prior to installation of rear bearing cover AUXILIARY SECTION AND CLUTCH HOUSING Lock the transmission by engaging two main shaft gears with sliding clutches Install the washer and or nut on output shaft and tighten nut using 450 500 Ibs ft of torque INSTALLATION SHIFTING CONTROLS SHIFT BAR HOUSING ASSEMBLY A Installation Install the new shift bar housing gasket posi 1 Place all three mainshaft sliding clutches in the tion on case neutral position 2 With all three shift bars in the neutral position in stall the shift bar housing assembly on case fit ting the shift yokes into slots of corresponding sliding clutches NOTE Avoid tilting the assembly during installation as the three sets of tension springs and balls are free to be released from bores in top of housing 3 Install the capscrews in housing and tighten to secure the assembly to case INSTALLATION SHIFTING CONTROLS GEAR SHIFT LEVER HOUSING ASSEMBLY A Installation NOTE For models equipped with a LRC or SRC Assembly the housing is installed in the same manner described in the following instructions
106. plitter cylinder at the port on right side of cylinder cover The Insert valve installed in cover see Page 37 provides the proper air flow needed to move the splitter piston in the cylinder rearward to engage splitter gearing forward to dis engage splitter gearing WHILE IN HIGH RANGE ONLY AIR needed to make the splitter selection and complete the shift is supplied to the control valve from tee fitting at the High Range or H Port of slave valve When the splitter selection is made the AIR passes through the control valve and is supplied to the Center Port of cylinder cover With Splitter Control Button in the DIR REARWARD position the D or SP Port of control valve is CLOSED and NO AIR is supplied to the Cen ter Port of Splitter cylinder cover Fuller 0D Fuller yin Roadranger Transmissions Button in DIR 0 Port CLOSED Button REARWARD SP Port CLOSED WHILE IN HIGH RANGE the button can be moved FORWARD to operate in UNDERDRIVE or OVER DRIVE The D or SP Port of valve is OPENED when splitter selection is made supplying AIR to the Center Port of Splitter cylinder cover 0D Fuller pir Roadranger Button in U D or O D 0 Port OPENED Button FORWARD Port OPENED NOTE WHILE IN LOW RANGE the mechanical in terlock of Master Valve prevents movement of Splitter Control Button to the FORWARD po sit
107. plunger DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 3 Install the plug and tighten to compress spring left Back the plug out 1 1 1 2 turns and stake plug through the small hole in yoke right 5 Holding shank of plunger install the actuating plunger in bore at top of center boss 4 With the shift bar housing secured in vise as during disassembly hold notched end of short LO Reverse speed shift bar and install in lower bore of housing bosses positioning the yoke on bar between the bosses Install the yoke lock screw tighten and wire securely NOTE Start with the lower shift bore of rear boss and move to the left front of housing Keep bars in the neutral position during installation DO NOT EXCEED the recommended torque ratings 6 Install one 3 4 interlock ball in bore at top of rear for yoke lockscrews as over tightening may dis boss This ball rides between LO Reverse and 1st tort shift bars 2nd speed shift bars DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 7 Holding notched end of bar install the 1st 2nd 9 1 A 1 E a LI il gt eta Holding notched end of bar install the 3rd 4th speed shift bar in middle bore of housing boss speed shift bar in upper bore of housing boss po positioning the shift block on bar between the sitioning the shift block on bar between the cen center and rear bosses and the yoke on bar be ter and rear bosses and t
108. press the output shaft through the bearing washer and gear DO NOT DAMAGE MAINSHAFT QUILL If necessary remove the snap ring from I D of splitter gear inset 4 Turn out the retaining capscrews and remove the rear bearing cover and gasket from auxiliary housing The rear bearing cone will drop from housing bore when cover is removed If neces sary remove the oil seal from cover inset REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS AUXILIARY SECTION 13 SPEED MODELS A Reassembly and Installation of Range Mainshaft Assembly Da i 3 Install the bearing in front bore of range main 1 Secure the output shaft in a vise with mainshaft shaft Use a small flanged end driver to properly quill up seat bearing in bore on mainshaft quill 4 Install the C ring in groove of mainshaft quill to 2 If necessary press the bushing in rear bore of retain bearing range mainshaft and install the mainshaft in posi tion on quill inset REASSEMBLY AUXILIARY SECTION 13 SPEED MODELS B Reassembly and Installation of Output Shaft and Rear Bearing Assemblies 3 IMPORTANT For timing purposes mark any two adjacent teeth on splitter gear and repeat the pro cedure for the two adjacent teeth directly oppo site the first set marked A highly visible color of 1 Remount the output shaft in vise with threaded toolmakers dye is recommended end up and secure on range mainshaft Install the stepped
109. provide splitter selections Cut 6152 3 84 Removal and Disassembly Reassembly and Installation 1 Disconnect all air lines to the valve Loosen the 1 Refer to the drawing for proper reassembly Use a jam nut securing the valve to gear shift lever and VERY SMALL amount of silicone lubricant on the turn the valve from lever O rings to avoid clogging ports 2 Turn out the three screws from bottom of valve 2 Install the air lines with their sheathing and O body and remove the top cover rings on the gear shift lever 3 Remove the actuator control button from cover 3 Install the jam nut and valve on lever Use the nut post and the springs seals O rings and detent to lock the valve in position with control button on parts from actuator drivers side 4 Connect the 1 8 O D air line from Center Port of splitter cylinder cover to D Port air line from tee fitting at the High Range or H Port of slave valve to 5 Port AIR SYSTEM ROADRANGER VALVE A 4900 ROADRANGER VALVE ASSEMBLY WAVEWASHER RETAINER O RING COVER SCREW 4 Cut 6145 G 2 88 Removal and Disassembly 1 Remove two screws holding bottom cover to valve and slide cover down gear shift lever to expose air line fittings Disconnect air lines Loosen jam nut and turn control valve from gear shift lever Pry medallion from recess in top cover 4 Turn out the two screws to remove the top cover from valve housing Remove the
110. r bearing with larger 1 0 lead chamfer to the front of shaft and install the snap ring in groove at rear of left countershaft REASSEMBLY FRONT SECTION E Reassembly Installation and Timing of Main Drive Gear Assembly PX E E 5 L 3 Mesh the marked tooth of left countershaft drive gear with either set of two marked teeth on main drive gear Slide the input shaft through the main drive gear inset 1 If previously removed install the snap ring in I D of main drive gear and the bushing in pocket of input shaft inset 4 Install spacer inset and bearing on the input shaft with external snap ring to the outside 2 Mark the main drive gear for timing purposes Mark any two adjacent teeth on drive gear and re peat the procedure for the two adjacent teeth directly opposite the first set marked A highly visible color of toolmakers dye is recommended for making timing marks REASSEMBLY FRONT SECTION 5 Tap the bearing into position in the bore with a 7 Use a soft bar and maul to drive the input shaft soft mallet through bearing Remove front bearing cover F Reassembly of Auxiliary Drive Gear Assembly NOTE Because the auxiliary drive gear assembly 15 used in checking reverse gear axial clearances and centering mainshaft in rear bearing bore during Reassembly and Partial Installation of Mainshaft Assembly it is necessary to complete the following instructions BE
111. rformed at this time as described in Part A of this section 4 With bearing installation complete install the Snap ring in groove at rear of right countershaft REASSEMBLY FRONT SECTION J Completed Installation of Mainshaft and Auxiliary Drive Gear Assemblies 3 Align the external splines of spacer with clutch i ing teeth of reverse gear and move spacer 1 Remove the auxiliary drive gear assembly from forward on mainshaft and into gear mainshaft and rear bearing bore Do not allow mainshaft to move to rear when removing aux liary drive gear 3 4 Install the snap ring hub of reverse gear and P 2 move the reverse gear forward on mainshaft and into proper position in case 2 Move the reverse gear to the rear as far as possi ble meshing teeth of gear with those of the re verse idler gears REASSEMBLY FRONT SECTION 5 Reinstall the auxiliary drive gear assembly on rear of mainshaft Use a flanged end driver and maul to seat bearing in case bore 4 7 Install the snap ring in groove at end of main 1 shaft K Installation of Drive Gear Nut and Front Bearing Cover 6 Align the six capscrew holes in retainer with the tapped holes in case and install capscrews Tighten to recommended torque ratings and lock wire the capscrews in groups of three 1 Apply Loctite grade 277 sealant to cleaned threads of new drive gear bearing nut
112. rom cylinder bore If necessary remove the O rings from piston I D and O D inset 7 Turn out the capscrews and remove the range cyl inder housing and gasket If necessary remove the small O ring from groove in housing bore inset 5 Remove range yoke from sliding clutch of syn chronizer assembly DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS BEARING SNAP RING COUNTERSHAFT ASSEMBLY Cut 6502 1 81 B Removal of Auxiliary Countershaft Assemblies 2 Remove the snap ring from groove at rear of each countershaft 1 Turn out the capscrews and remove both coun tershaft rear bearing covers NOTE For removal and disassembly of models equipped with an Auxiliary Oil Pump Assembly on rear of countershaft see OPTIONS DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS b F 3 Use a soft bar and maul to drive the coun tershaft forward and from rear bearings 4 If necessary secure the assembly in a vise and remove the bearing inner race from front of coun tershaft with jaw pullers NOTE The vise used should be equipped with brass jaws or wood blocks to prevent damage to the countershaft DISASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS SYNCHRONIZER LO SARA PUCER H SLIDING 1 Not used in current production CLUTCH or in K 1654 kit Was only used with A 4683 Synchronizer Do not use with A 4388 Synchronizer Cut 6408B 3 84 Ref Service Bulletin
113. s and remove the range cyl inder housing and gasket If necessary remove the small O ring from groove in housing bore in Set DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS SNAP RING COUNTERSHAFT ASSEMBLY BEARING BEARING Cut 6485 9 80 B Removal of Auxiliary Countershaft Assemblies 2 Remove the snap ring from groove at rear of each countershaft 1 Turn out the capscrews and remove both coun tershaft rear bearing covers and gaskets DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 3 Use a soft bar and maul to drive the coun tershaft forward and from rear bearings 5 If necessary secure the assembly in a vise and re move the bearing inner race from front of coun tershaft with jaw pullers NOTE The vise used should be equipped with brass jaws or wood blocks to prevent damage to the countershaft 4 Remove the bearings from bores in auxiliary plate by tapping lightly and evenly to the rear with a soft bar DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 4 oS SYNCHRONIZER LO SYNCHRONIZER HI Sra SLIDING in current production CLUTCH or in 1684 it PIN Was only used with A 4683 Synchronizer Do not use with A 4388 Synchronizer Cut 6408B 3 84 Ref Service Bulletin 130 7 81 C Removal and Disassembly of Synchronizer Assembly 2 Place the larger low range synchronizer ring on bench and pull
114. sing right REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS C Reassembly and Installation of Deep Reduction Cylinder Assembly fe Y Low 3 i ie 3 si T D 9 1 If previously removed install the small O ring in 16 If previously removed install the oil seal in rear bore of cylinder housing inset Position the cor bearing cover inset Seal should be installed so responding new gasket on housing mounting sur the spring is to the front of cover face and install the deep reduction cylinder housing in rear bore of auxiliary housing air channel to the right 17 Position gasket on cover mounting surface and 2 If previously removed install the O ring in groove install the rear bearing cover on auxiliary hous of yoke bar piston ing Use the nylon collar and brass washer with capscrew at the chamfered hole which intersects speedometer bore inset Tighten capscrews to se cure cover to housing NOTE Because the collar becomes distorted when compressed DO NOT REUSE OLD NYLON COLLAR REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 5 For models so equipped install the insert valve in bottom exhaust port of cylinder cover as shown left Install the valve retaining nut in ex haust port of cover and tighten to recommended torque ratings right NOTE Prior to installation of insert valve apply a small amount of silicone lubricant to O rings on O D of va
115. so see Operating Temperatures Additives and friction modifiers are not recom mended for use in Eaton Fuller transmissions Above 10 F 12 C Below IO F 12 C Proper Level Improper Oil Level Proper Oil Level Make sure oil is level with filler opening Be cause you can reach oil with your finger does not mean oil is at proper level One inch of oil level is about one gallon of oil Draining Oil Drain transmission while oil is warm To drain oil remove the drain plug at bottom of case Clean the drain plug before re installing Refilling Clean case around filler plug and remove plug from side of case Fill transmission to the level of the filler opening If transmission has two filler openings fill to level of both open ings The exact amount of oil will depend on the transmission inclination and model Do not over fill this will cause oil to be forced out of the transmission When adding oil types and brands of oil should not be mixed because of possible in compatibility LUBRICATION Operating Temperatures With Eaton Roadranger CD50 Transmission Fluid Heavy Duty Engine Oil and Mineral Oil The transmission should not be operated con sistently at temperatures above 250 120 C However intermittent operating temperatures to 300 F 149 C will not harm the transmis sion Operating temperatures above 250 F increase the lubricants rate of oxidation and shorten its effective l
116. t the capscrews and remove the rear bearing cover and gasket The rear bearing cone if will drop from bore in auxiliary plate when cover 5 Remove the splined spacer from output shaft is removed If necessary remove the oil seal from cover inset 6 Remove the stepped washer from shaft of models So equipped 8 Remove the two bearing cups and outer spacer from bore in auxiliary plate REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS AUXILIARY SECTION 9 SPEED MODELS A Reassembly and Installation of Output Shaft and Rear Bearing Assemblies 3 IMPORTANT Mark any two adjacent teeth on low range gear and repeat the procedure for the two adjacent teeth directly opposite the first set marked A highly visible color of toolmakers O dye is recommended 1 Secure the output shaft in a vise with threaded end up For models so equipped install the stepped washer on shaft large diameter step down arrow then install the splined spacer E i ur E a i P F p 773 4 If previously removed install the snap ring in low range gear of models so equipped inset Install 2 For 14609 models install the spacer with large the gear on output shaft clutching teeth down diameter splines down and engaged with splines of spacer REASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS LETTER 324 J 5
117. tall the splined spacer on output shaft For models equipped with stepped washer on shaft install the spacer with large diameter splines down right 4 If previously removed install the snap ring in deep reduction gear of models so equipped in set Install the gear on output shaft clutching teeth down and engaged with splines of spacer REASSEMBLY AUXILIARY SECTION 8 SPEED LL MODELS 5 Install the washer on shaft against deep reduc 8 Heat the front bearing cone and install on output tion gear small diameter step down Left shaft against oil retention ring bearing taper up 11608LL Models or side with large groove up left For models not equipped with the oil reten Right 14608LL Models tion ring in auxiliary housing install the heated NOTE For models not equipped with the oil reten bearing cone on shaft against washer taper up tion ring in auxiliary housing proceed to No 8 right NOTE DO NOT HEAT BEARING ABOVE 275 136 C If possible use heat lamps as source 6 14608LL Models only Place the oil retention ring in housing bore cupped side up left Use a soft bar and two rear bearing outer spacers stacked on top of each other to move the oil re tention ring 2 deep into bore The ring will be at the proper depth when top of second spacer is flush with housing bore Remove the spacers when installation is completed 9 Install the bearing inner spacer on output shaft aga
118. tch from mainshaft in the same manner previously detailed And if necessary re move the snap ring from 1 0 of each gear 8 Using a small screwdriver turn the limit washer in hub of LO speed gear to align its splines with those of the mainshaft MAIN DRIVE GEAR SPACER BEARING SNAP RING 5 qu i y n MAIN DRIVE GEAR BEARING 3 SNAP RING 9 1 ce C2 SNAP RING DISASSEMBLY FRONT SECTION INPUT SHAFT BUSHING INPUT SHAFT BUSHING SLEEVE INPUT SHAFT MAIN DRIVE GEAR SNAP RING Cut 6391A 2 84 BEARING F Removal and Disassembly of Main Drive Gear Assembly 1 Drive the input shaft back through bearing with a soft bar and maul Remove input shaft from case inset 2 Move upper countershaft to right and remove drive gear and spacer from case DISASSEMBLY FRONT SECTION 3 Drive the input shaft bearing out the front of case 4 If necessary remove the snap ring from drive gear a NL ES Fo 8 5 Check the bushing in pocket of input shaft and replace if worn or damaged 6 Remove the front and rear bearings from left countershaft as described in Part D of this sec tion DISASSEMBLY FRONT SECTION G Removal and Disassembly of NOTE Refer to the illustration provided at Part D of this section Except for the PTO gears the left and right countershaft assemblies are identical and dis
119. teady flow of air to atmosphere C COVER Air ONLY when ij NNT is i m PT QUT position 2 E RS Bl N d YOKE BAR Room m AND 2207 ES PISTON SS CONSTANT AIR from Air Filter Regulator REDUCTION CYLINDER ASSEMBLY Models equipped with Deep Reduction Valve ONLY AIR SYSTEM For Models Equipped with the Master Control Valve A 5015 If there is NO AIR check for a restriction in the 1 Air Supply See schematic below 1 8 O D air line between the control valve and With the gear shift lever in neutral select LOW s uL slave valve making sure this line is connected to RANGE and loosen the connection at the H tee fitting at the Low Range or L Port of slave Port of control valve until it can be determined en valve that AIR is supplied to valve Reconnect air line LO LO NOTE ARROWS INDICATE DIRECTION OF AIR FLOW S SHADED AREAS INDICATE CHARGED LINES Roadranger A 5000 VALVE Valve SLAVE VALVE IDENTIFICATION 4 4688 VALVE 19470 VALVE O Lo LAS IE 42 E o Slave Valve 19470 OR A 5000 Air Filter Regulator Reduction Cylinder Range Cylinder Assembly Assembly Assembly AIR to Port in Housing AIR FROM VEHICLE RCE Cut 7050 2 85 SHIFT YOKE AIR SYSTEM 2 Roadranger Valve See Page 34 and schematic on preceding page W
120. th the proper reverse gear limit washer stalled on mainshaft remove the auxiliary drive gear assembly and reverse gear 000006 27 Remove the snap ring from hub of reverse gear and reinstall the gear on mainshaft Engage the clutching teeth of gear with the splines of spacer and sliding clutch and move the reverse gear against the LO speed gear REASSEMBLY FRONT SECTION 28 Remove the mainshaft assembly from vise Align the missing internal spline of 3rd 4th speed slid ing clutch with key in mainshaft and install on front of shaft engaging the external splines of sliding clutch with clutching teeth of 3rd speed or Overdrive gear 30 Move the pilot end of mainshaft into pocket bush ing of input shaft 29 Block the right countershaft assembly against case wall and lower the mainshaft assembly into position with the reverse gear held against LO speed gear and rear of shaft moved into case bore REASSEMBLY FRONT SECTION il a 31 With the reverse gear remaining against LO speed gear mesh the corresponding forward speed gears of left countershaft assembly Check to make sure that marked tooth on left counter shaft drive gear has remained in mesh with marked set of teeth on main drive gear 32 Center rear of mainshaft in case bore and install the auxiliary drive gear assembly on shaft par tially seating the bearing in bore DO NOT COM PLETE INSTALL
121. the high range synchronizer from blocker pins However before doing so cover the assembly with a shop rag to prevent losing the three springs released from high range synchroni zer at pin locations A 1 Pull the synchronizer assembly from the splines of output shaft 3 Remove the sliding clutch from pins of low range synchronizer ring DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS N SPACER WASHER WASHER NUT WASHER MAINSHAFT PLUG CAPSCREW BEARING J SPACER SPEEDO i 2 OIL SEAL 00 0 LIN CAPSCREW ASH QU m 2 NS l REAR aS NE 24 HOUSING LIFTING up GASKET REAR BEARING EYE SLINGER COVER INSTALLATION DISASSEMBLY AUXILIARY SECTION 9 SPEED AND RT 8608L MODELS D Removal and Disassembly of Output Shaft and Rear Bearing Assemblies E a Trill 1 Use a soft bar and maul to drive the output shaft forward and through rear bearing assembly i Hf iub s i p Br i 2 3 Using the front face of low range gear as a base press the output shaft through the gear and bearing Remove the bearing and washer from hub of low range gear 2 Remove the bearing inner spacer from output 4 If necessary remove the snap ring from low range shaft gear of models so equipped DISASSEMBLYNAUXILIARY SECTION 9 SPEED AND RT 8608L MODELS 7 Turn ou
122. tion Power Flow UNDERDRIVE OVERDRIVE 13 Speed Splitter Models ONLY 7 The auxiliary drive gear splits torque between the 9 Torque is transferred to output shaft through slid two auxiliary countershaft drive gears ing clutch 8 Torque is delivered along both auxiliary counter 10 Output shaft delivers torque to driveline as 5th shafts to mating countershaft gears of UNDERDRIVE or OVERDRIVE engaged underdrive or overdrive splitter gear on output shaft 3 4 9 0 8 m g 1 e 10 Pulo 10 Figure 4 UNDERDRIVE OVERDRIVE POWER FLOW TIMING Timing Procedures All Models It is essential that both countershaft assemblies of the front and auxiliary sections are timed This as sures proper tooth contact is made between main shaft 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 appro priate teeth of a gear set prior to installation and placing them in proper mesh while in the transmis sion In the front section it is necessary to time only the drive gear set And depending on the model only the low range deep reduction or splitter gear set is timed in the auxiliary section Front Section A Marking countershaft drive

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