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1.
2. Z RE Output Shaft a Auxiliary Range Gear Input Shaft Mainshaft Gear Sliding Clutch Range Sliding Clutch Countershaft 21 Power Flow Front Section Power Flow Note The heavy lines in Figure 2 4 outline the power flow description below For help in understanding the transmission compo nents refer to Figure 2 3 Power torque from the vehicle s engine is transferred to the transmission s input shaft The input shaft rotates the main drive gear through internal splines in the hub of the gear The main drive gear meshes with both countershaft driven gears and the torque is split between both countershafts ie Because the countershaft gears are in constant mesh with the mainshaft gears all the front section gearing rotates However only the engaged or selected mainshaft gear will have torgue External clutching teeth on the sliding clutch will engage internal clutching teeth on the selected mainshaft gear Torgue will now be provided from both opposing countershaft gears into th
3. Sliding Clutch Forward Range Sliding Clutch Rear ward Sliding Clutch Rear ward Range Sliding Clutch Rear ward ep Low Low 1 Low Low 2 D cD 3 o Deep Reduction Deep Reduction D s ee Sliding Clutch Forward a Sliding Clutch Forward pn z L Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Rearward Low 1st Gear Deep Reduction Deep Reduction ee aan Sere Sliding Clutch Forward ee IO L h Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward 2nd Gear 3rd Gear 31 Power Flow RTO 1XXO9MLL Continued Deep Reduction Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Rear
4. Range Sliding Clutch Forward Sliding Clutch Rearward 5th Gear Deep Reduction ca e Ce Sliding Clutch Forward MN NYY N i ch i h is Ti i AN LU ih 7 MM Y a Sliding Clutch Forward Range Sliding Clutch Forward th Gear 30 Deep Reduction eC Sliding Clutch Forward
5. Sliding Clutch Forward Range Sliding Clutch Forward 6th Gear Deep Reduction Fd nee Sliding Clutch Forward nin erab LU e C DDD gt z pee Sliding Clutch Rearward Range Sliding Clutch Forward 8th Gear Power Flow RTO 1XXO9MLL Deep Reduction Deep Reduction ences rd aa eee Sliding Clutch Rearward Sliding Clutch Rear ward
6. Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Forward 5th Gear 6th Gear Deep Reduction s a a Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Forward 7th Gear 28 RTO X 1XX08LL Deep Reduction a ee Sliding Clutch Rearward in UL MM UD Sliding Clutch Forward Range Sliding Clutch Rearward Low Low Deep Reduction Sliding Clutch Forward ih TID
7. U ai Sliding Clutch Rearward Range Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward 3rd Gear 4th Gear 2 Power Flow RTO 1X707LL DLL MLL Continued Deep Reduction idi Deep Reduction Pe a Forwar id f u PUHODFORYATS Sliding Clutch Forward
8. valli CCC CM GEND TI Se i n CCC DDN Sliding Clutch Rearward 1st Gear Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward 3rd Gear Range Sliding Clutch Rearward Power Flow Deep Reduction Sliding Clutch Forward
9. 149 How to Remove the Auxiliary Section with Tapered Bearings cccccecesseceseseseeeees 151 How to Remove the Combination Cylinder Assembly 153 How to Remove the Auxiliary Countershaft Assembly 155 How to Disassemble the Output Shaft Assembly 158 How to Disassemble the Synchronizer Assembly 162 How to Assemble the Synchronizer Assembly 163 How to Assemble the Output Shaft Assembly 165 How to Install the Combination Cylinder Assembly 171 How to Install the Auxiliary Countershaft Assembly 173 How to Remove the Clutch Housing 177 How to Remove the Auxiliary Drive Gear Assembly 179 How to Disassemble the Upper Reverse Idler Gear Assembly 182 How to Disassemble the Lower Reverse Idler Gear Assembly 184 How to Remove the Upper and Lower Countershaft Bearings 185 How to Remove the Mainshaft Assembly 187 How to Remove the Countershaft Assemblies 188 How to Disassemble the Countershaft Assemblies 190 How to Remove the Input Shaft and Main Drive Gear 192 How to Disassemble the Mainshaft Assembly 195 How to Disassemble the Mainshaft Assembly with Low Force Gearing e e ui 197 How to Assemble the Mainshaft Assembly with Selective Adjustable Thickness Tolerance WaslleTo meal dn ar Y sett wd yda 199 How
10. Sliding Clutch Forward 8th Gear Deep Reduction a m Sliding Clutch Forward Sliding Clutch Rearward RT 9th Gear RTO 10th Gear 34 C O Sliding Clutch Forward Deep Reduction Sliding Clutch Forward Range Sliding Clutch Rearward Range Sliding Clutch Forward Range Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Forward RT 5th Gear RTO 4th Gear Deep Reduction Sliding Clutch Forward Range Sliding Clutch Rearward Sli
11. Sliding Clutch Forward Range Sliding Clutch Rearward Deep Reduction 3 Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward RT Deep Reduction 5 RTO Deep Reduction 4 Deep Reduction e UN bea Sliding Clutch Forward Cen il LTT LON Sliding Clutch Rearward Range Sliding Clutch Rearward 2nd Gear Low Range Power Flow Deep Reduction Sliding Clutch Rearward SIMD An fifili OE THYN
12. Ur cD 2 Lm D o co D o N D E eh co cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service Shim Procedure without a Shim Tool for Tapered Bearings Special Instructions The shim procedure can be done in the horizontal or vertical position The procedure is done the same A CAUTION Use genuine Eaton replacement gaskets for the auxiliary housing and countershaft bearing cover Do not omit the gaskets Bear ing endplay is influenced by the compressed thickness of the gasket 011 012 or 28 30 mm The bearing endplay must be checked and adjusted any time a countershaft bearing or housing is replaced If during reassembly the same countershaft bearings housing and shims are reused and kept in the same location it is not necessary to reset bearing endplay The following procedure is used to adjust the endplay for the auxiliary countershaft tapered bearings By correctly following this procedure each countershaft will have 001 005 03 12 mm endplay shims must be aligned properly or else the rear bearing cover may be damaged when final torque is applied 246 1 Procedure The auxiliary countershaft bearing covers or countershaft Straps and shims should be removed Make sure all old gas ket material is cleaned from the gasket mounting surfaces on the countershaft bearing covers and the auxiliary hous ing Verify that the auxiliary section
13. a a e Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward 3rd Gear Low Range 33 ep cD e cD Lm I o gt h i Lm o i Power Flow RT O X 1XX15 Continued Deep Reduction Sliding Clutch Rearward RT 4th Gear RTO 5th Gear Deep Reduction pe a aa Sliding Clutch Forward Sliding Clutch Forward 6th Gear Deep Reduction a r Ma ann Sliding Clutch Forward
14. C TT Sliding Clutch Rearward Range Sliding Clutch Rearward Deep Reduction 2 Deep Reduction Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Rearward RT Deep Reduction 4 RTO Deep Reduction 5 Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward 1st Gear Low Range Deep Reduction
15. 5 Remove the 15 16 nut on the range yoke bar 6 Remove the 3 4 nut on the reduction yoke bar 153 Transmission Overhaul Procedures Bench Service 7 Remove the cylinder housing and gasket 8 Remove the range and reduction pistons from the cylinder bores 9 f necessary remove the O rings from the range cylinder bore and the reduction cylinder bore 10 If necessary remove the O rings from the range piston I D and O D and the reduction piston O D 194 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Countershaft Assembly Special Instructions For ease of disassembly mount the auxiliary section upright in a vise Both countershafts are removed the same As the countershaft strap is removed the countershaft can fall Special Tools e See Tool Information see Table 6 e Vise with brass jaws or wood blocks e ltem T11 Bearing Puller e Soft bar and maul Procedure 1 To hold the auxiliary countershafts from turning place a Shop rag or equivalent between the splitter gear and one countershaft 2 From the output shaft loosen 1 1 2 nut Do not remove yet 155 0 m o Ur cD 2 Lm D o co D co N D mg i Ur cD jneuIoA0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service 156 3 Install countershaft retaining strap 4 Use a soft bar and maul to drive the output shaft forward far enough to partially uns
16. 1 From inside the clutch housing remove the nuts and wash ers 2 From inside the clutch housing remove the bolts 3 Jar clutch the housing to break the gasket seal 4 Pull the clutch housing from the studs and transmission case 177 0 Ur cD 2 Lm D o co D l N D E eh co cD jneuI9A0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service 5 Remove the gasket and clean all mounting surfaces of gas ket material 178 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Drive Gear Assembly Special Instructions Before removing the auxiliary drive gear the auxiliary section must be removed Special Tools e Large park of snap ring pliers 0 ba o cD 2 Le cD o gJ gt o N Lm T cD JneuI9A0 UOISSIUISUOJ e Brass maul e Crow s foot Standard Torque Capacity Models Procedure 1 Remove the mainshaft rear groove snap ring 2 Remove the six 6 auxiliary bearing retainer ring capscrews and bearing retainer ring 179 Transmission Overhaul Procedures Bench Service 3 Insert a prybar into the main case gearing and use it to slide the mainshaft assembly rearward to move the auxiliary drive gear bearing from its bore 4 fifdoes not move easily it may be necessary to install three capscrews in the threaded holes on the retainer plate Tight en the three screws evenly to for
17. General Troubleshooting General Troubleshooting Chart cont Hard Lever Shifting Shift lever is hard to gear into or out of gear Master clutch dragging Check master clutch for proper disen gagement Check master clutch for proper adjust ment both release bearing travel and clutch brake height shift linkage problem Remote shifter Check shift linkage or cables for proper adjustment binding lubrication or wear Shift bar housing problem Check shift bar housing components for binding wear or damage Transmission mainshaft problem Check mainshaft for twist Check sliding clutches for binding dam age or excessive wear Driver technique Driver not familiar or skilled with proper double clutching technique Driver contacting the clutch brake during shifts Shift Lever Jumpout Loose or worn engine mounts Check engine mounts for damage wear Shift lever comes out of gear on rough or excessive looseness roads Shift lever problem Check shift lever floor boot for binding or stretching Check shift lever isolator for excessive looseness or wear Check for excessive offset or overhang on the shift lever Check for extra equipment or extra weight added to shift lever or knob Worn or broke detent spring or mecha Check for broken detent spring nism Check for excessive wear on the detent key of detent plunger Replace detent spring with heavier spring or add additional spring 48 Ge
18. Sliding Clutch Forward Range Sliding Clutch Rearward Low Deep Reduction Sliding Clutch Forward Sliding Clutch Forward 2nd Gear Range Sliding Clutch Rearward Deep Reduction IB Sliding Clutch Forward TTT vi UT Sliding Clutch Rearward Range Sliding Clutch Rearward 4th Gear 29 G D D Lm I o h o mm 3 D r 5 Power Flow RTO X 1XX08LL Continued Deep Reduction ll 2 ee Sliding Clutch Forward
19. 106 see Tool Information see Table 8 Oil seal driver Oil seal slinger driver Procedure 1 The seal will be damaged during removal and must be re placed 2 Place a seal on the oil seal driver and drive the new seal into the rear bearing cover 3 Install the new slinger on the output yoke using a slinger driver 4 Install the output yoke over the output shaft The yoke should slide on when the splines are lined up If it does not clean the splines with solvent and oil them lightly 5 Inspect the output shaft nut for damage and wear If the ny lon locking material is damaged or excessively worn use a new output nut Note The nylon locking material must in good condition so that nut does not loosen when the vehicle is in use 6 Lightly oil the output shaft threads and the output nut threads Install the nut torque to 450 500 lb ft 610 12 677 91 Nem 7 Connect the driveshaft and U joint according to the OEM or driveshaft manufacturer s instructions In Vehicle Service Procedures How to Remove the Oil Seal Magnetic Speedometer Special Instructions Prior to replacing the seal carefully inspect the transmission to make sure the oil leakage is coming from the seal Pay particular attention to the speedometer parts the rear bearing cover gasket surfaces rear countershaft bearing covers and shift bar housing For additional information on rear seal service refer to the Rear Seal Maintenance Service
20. 1 Remove all air line brackets and ties 2 Remove swivel end 3 Remove fixed end 82 How to Install Rubber 1 4 Air Hoses Special Instructions For the 1 4 D air hoses install the fixed nut end first Special Tools e Typical service tools Procedure 1 If necessary apply Eaton thread sealant 71205 or equiva lent to threads 2 Install and tighten fixed end first then install and tighten swivel end 3 Replace all air line brackets and ties In Vehicle Service Procedure 83 gt lt D T D N D ba 1 o cp J ba o o cD Uu D In Vehicle Service Procedure How to Remove the Air Filter Regulator Special Instructions The air filter regulator has two 2 o rings located between the filter regulator and the auxiliary section Special Tools e Typical service tools Procedure 1 Remove the air lines from the air filter regulator 2 From the air filter regulator remove the two 2 capscrews 84 In Vehicle Service Procedure How to Install the Air Filter Regulator Special Instructions The air filter regulator has two 2 o rings located between the filter regulator and the range cylinder cover Special Tools e Typical service tools Procedure 1 Position the air filter regulator gt lt D T D N D ba 1 o cp J ba o o cD Lm D 2 Apply Eaton Sealant 71205 or equivalent to the two 2 re taining caps
21. 187 0 m o Ur cD 2 Lm D o co D co N D mg i Ur cD jneuIoA0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service How to Remove the Countershaft Assemblies Special Instructions Except for the PTO gears the upper and lower countershaft assemblies are the same Mark the countershafts as UPPER or LOWER as you remove them The mainshaft and main drive gear must be removed before removing the countershaft assemblies Special Tools e Typical service tools 188 Procedure 1 Mark the countershafts as UPPER or LOWER as you remove them Note The mainshaft and main drive gear must be removed before removing the countershaft assemblies Remove the rear snap ring from the rear upper countershaft bearing From inside the case use a long soft bar to drive the upper countershaft rear bearing rearward off the shaft Note Damage will likely occur to this bearing during remov al Itis strongly recommended that this bearing is dis carded Remove the capscrew and the retainer from the upper coun tershaft front Slide the lower countershaft forward This will move the front bearing forward to expose the external snap ring Transmission Overhaul Procedures Bench Service Use the appropriate bearing puller Tool ID T6 or two pryb ars to remove the lower front bearing from its bore Move the upper countershaft to the rear until the front bear ing journal clears t
22. Normal operation A burst of air will exhaust from this port when shifting into deep reduction the deep reduction button is moved forward while in low range Possible causes e Damaged defective insert valve e Leak past insert valve external O rings e Leak past deep reduction cylinder piston TY Remove insert valve Check for con Contamination or damage found Repair or replace as necessary tamination damaged seals or sticky movement Check the insert valve bore in the deep reduction cylinder cover for contamination or damage which would result in leakage past the insert valve O rings HATH HED No contamination or damage found Go to step B Remove the deep reduction cylinder Contamination or damage found Repair or replace as necessary cover and piston Check the piston bore for contamination or damage Check the piston seals for damage NOTE Early production transmis sions used a paper gasket to seal the piston to the yoke bar if neces sary replace this configuration with the current design which uses an 0 ring 99 Air System Procedure 5 Symptom No or Slow Range Shift into Low Normal Operation When the range selector on the shift knob is moved down to select low range air pressure will flow through the shift knob to the P port on the slave valve The slave valve will direct air pressure through the low range 1 4 rubber hose to the range cylinder to shift the range The
23. Place the synchronizer assembly on a clean flat surface Cover the synchronizer assembly with a shop rag to prevent losing the three 3 Springs under pressure from the HI range synchronizer pin locations Special Tools e Typical service tools synchronizer spring synchronizer i HI S O Q N O Procedure 1 Place the larger LO range synchronizer ring on the bench 2 Cover the synchronizer with a shop rag to contain the Springs 3 Grab both sides of the HI range synchronizer and pull 4 From the synchronizer ring LO range pins remove the slid ing clutch 162 Transmission Overhaul Procedures Bench Service How to Assemble the Synchronizer Assembly Special Instructions Assembly should be done on a clean flat surface slightly lower than your waist Pins on the LO range synchronizer must line up with the chamfered holes on the sliding clutch bottom When compressing the HI range synchronizer springs cover with a shop rag In the event compression is not achieved the first time this prevents the springs from leaving the bench area Special Tools e Typical service tools synchronizer spring synchronizer amp HI Ss O jneuI9A0 UOISSIUISUOJ v m cD n Lm cD P wo cD a cD mg cD Sliding Clutch Cdddddddo Procedure 1 On the bench place the larger LO range synchronizer ring face down with pins up 2 Wit
24. The following special tools are designed for this Fuller transmission The addresses and phone numbers of the tool suppliers are listed after the table This list is provided as a convenience to our customers These tools are manufactured by independent com panies with no relationship to Eaton Eaton does not warrant the fit or function of the listed tools To obtain the tools contact the tool supplier directly Table 6 Special Tools REFERENCE TOOL PURPOSE G amp WTOOL NO GREAT LAKES OTC NUMBER TOOL NO TOOL NO Output Yoke Puller May be required to remove a SP 450 7075 rusted output yoke Auxiliary Section To support or hang the aux Hanger oo Auxiliary Counter Shaft Support and Shim Tool shift Lever Spring Installation Tool Tension spring Driver Slide Hammer O gt co co O1 gt y Bearing Driver Bearing Driver Countershaft port Tools 2 as as Bearing Puller Sup To support and locate the front section countershafts To iliary section in the horizon tal position To hold the auxiliary coun tershafts in position while in stalling the auxiliary section in the horizontal position Also to simplify the checking and setting of the auxiliary countershaft bearing end play To install the shift tower ten sion spring To remove the output seal and reverse idler shafts Re guires 1 2 13 threads Op tional
25. The slave valve and interlock parts must be removed prior to installing the shift bar housing Special Tools e Typical service tools Procedure 1 Place the shift bar housing and shift blocks in the neutral po sition 2 Place the mainshaft sliding clutches in the neutral position V o oO 9 OD 5 N 3 N o o ona os a a ae 5 E lt S QO cD 3 Position a new shift bar housing gasket on the shift bar housing mounting surface Note The slave valve and interlock assembly must remain off until the shift bar housing is installed to avoid damaging the interlock pin 4 As you install the shift bar housing make sure the yokes fit into the corresponding sliding clutch slots and the housing aligns with the roll pin 5 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrew threads 133 Transmission Overhaul Procedures Bench Service 6 Install interlock parts pin spring and sleeve 7 Install slave valve and tighten to specifications 134 Transmission Overhaul Procedures Bench Service How to Disassemble the Standard Shift Bar Housing Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom sh
26. X 1 bar stock The auxiliary section can be removed without straps use caution Special Tools Procedure 1 To remove the auxiliary section in the horizontal position Remove the four 4 capscrews and the auxiliary counter Shaft rear bearing cover gasket and rear bearing shim 2 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap See Tool Information see Table 6 Item T2 Auxiliary section hanger bracket for horizontal removal A steel bar longer than the width of the output yoke for vertical removal A hoist with a lifting chain Auxiliary countershaft retaining straps Screws are snug 151 v cD n Lm cD P 5 cD oD cD Lu oD cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service 152 3 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary sec tion 4 Insert the two 2 longest capscrews in the housing flange tapped holes Tighten evenly to move the auxiliary section away from the front box Go far enough to break the gasket Seal 5 Remove the capscrews from the tapped holes 6 Attach an auxiliary section hanger bracket to the auxiliary section top 7 Attach a lifting chain to the auxiliary section hanger bracket 8 Move assembly to the r
27. 1 The range selector lever on the front of the knob is moved down to select low range When the range selector lever is moved up high range is selected 2 A blue deep reduction button on the side of the shift knob is moved forward to select the deep reduction ratios and moved rearward for remaining ratios A mechanical interlock prevents moving the deep reduction button forward when the range selector lever is up in high range Component Nomenclature and Auxiliary Countershaft Sectional View 1 Medallion 11 Screw 2 Spring 12 O Ring 3 Retainer 13 Spring 4 Housing 14 5 32 Ball 5 Spring 15 Spring 6 Washer 16 Ball 7 O Ring 17 Seal 8 Range Selector 18 Detent 9 Pin 19 Splitter Button 10 Cover 20 Old Style Shift Knob 36 Air System Air Filter Regulator The filter regulator assembly filters the vehicle supply air and regulates the pressure to 58 63 PSI Two holes in the front face of the air filter regulator assembly supply air to the range cylinder cover The filter element can be removed by turning out the end cap ag er es bD Component Nomenclature and Auxiliary Countershaft Sectional View 1 End Cap 4 Housing 2 O Rings 5 Capscrews 3 Filter Element 6 Air Regulator 37 cC cD cD Lm I o 5 mm o i Air system Slave Valve The slave valve controls the supply of air to the low and high range sides of the range shift cylinder A small ai
28. Install the shift arm on the splines of the inner shift shaft You may have to move the shift arm 4 or 5 to align the Splines of the two parts Disregard any movement of the gear shift lever at this point The gear shift lever will be ad justed later Tighten the capscrew B see figure A on the shift arm Connect the pivot link assembly ball joint to the selection le ver Secure it with the castle nut and cotter pin Loosen the jam nuts C see figure C on the pivot link Check to be sure the inner shift finger is still in place Rotate the pivot link until the curved end of the selection le ver is parallel with the shift arm as viewed from the rear see figure C Tighten the pivot link jam nuts C see figure C Loosen both capscrews on the turnbuckle D see figure A Check to be sure inner shift finger is still in place Rotate the turnbuckle to obtain the proper forward back ward neutral position of the gear shift lever in the cab Tighten one turnbuckle D capscrew see figure A Move the gear shift lever to the desired position Turn the second turnbuckle D capscrew Check for linkage obstructions in all gear positions In Vehicle Service Procedure Figure C F lt D T D N D Lu 1 o cp J uu o o cD 2 Lm 1 Selection Lever 2 L H Thread 3 R H Thread 4 Shift Arm 5 Parallel 93 In Vehicle Service Procedure Neutral Switch O
29. Transmission Overhaul Procedures Bench Service Install three 3 allen head capscrews and washers through the case front and into the pump housing Tighten the cap screws to 8 12 Lbeft of torque Replace the O ring on the suction tube Install the suction tube under the case rib and into the inte gral oil pump Bend the suction tube lock over the case rib Install the capscrews to hold the oil tube in position Tighten the capscrews to 35 45 Lbeft of torque if applicable Note Make sure the integral oil pump drive gear can turn 243 TATE EDDIE jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Section with Tapered Bearings Special Instructions There are different capscrew lengths install in the correct location Auxiliary sections can be installed either with the transmission in the horizontal position or the vertical position To install in the vertical position the clutch housing must be installed Special Tools e See Tool Information see Table 6 e Item T2 Auxiliary section hanger bracket for horizontal removal e _ Asteel bar longer than the width of the output yoke for vertical removal e A hoist with a lifting chain n Procedure n 1 244 10 To install the auxiliary section in the horizontal position Position a new gasket on the transmission mounting sur face Attach an auxiliary section hanger bracket to the auxilia
30. main drive gear V o oO a OD 5 amp y 3 A o o ona os THE Z aoe o gt Lu lt S QO cD Note The current design input shaft spline teeth have no ticeable clearance to the main drive gear internal Spline teeth This is normal 3 Install the snap ring in the main drive gear inside groove 4 Install the spacer washer over the input shaft With the bear ing external snap ring to the outside position the bearing on the input shaft 149 Transmission Overhaul Procedures Bench Service 5 Install the input shaft bearing over the input shaft Use a flanged end bearing driver which contacts both the bearing inner race and outer race Drive the bearing until it contacts the front case 6 Install the input shaft retaining snap ring Note Do not replace the small rubber lip seal It is used only to prevent leakage during shipping 7 Install the front bearing cover Apply Loctite 242 to cap screw threads and torque to 35 45 lb ft 47 45 61 01 Nem 150 Transmission Overhaul Procedures Bench Service How to Remove the Auxiliary Section with Tapered Bearings Special Instructions There can be different capscrew lengths note their location Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position Auxiliary countershaft retaining straps may be installed to hold the countershafts in place You can make retaining straps from 3
31. 32 air lines from push to P N 4301157 included in kit K 2394 connect fittings Air Line Cutting Tool To cut plastic air lines smoothly and P N 4301158 included in kit K 2394 sguarely Output Seal Driver To install output seal For 7 series Eaton P N 5564501 driver For 9 series Use Eaton P N 5564509 adapter with 5564501 driver Both parts included in complete Eaton seal kit P N TCMTO912 Output Seal Slinger Driver To install output seal slinger For 7 series Eaton P N 71223 For 9 series Eaton P N 4303829 Preventive Maintenance Preventive Maintenance Inspection Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition they can be referred to as failures looking for a place to break down They lack a proper and organized preventive maintenance program Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory service at the lowest possible cost short of removing and repairing the unit lt P a o gt ba D r A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmis sion Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost If the transmission is not cared for it will breakdown Preventati
32. 4th speed gear washer position a spacer washer against the tolerance washer With clutching teeth down and engaged with the spacer ex ternal splines position the proper gear on the mainshaft If necessary refer to the illustrated parts list to determine gear order With clutching teeth up and against this gear install the next gear and spacer washer Transmission Overhaul Procedures Bench Service 8 With the washer flat side down position a tolerance washer against the spacer Rotate the washer until the washer Splines and mainshaft splines align 9 Push the air line up to lock the washer on the mainshaft 10 Insert two large screwdrivers between the two gears Apply Slight downward pressure to spread the gears evenly Be tween the gear hub and mainshaft spacer insert 0 006 feel er gauge and 0 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer JneuI9A0 UOoISSIUISUOJ 0 o cD 2 Lm cD o CO o 5 N cD Lu T cD 11 With the missing internal splines aligned with the plastic line install a sliding clutch 12 With the washer flat side up position tolerance washer white in the next available groove Rotate the washer until the washer splines and mainshaft splines align 13 Push the air line up to lock the washer on the mainshaft 14 Install a gear spacer 201 Transmission Overhaul Procedures Bench Service 202 15 With clu
33. 6 From the drive gear front remove drive gear spacer 7 Remove the drive gear internal snap ring 193 Transmission Overhaul Procedures Bench Service 8 Pull the input shaft forward and out of the drive gear 9 From inside the case remove the drive gear 10 Inspect the bushing in the input shaft pocket replace if dam aged 194 Transmission Overhaul Procedures Bench Service How to Disassemble the Mainshaft Assembly Special Instructions Lay all parts on a clean bench in order of removal to facilitate assembly Special Tools e Typical service tools Procedure 1 Lay the mainshaft on its side and from the front remove the 4th or overdrive and 5th sliding clutch 2 Place the mainshaft in a vertical position pilot end down 3 Remove snap ring if applicable 4 Remove key washer and reverse gear Mark keyway loca tion Note When removing washer and reverse gear note their Orientation Keep the washer with the reverse gear 5 Remove the 1st and reverse sliding clutch 195 v o co cD O Lm cD P 5 cD oD cD Lu oD cD JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service 196 6 l 10 11 12 Remove the offset washer and 1st gear Remove the flat washer and 2nd gear Remove the offset washer and sliding clutch Remove the offset washer and 3rd gear Remove the flat washer Remov
34. After the mainshaft drops into the case slide the counter Shaft back and the mainshaft should fall down between the countershafts Move the mainshaft pilot end into the input shaft pilot bush ing Mesh the mainshaft gears with the corresponding coun tershaft assembly gears Position the upper reverse idler gear in case Note At this time other components of the front section must be installed before the mainshaft installation can be completed see the procedure How to Install the Upper Countershaft Bearings Transmission Overhaul Procedures Bench Service Mesh the reverse gear teeth with the reverse idler gear teeth and move the reverse gear to the rear as far as possible Align the reverse gear spacer external splines with the re verse gear and move the spacer into the reverse gear Install the reverse gear D snap ring and move the reverse gear forward on the mainshaft and against the reverse gear limit washer Push the input shaft bearing back into the case bore Position a new gasket on the bearing cover mounting sur face make sure to align the gasket oil return hole with case oil return hole Position the front bearing cover make sure to align the cov er oil return hole with case oil return hole Secure the front bearing cover with six 6 capscrews torque to 35 45 lb ft 47 45 61 01 Nem Note Make sure the drive gear is timed with the both coun tershafts Note Make sure the fro
35. Brochure TRSM0912 Special Tools e See Tool Information see Table 6 Special Tools e Brass drift e tem T1 Output yoke puller e tem T15 Slide hammer Pi Mh Cg Fd 3 5 a i f 2 X fe WN yM fi A Wr sd li NW 1 WN NO un A WAN N AN AS M YX NE we A J SZ Sy Cn F A AP je MA 1 Rear Bearing Cover 2 Sensor Retaining Capscrew 3 O Ring 4 Speedometer Sensor 5 Capscrew z lt T co N Le T cD J o cD 2 Lm cD 7 as f ais A Z Y 3 A r yy y i y SS A KN N As gt NN gt VV YA AS W AK WD I XY YW HA S NI IK N S 6 Oil Seal 7 Slinger 8 O Ring 9 Speedometer Spacer Assembly 10 Slinger 107 In Vehicle Service Procedures 108 Procedure 1 Disconnect the driveshaft and U joint from the output yoke according to the OEM or driveshaft manufacturer s instruc tions Shift the transmission into 1st gear or low gear Low Range to prevent the output yoke from turning when you loosen the output yoke nut Remove the output yoke nut using a 70 mm or 2 3 4 socket Remove the output yoke If necessary use an output yoke puller See How to Remove the Output Yoke Companion Flange Remove the speedometer sensors from the rear bearing cover Note If the sensor is a thread in type note the number of threads expo
36. Cover Check return threads for damage If threads damaged replace the input shaft Check the capscrews for tightness Torque the capscrews to 35 45 Ib ft 47 45 61 01 Nem Oil Cooler and Oil Filter Check all connectors fittings hoses Tighten any loose fittings and filter element for tightness Oil Drain Plug Oil Fill Plug Check the oil drain plug and the oil fill Torque the oil drain plug to 45 55 lb ft 61 01 74 57 plug for leakage Nem oil fill plug to 60 70 Ib ft 81 35 94 91 Nem ep cD cD a co a Lu co a a Preventive Maintenance Oil Leak Inspection Process Inspect for Oil Leak Determine if it is a Weep or a Leak Weep Stained damp no drips light oil film Leak Extremely wet or dripping of oil in the dirt adhered to the contaminated area contaminated area Step 1 1 Clean suspected oil weep 1 Do not repair Rear seal is 1 Determine the origin of the leak path area with a clean dry cloth designed to allow minimal 2 If origin of leak is obvious skip to Step 3 or mild soluble degreaser seepage refer to Roadranger 3 If the origin of the oil leak is not obvious then TCSM 0912 Seal Maintance use either of the two following steps to determine 2 Ensure lube is to proper Guide the oil leak level Rear Seal 2 Ensure lube is to proper Note Do not use a high pressure spray washer to 3 Notify the customer that it level clean the area Use of a high press
37. Oil Seal Mechanical Speedometer 0 c 106 How to Remove the Oil Seal Magnetic Speedometer scce 107 How to Install the Oil Seal Magnetic Speedometer 110 How to Remove the Output Yoke Companion Flange and Nut 112 How to Install the Output Yoke Companion Flange and Nut ee Liu GL do DGM Lu 114 How to Removethe Output Yoke Flange and Retaining Capscrews 116 How to Install the Output Yoke Flange and Retaining Capscrews 117 How to Remove the Auxiliary Section in Chassis 118 How to Install the Auxiliary Section in Chassis 120 How to Remove the Combination Cylinder Assembly 123 How to Install the Combination Cylinder Assembly 125 Transmission Overhaul Procedures Bench Service How to Disassemble the Gear Shift Lever 127 How to Assemble the Gear Shift Lever 129 How to Remove the Shift Bar Housing 131 How to Install the Shift Bar Housing 133 How to Disassemble the Standard Shift Bar Housing eee eeueueuuuun 135 How to Assemble the Standard Shift Bar Housing 138 How to Disassemble the Forward Shift Bar Housing 141 How to Assemble the Forward Shift Bar Housing 144 How to Remove the Input Shaft Assembly without main case disassembly 147 How to Install the Input Shaft Assembly without main case disassembly
38. Pull the air line from the spline while installing the key 18 Install the snap ring in the mainshaft groove 19 Install the 1st reverse sliding clutch 20 Install the clutch hub with the bezel facing up 21 Install the reverse gear 22 Remove the mainshaft from the vise and lay on its side In Stall the front sliding clutch into position 210 Transmission Overhaul Procedures Bench Service How to Prepare the Main Case for Assembly Thoroughly clean case of metal particles Remove the gasket material from flange surfaces Inspect flange surfaces for damage Inspect bearing bores for damage or excessive wear Replace as necessary If necessary replace any damaged or worn clutch housing or rear support studs Apply Eaton Fuller thread sealant 71205 or equivalent to any replacement studs before installing them Verify the three magnetic discs are firmly attached to the bottom of the main case If they are not firmly attached apply 3M scotch grip or equivalent adhesive to the bottom of the discs and attach them to the main case jneuI9A0 UOISSIUISUOJg v cD cn Lm cD P oo cD oD cD Lu oD cD 211 Transmission Overhaul Procedures Bench Service How to Assemble the Countershaft Assemblies Special Instructions Except for the PTO gears the upper and lower countershaft assemblies are the same To avoid confusion during installation mark the upper countershaft 45 tooth
39. Reduction Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Rearward Figure 2 6 Reverse Gear Deep Reduction Deep Reduction Deep Reduction ar Sliding Clutch Forward Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Rearward Range Sliding Clutch Forward Figure 2 7 Reverse Gear Low Range Figure 2 8 Reverse Gear High Range 24 Power Flow Auxiliary Section Power Flow Low Range The auxiliary drive
40. Some models do not have an oil trough Install the three 3 tension balls one in each housing top bore Install the three 3 detent springs one over each ten sion ball Note Make sure interlocking system is working should not shift into 2 gears at the same time Note Make sure all lockscrews are lockwired Transmission Overhaul Procedures Bench Service How to Disassemble the Forward Shift Bar Housing Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom shift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical service tools Procedure jneuI9A0 UOISSIUISUOJg 1 If the three 3 sets of tension springs and balls from hous ing bores have not been removed place the shift bar hous ing on its side to remove them 0 Ur cD 2 Lm D o co D l N D E eh co cD 2 Remove the oil trough retaining capscrews and oil trough Some models do not have an oil trough 3 With the housing rear to the right lay the assembly on a flat surface 141 Transmission Overhaul Procedures Bench Service 4 While removing the top yoke bar to the right remove the two 2
41. at shift knob po i ____n 4AF Remove lower skirt on shift Knob Check for leaking fitting at the shift knob Check air lines to make sure all lines are connected to the proper ports on the shift knob Reversal of S and P lines will result in a constant leak from the exhaust when high range is selected Reversal of the H L and SP lines will result in a constant leak when the deep reduction button is rearward Move the range selector lever down to Low range Check for constant air flow from the exhaust E port Move the range selector up to high range Disconnect the small air line con nected to the P port of the shift knob Check for air flow from the port and air line Leak found No leak found Air lines are not connected to the proper ports Air lines are connected to proper ports Constant air flow from E port No air flow from E port Constant air is leaking from the P port or the E port Air is coming out of the disconnected air line Air is not leaking from either port or disconnected air line Repair leaking fitting or air line Go to step B Connect lines properly Go to step C Replace knob Go to Step D Repair or replace the shift knob 1 Verify that the air line is connected to the slave valve 6 nI p port 2 If properly connected replace the slave valve Go to Step D 51 TATOU EENEN Air Syste
42. blocks Procedure 1 From the assembly remove the outer oil pump element 2 From the drive shaft remove the drive gear retaining snap ring 3 From the pump drive shaft remove the drive gear 4 From the drive shaft keyway remove the key 234 Transmission Overhaul Procedures Bench Service 5 From the drive shaft remove the element snap ring 6 From the drive shaft remove the internal oil pump element 7 From the drive shaft keyways remove the two 2 keys 9 From the integral oil pump housing remove the drive shaft 9 If damaged from the drive shaft remove the rear drive gear retention snap ring 239 v Lm o co cD Lm cD 2 Ss cD oD cD Lu oD cD jneuIoA0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service 236 10 From the pump housing remove the relief valve roll pin 11 From the relief valve housing bore remove the relief valve Spring 12 From the housing bore remove the relief valve 13 Inspect all parts for damage replace damaged parts Transmission Overhaul Procedures Bench Service How to Assemble the Integral Oil Pump without Auxiliary Oil Tube Special Instructions When installing the drive shaft keys the round key goes in the round keyway and the square key in the square keyway Special Tools e Avise with brass jaws or wood blocks Procedure 1 Install the relief valve in the integral oil pump
43. cD n Lm cD 2 5 cD a cD mg cD jneuIoA0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service Procedure 1 With housing bottom facing up secure the assembly in a vise 2 Ifthe spade pin is damaged replace and install the spade pin in housing tower bore 3 In models so equipped install the nut and washer in the housing bore 4 Ifthe O ring is damaged replace it and lubricate the O ring with Eaton Fuller lubricant 71206 or equivalent Install the O ring in the housing tower inside groove 5 Align the lever ball slot with the spade pin and position the gear shift lever in the housing tower 6 With dished side up install the washer over the ball 7 Use a tension spring driver to install the tension spring un der the housing lugs 8 Remove the assembly from the vise 9 Install a rubber boot over the gear shift lever and against the 130 housing Note Make sure the gear shift lever can move Transmission Overhaul Procedures Bench Service How to Remove the Shift Bar Housing Special Instructions Before removing the shift bar housing the air lines must be disconnected For models equipped with an oil pump and or cooler assemblies make sure to disconnect the oil line connected to the shift bar housing There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other locations except the left f
44. countershaft bearing cover Secure the bearing covers with the capscrews Install sealer Tighten the capscrews to 40 45 Lb ft 54 61 Nm Connect all removed air hoses and lines Use Eaton Full er thread sealant 71205 or equivalent as necessary Connect the driveshaft and U joint and refill the transmis sion with the recommended lubricant For lubrication in structions refer to the Lubrication section In Vehicle Service Procedures How to Remove the Combination Cylinder Assembly Special Instructions None Special Tools e Typical service tools Procedure 1 Drain lube 2 At the combination cylinder cover remove the 5 capscrews with washers 3 Remove the cylinder cover and gasket gt lt T co N cD Lu T cD J La o cD 2 La cD 7 4 If necessary remove the insert valve retaining nut from the cylinder cover Remove the insert valve from the bore 5 Remove the 15 16 nut on the range yoke bar 6 Remove the 3 4 nut on the reduction yoke bar 123 In Vehicle Service Procedures 7 Remove the cylinder housing and gasket 8 Remove the range and reduction pistons from the cylinder bores 9 f necessary remove the O rings from the range cylinder bore and the reduction cylinder bore 10 If necessary remove the O rings from the range piston I D and O D and the reduction piston O D 124 In Vehicle Service Procedures How to Install the Com
45. have exactly the same num ber of teeth on the Reduction gear between the marked teeth 3 Locate the two stamped O s on the Countershaft Reduc FR and RT Stamp Position tion gears and mark both teeth with a highly visible paint gc preferably a yellow or white a Lercation of Stamped 0 s 67 Timing 4 Use a round file or bar to properly align from the marked teeth on the Auxiliary Countershaft to the Auxiliary Splitter gear When the bar is lined up with the root between the cor rect teeth you will notice it s parallel with the Auxiliary Coun tershaft Mark both the teeth with a highly visible paint Example of correct alignment Bar in correct position parallel with the countershaft and be tween the marked Splitter gear and Reduction gear teeth Examples of Left or Right Misalignment Example showing correct view of Reduction gear timed to Countershaft gears on the bench 68 Lay the Splitter gear on a flat surface and mark it similar to Steps 1 and 2 of this procedure Make sure the teeth are painted on both faces of the Splitter gear front and rear Install the Reduction gear and Outputshaft assembly into the Auxiliary case Then install the Auxiliary Countershafts and Splitter gear Countershaft retaining straps must be used to hold the Auxiliary Countershafts in place until the Aux iliary section is fully installed Failure to use the straps could result in the Auxiliary section moving
46. housing JneuI9A0 UOISSIUISUOJ J La o Ur cD 2 ba D o co D o N D E eh T cD 2 Install the relief valve spring in oil pump housing 3 Secure the oil pump housing in a vice 4 Depress the relief valve spring and drive the relief valve re tention roll pin into the roll pin bore 23 Transmission Overhaul Procedures Bench Service 238 5 If removed replace the drive shaft snap ring on the pump drive shaft 6 Insert the drive shaft through the pump housing bore 7 Install the two 2 keys on the drive shaft 8 Align the inner element keyways with the drive shaft keys and install the integral oil pump inner element 9 Install the inner element retention snap ring in drive shaft Snap ring groove Transmission Overhaul Procedures Bench Service 10 Install drive gear key in drive shaft keyway 11 Align drive gear keyway with drive shaft key and install the drive gear on the drive shaft 12 Install the outer drive gear retention snap ring in drive shaft groove 13 Install the outer integral oil pump element over the inner el ement 239 0 Ur cD 2 Lm D o co D l N D E eh co cD jneuI9A0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service How to Remove the Integral Oil Pump Special Instructions None Special Tools e Typical service tools Procedure 1 Remove the capscrews holding the suctio
47. in case bore If the bearing spins freely in the bore the case should be replaced Bearing Covers e Check covers for wear from thrust of adjacent bearing Replace covers damaged from thrust of bearing outer race e Check cover bores for wear Replace those worn or oversized Clutch Release Parts e Check clutch release parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pads e Check pedal shafts Replace those worn at bushing surfaces Gears e Check gear teeth for frosting and pitting Frosting of gear teeth faces presents no threat of transmission failure Often in continued operation of the unit frosted gears heal and do not progress to the pitting stage In most cases gears with light to moderate pitted teeth have considerable gear life remaining and can be reused but gears in the advanced Stage of pitting should be replaced e Check for gears with clutching teeth abnormally worn tapered or reduced in length from clashing during shifting Re place gears found in any of these conditions e Check axial clearance of gears Introduction Gear Shift Lever Housing Assembly e Check spring tension on shift lever Replace tension spring if lever moves too freely e f housing is disassembled check gear shift lever bottom end and shift finger assembly for wear Replace both gears if excessively worn Gray Iron Parts ep cD cD a co a Lu co a a e Check all gray i
48. listed on the front How to use this Manual The service procedures have been divided into two sections In Vehicle Service Procedures and Transmission Overhaul Proce dures Bench Service In Vehicle Service Procedures contain procedures that can be performed while the transmission is still installed in the vehicle Transmission Overhaul Procedures contain procedures that are performed after the transmission has been removed from the vehicle The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific headings and the procedures To find the information you need in these sections first go to the section that contains the procedure you need Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the transmission Note In some instances the transmission appearance may be different from the illustrations but the procedure is the same Disassemble Precautions It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission the necessary link age and vehicle air lines disconnected and the transmission has been removed from vehicle chassis Removal of the gear shift lever housing assembly or remote control assembly is included in the detailed instructions How to Remove
49. or wood blocks Procedure 1 Assemble the yoke actuator assembly 2 From the shift bar housing bottom install the actuator pin and yoke actuator 3 On the shift bar housing top install the washer and nut 144 Transmission Overhaul Procedures Bench Service Assemble the 1st and reverse shift yoke assembly e Install the plunger in the 1st and reverse shift yoke bore plunger shank to the outside e Install the spring into the bore over the plunger shank e Install the plug and tighten to compress the spring e After plug bottoms out back the plug out 1 to 1 1 2 turns e Complete the block assembly process by staking the plug through the small hole in block With the housing rear to the right lay the assembly on a flat surface Start installation of the bottom shift bar as the bar passes the bosses install the two 2 bottom shift yoke assemblies Install the shift yoke lockscrew torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place the actuating plunger in the top center bore Place one 3 4 interlock ball in the interlock bore against the bottom bar Holding the middle bar notched end start installation As the bar passes the rear boss position the shift block As the bar passes the center boss position the shift yoke on bar long hub to the housing front Just prior to inserting notched end of bar in rear boss install the small interlock pin vertically in the n
50. out of time lt P cD Lu o gt ba D r 5 Example of Splitter gear timed to the Auxiliary Counter shafts To ensure the timing is correct check that the marked tooth on the Splitter gear is between the two marked teeth on the Auxiliary Countershaft gears as shown in the illustrations below 69 In Vehicle Service Procedure How to Disassemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft Sectional View 1 Medallion 17 Screw 2 Spring 12 O Ring 3 Retainer 13 Spring 4 Housing 14 5 32 Ball 5 Spring 15 Spring 6 Washer 16 Ball 7 O Ring 17 Seal 8 Range Selector 18 Detent 9 Pin 19 Splitter Button 10 Cover 20 Old Style Shift Knob 70 In Vehicle Service Procedure Procedure 1 Remove the two screws holding the bottom cover to the valve and slide the cover down the gearshift lever to expose the air line fittings Disconnect the air lines 2 Loosen the jam nut and turn the control valve from the gear shift lever 3 Pry the medallion from the recess in the top cover 4 Turn out the two screws to remove the top cover from the valve housing 5 Turn out the two screws in the side of the valve housing to separate the housing 6 Remove the range selection lever from the left housing along with the position balls and guide 7 lf neces
51. place with the capscrews Ex cessive force may damage the transmission If excessive force is necessary the gearing Is likely out of time lf the auxiliary section does not install fully slide it back and check the following a The output yoke and nut should be installed to pull back and center the auxiliary mainshaft assembly b The countershaft support tool center capscrew should be snug to level the countershafts c The dowel pins and auxiliary housing mating holes Should be clean and well oiled d The internal gearing on the auxiliary section must have been properly timed during reassembly Apply Eaton Fuller thread sealant 71205 or equivalent to the all the retaining capscrew threads Install the cap screws to secure the auxiliary section to the main case Torque the capscrews to 40 45 Lb ft 54 61 Nm In Vehicle Service Procedures 121 a lt T co N cD uu T cD J m o cD 2 ba I cD 7 In Vehicle Service Procedures 122 13 14 15 16 If the countershaft countershaft bearings or auxiliary hous ing have been replaced or if the countershafts bearings or shims were not marked and reassembled in the same loca tion the bearing endplay must be checked and set by shim ming Shim the countershaft bearings using Shim Procedure without a Shim Tool If shimming is not required remove the support tools and install the proper shim gasket and
52. sion into high range Note The slave valve preselection system interlock will prevent the slave valve from changing from low to high or vise versa if the transmission is engaged in a front section gear This system allows the driver to preselect by moving the range selection lever while still in gear the range change will then occur as the driver moves the shift lever through neu tral 43 Air system Roadranger Valve Up Rearward H L P S SP 19470 or A 5000 Slave Valve Cylinder Assembly HI Air to Cover j No Air LO TALA J Wy 7 VN TT Port Y ay A gre si SP Air from KE E MUMMY Ups NEU nae A aa AF L isi SE on A ip j i G H C VAM MA Vehicle Source s Deep Reduction Air Filter Regulator Insert Valve Assembly 44 Air system Deep Reduction Roadranger Valve Forward 1 A tee fitting on the low range port of the slave valve will supply air through a 5 32 or 1 8 air line to the H L port on the shift knob Because this line is connected to the low range port air is only available when low range has been selected cC cD cD Lm I o 5 mm o i _ 19470 or A 5000 Slave Valve 2 When the deep reduction button is moved forward air from the H L port will pass through the shift knob to the SP port A 1 9 or 5 32 air line connected to the shif
53. speed gear as a base press the drive gear PTO gear and 3rd Overdrive speed gear from each countershaft This removes the front bearing inner race from the countershaft 3 Position the countershaft in the press as shown Press the next two gears from the shaft 4 Inspect the keys and roll pin Remove and replace if dam aged 191 0 m o cD 2 Lm cD o gJ D o N mg T cD JneuI9A0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft and Main Drive Gear Special Instructions None Special Tools e See Tool Information see Table 6 e tem 116 Bearing puller e Soft bar and maul Procedure 1 From the front bearing cover remove the six 6 retaining capscrews and cover Remove any remaining gasket mate rial from the case and cover 2 lf present remove and discard the rubber seal ring on the in put shaft The ring is used only to seal the transmission dur ing shipment 3 From the input shaft groove remove the bearing retaining snap ring 192 Transmission Overhaul Procedures Bench Service 4 Use a soft bar and maul to drive the input shaft toward the case rear as far as possible Pull the input shaft forward TATE EDDIE JneyJ9A0 UOISSIUISUPJ 5 Install the bearing puller tool and remove the input bearing from the case and input shaft or use pry bars or screwdriv ers to complete removal of the bearing
54. that this bearing is discarded 4 From inside the case use a soft bar and maul to drive the countershaft rear bearings rearward off the shaft 185 Transmission Overhaul Procedures Bench Service 186 From the front of each countershaft remove the capscrew and front retainer plate Use the soft bar and maul to drive each countershaft to the rear as far as possible This partially unseats the front bear ings Return to the case rear and drive each countershaft forward as far as possible This exposes the external snap ring Use the appropriate bearing puller T9 or prybars to remove the countershaft front bearings Transmission Overhaul Procedures Bench Service How to Remove the Mainshaft Assembly Special Instructions None Special Tools e See Tool Information see Table 6 e tem 115 Mainshaft hook Procedure 1 Secure the upper countershaft to the side and away from the mainshaft Optional Insert prybar between upper counter Shaft and main drive gear as shown 2 Insertthe mainshaft hook tool or rope around the mainshaft Note Keep the upper countershaft forward against the case front wall A WARNING Be careful when removing the mainshaft assembly The slid ing clutch on the front and the reverse gear on the back can slip off the shaft 3 Pull the mainshaft to the rear to free the pilot from the input Shaft pocket 4 Tilt the mainshaft front up and lift the assembly from the case
55. the Gear Shift Le ver This assembly MUST be detached from the shift bar housing before the transmission can be removed Follow closely each procedure in the detailed instructions make use of the text illustrations and photographs provided Assemblies e When disassembling the various assemblies such as the mainshaft countershafts and shift bar housing lay all parts on a clean bench in the same sequence as removed This procedure will simplify assembly and reduce the possibility of losing parts Bearings e Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use Remove bearings planned to be reused with pullers designed for this purpose Cleanliness e Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Dirt is an abrasive and can damage bearings It is always a good practice to clean the outside of the unit before starting the planned disassembly Input Shaft e The input shaft can be removed from the transmission without removing the countershafts mainshaft or main drive gear Special procedures are required and provided in this manual ep cD cD a co a Lu co a a Introduction Snap Rings e Remove snap rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose When Using Tools to Move Parts e Always
56. the bearing inner race and outer race Drive the bearing until it contacts the front case 9 Temporarily install the front bearing cover with two cap screws a o z o o o 5 A 3 y o o o o 5 THE a 2 5 E lt S QO cD 10 From inside the main case drive the input shaft forward until it is fully seated 11 Install the input shaft retaining snap ring Note Do not replace the small rubber lip seal It is used only to prevent leakage during shipping 12 Do not reinstall the input bearing cover at this time Instead pull the input shaft and bearing forward to allow for main Shaft installation 221 Transmission Overhaul Procedures Bench Service How to Install the Mainshaft Assembly Special Instructions The lower countershaft bearings and the input shaft must be installed but for higher torque ratings do not install the front bearing cover Check to make sure the lower countershaft drive gear marked tooth Is in time with main drive gear set of marked teeth Special Tools 222 A large hook or 3 piece of rope Procedure Block the upper countershaft forward and as close to the case wall as possible With reverse gear forward against the next speed gear and mainshaft pilot end over the integral oil pump gear lower the mainshaft assembly while pulling the shaft rear through the case bore Pull the input shaft forward until the drive gear is against the case
57. the brake slows down and can stop the transmission front box gearing It is a disc type brake incorporated into the clutch and transmission drive gear assem blies Never use the Clutch Brake when upshifting or downshifting Use only for initial gear engagement when the vehicle is Standing still Countershaft Brake Used with push type clutches The control button is mounted on the shift lever just below the shift knob To operate the brake disengage the clutch press down the control button and shift into 1st or reverse This is an air operated mechanical brake which slows down the transmission gearing by forcing a piston against the countershaft PTO gear Note Never use the Countershaft Brake when upshifting or downshifting Use only for initial gear engagement when the vehicle is standing still Recommended Tools Tool Specifications some repair procedures pictured in this manual show the use of specialized tools Their actual use is recommended as they make transmission repair easier faster and prevent costly damage to critical parts For the most part ordinary mechanic s tools such as socket wrenches screwdrivers etc and other standard shop items such as a press mauls and soft bars are the only tools needed to successfully disassemble and reassemble any Fuller transmission The following tables list and describe the typical tools required to properly service this model transmission above and beyond the necessary basic wrenches s
58. the remaining steps 179 v o co cD Lm cD 2 5 cD oD cD Lu oD cD JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service 176 6 10 11 12 13 14 19 16 Install the assembled outputshaft see Outputshaft Assem bly between the countershafts and match the timing marks Install range and reduction yokes Place the auxiliary housing over the countershaft assemblies and the outputshaft assembly Make sure the outputshaft bearing spacer is on the output shaft Heat the rear output bearing cone and install the bearing ta pered side down on the shaft Position a new gasket on the rear bearing cover mounting surface Position the rear bearing cover Apply Eaton Fuller Sealant 771205 or eguivalent to the re taining capscrews Install the six 6 retaining capscrews in the non chamfered hole tighten to 35 45 Lbe t of torque Install the bearing races Install each auxiliary countershaft retaining strap with 2 3 8 NC x 1 and 1 3 8 NC x 21 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap Screws are snug Transmission Overhaul Procedures Bench Service How to Remove the Clutch Housing Special Instructions Removal of the clutch housing is done in the horizontal position The clutch release mechanism must be removed Special Tools e Typical service tools Procedure
59. wear Washers e Check surfaces of all washers Washers scored or reduced in thickness should be replaced Introduction Assembly Precautions Make sure that case interiors and housings are clean It is important that dirt and other foreign materials are kept out of the trans mission during assembly Dirt is an abrasive and can damage polished surfaces of bearings and washers Use certain precau tions as listed below during assembly Axial Clearances e Maintain original axial clearances of 0 006 0 015 in for mainshaft gears Bearings e Use a flange end bearing driver for bearing installation These special drivers apply equal force to both bearing races preventing damage to balls rollers and races while maintaining correct bearing alignment with bore and shaft Avoid us ing a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races Capscrews e To prevent oil leakage and loosening use Fuller sealant 71205 on all capscrews Gaskets e Use new gaskets throughout the transmission as it is being rebuilt Make sure all gaskets are installed An omission of any gasket can result in oil leakage or misalignment of bearing covers Initial Lubrication e Coat all limit washers and shaft splines with Lubricant during assembly to prevent scoring and galling of such parts O Rings e Lubricate all o rings with silicon lubricant Universal Joint Companion Flange or Yoke e Pull the companio
60. will contact the speedometer rotor 114 In Vehicle Service Procedures Install the output shaft nut tighten to 450 500 Lb ft of torque Make sure the output shaft nut is properly torqued and un lock the transmission or remove the holding tool gt lt 5 o co N cD Uu T cD J ba o cD 2 ba cD 7 115 In Vehicle Service Procedures How to Remove the Output Yoke Flange and Retaining Capscrews Special Instructions None Special Tools e Typical service tools Procedure 1 Remove drive shaft from transmission Reference OEM removal guidelines Remove the end yoke retaining capscrews and washer from auxiliary mainshaft Remove the end yoke flange 116 In Vehicle Service Procedures How to Install the Output Yoke Flange and Retaining Capscrews Special Instructions For proper cleaning and maintenance see TCSM0912 Seal Maintenance Guide Special Tools e Typical service tools Procedure 1 Install end yoke retaining washer and capscrews Apply Eaton Fuller 71205 liquid thread sealant to capscrews and then snug each capscrew to 35 Ibs ft 47 N m 2 Fully tighten both retaining capscrews to specified torque rating 74 81 Ibs ft 100 110 N m J gt o a lt N cD for o Note This fastening design employs Spiralock threads A conventional metric thread pitch tap cannot be used for thread restorat
61. 136 puller at countershaft tapered bearing tached to 1155 outer races slide hammer Bearing Race In To install the auxiliary coun 21524 21530 staller tershaft tapered bearing out discs used with er races 2 488 handle and 10020 screw Tool ID numbers are referenced in the service procedures Special Tools Table 7 Shop Equipment 20 Ton capacity press To press countershaft gears from countershaft Specialty Tool Manufacturers Below are the addresses and phone numbers of the companies that make tools specifically for Eaton Fuller transmissions G and W Tool Company 1105 E Louisville Broken Arrow OK 74012 5724 Phone 800 247 5882 or 918 258 6881 Great Lakes Tool 8530 M 89 Richland MI 49083 Phone 800 877 9618 or 269 629 9628 0 T C 655 Eisenhower Dr Owatonna MN 55060 117 Phone 800 533 6127 or 507 455 7000 The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user Detailed Fuller Transmission Tool Prints are available upon request by writing to Eaton Corporation Truck Components Operations Technical Service P O Box 4013 Kalamazoo Michigan 49003 HATH ELA ETEN Recommended Tools Eaton Aftermarket Parts The following tools are available through Eaton Aftermarket Parts To obtain any of the tools listed contact your local Eaton parts distributor Table 8 TOOL PURPOSE EATON PART NUMBER 5 32 Air Line Release Tool To remove 5
62. 198 Transmission Overhaul Procedures Bench Service How to Assemble the Mainshaft Assembly with Selective Adjustable Thickness Tolerance Washers Special Instructions There are three distinct mainshaft washer and mainshaft key designs They are listed from oldest design to newest design a Six 6 sided mainshaft key with selective adjustable thickness tolerance washers b Three 3 sided mainshaft key with selective adjustable thickness tolerance washers c Three 3 sided mainshaft key with non selective non adjustable tolerance washers Note Between 1993 and 1996 some models were produced with a mixture of selective thickness washers and non selective tol erance washers on the same mainshaft Note The proper mainshaft key must always be used with the proper design mainshaft washers If necessary refer to the parts manual for your specific model to confirm the proper parts Note Previous design levels can be updated to the current design Each mainshaft gear must have its inside snap ring installed before placement on the mainshaft Do not install reverse gear inside snap ring at this time jneuI9A0 UOISSIUISUOJg v cD cn Lm cD P oo cD oD cD Lu oD cD Gear tolerance washers are internally splined and locked to the mainshaft by the key Gear spacers are externally splined to engage with gear hub clutching teeth There is one tolerance washer and one spacer for each mainshaft
63. Auxiliary Case Assy FF r 0 ga f IA Auxiliary Section o 4 A nwy ee _ Mainshaft amp Synchro MSS NE a a ee ront Section __j OWM i AW A EN Clutch Housing Case Assembly TRA Ses 3i aN ax Auxiliary Section eR Wb BRS RAS SL YM y y Auxiliary Drive Gear ABZ CRE Front Section t AN g ce 3 Mainshaft cC JP NIW Front Section N ss XK a Input Shaft Drive Gear g Auxiliary Section NN a Countershaft d JL ae Air System Front Section Slave Valve Reverse Idler Front Section Countershafts This page intentionally left blank Table of Contents General Information Purpose and Scope of Manual een 1 Serial Tag Information and Model Nomenclature 5 Lubrication Specifications a ee uu i YG Id uw 7 Transmission Operation csecsen 9 Tool SpeeiTicatlOll8 uu ou e NG Se AU 13 Preventive Maintenance Inspection 17 Power Flow Diagrams ccccccecesseeeseseseeeseeeesenenes 21 Air System OvervieW eeueeue rr Fr FF FF 35 General Troubleshooting Chart eee eeeee 47 Air System Troubleshooting ccecce 50 In Vehicle Service Procedures Timing Procedures O AC a cicuceitiad 66 How to Disassemble Roadranger Valve A 4900 70 How to Assemble Roadranger Valve A 4900 12 How to Remove the Air Lines and Hoses 74 How to Install the Air Lines and Hoses 76 How to Remo
64. D oD cD Lu oD cD JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service How to Install the Input Shaft and Main Drive Gear Special Instructions None Special Tools e See Tool Information see Table 6 e tem T10 Input bearing driver e Toolmaker s dye Procedure 1 Use a highly visible toolmaker s dye and mark the main drive gear for timing purposes To mark the gear paint toolmak er s die on any two adjacent teeth and then paint the two ad jacent teeth directly opposite the first two teeth 2 If necessary install the bushing in the back of the input shaft 3 Temporarily position the upper countershaft up and away from the transmission center 4 From inside the case mesh the lower countershaft drive gear marked tooth with either set of main drive gear marked teeth 5 From the front engage the input shaft spline teeth into the main drive gear Note The current design input shaft spline teeth have no ticeable clearance to the main drive gear internal spline teeth This is normal 6 Install the snap ring in the main drive gear inside groove 220 Transmission Overhaul Procedures Bench Service 7 Install the spacer washer over the input shaft With the bear ing external snap ring to the outside position the bearing on the input shaft 8 Install the input shaft bearing over the input shaft Use a flanged end bearing driver which contacts both
65. Fuller Heavy Duty Transmissions E N Roadranger More time on the road Service Manual TRSM1500 June 2009 RTO 11707LL RTO 11708LL RTOF 11707LL RTOF 11708LL RTOF 14708LL RTX 11708LL RTX 14708LL RTXF 11708LL RTXF 14708LL RTO 11707DLL RTO 11709MLL RTO 11908LL RTO 11909ALL RTO 11909MLL RTO 13707DLL RTO 13707MLL RTO 14709MLL RTO 14908LL RTO 14909ALL RTO 14909MLL RTO 16908LL RTO 16909ALL RTOF 11709MLL RTOF 11908LL RTOF 11909ALL RTOF 11909MLL RTOF 13707DLL RTOF 13707MLL RTOF 14709MLL RTOF 14908LL RTOF 14909ALL RTOF 14909MLL RTOF 16908LL RTOF 16909ALL RTX 11715 RTX 14715 RTXF 11715 RTXF 14715 RTXF 15715 Warnings and Precautions Warnings and Precautions AWARNIN Before starting a vehicle always be seated in the driver s seat place the transmission in neutral set the parking brakes and disengage the clutch Before working on a vehicle place the transmission in neutral set the parking brakes and block the wheels Before towing the vehicle place the transmission in neutral and lift the rear wheels off the ground remove the axle shafts or disconnect the driveline to avoid damage to the transmission during towing The description and specifications contained in this service publication are current at the time of printing Eaton Corporation reserves the right to discontinue or modify its models and or procedures and to change specifications at any time without notice Any reference to
66. O NOT CHANGE RANGE WHILE MOVING IN REVERSE co PUT TRANSMISSION IN NEUTRAL S WAR N l N G BEFORE STARTING ENGINE 2 15 SPEED RTO DEEP REDUCTION RANGER SELECTOR LO LO lt ALL RANGE J PT Rie seret tok BEFORE MOVNG HT LEVER U PSHIFTING START WITH RANGE SELECTOR DOWN SHIFT 1 2 3 4 5 RAISE RANGE SELECTOR SHET 67 8910 DOWNSHIFTING SHIFT 10 9876 MOVE RANGE SELECTOR DOWN Eaton Fuller Roadranger DU 00 NOT CHANGE RANGE WHILE MOVING IN REVERSE N PUT TRANSMISSION IN NEUTRAL WA R N l N G BEFORE STARTING ENGINE 2 Transmission Operation and Theory Initial Start Up A WARNING Before starting a vehicle always be seated in the driver s seat move the shift lever to neutral and set the parking brakes A CAUTION Before moving a vehicle make sure you understand the shift pattern configuration 1 2 3 8 9 Make sure the shift lever is in neutral and the parking brakes are set Turn on the key switch and start the engine Allow the vehicle air pressure to build to the correct level Refer to your Operator and Service Manual supplied with the truck Apply the service brakes Release the parking brakes on the vehicle Make sure the Range Selector is down in the low range position Figure 2 2 ___ Range Selector MUST be in the Low Range position for Low Range Figure 2 2 Depress the clutch pedal to the floor Move the shift lever to the desired initial gear Slowly
67. PTO gear with an U The lower countershaft has a 47 tooth PTO gear Special Tools e Snap ring pliers e Press Procedure 1 If previously removed install the keys in each countershaft keyway 2 Align smallest diameter gear keyway with the countershaft key long hub to countershaft front and press the gear on the countershaft 3 Align 2nd smallest diameter gear keyway with the counter Shaft key long hub against 1st speed gear and press the gear on the countershaft 212 Transmission Overhaul Procedures Bench Service 4 Align 3rd smallest diameter gear keyway with the counter Shaft key long hub to countershaft front and press the gear on the countershaft 5 Align PTO gear keyway with the countershaft key bullet nose of teeth facing up shaft rear Align drive gear keyway with the countershaft key long hub against PTO gear and press both gears on the countershaft JneuI9A0 UOoISSIUISUOJ v o co cD Lm cD 2 5 cD oD cD Lu oD cD 6 On each countershaft front install the drive gear retaining Snap ring in groove 7 Useaflanged driver or the press to install the bearing inner race on the countershaft front against the drive gear Note Make sure all gears are pressed into place Note Make sure the bearing inner race is installed 213 Transmission Overhaul Procedures Bench Service How to Assemble the Lower Reverse Idler Gear Assembly Spec
68. R SELECTOR ee LO LO ao i LO O Gy Eg PRE SELECT __ ALL RANGE SHIFTS WN RANGE SELECTOR BEFORE MOVING SHIFT LEVER FTING Ural WITH RANGE SELECTOR DOWN Neutral SHIFT LO 1 2 3 4 RAISE RANGE SELECTOR SHI DOWNSHIFTI TING 9 SHIFT 8 7 6 5 MOVE RANGE SELECTOR DOWN DO NOT CHANGE RANGE WHILE MOVING IN REVERSE ico PUT TRANSMISSION IN NEUTRAL AG AWARNING Figure 2 1 RTO 11709MLL RTO 14709MLL RTO 11909MLL RTO 14909MLL RT 11715 RT 14715 RT 19715 RT 14915 RTX 11719 RTX 14715 RTX 19715 RTO 14915 RTO 16915 RTO 11715 RTO 14715 RTO 15715 Shift Pattern Decal Eaton Fuller Roadranger Transmissions ep cD e cD Lm I o gt h i Lm o f 9 SPEED L0 amp Lo Lo RANGE DEEP REDUCTION SELECTO SELECTOR ELECTOR R 5 7 LO LO IN CR 12 PRE SELECT _ ALL RANGE SHIFTS MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER U PSHIFTING Neutral START WITH RANGE SELECTOR DOWN SHIFT LO 1 2 3 4 RAISE RANGE SELECTOR SHIFT 5 6 7 8 LO 6 DOWNSHIFTING SHIFT 8 7 6 8 MOVE RANGE SELECTOR DOWN 00 NOT CHANGE RANGE WHILE MOVING IN REVERSE ee TRANSMISSION IN NEUTRAL AwaRninc EE Eaton Fuller Roadranger 15 SPEED RT amp RTX iss DEEP REDUCTION Transmissions DEF y SELECTOR NQ out ALL RANGE SHI aie SELECTOR MER MOVING SHIFT LEVER PSHIFTING START WITH RANGE SELECTOR DOWN THREE 2 3 45 RAISE RANGE SELECTOR DOWNSHI FING SHIFT 10 9 8 7 6 MOVE RANGE SELECTOR DOWN SHIFT 5 4 Y f D
69. Range synchronizer worn or defective Check range synchronizer and mating parts for excessive wear or damage 49 Air System Air System Troubleshooting The symptoms listed below are covered on the following pages Before beginning any of those troubleshooting procedures place the transmission in neutral and move the range selection lever from low to high Listen for any constant air leak from the shift knob air module base exhaust or transmission breather If a constant leak is heard go to that particular leak troubleshooting procedure first If you do not see the symptom you need to correct refer to the General Troubleshooting chart Symptom e Air Leak from Air Module Base Exhaust Leak e No or Slow Range Shift into High Shift into low range is good e No or Slow Range Shift into Low Shift into high range is good e Constant Air Leak from Shift Knob e Range Shifts in Gear e Air Leak from Transmission Breather or Transmission Case is Pressurized Note Use the air system troubleshooting procedures for part replacement only if the symptom can be duplicated If the problem is intermittent parts that are not defective could be replaced Note During all testing the vehicle air pressure must be greater than 90 PSI 620 kPa If during testing the pressure falls below 90 PSI 620 kPa make sure the transmission is in neutral start the engine and let the pressure build to governor cutoff After the pressure reaches the governo
70. Sliding Clutch Forward a ATLA TM LU LUD Sliding Clutch Forward Range Sliding Clutch Forward 7th Gear RT O X 1XX15 Deep Reduction Sliding Clutch Rear ward Sliding Clutch For ward Range Sliding Clutch Rear ward Deep Reduction 1 Deep Reduction Prun lb G Sliding Clutch Forward Se 3 TH Pe HR LI U 22 in
71. System Low Range 1 Vehicle supply air 110 130 PSI is supplied to inlet port on filter regulator where it is filtered and regulated to 58 63 PSI 2 Thru a 1 4 I D rubber air line a constant 58 63 PSI regulated air is supplied to the S supply port on the slave valve 3 Thru a 5 32 or 1 8 air line a constant 58 63 PSI regulated air is also supplied to the S supply port on the shift knob 4 The driver selects low range by moving the range selection lever down This allows the constant supply air at the shift knob to exit at the P pilot port air line This 1 8 or 5 32 P air line connects to the P pilot 1 8 or 5 32 P air line connects to the P pilot port on the slave valve The air pressure on the P line causes a valve within the slave valve to move to the low range position 5 The constant supply air at the slave valve is now supplied thru a 1 4 hose to the low range port on the range cylinder This air pressure moves the range piston range bar range yoke and range sliding clutch rearward to shift the trans mission into low range Note The slave valve preselection system interlock will prevent the slave valve from changing from low to high or vise versa if the transmission is engaged in a front section gear This system allows the driver to preselect by moving the range selec tion lever while still in gear the range change will then occur as th
72. Typical service tools 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 98 Procedure 1 2 Remove 2 screws retaining wire terminals Remove the switch using a 7 8 deep well socket or box end wrench In Vehicle Service Procedure How to Install the Reverse Switch Special Instructions None Special Tools e Typical service tools Procedure 1 Insert the reverse pin in the reverse switch bore gt lt D T D N D Lu 1 o cp ms mm o o cD 2 mm 2 Install new gasket on switch 3 Install the reverse switch torque to 15 20 Ib ft 20 34 27 12 rm 4 Connect the wiring to the switch 1 Reverse Light Switch 2 Gasket a Pin 4 Shift Bar Housing 5 Gasket 99 In Vehicle Service Procedure How to Remove the Shift Bar Housing Special Instructions Before removing the shift bar housing the air lines must be disconnected For models equipped with an oil pump and or cooler assemblies make sure to disconnect the oil line connected to the shift bar housing There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other locations except the left front corner at the roll pin location This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes Special Tools e Typical service tools Procedure 1 Fr
73. ads during auxiliary section disassembly Special Tools e See Tool Information e A large breaker bar or air impact wrench Procedure 1 Engage two 2 mainshaft sliding clutches into two 2 main Shaft gears to lock the transmission or use a yoke holding tool if available 2 Use a large breaker bar or air impact wrench to remove the output shaft nut 112 In Vehicle Service Procedures 3 Remove the output yoke Use the output yoke puller Tool ref ID T1 gt lt 5 o co N cD Uu T cD J ba o cD 2 ba cD 7 113 In Vehicle Service Procedures How to Install the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TCSM0912 Seal Maintenance Guide Special Tools e See Tool Information e Torque wrench with 0 600 Lbeft capacity Procedure 1 Engage two 2 mainshaft sliding clutches into two 2 main Shaft gears to lock the transmission or use a yoke holding tool if available 2 Install the speedometer drive gear rotor or replacement Spacer on the output shaft inside the rear bearing cover 3 Ifthe slinger on the yoke is damaged replace using a Sling er Seal kit 4 Install the output yoke over the output shaft The yoke Should slide on and stop before contacting the speedometer rotor As the output shaft nut is installed the output yoke
74. aft w Forward Shift Bar Housing w Overdrive ep cD cD Lm I o 5 mm o f _ L or LL notation used here indicates one L or two Low LL gears in addition to designated speeds PTO Code Eaton Fuller Transmissions ar Eaton Corporation l FTN pec _ ns Kelamares MI ADDED The model number gives basic information about the transmission Use this number when calling for service assistance or re placement parts Serial Number The serial number is the sequential identification number of the transmission Before calling for service assistance write the num ber down It may be needed Bill of Material or Customer Number This number may be located below the model and serial numbers It is a reference number used by Eaton Model Designations and Specifications Model Options Torque Rating The torque rating of the transmission specified in the model number is the input torque capacity in Lb ft Various torque ratings are available For more information call your Eaton Fuller regional sales and service office at 1 800 826 HELP 4357 Shift Bar Housings Two types of shift bar housings are available for this transmission Both are described and shown below Standard The standard shift bar housing has a gear shift lever opening that is located toward the rear of the transmission Forward The forward shift bar housing has a gear shift lever opening located three inches closer to the transm
75. air line 1 long e Vise with brass jaws Procedure 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with brass jaws or wood blocks 2 If previously removed install the roll pin in keyway 3 With mainshaft pilot end down install offset washer flat Surface up Rotate the washer until the washer splines and mainshaft splines align 4 Start at the mainshaft bottom and install a plastic line in the marked keyway to lock the washer in place 5 With clutching teeth down position the proper gear on the mainshaft Refer to the illustrated parts list for correct gear 6 Install the flat washer Rotate the washer until the washer Splines and mainshaft splines align jneuI9A0 UOISSIUISUOJg v cD n Lm cD P 5 cD oD cD Lu oD cD 205 Transmission Overhaul Procedures Bench Service 206 10 11 12 13 14 With clutching teeth up and against the spacer install the next gear Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main Shaft splines align Push the air line up to lock the washers on the mainshaft With the missing internal splines aligned with the plastic line install the proper sliding clutch Position the next offset washer in the next available groove Rotate the washer until the washer splines and mainshaft Splines align Push the air line
76. apply force to shafts housings etc with restraint Movement of some parts is restricted Never apply force to driven parts after they stop solidly The use of soft hammers soft bars and mauls for all disassembly work is recom mended Inspection Precautions Before assembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Fuller Transmission parts to assure continued performance and extended life from your unit since the cost of a new part is generally a small fraction of the total cost of downtime and labor avoid reusing a questionable part which could lead to additional repairs and expense soon after assembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the unit s history mileage application etc Recommended inspection procedures are provided in the following checklist Bearings e Wash all bearings in clean solvent Check balls rollers and raceways for pitting discoloration and spalled areas Re place bearings that are pitted discolored spalled or damaged during disassembly e Lubricate bearings that are not pitted discolored or spalled and check for axial and radial clearances e Replace bearings with excessive clearances e Check bearing fit Bearing inner races should be tight to shaft outer races slightly tight to slightly loose
77. ar Bearing Cover Assembly 6 O Ring 3 Capscrew 7 Speedometer Spacer Assembly 4 Speedometer Drive Gear Procedure 1 Disconnect the driveshaft and U joint from the output yoke according to the OEM or driveshaft manufacturer s instruc tions 2 Shift the transmission into 1st gear or low gear Low Range to prevent the output yoke from turning when you loosen the output yoke nut 104 Remove the output yoke nut using a 70 mm or 2 3 4 socket see How to Remove Output Yoke Companion Flange Remove the output yoke If necessary use an output yoke puller Remove the seal sleeve Use a slide hammer with a hook attachment to remove the seal Or remove output bearing cover and drive seal out from front side Note The seal will be damaged during removal and must be replaced Remove seal slinger from the output yoke using a brass drift and hammer Inspect all parts of the seal surface for wear scratches burrs or other damage Note Replace the seal surface if it is worn or damaged Do not attempt to salvage the seal mating surface with crocus cloth filing etc In Vehicle Service Procedures 105 a lt 5 T co N cD Lu T cD J ba o cD 2 uu cD 7 In Vehicle Service Procedures How to Install the Oil Seal Mechanical Speedometer Special Instructions A CAUTION To prevent oil leaks do not touch the seal lip and make sure the seal driver is clean Special Tools
78. bearing cover remove the six 6 retaining capscrews and cover Remove any remaining gasket mate rial from the case and cover a o z o o o 5 A 3 y o o o o 5 THE a 2 5 E lt S QO cD 2 If present remove and discard the rubber seal ring on the in put shaft The ring is used only to seal the transmission dur ing shipment 3 From the input shaft groove remove the bearing retaining snap ring 147 Transmission Overhaul Procedures Bench Service 148 4 Usea soft bar and maul to drive the input shaft toward the case rear as far as possible Pull the input shaft forward 5 Install the bearing puller tool and remove the input bearing from the case and input shaft or use pry bars or screwdriv ers to complete removal of the bearing 6 From the drive gear front remove drive gear spacer 7 Remove the drive gear internal snap ring 8 Pull the input shaft forward and out of the drive gear 9 Inspect the bushing in the input shaft pocket replace if dam aged Transmission Overhaul Procedures Bench Service How to Install the Input Shaft Assembly without main case disassembly Special Instructions None Special Tools e See Tool Information see Table 6 e Item T12 Input bearing driver e Toolmaker s dye Procedure 1 If necessary install the bushing in the back of the input Shaft 2 From the front engage the input shaft spline teeth into the
79. bination Cylinder Assembly Special Instructions Apply Eaton lubricant 71206 or equivalent to all shift cylinder assembly and spool valve O rings so a film covers the entire sur face Apply Eaton rust preventative 71213 or equivalent to all shift cylinder walls and yoke bars cover the entire yoke bar surface that comes in contact with the shift cylinder O ring Special Tools e Typical service tools Procedure 1 Lightly lubricate O rings with Eaton Fuller Silicone lubri cant P N 71206 or equivalent 2 Install O rings into range and deep reduction shift cylinders gt lt 5 o co N cD Uu T cD J ba o cD 2 ba cD 7 3 Install O rings onto range and reduction pistons 4 Install gasket and shift cylinder 125 In Vehicle Service Procedures 126 cn Install range piston with flat side to rear Install range piston nut and torque to 70 85 Lbeft 6 Install deep reduction piston with flat side to rear Install nut and torgue to 50 65 Lbeft Note If reusing existing nut make sure nylon locking mate rial is in good shape if not use new nut 7 Lightly lubricate insert valve O rings with Eaton Fuller Silicone lubricant P N 71206 or equivalent Install insert valve with flat side to the inside Install insert valve retaining nut and torque to 40 50 Lbeft 8 Install gasket and cover Apply Eaton Fuller thread seal ant P N 71205 or equivalent to capscrew thr
80. brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents may be used This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow Specific instructions may result in personal injury and or component damage A Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technican or vehicle operator Warning Failure to follow indicated procedures creates a high risk of personal injury to the service technician Caution Failure to follow indicated procedures may cause component damage or malfunction Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the service of this unit Always use genuine Eaton replacement parts Introduction Transmission Overview Air System Roadranger Valve Shift Bar Housing Levers Housings amp Isolators Auxiliary Section Combination Cylinder ep cD e cD Lm I o gt h i Lm o i Air System OW Air Filter Regulator shift Bar Housing Shift Bar Housing Assemby Front Section Reverse Idler Auxiliary Section Auxiliary Countershaft Auxiliary Section
81. ce the auxiliary drive gear assembly from the case The three threaded holes are only found on earlier models High Torque Capacity Models Procedure 1 Remove the mainshaft rear groove snap ring 2 Slide the auxiliary drive gear off the mainshaft 180 Transmission Overhaul Procedures Bench Service 3 Remove six capscrews from auxiliary drive gear bearing re tainer and remove the retainer plate a o z o o o 5 amp y y o o o o 5 5 THE a 2 5 Lm lt S r MM cD 4 Insert prybar into main case gearing use to slide mainshaft assembly rearward to move mainshaft rear bearing slightly rearward 5 Use a rolling head prybar crow s foot to work the main shaft rear bearing from its bore 6 Ifthe bearing must be replaced press the inner spacer from the mainshaft rear bearing 181 Transmission Overhaul Procedures Bench Service How to Disassemble the Upper Reverse Idler Gear Assembly Special Instructions Before the upper reverse idler gear assembly can be removed mainshaft reverse gear must be positioned forward against the next gear While removing the reverse idler shaft the thrust washer can drop to the transmission case bottom The mainshaft reverse gear must be moved in order to remove the upper reverse idler gear Special Tools e Typical service tools e Jaw pullers or impact puller e Soft bar and maul Procedure 1 Remove retaining bolt fro
82. ce the bearing is fully installed it is normal for clearance to exist between the auxiliary drive gear hub and the mainshaft rear bearing inside 3 Install the snap ring in gear hub groove to retain the bearing jneuI9A0 UOISSIUISUOJg v cD n Lm cD P 5 cD oD cD Lu oD cD 4 Install the outer retainer ring grooved side down inset with a flanged driver 5 Install the auxiliary drive gear assembly on the mainshaft rear Use a flanged end driver to fully seat the assembly in the case bore 231 Transmission Overhaul Procedures Bench Service 232 6 Apply Eaton Fuller thread sealant 71205 or equivalent to the capscrew threads and install the six 6 capscrews Torque the capscrews to 35 45 Lbeft NOTE On some pre vious designs lock wire was used on the capscrews lock wire as needed Install the snap ring in the mainshaft groove rear The main Shaft may need to slide rearward Procedure High torque capacity models 16908LL and 16915 Press the inner sleeve into the rear mainshaft bearing Slide the bearing and sleeve assembly over mainshaft rear Note The missing spline tooth is positioned over the main shaft key Use a flanged driver to fully seat the rear mainshaft bearing assembly With the stepped side facing forward install the rear main Shaft bearing retainer plate Apply Eaton Fuller thread Sealant 71205 or equivalent to the capscre
83. ch Service How to Assemble the Standard Shift Bar Housing Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The Sealant should be applied so at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the way of any part interference Keep yoke bars in neutral while assembling Special Tools e Vise with brass jaws or wood blocks Procedure 1 Assemble the yoke actuator assembly 2 From the shift bar housing bottom install the actuator pin and yoke actuator 3 On the shift bar housing top install the washer and nut 138 Transmission Overhaul Procedures Bench Service Assemble the 1st and reverse shift yoke assembly e Install the plunger in the 1st and reverse shift yoke bore plunger shank to the outside e Install the spring into the bore over the plunger shank e Install the plug and tighten to compress the spring e After plug bottoms out back the plug out 1 to 1 1 2 turns e Complete the block assembly process by staking the plug through the small hole in block With the housing rear to the right lay the assembly on a flat surface Start ins
84. conditions are encountered ep cD cD Lu co a Lu co nr a Lubrication Oil Cooler Chart Table 4 TRANSMISSION OIL COOLERS ARE Recommended e With engines of 350 H P and above e With engines 399 H P and above and GCW s over 90 000 Ibs e With engines 399 H P and above and 1400 Ib ft 1898 15 Nem or greater torque e With engines 1500 Ib ft 2033 73 Nem and above 18 speed AutoShift transmissions require use of an Eaton supplied oil to water cooler or approved equivalent e With engines 450 H P and above Transmission Operation Transmission Operation and Theory Depending on specific model this Fuller transmission model contains from 9 to 15 forward gear ratios and three reverse gear ratios The gear shift lever mechanically engages and disengages five forward gears and one reverse gear in the transmission front section The rear section of the transmission auxiliary section contains three additional gear sets which are shifted with air The auxiliary section provides deep reduction low low range low range and high range The driver can shift in or out of deep reduction by moving the deep reduction button found on the shift knob side Low and high range are shifted by moving the range selection lever found on the shift knob front Therefore when a front section gear is combined with the proper auxiliary section condition deep reduction low range or high range a corre
85. crews 3 Install the two 2 retaining capscrews torque to 8 12 Ib ft 10 85 16 30 Nem 85 In Vehicle Service Procedure How to Remove a Roadranger Valve Special Instructions A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the vehicle air tanks must be exhausted Special Tools e Typical service tools Procedure 1 From the Roadranger valve cover remove the two 2 mounting screws 2 Slide the Roadranger valve cover down 3 From the air fittings disconnect the air lines 4 From the Roadranger base loosen the jam nut Rotate the Roadranger valve until the valve is removed 5 Inspect the parts nut valve cover air lines sheathing and o rings from the lever shaft 6 Inthe Roadranger valve inspect the air fittings and remove if damaged 86 In Vehicle Service Procedure How to Install a Roadranger Valve Special Instructions To position the Roadranger valve the range lever must be to the front or the splitter button to the left when facing forward Special Tools e Typical service tools Procedure 1 Make sure the nut valve cover air lines sheathing and o rings are in position on the lever shaft I lt cD oD cD cD Uu 1 cp v ba o oD cD Lm cp 2 If previously removed replace the air fittings and torque to 84 120 Ib in 9 49 13 56 Nem 3 Place the Road
86. ding Clutch Rearward Range Sliding Clutch Forward 7th Gear Deep Reduction F Wee Sliding Clutch Forward CC Ty Sliding Clutch Forward Range Sliding Clutch Forward RT 10th Gear RTO 9th Gear Air System Air System Overview Pressurized air from the vehicle s air system is used to shift the transmission low high range and deep reduction ratios The low high range and deep reduction gearing and shift mechanisms are located in the auxiliary section of the transmission The vehicle operator controls these shifts with two separate switches on the shift knob master control valve The following components are part of the air shift systems Air System Components G D D Lm I o o mm 3 D r 5 RANGE AND DEEP REDUCTION CYLINDER AIR LINES SLAV COMBINATION VALVE CYLINDER LOW RANGE HIGH RANGE SN ce SUPPLY PORT SUPPLY PORT SP DEEP REDUCTION SIGNAL LINE ra AIR FILTER REGULATOR Ya RUBBER AIR LINES 35 Air system Shift Knob The shift knob contains two switches
87. ding clutch into high range ratio Deep Reduction Cylinder The deep reduction cylinder contains a piston and reduction yoke bar Air pressure on the front side of the piston shifts the trans mission into the deep reduction ratio Air pressure on the rear of the piston shifts the transmission out of deep reduction 40 Range Piston Low Range Port High Range Port Range Yoke Bar a Z X N N Deep Reduction Signal Line Z N am Z Z LITZA 1 I o Sr N fp Insert Valve Pe yg ee Deep Reduction Commi SO Yoke Bar a Filter Regulator Deep Reduction Piston Air system Insert valve The insert valve is a small 3 16 diameter self contained switching valve which is located adjacent to the deep reduction cylinder When deep reduction is selected at the shift knob master control valve an air pressure signal is applied to the insert valve which then exhausts the air on the rear side of the deep reduction cylinder piston LO Range and HI Range No air on Signal Line __ Constant Air To deep reduction piston back side moves G D D Lm I o o mm 3 D r 5 Deep Reduction Air on Signal Line Constant air sealed off at this point Air exhausted through bottom port from piston back side Deep reduction piston moves rear ward due to constant air on front side 41 Air
88. dowel pins are not installed in the main case to the proper depth the auxiliary section will not properly align with the main case and bearing or synchronizer failure may occur Install the dowel pins into the main case so that 3 8 1 2 of the shoulder is exposed or pin is flush with front of case ear Clean all rust and paint from the dowel pin holes in the aux iliary section housing and lightly grease the dowel pins on the main case and the dowel pin holes on the auxiliary sec tion housing Make sure the auxiliary section is in low range If not blow shop air max 100 PSI into the low range supply port to shift the range synchronizer to low If necessary make sure the deep reduction clutch is engaged into gear Position the gasket onto the main case mounting surface Mount the auxiliary section on the lifting device or jack Tighten the center capscrew on the countershaft support tools to draw the countershafts into a level position Do not overtighten the capscrews The output yoke and shaft must be able to rotate Position the auxiliary section in line with the main case and slide the housing onto the dowel pins Mesh the counter shafts with the auxiliary drive gear Rotate the output yoke and shaft slightly to help the gears mesh and slide the auxil iary section forward until it is flush with the main section A CAUTION The auxiliary section should slide into place fairly easily DO NOT force it on or pull it into
89. e coupler from the LO range gear If necessary remove the bushings from inside the coupler Remove the splined washer from inside the LO range gear 159 0 Ur cD 2 Lm D o co D o N D E eh co cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service 8 Remove the sliding clutch and the reduction yoke assembly from the auxiliary housing 9 Useasoft bar and maul to completely drive the output shaft forward and through the rear bearing assembly 10 Remove the bearing inner spacer from the output shaft 11 Use the reduction gear front face as a base press the output Shaft through the bearing and gear This frees the bearing reduction gear washer and the splined washer 160 Transmission Overhaul Procedures Bench Service 12 Remove the flat washer reduction gear and the stepped washer from the shaft 13 Remove the rear bearing cover retaining capscrews rear bearing cover and the gasket from the auxiliary housing The rear bearing cone drops from the housing bore when the cover is removed If necessary replace the oil seal on the rear bearing cover 14 Remove the complete bearing race from the bearing bore 161 0 La o cD 2 ba cD gJ o N Uu T cD JneuI9A0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service How to Disassemble the Synchronizer Assembly Special Instructions
90. e driver moves the shift lever through neutral 42 Roadranger Valve Insert Valve Assembly cC z High Range 1 Vehicle supply air 110 130 PSI is supplied to inlet port on the filter regulator where it is filtered and regulated to 58 5 o Air System Cylinder Assembly No Air LO ATO mY Air to Cover OP yi WW a Port Ne O a ans Fog A ZZ N we Air from Range 3 am Hi as AM ju y 7 Gas mw ON zy eee AR a _ gt Deep Reduction NL A SA re Z D Air Filter Regulator 63 PSI Thru a 1 4 D rubber air line a constant 58 63 PSI regulated air is supplied to the S supply port on the slave valve Thru a 5 32 or 1 8 air line a constant 58 63 PSI regulated air is also supplied to the S supply port on the shift knob The driver selects high range by moving the range selection lever up This shuts off the supply air to the P line The air in the P line will then exhaust at the shift knob port E With the air pressure off of the P port at the slave valve a the valve will shift and air will be supplied to the high range H port The constant supply air at the slave valve is now supplied thru a 1 4 hose to the high range port on the range cylinder This air pressure moves the range piston range bar range yoke and range sliding clutch forward to shift the transmis
91. e engaged mainshaft gear and through the sliding clutch to the front section mainshaft 5 The rear of the front section mainshaft is splined into the auxiliary drive gear and torque is now delivered to the auxiliary section Deep Reduction Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward Figure 2 4 Front Section Power Flow 22 Power Flow Front Section Power Flow Direct Gear In direct gear the front sliding clutch is moved forward and engages into the back of the main drive gear Torque will flow from the input shaft to the main drive gear main drive gear to sliding clutch sliding clutch straight into the front section mainshaft which delivers the torque to the auxiliary drive gear See Figure 2 5 Note All countershaft and mainshaft gears will rotate but the gears will not be loaded Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward cC cD cD Lm I o 5 mm o i Figure 2 5 Front Section Power Flow Direct Gear 23 Power Flow Front Section Power Flow Reverse Gear Torque will flow from the countershafts to the reverse idler gears Torque will then flow from the reverse idler gears to the main Shaft reverse gear Torque will now travel through the mainshaft reverse gear the sliding clutch in the reverse position and then to the mainshaft and auxiliary drive gear See Figure 2 6 2 7 2 8 Deep
92. e still in gear preselect for low by moving the range selector down Then move the shift lever double clutching to the next desired gear position in low range As the shift lever passes through neutral the transmission automatically shifts from high range to low range cC cD cD Lm I o 5 mm o i Deep Reduction Shifts Note Deep reduction is only available in low range Button back deep reduction not selected Button forward deep reduction selected To obtain deep reduction low low first make sure range selection lever is down for low range Then move deep reduction but ton forward Upshifts An upshift from deep reduction can be performed while the vehicle is moving If the driver is not moving the shift lever during the shift example RTO 14708LL depress the clutch pedal once immediately after moving the deep reduction button rearward Decrease engine RPM to obtain synchronous for shift completion If the driver is moving the shift lever during the shift example RTO 14715 move the deep reduction button rearward and imme diately double clutch while moving the shift lever Decrease engine RPM to obtain synchronous for shift completion Transmission Operation and Theory Downshifts Downshifts into deep reduction while moving are generally not recommended but are possible if Operating conditions make it necessary In this situation complete the shift immediately after moving the dee
93. e the 4th or overdrive gear Remove the offset washer Transmission Overhaul Procedures Bench Service How to Disassemble the Mainshaft Assembly with Low Force Gearing Special Instructions The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft It still utilizes Non Selective Non Adjustable Tolerance Washers but the 1st and reverse gears and sliding clutch have been redesigned In this configuration the 1st reverse sliding clutch rides on a clutch hub and the 1st and reverse gears have been redesigned to accommodate this change Lay all parts on a clean bench in order of removal to facilitate assembly Special Tools e Typical service tools Procedure 1 Lay the mainshaft on its side and from the front remove the 4th or overdrive and 5th sliding clutch V o TER 5 N 3 77 o o ona os THE gt Z aoe 5 mg lt S r M ras 2 Place the mainshaft in a vertical position pilot end down Remove the reverse gear clutch hub and sliding clutch 3 Remove the snap ring and key Mark keyway location 197 Transmission Overhaul Procedures Bench Service 4 Remove the offset washer and 1st gear 5 Remove the flat washer and 2nd gear 6 Remove the offset washer and sliding clutch and then re move the offset washer and 3rd gear 7 Remove the flat washer remove the 4th or overdrive gear and remove the offset washer
94. eads Install capscrews and torque to 35 45 Lbeft Transmission Overhaul Procedures Bench Service How to Disassemble the Gear Shift Lever Special Instructions If total disassembly is needed the Roadranger valve must be removed first Release the spring one coil at a time Special Tools e Vise with brass jaws or wood blocks 1 Pin 2 Bushing 3 Upper Lever 4 Snap Ring 5 Rubber Boot 6 Spade Pin Housing S 41 ri im a a 12 Ed a a Pol a a a h i an Pail a NN a a ec Wro i Pa e a y ner Hoa Ti 8 D a Tn n br tb a Ss A ee a 1 4 Hl ae i eo n i le ea i y a l i m cn a 9 a a en 8 Capscrew 9 Gasket 10 O Ring 11 Washer 12 Lower Lever 13 Stepped Washer 14 Tension Spring jneuIoA0 UOISSIUISUOJ 0 m o Ur cD 2 Lm D o co D co N D mg i Ur cD 127 Transmission Overhaul Procedures Bench Service 128 Procedure 1 On a non isolated shift lever remove the Roadranger valve using the How to Remove the Roadranger valve instruc tions in In Vehicle Service Procedures If the shift lever is equipped with a lever isolator remove the snap ring bush ing and cross pin to disconnect and remove the upper lever Slide the rubber boot up and off the shift lever shaft With housing bottom facing up secure the assembly in a vise Use large screwdri
95. ear until auxiliary section is free 9 Remove the gasket and clean all mounting surfaces of gas ket material Procedure 1 To remove the auxiliary section in the vertical position With blocks under the clutch housing to prevent input shaft damage place transmission in the vertical position clutch housing down 2 Remove the four 4 capscrews and the auxiliary counter Shaft rear bearing cover gasket and rear bearing shim Clean the gasket surface area 3 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap screws are snug 4 From the auxiliary section housing remove the retaining capscrews that attach the front box to the auxiliary section 5 Install a steel bar through the yoke 6 Attach a lifting chain to the steel bar 7 Lift assembly from the front section Transmission Overhaul Procedures Bench Service How to Remove the Combination Cylinder Assembly Special Instructions None Special Tools e Typical service tools Procedure 1 Drain lube 2 At the combination cylinder cover remove the 5 capscrews with washers 3 Remove the cylinder cover and gasket V o TER 5 amp y 3 N o o ona o 5 a a nm 2 5 E lt S QO cD 4 If necessary remove the insert valve retaining nut from the cylinder cover Remove the insert valve from the bore
96. eat the bearing 5 Support the auxiliary countershaft while removing the auxil iary countershaft retaining strap 6 Remove the auxiliary countershaft 7 Remove the auxiliary countershaft bearing race from bore Transmission Overhaul Procedures Bench Service 8 If necessary secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing Separator and jaw pullers a o z o o o 5 A E T o o o o 5 THE a 2 5 E lt S QO cD 157 Transmission Overhaul Procedures Bench Service How to Disassemble the Output Shaft Assembly Special Instructions When using the soft bar and maul on the output shaft be careful not to damage the threads When removing the rear bearing cover the rear bearing cone drops from the housing bore Special Tools e Vise with brass jaws or wood blocks e Press e Soft bar and maul Procedure 1 Remove the range yoke assembly and synchronizer Re move the range yoke assembly from the synchronizer slid ing clutch 2 Usea 1 1 2 socket or wrench to remove the auxiliary main Shaft nut 3 Remove the washer and dowel pin from the auxiliary main shaft 158 4 l Transmission Overhaul Procedures Bench Service Remove the low range gear and coupler assembly From front with a punch and hammer drive the two coupler pins from the coupler Align the coupler splines with the washer splines and remove the rang
97. eduction button rearward Discon nect the air line connected to the SP port Check for air flow from the SP port Move deep reduction button forward Check for air flow from SP port Disconnect air line H L port on shift knob Check for air flow from the dis connected line Air flows from SP port No air flow from SP port Air flows from SP port No air flow from SP port Air flows from disconnected line No air flow from disconnected line Replace shift knob Go to Step G 1 Check for proper air line connec tion from SP port on shift knob to SP port on deep reduction cyl inder 2 Check for obstruction in SP air line or fittings 3 If clear reconnect the air line at the shift knob go to step A Go to step H Replace shift knob 1 Check to make sure that the shift lever is in neutral the range selec tor is down in low range and the H L line is properly connected to the low range hose at the slave valve 2 lf no air pressure is available on low range hose perform low range shift troubleshooting procedure to correct this problem Air System Procedure 8 Symptom Range shifts with shift lever in gear Normal Operation Range shift should only occur when the shift lever is in neutral The range selector can be moved up or down while the shift lever is in a gear position but the shift will not occur until the shift lev
98. eely move 1 32 Remove the deep reduction cylinder cover and deep reduction piston Inspect piston and bore for contami nation or damage Pressure rapidly changes between 58 63 PSI and 0 PSI at the gauge Pressure does not respond rapidly at gauge Insert valve is contaminated sticking or damaged Insert valve is clean and small internal piston moves freely Deep reduction cylinder bore or piston is contaminated or damaged Deep reduction cylinder bore or piston is in good condition Go to Step D Go to Step F Replace insert valve reconnect air line and check if deep reduction shifts normally Go to step E Repair as necessary replace insert valve and air line Check if deep reduction shifts normally 1 Remove deep reduction cylinder assembly Inspect for contamina tion or damage causing deep reduction yoke bar to bind in cylin der Repair as necessary 2 Remove auxiliary section and inspect deep reduction yoke slid ing clutch and gearing for damage which would prevent deep reduc tion shift Repair as necessary 63 HATH HED Air System O 1 NW Step F Step G Step H 64 At the shift knob remove the two screws attaching the lower cover and Slide the lower cover down to access the fittings Confirm that the air lines are connected to the proper ports Make sure the shift lever is in neutral Move the range selector down to select low range and move the deep r
99. en port on the range cylinder Note If the air leak at the slave valve only occurs when the transmission is in high range repeat the above test but remove the low range air hose and check with high range selected Air is leaking from fitting or air line Air is definitely leaking from slave valve exhaust port Air is flowing from high range sup ply port on range cylinder No air flow from high range port Repair or replace fitting or air line Go to Step B Remove range cylinder cover and repair leaking range piston or piston seal After repair check for proper range operation Repair or replace slave valve D3 TATOU EA ENTEN Air System Procedure 3 Symptom Air Leak from Transmission Breather or Transmission Case is Pressurized Normal Operation There should be no measurable air flow from the transmission breather Possible causes e Leak at range yoke bar O ring e Leak at deep reduction yoke bar O ring eee Listen for the air leak with the trans Leak is only in low range Remove range cylinder and inspect mission shifted to both low and high for damaged range yoke bar yoke bar range O ring or range cylinder Repair as necessary Leak is in both low and high range Remove deep reduction cylinder Inspect for damaged deep reduction yoke bar O ring or cylinder Repair as necessary 54 Air System Procedure 4 Symptom Air leak at deep reduction cylinder cover exhaust port
100. ened bolt and remove washer Reinstall bolt 3 4 threads Install an impact puller 1 2 13 threaded end and remove the shaft from case bore As the idler shaft and idler plate are removed remove the thrust washers and gear Inspect the reverse gear assembly remove the inner race and needle bearing if damaged Transmission Overhaul Procedures Bench Service How to Remove the Upper and Lower Countershaft Bearings Special Instructions The following instructions are used to remove the upper and lower countershaft bearings To remove the mainshaft assembly only the upper countershaft bearings need to be removed Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned The bearing inner race remains pressed on the countershaft after removal of the front bearings Special Tools e Soft bar and maul e tem T8 Countershaft Pusher e tem T9 Bearing Puller Procedure 1 To keep the mainshaft pilot from falling out of the input shaft pocket temporarily install the auxiliary drive gear on the mainshaft V o oO 9 OD 5 N 3 77 o o ona os THE gt Z aoe 5 mg lt S r M ras 2 From each countershaft rear groove remove the snap ring 3 Remove six capscrews from front bearing cover and remove front bearing cover A CAUTION Damage will likely occur to this bearing during removal It is strongly recommended
101. er is moved to neutral Possible Causes e Worn or missing actuating pin or air valve shaft e Worn shift rail Procedure If the range has been confirmed to shift with the shift lever in gear unbolt the slave valve from the side of the transmission Con firm that the actuating pin is present and that it is the proper P N for the corresponding slave valve If correct remove the shift bar housing assembly and check for a worn or damaged air valve shaft or worn shift rails Replace necessary parts ep cb e cD Lm D gt n i Lu o i 65 Timing Timing Procedures Special Instructions It is essential that both countershaft assemblies of the front and auxiliary sections are timed This assures proper tooth contact is made between mainshaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that distribute the load evenly If not properly timed serious damage to the transmission is likely to result from unequal tooth contact causing the mainshaft gears to climb out of equilibrium Timing is a simple procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh while in the transmission In the front section it is necessary to time only the drive gear set And depending on the model only the LO range deep reduction or splitter gear set is timed in the auxiliary section Procedure Front Section 1 Marking count
102. ershaft drive gear teeth Prior to placing each countershaft assembly into the case clearly mark the tooth located directly over the drive gear keyway as shown This tooth is stamped with an O to aid identification Figu re 2 2 Marking main drive gear teeth Mark any two adjacent teeth on the main drive gear yn Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear As shown to the left there should be an egual number of unmarked gear teeth on each side between the marked sets 3 Meshing marked countershaft drive gear teeth with marked main drive gear teeth After placing the mainshaft l assembly into the case the countershaft bearings are in Figure 3 Stalled to complete installation of the countershaft assem blies When installing the bearings on the left countershaft mesh the countershaft drive gear marked tooth with either set of main drive gear two marked teeth Repeat the procedure when installing the bearings on the right countershaft make use of the remaining set of main drive gear two marked teeth to time assembly 66 Timing Procedure Time the RT Auxiliary Section 1 Mark a tooth on the reduction gear with a highly visible paint preferably a yellow or white G D Lu o o Lu D o 2 Mark a second tooth 180 degrees away from the first En sure the marks are in the correct position by counting the teeth between them You should
103. ervice Manual be consulted first Special Tools e Typical service tools Procedure Figure A 1 Reach Rad A Shift Arm 2 Turnbuckle 6 Pivot Link Assembly f 3 Selection Lever 7 Inner Shift Shalt 4 Inner Shift Finger Figure B 1 Selection Lever 2 shift Arm 92 1 Move the gear shift lever forward or backward to the neutral position Move the gear shift lever sideways toward reverse until you feel resistance from the reverse plunger spring DO NOT shift to reverse The shift finger must remain in this position while you are making all the adjustments Remove the cotter pin castle nut and ball joint A see figure A from the selection lever Do not remove the ball joint from the pivot link Loosen the capscrew B see figure A and remove the shift arm from the inner shift shaft Do not disconnect the selec tion lever from the shift arm Turn the shift arm until it is at a right angle 90 to the se lection lever as viewed from the side see figure B Note Ideally the shift arm should be adjusted 90 to the se lection lever as described but in some chassis config urations it may be necessary to index the shift arm in the vertical position Indexing the shift lever is done to prevent shift lever jump out This type of adjustment will cause an unequal amount of gear shift lever travel between neutral and a forward lever position as com pared to neutral and a rearward lever position
104. eutral notch bore Install the shift block and shift yoke lockscrews torque to 35 45 lb ft 47 45 61 01 Nem Lockwire securely Place one 3 4 interlock ball in the interlock bore against the middle bar 145 v o co cD O Lm cD P 5 cD oD cD Lu oD cD JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service 146 19 17 18 19 Holding the top bar notched end start installation As the bar passes the rear boss position the shift block 16 As the bar passes the center boss position the shift yoke on bar long hub to the housing rear Install the shift block and shift yoke lockscrews torque to 39 45 lb ft 47 45 61 01 Nem Lockwire securely Install the oil trough torque the retaining capscrews to 8 12 lb ft 10 85 16 30 Nem Some models do not have an oil trough Install the three 3 tension balls one in each housing top bore Install the three 3 detent springs one over each ten sion ball Note Make sure interlocking system is working should not shift into 2 gears at the same time Note Make sure all lockscrews are lockwired Transmission Overhaul Procedures Bench Service How to Remove the Input Shaft Assembly without main case disassembly Special Instructions None Special Tools e See Tool Information see Table 6 e item T21 Bearing puller e Soft bar and maul Procedure 1 From the front
105. ever mix engine oils and gear oils in the same transmission Buy from a reputable dealer For a complete list of approved and reputable dealers write to Eaton Corporation Worldwide Marketing Services P O Box 4013 Kalamazoo MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication will occur The operating angle is the transmis sion mounting angle in the chassis plus the percent of upgrade expressed in degrees For operating angles over 12 degrees the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication Operating Temperatures with Oil Coolers The transmission must not be operated consistently at temperatures above 250 F Operation at temperatures above 250 F 121 C causes loaded gear tooth temperatures to exceed 350 F 177 C which will ultimately destroy the heat treatment of the gears If the elevated temperature is associated with an unusual operating condition that will reoccur a cooler should be added or the ca pacity of the existing cooling system increased The following conditions in any combination can cause operating temperatures of over 250 F 121 C e Operating consistently at slow speed e High ambient temperatures e Restricted air flow around transmission e Use of engine retarder e High horsepower operation Note Transmission coolers must be used to reduce the operating temperatures when the above
106. everse Idler Gear Assembly Special Instructions In 1996 Eaton changed the reverse idler system design In the nut design the reverse idler bearing was lubricated through a hole in the main case reverse idler support boss and a oil passage through the idler shaft middle Special Tools e See Tool Information see Table 6 e tem 118 Bearing race installer Previous Design TATE EDDIE neysaAGQ UOISSIUISUOJ 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shatt 4 Nut and Washer 8 Plug 22 Transmission Overhaul Procedures Bench Service The capscrew design eliminates the case hole and idler shaft hole The reverse idler bearing is supplied oil through the use of star design thrust washers If the nut design parts are used with the capscrew design main case which does not have the oil feed hole the reverse idler bearing will fail Current Design 1 Star Washer 2 Inner Race 3 Star Washer 4 Retaining Ring 5 Capscrew 6 Idler Plate Bearing 8 Reverse Idler Gear 9 Reverse Idler Shaft 228 4 3 Procedure 1 Place the rear thrust washer on the idler shaft 2 From the rear insert the idler shaft through the main case bearing bore and into the reverse idler gear bearing Transmission Overhaul Procedures Bench Service As the idler shaft slides into the gear insert the front thrust washer into position Continue sliding the idler shaft i
107. f the way Pull the air line and attached collet from the fitting br a 1 Connector 4 Inspect the fitting air line collet and nut for damage or 2 Collet wear Replace as necessary 3 Nut 4 Air Line 78 In Vehicle Service Procedure How to Install Compression Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tanks A CAUTION Small air lines are available in 1 8 or 5 32 sizes Make sure 1 8 air lines are used with 1 8 fittings and 5 32 air lines are used with 5 32 fittings Mixing sizes can cause air leaks or damage to fittings lt D T D 7 D Lu 1 o cp J mm o o cD 2 mm D Special Tools e Typical service tools Procedure 1 Check the threads of the fitting for thread sealant If no seal ant is present apply Eaton thread sealant 71205 or equiva lent 2 Install the fitting Note Do not overtighten the nut Overtightening can com press the collet too much and cause an air line restric AWW tion 3 Install the air line collet and nut If installing a new fitting place the collet in the fitting and loosely install the nut Do not tighten the nut yet Insert the air line through the nut i 1 C t and into the collet Tighten the nut as usual 9 ie di 3 Nut 4 Enable the vehicle air system Allow the a
108. fted into gear and retract when shifted into neutral NOTE If desired the slave valve can be actuated and tested while unbolted from the transmission case The air lines of course must remain attached Actuating plunger pin moves freely If air system has been tested and found to operate satisfactory the auxiliary section must be removed to inspect for a mechanical problem Remove the auxiliary section and inspect for Binding of range yoke bar or piston Damaged or defective range yoke Damaged or defective range synchro nizer Cracked c s weld resulting in gear turning on shaft Damaged or defective range sliding clutch Auxiliary section gearing out of time Air system What to do next 2 Check for a restricted exhaust port on the shift knob 3 Check for a plugged or dirty filter in the filter regulator assembly 4 Check for a pinched or obstructed 1 4 rubber air line between the filter regulator and slave valve 5 Check for a pinched or obstructed air line between the slave valve and the S port on the shift knob 6 If all are good replace the shift knob Go to Step I 1 Remove actuating plunger pin and check for damage ep cD e cD Lu D 5 my o a 2 Check for missing or broken spring Repair or replace slave valve and check for proper range operation 61 Air system Procedure 7 Symptom No or slow shift into Deep Reduction Normal Operat
109. g is correct 14 Install stepped washer over auxiliary mainshaft with stepped Side up 168 Transmission Overhaul Procedures Bench Service 15 Mark with toolmaker s dye two opposing teeth on the re duction gear 16 Install reduction gear over auxiliary mainshaft Line up marked teeth 17 Apply grease to reduction gear rear thrust surface 18 Install large flat washer 19 Select front tapered output bearing bearing with longer roll ers Heat and install 169 0 o cD 2 Lm cD gJ cD o 5 N Lu T cD JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service 170 20 21 22 23 24 20 26 2 Install inner bearing spacer If not previously installed install dowel pins Confirm instal lation to proper distance Position gasket and install auxiliary housing Install bearing cup Heat rear tapered bearing and install over outputshaft Position a new gasket on the rear bearing cover mounting surface Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews Install the bearing cover and capscrews Tighten to 35 45 Lbeft Transmission Overhaul Procedures Bench Service How to Install the Combination Cylinder Assembly Special Instructions Apply Eaton lubricant 71206 or equivalent to all shift cylinder assembly and spool valve O rings so a film covers the entire sur face Apply Eato
110. g procedure Step A Move range selector down to select Air flows from the disconnected line Go to Step K low range Move the deep reduction button rearward At the deep reduc tion cylinder on the transmission back remove the small air line which provides the signal to the insert valve SP line Make sure this line was connected to the proper port location on the cylinder cover Check for air flow from the line No air flow from disconnected line Go to Step B Step B Connect a 100 PSI pressure gauge to Gauge reads 0 PSI Go to Step F the disconnected signal port line Move the deep reduction button for ward Read the pressure on the gauge Gauge reads pressure but is lower Replace filter regulator assembly than 58 PSI or higher than 63 PSI Gauge reads between 58 PSI and 63 Go to Step C PSI 62 Air System OO LL Step C step D Step E Have an assistant move the deep reduction button forward and rear ward Observe the pressure gauge Remove the insert valve NOTE After the insert valve plug has been removed cover the opening with a shop rag and apply shop air to the Signal line port to blow the insert valve out of it s bore Catch the valve with the shop rag If the vehicle air pressure is still present constant air flow should be blowing out of the insert valve bore Inspect the insert valve for contamination or damage Make sure the small piston inside the valve can fr
111. gear Axial clearance end play limits are 0 006 0 015 for all mainshaft gears If the axial clearance is less than the minimum 0 006 tolerance the tolerance washer should be replaced with a thinner tolerance washer This will increase the axial clearance between the gears If the axial clearance is greater than the maximum 0 015 toler ance a thicker tolerance washer should be installed This will decrease the axial clearance between the gears If necessary refer to the parts manual for your specific transmission model to determine the correct position of each mainshaft gear The mainshaft you are using may have 3 grooves in certain gear positions The middle groove is not used with the selective washer design Special Tools e Apiece of 5 32 air line 1 long e Vise with brass jaws 199 Transmission Overhaul Procedures Bench Service 200 Procedure 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with brass jaws or wood blocks If previously removed install the roll pin in keyway With the washer flat side up position a gear tolerance wash er white in the mainshaft 1st or bottom groove Rotate the washer until the washer splines and mainshaft splines align Start at the mainshaft bottom and install a 1 8 or 5 32 di ameter plastic line in the keyway to lock the washer in place As limit washers and gears are installed continue to push the plastic line up Against the
112. gear transfers torque to both auxiliary countershafts If the auxiliary section is in low range the range sliding clutch is rearward and engaged into the auxiliary mainshaft reduction gear Torque will flow from the auxiliary countershafts into the auxiliary mainshaft reduction gear through the range sliding clutch and then into the output shaft auxiliary mainshaft Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Rearward cC cD cD Lm I o 5 mm o i Figure 2 9 Low Range Selected Range Sliding Clutch Rearward 20 Power Flow Auxiliary Section Power Flow High Range If the auxiliary section is in high range the range sliding clutch is forward and engaged into t
113. h the sliding clutch recessed side up place the sliding clutch on the LO range synchronizer pins 163 Transmission Overhaul Procedures Bench Service 164 In the HI range synchronizer bores install the three 3 Springs Place the HI range synchronizer ring over the LO range syn chronizer ring Rotate the HI range synchronizer until the Springs are seated against the pins Cover the assembly with a shop rag Apply downward pressure to the HI range synchronizer ring while twisting counterclockwise This compresses the Springs to fully seat HI range on the LO range synchronizer This should be done with a rapid twist and push motion Note Make sure there are three springs and they are fully compressed Note Make sure you can move the sliding clutch from HI to LO range and back Transmission Overhaul Procedures Bench Service How to Assemble the Output Shaft Assembly Special Instructions Make sure the magnetic plugs are installed in the auxiliary housing When heating the bearings do not heat above 275 F 136 C Special Tools e See Tool Information see Table 6 e Toolmakers s dye e Heat lamp or hot plate and oil e Qil seal installation tool Procedure 1 From auxiliary mainshaft front assemble deep reduction clutch over splines jneuI9A0 UOISSIUISUOJg 0 Ur cD 2 Lm D o co D o N D E eh co cD 2 Mark with toolmaker s dye two opposing teeth on t
114. haft capscrew bore to help center the countershaft Move the countershaft forward into the bearing Use a flanged end bearing driver and maul to completely seat the front bearing in the case bore Note Make sure to contact only the bearing and not the tem porary race with the driver The temporary race should fall out when installation is complete On the countershaft front position the retainer plate with roll pin in hole at shaft end Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller thread sealant 71205 or equivalent Torque the capscrew to 90 120 Ib ft 122 02 162 70 Nem Note Earlier models may have a roll pin in the retainer This roll pin is not required and was removed on units built after 1994 229 TATE EDDIE JneyJ9A0 UOISSIUISUPJ Transmission Overhaul Procedures Bench Service 226 12 13 14 From the rear remove the countershaft support tool Install the rear countershaft bearing Position the bearing so that the larger chamfer on the bearing inside diameter is in Stalled towards the shaft Use a bearing driver that contacts both the bearing inner race and outer race In the countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torqued Note Make sure the rear snap ring is in place Transmission Overhaul Procedures Bench Service How to Assemble the Upper R
115. he back of the auxiliary drive gear Torque will flow from the auxiliary drive gear to the range sliding clutch Because the range sliding clutch has internal splines which connect to the output shaft torque will flow straight through the auxiliary section Note The auxiliary gearing will still turn but the gears will not be loaded Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Forward Figure 2 10 High Range Selected Range Sliding Clutch Forward 26 Power Flow RTO 1X707LL DLL MLL Deep Reduction Deep Reduction GG eee Sliding Clutch Rearward zz di Sliding Clutch Forward Conny I WULAN Coo COATT OON Ul ccm Sliding Clutch Forward Range Sliding Clutch Rearward S
116. he front case bore Swing the front of the countershaft to the center of the case and lift out the countershaft assembly Note A large hook or piece of rope may help support the countershaft Note Follow the same procedure for lower countershaft re moval 189 v cD n Lm cD 2 5 cD oD cD Lu oD cD o N 7 2 fan D ba gt D Transmission Overhaul Procedures Bench Service How to Disassemble the Countershaft Assemblies Special Instructions As you disassemble the countershafts mark each part as belonging to the upper or lower countershaft and mark the gears for front or back orientation Except for the PTO gears the left and right countershaft assemblies are identical and disassembled in the same manner Special Tools e See Tool Information see Table 6 e Snap ring pliers e Press 10364 11 96 CS RT 1 Snap Ring 8 Gear 2 Bearing 9 Gear 3 Countershaft with Re 10 PTO Gear verse and LO 11 Drive Gear 4 Key 12 Snap Ring 5 Roll Pin 13 Bearing 6 Key 14 Retainer Kit Gear 15 Capscrew 190 Transmission Overhaul Procedures Bench Service Procedure A CAUTION NEVER USE THE PTO GEAR AS A PRESSING BASE The narrow face width of this gear makes it very susceptible to breakage 1 Remove the front countershaft snap ring 2 Place the countershaft in the press as shown Using the rear face of 3rd Overdrive
117. he low range gear 165 Transmission Overhaul Procedures Bench Service 3 Assemble low range gear to coupler and install bushings if removed 4 Install splined washer in low range gear 5 Assemble gear over coupler 6 Rotate splined washer to align pins and drive pins through lock washer Note Make sure pins are installed below coupler thrust surface 166 Transmission Overhaul Procedures Bench Service 7 Slide low gear assembly on auxiliary mainshaft front 8 Install dowel pin jneuI9A0 UOISSIUISUOJg v cD n Lm cD P 5 cD oD cD Lu oD cD 9 Place retainer washer in position 10 If reusing nut apply a thread locking compound to the threads New nuts should have a pre applied locking com pound Torque the nut to 180 210 Lbf ft 167 Transmission Overhaul Procedures Bench Service 11 Assemble mainshaft assembly into transmission rear Splines on mainshaft end must slide into range synchroniz er Marked teeth on low a range gear must be aligned with marked teeth on countershafts 12 Install O ring or gasket onto deep reduction yoke end NOTE Early versions used P N 21338 gasket with P N 21337 pis ton Current designs use a P N 4301348 O ring with P N 43013320 piston The proper gasket or O ring must be in Stalled with the respective piston 13 Install deep reduction yoke into slot on deep reduction slid ing clutch Make sure positionin
118. he output shaft Note To avoid creating oil leaks make sure the speedome ter rotor seal sleeve is free from contaminants 110 Install the speedometer rotor seal sleeve over the output Shaft and install the soeedometer sensors Install the output yoke over the output shaft The yoke Should slide on an stop before contacting the speedometer rotor As the output shaft nut is installed the output yoke will contact the speedometer rotor Inspect the output shaft nut for damage and wear If the ny lon locking material is damaged or excessively worn use a new output nut Note The nylon locking material must be in good condition So the nut does not loosen when the vehicle is in use Lightly oil the output shaft threads and output nut threads and install the nut Torque the nut to 450 500 Ib ft 610 12 677 91 Nem Connect the driveshaft and U joint according to the OEM or driveshaft manufacturer s instructions In Vehicle Service Procedures 111 5 lt cD r cD cD UL co cD v ba cD a uu cD N In Vehicle Service Procedures How to Remove the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TRSM0912 Rear Seal Maintenance Guide After removal of the output yoke companion flange temporarily replace the output shaft nut to protect the output shaft thre
119. hould not be Applied hydraulic thread sealant 71208 to threads torque speedometer sleeve to 35 50 lb ft 47 45 67 79 Nem Should be an o ring or gasket between Replace the o ring gasket if damaged or missing the mating speedometer sleeve and the rear bearing cover Rear Bearing Cover Capscrews Check retaining capscrews for tight Apply Eaton Sealant 71205 to the capscrew Gasket and Nylon Collar ness threads torque to 35 45 Ib ft 47 45 61 01 Nem Verify nylon collar and gasket are in Use new parts if need to replace Apply Eaton Seal Stalled at the chamfered hole aligned ant 71205 to the capscrew threads torque to 35 45 near the mechanical speedometer lb ft 47 45 61 01 Nem opening Verify that a rear bearing cover gasket Install a new gasket if rear bearing cover was re is in place moved Output Yoke Retaining Nut Check the output yoke retaining nut for Torque the output yoke retaining nut to 450 500 tightness lb ft 610 12 677 91 Nem Do not over torque the Output nut PTO Covers and Openings Check the capscrews for tightness Apply Eaton Sealant 71205 to the capscrew threads Torque 6 bolt PTO capscrews to 35 45 Ib ft 47 45 61 01 Nem 8 bolt PTO capscrews to 50 65 lb ft 67 79 88 13 Nem Gray Iron Parts Check front bearing cover front case Replace parts found to be damaged shift bar housing rear bearing cover and clutch housing for cracks or breaks Front Bearing
120. ial Instructions In 1996 Eaton changed the reverse idler system design In the nut design the reverse idler bearing was lubricated through a hole in the main case reverse idler support boss and a oil passage through the idler shaft middle Special Tools e See Tool Information see Table 6 e tem 118 Bearing race installer Previous Design 1 Idler Plate 5 Bearing 2 Inner Race 6 Reverse Idler Gear 3 Washer 7 Reverse Idler Shaft 4 Nut and Washer 8 Plug 214 Transmission Overhaul Procedures Bench Service The capscrew design eliminates the case hole and idler shaft hole The reverse idler bearing is supplied oil through the use of star design thrust washers If the nut design parts are used with the capscrew design where main case does not have the oil feed hole the reverse idler bearing will fail Current Design V o TER 5 N 3 77 o o ona os THE a ae 5 E lt S r ii cD 1 Star Washer 6 Idler Plate 2 Inner Race Bearing 3 Star Washer 8 Reverse Idler Gear 4 Retaining Ring 9 Reverse Idler Shaft 5 Capscrew Procedure 1 Position the reverse idler bearing and inner race into the re verse idler gear 219 Transmission Overhaul Procedures Bench Service 216 Position the gear in the case The gear s long hub is posi tioned forward Place the rear thrust washer on the idler shaft From the case rear insert the idler shaft through the ma
121. idler shaft can be driven out from front To install front section coun tershaft bearings 3 97 OD 1 78 ID To install the front counter Shaft rear bearings 3 5 OD 1 6 ID during bearing removal and installation Input Bearing Driver To install input bearing on 35 input shaft remove the auxiliary countershaft tapered bear ings k o G 250 T 311 5062 E E mM T 150 1155 Slide Hammer 8007 1 2 13 Adapt er Bearing Puller To remove front section G 10 or G 15 T 1 and T 2 7070A Kit countershaft bearings for 9 Series G200 Kit T 101 Kit MM G200 Kit T 101 Kit ME G 50 G 51 G 58 T 1458 7109 Ihe an 9066 o Recommended Tools Table 6 Special Tools Continued REFERENCE TOOL PURPOSE G amp WTOOL NO GREAT LAKES OTC NUMBER TOOL NO TOOL NO T12 Bearing Driver To install the auxiliary coun G 200 Kit T 105 Kit tershaft tapered bearings Output Seal Remov To remove the output seal in Use 2 315 al Tool chassis Can use slide ham hook with 1155 mer Slide hammer Auxiliary Section To attach transmission jack G 115 49611 Used Removal Adapter to auxiliary section for auxil with OTC trans Plate a section removal in chas mission jack P N 5019 T15 Mainshaft Hook To assist in lifting of main G 225 T ae Shaft from front section Input Bearing Puller To remove input bearing lt 7070A Kit Bearing Race Puller To remove the auxiliary 7
122. ift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical service tools Procedure JneuI9A0 UOoISSIUISUOJ 1 If the three 3 sets of tension springs and balls from hous ing bores have not been removed place the shift bar hous ing on its side to remove them 0 o cD 2 Lm cD gJ cD o 5 N cD Lu T cD 2 Remove the oil trough retaining capscrews and oil trough Some models do not have an oil trough 3 With the housing rear to the right lay the assembly on a flat surface 135 Transmission Overhaul Procedures Bench Service 4 While removing the top yoke bar to the right remove the two 2 shift blocks 5 From the middle yoke bar remove the shift yoke and shift block As the neutral notch in the bar clears the rear boss remove the small interlock pin from the notch bore 6 Remove the actuating plunger from the center top bore boss 7 From the bottom yoke bar remove the two 2 shift yokes 136 Transmission Overhaul Procedures Bench Service 8 As the shift bar clears the last boss two 2 3 4 interlock balls drop from the bottom rear boss bore 9 If damaged from the 1st and reverse shift yoke remove the plug spring and plunger TATE EDDIE JneyJ9A0 UOISSIUISUPJ 10 Inspect the yoke or block parts replace the worn parts 137 Transmission Overhaul Procedures Ben
123. ift bar housing gasket on the shift bar housing mounting surface Note The slave valve and interlock assembly must remain off until the shift bar housing is installed to avoid damaging the interlock pin 4 As you install the shift bar housing make sure the yokes fit into the corresponding sliding clutch slots and the housing aligns with the roll pin 5 Apply Eaton Sealant 71205 or equivalent to the retaining capscrews Torque the capscrews to 35 45 lb ft 47 45 61 01 Nem 102 In Vehicle Service Procedure 6 Install interlock parts pin spring and sleeve 7 Install slave valve Apply Loctite 242 to capscrew threads and torque to 8 12 lb ft 10 85 16 30 Nem gt lt D T D N D ba 1 o cp J ba o o cD Uu cD 103 In Vehicle Service Procedures How to Remove the Oil Seal Mechanical Speedometer Special Instructions Prior to replacing the seal carefully inspect the transmission to make sure the oil leakage is coming from the seal Pay particular attention to the speedometer parts the rear bearing cover gasket surfaces rear countershaft bearing covers and shift bar housing For additional information on rear seal service refer to the Seal Maintenance Service Brochure TRSM0912 Special Tools e See Tool Information see Table 5 and 6 e Brass drift e item T1 Output yoke puller e item 115 Slide hammer i 6 gt a 1 Bushing 5 Oil Seal with Slinger 2 Re
124. in case bearing bore and into the reverse idler gear bearing As the idler shaft slides into the gear insert the front thrust washer into position Continue sliding the idler shaft into the case support boss From the rear gently tap the idler shaft forward until resis tance is felt Install the flat washer over the shaft threaded portion Apply Eaton Fuller Sealant 71205 or equivalent Install capscrew and torque to 67 75 lb ft 90 84 101 69 Nem Using a bearing race driver install the auxiliary countershaft bearing race into the lower reverse idler bore Note The bearing races have a slip fit in their bores They Should slide or rotate easily into the case bore if they are not cocked Transmission Overhaul Procedures Bench Service How to Install Countershaft Assemblies Special Instructions Make sure the countershaft assemblies have been marked for proper position 47 tooth PTO gear in the lower position Prior to installing the countershafts the lower reverse idler gear assembly should be installed In addition if the transmission is equipped with an internal oil pump this should also be installed Special Tools e Toolmaker s dye Procedure 1 On the drive gear of each countershaft assembly mark the tooth aligned with the gear keyway and stamped with an 0 for easy identification A highly visible color of toolmaker s dye is recommended for making timing marks Note Prior to installing the counte
125. ion When the deep reduction button is moved forward to select deep reduction air pressure is supplied through the SP air line to the insert valve signal port This air pressure causes the insert valve to exhaust the air pressure on the rear of the deep reduction piston and the piston moves rearward A burst of air occurs at the deep reduction cylinder exhaust port as this air is exhausted from the piston back side A burst of air also occurs at the shift knob when the deep reduction button is moved rearward This is the signal air being exhausted out of the SP line Possible causes e Incorrect air line hook up Plugged filter e Incorrect regulator pressure Insufficient air supply to transmission e Damaged or defective shift knob master valve e Damaged or defective deep reduction insert valve e Damaged or defective deep reduction piston or cylinder e Damaged or defective deep reduction yoke bar or yoke e Damaged or defective deep reduction sliding clutch or gearing Note Before completing the following troubleshooting procedure move the deep reduction button both rearward and forward an check for constant exhaust air at either the shift knob or deep reduction cylinder exhaust port If a constant leak is noticed go to that troubleshooting procedure first In addition confirm that the low and high range shifts are occurring properly If not go to the appropriate range shift troubleshooting procedure before completing the followin
126. ion on this product A WARNING Use only Eaton Fuller 71205 liquid thread sealant or liquid equivalent on the yoke retaining capscrews Do not use any type of thread locking tape on the end yoke retaining capscrews This may cause the capscrews threads to strip and cause the end yoke to loosen 3 Reinstall driveshaft per OEM guidelines 117 In Vehicle Service Procedures How to Remove the Auxiliary Section in Chassis Special Instructions None Special Tools e See Tool Information see Table 6 e tem T2 Auxiliary section hanger e tem 114 Auxiliary section removal adapter plate e A hoist with lifting chain Procedure 1 Drain the transmission oil 2 Disconnect the driveshaft and U joint from the output yoke 3 If the auxiliary section is to be disassembled remove the output nut To prevent the output shaft from rotating while removing the nut engage the transmission into two gears or use a yoke holding tool 4 Disconnect the vehicle air supply line from the filter regula tor assembly 5 Mark the locations and disconnect the large rubber air lines placing them aside 6 Label and remove the small air lines 7 Remove the four 4 capscrews and the auxiliary counter Shaft rear bearing cover gasket and rear bearing shim 8 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap scre
127. ir tanks to pressur 4 Air Line ize and check for leaks Repair as necessary 19 In Vehicle Service Procedure How to Remove Push To Connect Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tank A CAUTION Make sure only 5 32 air lines are used with push to connect fittings Using sizes other than 5 32 can cause air leaks or dam age to fittings Before removing the air lines and hose label or record their location Special Tools e See Tool Information see Table 8 e For push to connect fittings the Eaton service tool kit K 2394 is recommended The kit contains the release tool and the tubing cutter Procedure 1 Exhaust the vehicle air tanks before continuing 1 Cutter 2 Release Tool 2 Use the air line release tool from kit K 2394 to press the re lease sleeve down while pulling the air line from the fitting 3 Inspect the fitting for damage or wear Remove and replace as necessary 80 How to Install Push To Connect Type Fittings Special Instructions A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage In Vehicle Service Procedure A WARNING exhaust the vehicle air tanks A CAUTION Make sure only 5 32 air lines are used with push to connect fittings Using sizes othe
128. is in gear When the output Shaft is rotated the countershafts must also rotate If not shift the auxiliary into gear by applying shop air to the high range air port on range cylinder to shift into gear Make sure a 0 100 countershaft rear bearing shim is in Stalled Be sure the countershaft rear bearing races are seat ed in the bearing bores Install two 2 clean 3 8 x 1 capscrews without washers di rectly across from each other in each bearing cover Tapped holes in auxiliary case must be free of thread adhesive Evenly tighten the capscrews to 7 Lb in of torque Do not in Stall the countershaft rear bearing cover gasket The gap be tween the bearing cover and the housing surface should be even from side to side Transmission Overhaul Procedures Bench Service Note 7 Lb in is slightly more than finger tight Do not over tighten the capscrews If the capscrews are too tight the bearing cover will become distorted Rotate the output shaft 4 times clockwise and 4 times coun terclockwise The rotation will seat and align the rollers in each tapered bearing Re torgue the capscrews to 7 Lb in If the countershafts do not rotate the range sliding clutch or deep reduction sliding clutch is in neutral Apply shop com pressed air to shift cylinders to shift the sliding clutches into gear Use a feeler gauge as close to each capscrew location as possible and measure the gap between the countershaft rear bearing cover and the a
129. ission front than the standard opening This forward design allows greater flexibility in mounting the transmission and is indicated by an F in the model number otandard Opening Forward Opening Lubrication Pumps Internal An internal lubrication pump is located in the lower front of the transmission and is driven off the upper coun tershaft Transmissions rated 1550 Lb ft and above include the internal pump standard PTO Driven A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear Power Take Off PTO Usage PTOs can be mounted in the following way 6 or 8 Bolt The 6 or 8 bolt openings are standard with the transmission The PTO is mounted to the opening and driven from the PTO gear on the front countershaft Thru Shaft The thru shaft PTO mounts on the rear of the transmission It requires a special auxiliary housing and main case countershaft with internal splines Lubrication Lubrication Specifications A IMPORTANT Transmission filters should be changed during regular lube intervals Inspection of the transmission filter should be conduct ed during preventive maintenance checks for damage or corrosion Replace as necessary Note For a list of Eaton Approved Synthetic Lubricants see TCMT0021 or call 1 800 826 HELP 4357 Note The use of lubricants not meeting these requirements will affect warranty coverage Note Additives and friction modifiers must not be introduced N
130. liding Clutch Forward Range Sliding Clutch Rearward ep Low Low Low D cD D 5 eep Reduction Deep Reduction D Sliding Clutch Forward Ro a Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Rearward Sliding Clutch Forward Range Sliding Clutch Rearward 1st Gear 2nd Gear Deep Reduction Deep Reduction Poo ee Sliding Clutch Forward A Sliding Clutch Forward
131. m eee Reattach the air line to the P port Air is flowing from the SP line 1 Check to make sure the Move the range selector down to low SP line is connected to the range and move the deep reduction but deep reduction cylinder ton rearward Disconnect the air line cover from the SP port Check for air flowing from the SP line 2 If the line is properly attached check that the insert valve is properly installed stem facing inward and that the insert valve bore is not defective 3 Replace the insert valve Air is not flowing from the line Repair or replace the shift knob 52 Procedure 2 Symptom Air leak at slave valve Normal operation Air System A momentary exhaust of air at the slave valve occurs during a range shift The air from the low side of the range cylinder is exhausted as air pressure is applied to the high range side Likewise air from the high range side of the piston is exhausted as air pressure is applied to the low range side The exhaust port is located at the slave valve to transmission mounting interface Possible Causes e nternal leak in range cylinder e internal leak in slave valve MM O O Confirm that air is leaking from the exhaust port on the slave valve and not a fitting or air line Move range selector down to select low range Remove the 1 4 I D rubber air line at the high range supply port on the range cylinder Feel for air flow from the op
132. m the Idler Shaft Note If Idler Shaft spins in case bore slightly heat bolt with torch to release loctite adhesive 2 The mainshaft reverse gear must be moved in order to re move the upper reverse idler gear Remove reverse gear Snap ring and slide reverse gear forward over clutch 3 Remove the loosened bolt and remove washer Reinstall bolt 3 4 threads 182 Transmission Overhaul Procedures Bench Service 4 Install an impact puller 1 2 13 threaded end and remove the shaft from case bore 5 As the idler shaft and idler plate are removed remove the thrust washers and gear JneuI9A0 UOoISSIUISUOJ 0 o cD 2 Lm cD o gJ cD o 5 N cD Lu T cD 6 Inspect the reverse gear assembly remove the inner race and needle bearing if damaged 183 Transmission Overhaul Procedures Bench Service How to Disassemble the Lower Reverse Idler Gear Assembly Special Instructions Before the lower reverse idler gear assembly can be removed the mainshaft and countershaft assemblies must be removed While removing the reverse idler shaft the thrust washer can drop to the transmission case bottom Special Tools e Typical service tools e Jaw pullers or impact puller e Soft bar and maul Procedure 184 1 Remove retaining bolt from the Idler Shaft Note If Idler Shaft spins in case bore slightly heat bolt with torch to release loctite adhesive Remove the loos
133. mainshaft Engage the gear clutching teeth with spacer external splines and sliding clutch Move the reverse gear down against the 1st speed gear At this time remove the air line and insert the mainshaft key Be careful not to move the gears while doing this procedure the tolerance washers are unlocked and can rotate which would cause the gears to drop Remove the mainshaft from the vise On the shaft front align the sliding clutch missing internal Spline with the mainshaft key and install the front sliding clutch Engage the sliding clutch external splines with the gear clutching teeth 203 J La o Ur cD 2 ba D o co D o N D E eh T cD JneuI9A0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service Washers for 6 Sided Key PART SIZE COLOR 14711 0 248 0 250 14712 0 253 0 255 Washers for 3 Sided Key 4300384 0 259 Orange Light Blue 4300385 0 264 Purple Light Blue 4300386 0 269 Yellow Light Blue 4300387 0 274 Black Light Blue 204 Transmission Overhaul Procedures Bench Service How to Assemble the Mainshaft Assembly with Non Selective Non Adjustable Tolerance Washers Special Instructions The proper mainshaft key must always be used with the proper design mainshaft washers If necessary refer to the parts manual for your specific model to confirm the proper parts Previous design levels can be updated to the current design Special Tools e A piece of 5 32
134. n flange or yoke tightly into place with the output shaft nut using 450 500 Ib ft 610 12 677 91 Nem of torque Make sure the speedometer drive gear or a replacement spacer of the same width has been installed Failure to pull the companion flange or yoke tightly into place can result in damage to the mainshaft rear bearing A IMPORTANT see the appropriate Illustrated Parts Lists specified by model series to ensure that proper parts are used during assembly of the transmission Model Designations and Specifications Serial Tag Information and Model Nomenclature Transmission model designation and other transmission identification information are stamped on the transmission tag To iden tify the transmission model designation and serial number locate the tag on the transmission and then locate the numbers as shown When calling for service assistance or parts have the model and serial numbers handy Do not remove or destroy the transmission identification tag RTO 119O0O9MLL Eaton Fuller Model Designation Prefix T__ Ratio Set Forward Speeds See options below 6 Multi Mesh Gearing w Overdrive and Forward Shift Bar Housing 7 Helical Auxilary Gearing and w Overdrive and Direct Shift Pattern Multi Mesh Front Gearing w Overdrive Direct Shift Pattern and Forward Shift Bar Housing a Improved Seal System This x 100 Nominal Torque Capacity Prefix Definition Roadranger Twin Countersh
135. n rust preventative 71213 or equivalent to all shift cylinder walls and yoke bars cover the entire yoke bar surface that comes in contact with the shift cylinder O ring Special Tools e Typical service tools Procedure 1 Lightly lubricate O rings with Eaton Fuller Silicone lubri cant P N 71206 or equivalent 2 Install O rings into range and reduction shift cylinders V o oO a OD 5 N 3 A o o ona os THE Z a 2 o gt Lu lt S QO cD 3 Install O rings onto range and reduction pistons 4 Install gasket and shift cylinder 171 Transmission Overhaul Procedures Bench Service i Install range piston with flat side to rear Install range piston nut and torque to 70 85 Lbeft 6 Install deep reduction piston with flat side to rear Install nut and torque to 50 65 Lbeft Note If reusing existing nut make sure nylon locking mate rial is in good shape if not replace nut 7 Lightly lubricate insert valve O rings with Eaton amp Fuller Silicone lubricant P N 71206 or equivalent Install insert valve with flat side to the inside Install insert valve retaining nut and torque to 40 50 Lbeft 8 Install gasket and cover Apply Eaton Fuller thread seal ant P N 71205 or equivalent to capscrew threads Install capscrews and torque to 35 45 Lbeft 172 Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Countershaft Assembly Special Inst
136. n tube in position 2 Straighten tube lock on suction tube 3 Remove suction tube from oil pump If necessary remove O ring from suction tube Remove three 3 allen head capscrews and washers that re tain the integral oil pump to the case 240 Transmission Overhaul Procedures Bench Service 5 Remove the integral oil pump assembly from inside the case 6 Remove the integral oil pump retainer plate from inside the case V o oO 9 OD 5 N 3 N o o ona os a a ae 5 E lt S QO cD 7 If necessary the front case plug can be removed from the case To remove insert a bar from inside the case and tap the plug out 8 Inspect the plug O ring replace if damaged 241 Transmission Overhaul Procedures Bench Service How to Install the Integral Oil Pump Special Instructions None Special Tools e Typical service tools 242 Procedure 1 4 If removed replace the front case plug O ring Lubricate the groove of the plug install the O ring onto the plug and then lubricate the outer diameter of the O ring Seat the front case plug in the case bore by hand Do not in stall the pump plug using any type of impact tool i e ham mer maul etc With the retainer bore facing the case rear install the integral oil pump over the alignment pin inside the case Align oil pump with retainer and alignment pin and install the integral oil pump assembly
137. neral Troubleshooting General Troubleshooting Chart cont shift Lever Slipout Internal transmission problem Check for excessively worn or damaged Transmission comes out of gear under sliding clutches or shift yokes torque Transmission goes to neutral Low air pressure Check air regulator pressure Shift lever doesn t move Internal transmission problem Check for excessively worn or damaged range sliding clutch or yoke Transmission air system problem Preform air system troubleshooting pro cedure Check for proper air signal from master valve Check air module test ports for proper air delivery No range shift or slow range shift Also see Air System Troubleshooting Range cylinder problem Check for failed or damaged range pis ton piston bar or cylinder Check for failed or loose range piston Snap ring ep cp e cD Lu D 5 So Lm o f Range yoke assembly problem Check for failed or damaged range yoke Check for failed or loose range yoke snap rings Check for excessively long fastener installed in rear support hole Check for binding between range yoke bar and range alignment lock cover Range synchronizer problem Check for failed or damaged range syn chronizer sliding clutch or mating gear Check for excessively worn range syn chronizer friction material Grinding Noise on Range Shift Driver not preselecting range shift Instruct driver to preselect range shifts
138. ngine s power flow through a transmission in each particular gear will assist the technician in trouble Shooting and servicing a transmission The Fuller transmission can be thought of as two separate transmissions combined into one unit The first transmission or front section contains six gear sets which are shifted with the gear shift lever The second transmission called the auxiliary sec tion contains two gear sets and is shifted with air pressure Note This transmission is referred to as a constant mesh type transmission When in operation all gears are turning even though only some of them are transferring power The illustration below shows the transmission with the main components called out Note that the transmission is in the neutral position because the sliding clutches are all in their center positions and not engaged in any gears Mainshaft Gear Auxiliary Countershaft Auxiliary Drive Gear Deep Reduction Sliding Clutch cC cD cD Lm I co 5 mm o i Auxiliary Deep Reduction Gear ym l
139. nt bearing cover capscrews are tighten properly 223 0 Ur cD 2 Lm D o co D l N D E eh co cD jneuI9A0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service How to Install the Upper Countershaft Bearings Special Instructions The front bearing inner race must be pressed on the countershaft front The flanged end driver must cover the bearing outer race for proper installation Temporarily use the assembled auxiliary drive gear to hold the mainshaft in the input shaft pilot CAUTION The upper countershaft bearings must be installed after the installation of the mainshaft Special Tools e See Tool Information see Table 6 e item T7 Flanged end bearing driver e tem T8 Bearing driver e tem T9 Countershaft support tool Procedure Figure 3 1 Make sure the lower countershaft and main drive gear timing marks are aligned 2 Mesh the upper countershaft marked tooth with the two re maining main drive gear marked teeth 3 Move the countershaft to the rear and insert the countershaft Support tool to center shaft in rear case bore 224 4 3 10 11 Transmission Overhaul Procedures Bench Service Obtain a spare inner countershaft race Temporarily install a spare countershaft inner race inside the front roller bearing for installation Use a flanged end driver to start the front bearing in case bore Use a screwdriver inserted in the counters
140. nto the case support boss From the rear gently tap the idler shaft forward until resis tance is felt Install the flat washer over the shaft threaded portion Inspect the reverse idler nut nylon locking material Replace the capscrew if necessary Install the capscrew and torque to 67 75 Ib ft 90 84 101 69 Nem Using a bearing race driver install the auxiliary countershaft bearing race into the lower reverse idler bore Note The bearing races have a slip fit in their bores They Should slide or rotate easily into the case bore if they are not cocked 229 v cD n Lm cD P 5 cD oD cD Lu oD cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service How to Install the Auxiliary Drive Gear Assembly Special Instructions Before installing the auxiliary drive gear the mainshaft must also be completely installed Special Tools e See Tool Information see Table 6 e Large pair of snap ring pliers e tem T10 Flanged end driver and maul Standard Torque High Torque Procedure Standard torque capacity models 1 Install the retainer ring on the front auxiliary drive gear snap ring groove facing hub and away from gear teeth 230 Transmission Overhaul Procedures Bench Service 2 Start the front auxiliary drive gear bearing on the hub bear ing snap ring facing groove in retainer ring Press the bear ing fully into position Note On
141. o low range repair leaking range piston or piston position At the transmission rear Seal After repair check for proper disconnect the 1 4 rubber air line range operation from the range cylinder high range supply port Check for air flow from the cylinder high range port No air flow from high range port Go to step C Check for air flow from the discon Air flows from disconnected air line Go to step F nected air line 99 Air system O rr e CU 60 Install a 100 PSI air gauge in the dis connected air line end With the shift lever in neutral move the range Selector up to select high range Observe the gauge Confirm that a shift lever is still in neutral Have an assistant move the range selector up and down between low and high range Does the pres Sure measured at the gauge respond rapidly when going from low to high to low Place shift lever in neutral At the shift knob move the range selector up to Select high range At the slave valve remove the air line from the P port should be black line Check for air flow from the disconnected line Check for air coming out of the slave valve P port Place the shift lever in neutral Install a 100 PSI pressure gauge in line with the P line end Move the range Selection lever back and forth from low to high range The gauge should show rapid pressure change The gauge reads 0 PSI The gauge reads pressure but is lower than 58 PSI or highe
142. ockets screwdrivers and prybars General Tools The following tools are available from several tool manufacturers such as Snap On Mac Craftsman OTC and many others Table 5 General Tools TOOL PURPOSE 0 100 Ib ft 1 2 drive Torque Wrench General torquing of fasteners Typically 15 80 Ib ft 20 34 108 47 Nem 0 600 Ib ft 3 4 or 1 drive Torque Wrench Torguing of output nut to 500 lb ft 677 91 Nem 0 50 Ib in 3 8 drive Torque Wrench General torquing of fasteners 0 30 Ib in 1 4 drive Torque Wrench Torguing of capscrews to 7 Ib in 0 79 Nem during auxiliary coun tershaft bearing endplay setting procedure 70 MM or 2 2 4 Socket Standard Depth To remove the output yoke nut Large Brass Drift Used to protect shafts and bearings during removal Large Dead Blow Hammer or Maul To provide force for shaft and bearing removal Snap Ring Pliers Large Standard External To remove the snap rings at the auxiliary drive gear input shaft bearing and countershaft bearings Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing endplay Rolling Head Crow s Foot Prybar To remove the auxiliary drive gear bearing 2 Air Pressure Gauges 0 100 PSI 0 1034 kPa To troubleshoot and verify correct operation of air system Universal Bushing Driver To remove and install clutch housing bushings Bushing OD 1 125 in ID 1 000 in ep cD cD a co a Lu co a a Recommended Tools
143. om the shift bar housing remove the two retaining cap screws securing the oil cooler Remove oil cooler and set aside 2 Remove slave valve 100 3 Remove interlock parts pin spring and sleeve 4 From the shift bar housing rim remove the retaining cap Screws 5 To break the gasket seal jar the shift bar housing 6 Remove the shift bar housing 7 Inspect the roll pin replace if damaged 8 Remove the gasket and clean all mounting surfaces of gas ket material 9 lf the three 3 sets of tension springs and balls from the housing top bores are loose tilt the assembly and remove them In Vehicle Service Procedure 101 gt lt D T D N D ba 1 o cp J ba o o cD Uu D In Vehicle Service Procedure How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other locations except the left front corner at the roll pin This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes The slave valve and interlock parts must be removed prior to installing the shift bar housing Special Tools e Typical service tools Procedure 1 Place the shift bar housing and shift blocks in the neutral po sition 2 Place the mainshaft sliding clutches in the neutral position 3 Position a new sh
144. on Overhaul Procedures Bench Service Use a flanged end driver to start the front bearing in case bore Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft Move the countershaft forward into the bearing Use a flanged end bearing driver and maul to completely seat the front bearing in the case bore Note Make sure to contact only the bearing and not the tem porary race with the driver The temporary race Should fall out when installation is complete On the countershaft front position the retainer plate with roll pin in hole at shaft end Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller thread Sealant 71205 or equivalent Torque the capscrew to 90 120 Ib ft 122 02 162 70 Nem Note Earlier models may have a roll pin in the retainer This roll pin is not reguired and was removed on units built after 1994 From the rear remove the countershaft support tool Install the rear countershaft bearing Position the bearing so that the larger chamfer on the bearing inside diameter is in stalled towards the shaft Use a bearing driver that contacts both the bearing inner race and outer race n the countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torgued Note Make sure the rear snap ring is in place 219 v o co cD O Lm cD P 5 c
145. or oil leakage due to faulty gasket Gear Shift Lever e Check for looseness and free play in housing If lever is loose in housing proceed with Check No 10 10 Gear Shift Lever Housing Assembly e _ f present remove air lines at air valve or slave valve Remove the gear shift lever housing assembly from the trans mission e Check the tension spring and washer for set and wear e Check the gear shift lever spade pin and slot for wear e Check bottom end of gear shift lever for wear and check slot of yokes and blocks in shift bar housing for wear at contact points with shift lever Checks With Drive Line Dropped 11 Universal Joint Companion Flange or Yoke Nut e Check for tightness Tighten to recommended torque Preventive Maintenance 12 Output Shaft Not Shown e Pry upward against output shaft to check radial clearance in mainshaft rear bearing Checks With Universal Joint Companion Flange or Yoke Removed Note If necessary use solvent and shop rag to clean sealing surface of companion flange or yoke Do not use crocus cloth emery paper or other abrasive materials that will mar surface finish 13 Splines on Output Shaft Not Shown e Check for wear from movement and chucking action of the universal joint companion flange or yoke 14 Mainshaft Rear Bearing Cover Not Shown e Check oil seal for wear Inspection PART TO INSPECT WHAT TO CHECK FOR ACTION TO BE DONE Speedometer Connections Speedometer cables s
146. osition the 4th gear on the mainshaft 6 Install the flat washer Rotate the washer until the washer Splines and mainshaft splines align Transmission Overhaul Procedures Bench Service With clutching teeth up and against the spacer install the 3rd gear Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main Shaft splines align Push the air line up to lock the washers on the mainshaft With the missing internal splines aligned with the plastic line install the proper sliding clutch Position the next offset washer in the next available groove Rotate the washer until the washer splines and mainshaft Splines align Push the air line up to lock the washer on the mainshaft With clutching teeth down position the 2nd gear on the mainshaft Position the flat washer against the gear Rotate the washer until the washer splines and mainshaft splines align 209 J La o Ur cD 2 ba D o co D o N D E eh T cD JneuI9A0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service 15 With clutching teeth up install the 1st gear on the shaft against previously installed gear 16 Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main Shaft splines align 17 From the mainshaft rear install the mainshaft key into the Spline with the air line
147. p reduction button Single clutch if not moving the shift lever double clutch if the shift lever will be moved Special Notes 15 Speed Models When upshifting from a deep reduction gear into a low range gear it is recommended that the shift lever is moved back one gear position during the shift out of deep reduction For example If the driver is in deep reduction 5th gear position he she should double clutch and move the shift lever to the 4th gear position immediately after moving the deep reduction button If the shift lever is not moved during this shift the vehicle must have enough speed to make a 42 step upshift Ath Gear Position Low Range Neutral 5th Gear Position Deep Reduction DLL and MLL Models The three lowest gears LL1 LO LL2 are used for road speed control These shifts are not intended to be used as progressive shifts Additional Operating Information Preselect IMPORTANT Always preselect all range shifts when upshifting or downshifting Preselection reguires that the Range Selector is moved to the needed position before starting the lever shift Preselected range shifts are completed automatically as the lever is moved through neutral and into the next gear Preselecting all range shifts prevents damage to the transmission and provides for smoother shifts Clutch Brake Used with pull type clutches The Clutch Brake is applied by fully depressing the clutch pedal to the floor board When applied
148. peration and Testing Special Instructions The neutral switch is a normally closed switch An electrical current flows through it when the transmission shifter is in the neutral position When the transmission shifter is in gear the switch is open and no current flows through it Likewise the switch is open when the ball is depressed The switch is actuated by the air valve shaft Special Tools 94 Typical service tools Volt Ohm meter Procedure Disconnect the wiring from the switch Connect an ohm meter to check for continuity or a small reading Place the transmission shift lever in the neutral position The ohm meter should register continuity or a small reading If it does go to the next step If it does not remove the switch and replace it shift the transmission into all gear positions The ohm meter Should read open or infinity If it does not remove the switch Then depress the switch ball and check for continu ity The ohm meter should read open or infinity when the ball is depressed Look into the neutral switch hole and verify that the air valve Shaft moves as the transmission is shifted from neutral into gear a If it does replace the switch b If not remove the shift bar housing and check the air valve and shift rails for excessive wear Also check the Slave valve plunger and spring for free movement How to Remove the Neutral Switch Special Instructions None Special Tools e Typical ser
149. r Regulator Insert Valve Assembly General Troubleshooting General Troubleshooting Chart The chart on the following pages contains some of the most common problems that may occur with this transmission along with the most common causes and solutions Noise Growl Rumble Noise Growl Rumble at Idle Idle Gear Rattle Noise High Pitched Whine Torsional Vibration Noise may be most pronounced when transmission is in a float low torque condition May also be confined to a par ticular vehicle speed Transmission bearing or gear failure Noise may be most pronounced under hard pull or coast high torque Excess engine torsional vibration at idle Gear Noise Isolate as to axle or transmission noise If transmission isolate to specific gear Or gears Check driveline angles for proper u joint working angles Check driveline for out of balance or damage Check u joints for proper phasing Check clutch assembly for broken damper springs Check for inadequate clutch disc damp ing Check transmission oil for excessive metal particles Check for low engine RPM Check for uneven engine cylinder perfor mance Check for proper clutch damper opera tion Check for worn or defective shift lever isolator Check for direct cab or bracket contact with transmission grounding Check for proper driveline u joint work ing angles Check for damaged or worn gearing 47 HATH HEH
150. r cutoff continue testing The pressure is critical if the vehicle is equipped with a vehicle air system Pressure Protection Valve that would shut off the air supply to certain air circuits if the system pressure dropped below a preset level Note A 0 150 PSI 0 1034 kPa air gauge with a 1 16 male pipe thread fitting attachment is required for some of the test proce dures A WARNING Prior to removing the air module exhaust the air from it Failure to exhaust the air module may result in personal injury or dam age to parts from the sudden release of air A WARNING Use care when removing the test port pipe plugs If air pressure is present on the plug it can become a projectile during removal When removing the L plug or H plug pressure can be shut off by selecting the opposite range mode If removing the F plug exhaust the air to the module inlet 90 Procedure 1 Symptom Air leak at shift knob Normal operation Air System A burst of air will be exhausted from the shift knob when moving the range selector from low to high This is the air being exhausted from the P air line A burst of air will be exhausted from the shift knob when moving the deep reduction button rearward shifting out of deep reduc tion This is the air being exhausted from the SP air line Possible causes e Incorrectly attached air lines e nternal leak in slave valve e nternal leak at insert valve Internal leak
151. r line from the shift knob master control valve provides a signal pressure to the slave valve ig 8 8 Sy LC A Sleeve Pa G Plunger Pin Slave Valve O Assembly a spring Gasket Poppet Type Component Nomenclature and Auxiliary Countershaft Sectional View 1 Slave Valve Housing 2 U Seal 3 Washer 4 Spring 5 Plug 6 Snap Ring 7 O Rings 8 Plate 9 Capscrew 10 Cap 39 11 Gasket 12 Seal 13 O Ring 14 Piston 15 U Seal 16 Cap 17 O Ring 18 Seal 19 Spring Slave Valve 15 16 Air system Slave Valve Preselection System This interlock mechanism prevents the slave valve from shifting when the transmission is engaged into gear The air valve shaft is moved towards the slave valve by the shift rails when the transmission is shifted into gear A spring pushes the air valve shaft back when the front section is shifted into a neutral position ep cb e cD Lm o Lu o i 6 Component Nomenclature and Auxiliary Countershaft Sectional View 1 Actuation Spring 4 Shift Bar Housing 2 Actuating Pin 5 Slave Valve 3 Air Valve Shaft 6 Alignment Sleeve 39 Air system Range Cylinder Within the range cylinder is a piston which is fastened to the range yoke bar Air pressure on the front side of the piston shifts the range sliding clutch into low range ratio Air pressure on the rear side shifts the range sli
152. r lines and hose location see the Air System Troubleshooting Guide TRTS0920 Special Tools e Typical service tools e For push to connect fittings the Eaton service tool kit K 2394 is recommended The kit contains the release tool and a tubing cutter Procedure y cn A 1 Replace damaged air fittings Air Line Fitting Types 1 1 8 tube 1 8 NPTF 2 Push to connect 3 5 32 tube 1 8 NPTF 76 In Vehicle Service Procedure 2 Connect the air lines from the slave valve to the range cylin der 3 Connect all removed air lines and hoses 4 Make sure the fittings are tight and the lines are not kinked gt lt D T D N D ba 1 o cp J ba o o cD Uu cD A In Vehicle Service Procedure How to Remove Compression Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tanks A CAUTION Small air lines are available in 1 8 or 5 32 sizes Make sure 1 8 air lines are used with 1 8 fittings and 5 32 air lines are used with 5 32 fittings Mixing sizes can cause air leaks or damage to fittings Before removing the air lines and hoses label or record their location Special Tools e Typical service tools Procedure 1 Exhaust the vehicle air tanks before continuing Loosen the nut onthe fitting and slide it back out o
153. r than 5 32 can cause air leaks or dam age to fittings Special Tools e See Tool Information see Table 5 F lt D T D 7 D Lu 1 o cp J mm o o cD 2 mm D e For push to connect fittings we recommend Eaton service tool kit K 2394 The kit contains the release tool and the tub ing cutter Procedure 1 Check the threads of the fitting for thread sealant If no seal ant is present apply Eaton thread sealant 71205 or equiv alent Install the fitting Inspect the air line for burrs or deformed areas Trim the air line if necessary using a sharp razor blade or the air line cut ting tool from kit K 2394 The cut must be smooth and Square If the tubing end is deformed or burred the internal o ring in the fitting will be damaged when the air line is in serted Push the air line into the fitting It should insert approximate ly 3 4 If it does not insert far enough or is difficult to insert the fitting may be damaged and should be replaced After in serting give the air line a slight tug to make sure the line Stays in place If line does not stay in place replace the fit ting Enable the vehicle air system Allow the air tanks to pressur ize and check for leaks 81 In Vehicle Service Procedure How to Remove Rubber 1 4 Air Hoses Special Instructions For the 1 4 I D air hoses install the fixed nut end first Special Tools e Typical service tools Procedure
154. r than 63 PSI The gauge reads between 58 63 PSI Pressure rapidly changes between 58 63 PSI and O at the gauge Pressure does not respond rapidly at gauge Air flows from the disconnected line No air flow from the disconnected line Air flows from this port No air flow from this port The gauge responds slowly Go to step F Replace the filter regulator and check for proper range operation Go to Step E Air system appears to be operating Satisfactory Go to Step R 1 Check for a plugged or dirty filter inthefilter regulatorassembly 2 Check for a pinched or obstructed 1 4 rubber air line between the filter regulator and slave valve 3 Check for a pinched or obstructed 1 4 rubber air line between the slave valve and the test gauge 4 If all are satisfactory Go to Step F 1 Confirm proper air line hook up at the shift knob 2 If correct hook up replace the shift knob Go to Step G Replace the slave valve Continue to Step H 1 Check for a restricted line between theshiftknobandslave valve Step I step R Procedure Result The gauge rapidly moves between 58 63 PSI and 0 PSI Actuating plunger pin does not move freely If possible leave air lines attached to Slave valve Unbolt the slave valve from the transmission side Check for free movement of the plunger pin protruding from the case under the Slave valve The pin should extract when the transmission is shi
155. range supply port on the range cylinder Check for air flow from the low range port No air flow from low range port Go to step C Step C Check for air flow from the discon Air flows from disconnected air line Go to step F nected air line No air flow from disconnected line Go to step D Step D Install a 100 PSI air gauge in the dis The gauge read 0 PSI Go to step F connected air line end With the shift lever in neutral move the range selector down to select low range and observe the gauge 06 Step E Step F Step G Step H Procedure Confirm that shift lever is still in neu tral Have an assistant move the range selector up and down between low and high range Does the pressure measured at the gauge respond rapidly when going from high to low Place shift lever in neutral At the shift knob move the range selection lever up to select high range At the slave valve remove the air line from the P port should be black line Check for air flow from the discon nected line Check for air flow from the P por tion the slave valve Place the shift lever in neutral Install a 100 PSI pressure gauge in line with the P line Move the range selector back and forth from low to high range The gauge should show rapid pressure change Result The gauge reads pressure but is lower than 58 PSI or higher than 63 PSI The gauge reads between 58 63 PSI Pressure rapidl
156. ranger valve on the lever shaft and rotate so the range selector faces the vehicle front 4 From the Roadranger valve bottom torque the jam nut to 35 45 lb ft 47 45 61 01 Nem 5 Connect the air lines to the air fittings 6 Slide the cover into position on the Roadranger valve 7 Install the Roadranger valve cover mounting screws Note Make sure the air lines are seated fully 8 In Vehicle Service Procedure How to Remove a Slave Valve Special Instructions A WARNING A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the vehicle air tanks must be exhausted Special Tools 88 Typical service tools Procedure Retaining Capscrews 2 3 A Plunger y F 0 Spri Sleeve Air Line a Fittings ag n Record or mark air line locations Remove all air lines Note Remove three 1 4 ID air hoses at swivel fitting at range cylinder location Remove air line bracket at rear of transmission Remove slave valve with air hos es still attached Remove the retaining capscrews around valve perimeter Remove slave valve and gasket From the transmission case remove the sleeve spring and plunger pin Inspect the air fittings replace if damaged How to Install a Slave Valve Special Instructions None Special Tools e Typical service tools Procedure 1 Clean gasket surface and install air fittings 2 Lightly l
157. re will be a brief burst of air at the slave valve as the high range side of the range piston exhausts Likewise when high range is selected the air pressure in the P will be exhausted at the shift knob This will cause the slave valve to direct air to the rear side of the range cylinder piston The air pressure on the low range side will be exhausted at the slave valve Possible Causes e _ ncorrect air line hook up e Insufficient air supply to transmission e Damaged or defective air filter regulator assembly e Damaged or defective shift knob master valve e Damaged or defective slave valve e Damaged or defective range cylinder e Damaged or defective range yoke or yoke bar e Damaged or defective range synchronizer e Damaged or defective gearing in auxiliary section of transmission Le rr rr EYN Step A Place the shift lever in neutral Check Constant air leak is detected Go to the other corresponding symp for constant air leakage at the shift tom first See beginning of Air System knob slave valve and transmission Troubleshooting section case breather when both low and high range have been selected No constant leak is detected Go to step B step B Place shift lever in neutral Move Air flows from the low range port Remove range cylinder cover and range selector up to high range posi repair leaking range piston or piston tion At the rear of the transmission Seal disconnect the 1 4 rubber air line from the low
158. release the clutch pedal and apply the accelerator Double Clutching Procedure 1 2 3 4 D Depress the pedal to disengage the clutch Move the shift lever to neutral Release the pedal to engage the clutch a Upshifts decelerate engine until engine RPM and road speed match b Downshifts accelerate engine until engine RPM and road speed match Quickly depress the pedal to disengage the clutch and move the shift lever to the next gear speed position Release the pedal to engage the clutch Note By engaging the clutch with the shift lever in the neutral position the operator is able to control the mainshaft gear RPM since it is regulated by engine RPM This procedure allows the operator to Transmission Operation and Theory Speed up or slow down the mainshaft gearing to properly match the desired gear speed and the outputshaft speed Lever Shifts When moving the shift lever double clutching is recommended Range Shifts Avoid moving the Range Selector with the shift lever in neutral while the vehicle is moving Low range to high range When in the last gear position for low range and ready for the next upshift preselect by moving the range selector lever up The move the shift lever double clutch to the next higher speed position according to your shift pattern As the shift lever passes through neutral the transmission will automatically shift from low to high range High range to low range Whil
159. res 119 a lt T co N cD uu T cD J m o cD 2 ba I cD 7 In Vehicle Service Procedures How to Install the Auxiliary Section in Chassis Special Instructions None Special Tools e See Tool Information see Table 6 e ltem T3 Countershaft support tools e tem T14 Auxiliary section removal adapter plate e A hoist with lifting chain 1 120 Procedure Install the countershaft support tools on the auxiliary section countershafts to center and hold the countershafts in posi tion Install a 3 8 16 X 2 1 2 long capscrew into counter Shaft center If removed slide the output yoke over the output shaft Lightly oil the threads and install the output nut on the out put shaft Torque the nut to 450 500 Lb ft 610 677 Nm Note To prevent the output shaft from rotating while install ing the nut place a clean shop rag in the gear mesh or use a yoke holding tool Note Due to chassis interference it may not be possible to install the yoke at this step However the output shaft must be drawn fully into position to prevent it from Sagging when the auxiliary section is installed in the chassis If the chassis causes interference the yoke can be temporarily installed to draw up the output Shaft and then removed before the auxiliary section is installed Use crocus cloth or a wire wheel to clean rust and paint from the dowel pins before installing them A CAUTION If the
160. ring to the switch 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft 96 In Vehicle Service Procedure Reverse Switch Operation and Testing Special Instructions The reverse switch is a normally open ball switch When the transmission is shifted into reverse a ramp on the reverse yoke bar contacts and raises a pin The pin depresses the ball on the switch which closes the switch contact allowing current to flow through the switch and light up the vehicle s backup lights Special Tools e Typical service tools e Volt Ohm meter Procedure 5 lt cD oD cD cD Uu 1 cD v Lm cD Uu cD 1 Disconnect the wiring from the switch 2 Connect an ohm meter to check for continuity 3 Place the transmission shift lever in any position except re verse If the switch is working properly the ohm meter Should read open or infinity If it is not remove the switch and recheck it for continuity Replace as necessary 4 Place the transmission shift lever in the reverse position If the switch is working properly the ohm meter should regis ter continuity or a small reading If it does not remove the switch and recheck it for continuity Replace it as necessary Also check for sticking or excessive wear of the reverse pin 97 In Vehicle Service Procedure How to Remove the Reverse Switch Special Instructions None Special Tools e
161. ron parts for cracks and breaks Replace parts found to be damaged Oil Return Threads and Seals e Check oil return threads on the input shaft If return action of threads has been destroyed replace the input shaft e Check oil seal in rear bearing cover If sealing action of lip has been destroyed replace seal O Rings e Check all o rings for cracks or distortion Replace if worn Reverse Idler Gear Assemblies e Check for excessive wear from action of roller bearings Shift Bar Housing Assembly e Check for wear on shift yokes and block at pads and lever slot Replace excessively worn parts e Check yokes for correct alignment Replace sprung yokes e Check lockscrew in yoke and blocks Tighten and rewire those found loose e f housing has been disassembled check neutral notches of shift bars for wear from interlock balls Sliding Clutches e Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat e Check engaging teeth of sliding clutches for partial engagement pattern Splines e Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub has wear marks in the spline sides replace the specific shaft effected Synchronizer Assembly e Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles e Check blocker pins for excessive wear or looseness e Check synchronizer contact surfaces on the synchronizer cups for
162. ront corner at the roll pin location This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes Special Tools e Typical service tools Procedure 1 From the shift bar housing remove the two shift bar retain ing capscrews securing the oil cooler Remove oil cooler and set aside 2 Remove slave valve 131 v cD n Lm cD P 5 cD oD cD Lu oD cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service 132 3 Remove interlock parts pin spring and sleeve 4 From the shift bar housing rim remove the retaining cap Screws 5 To break the gasket seal jar the shift bar housing 6 Remove the shift bar housing 7 Inspect the roll pin replace if damaged 8 Remove the gasket and clean all mounting surfaces of gas ket material 9 If the three 3 sets of tension springs and balls from the housing top bores are loose tilt the assembly and remove them Transmission Overhaul Procedures Bench Service How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other locations except the left front corner at the roll pin location This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes
163. rshafts the lower reverse idler gear assembly should be installed In addition if the transmission is equipped with an internal oil pump this should also be installed V o oO N 3 77 o o ona os THE a ae 5 E lt S r ii cD 2 Place the lower 47 tooth PTO gear countershaft into the main case with the shaft seated in the lower countershaft case bores Note Use a large hook or piece of rope to support the coun tershaft if necessary 3 Place the upper countershaft with the 45 tooth PTO gear into the main case with the shaft seated in the upper coun tershaft case bores 217 Transmission Overhaul Procedures Bench Service How to Install the Lower Countershaft Bearings Special Instructions The lower reverse idler assembly should be installed before the lower countershaft The front bearing inner race must be pressed on the countershaft front The flanged end driver must cover the bearing outer race for proper installation Special Tools e See Tool Information see Table 6 e item T7 Flanged end bearing driver e tem T8 Bearing driver e item T9 Countershaft support tool Procedure 1 Move the countershaft to the rear and insert the countershaft support tool to center shaft in rear case bore 2 Obtain a spare inner countershaft race 3 Temporarily install the spare countershaft inner race inside the front roller bearing for installation 219 Transmissi
164. ructions To make auxiliary section assembly easier you can make an auxiliary section fixture out of a 2 x 12 piece of wood e This fixture is designed to ease the assembly of the auxiliary gearing Set the auxiliary countershaft rear bearings in the 3 holes Set the assembled auxiliary mainshaft between the countershafts with the timing marks aligned 0 m o Ur cD 2 Lm D o co D co N D mg i Ur cD jneuIoA0 UOISSIUSULIL Special Tools e Auxiliary countershaft retaining straps e Toolmakers dye 173 Transmission Overhaul Procedures Bench Service Procedure 1 Place the front section in a vertical position 2 Install the auxiliary countershaft bearing cups into their re spective bores in front section 3 Mark with toolmaker s dye two opposing teeth on the aux iliary drive gear 174 J Transmission Overhaul Procedures Bench Service For timing purposes identify and mark with toolmaker s dye the two teeth on each countershaft that are identified with a O Use a straight edge to line up the marked teeth with the teeth on the remaining two countershaft gears paint these teeth Install both countershaft assemblies Match the timing marks on the auxiliary drive gear with the timing marks on the countershafts Note If assembling auxiliary section on a bench using fix ture position the auxiliary countershaft with timing marks facing inward Follow
165. ry section top Attach a lifting chain to the auxiliary section hanger bracket Position the auxiliary section on the two 2 dowel pins Slide the auxiliary section on until the hanger bracket con tacts the front section back Remove the auxiliary section hanger bracket Slide the auxiliary section the rest of the way into position Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews Install the retaining capscrews tighten to 35 45 Lb ft of torque To finish installation see The Shimming Procedure for Ta pered Bearings Transmission Overhaul Procedures Bench Service Procedure 1 To install the auxiliary section in the vertical position With blocks under the clutch housing to prevent input shaft damage place the transmission in the vertical position clutch housing down Position a new gasket on the transmission mounting sur face Install a steel bar through the yoke Attach a lifting chain to the steel bar Position the auxiliary section over the two 2 dowel pins Slide the auxiliary section down the dowels Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews Install the retaining capscrews tighten to 35 45 Lb ft of torque Remove the steel bar and chain To finish installation see The Shimming Procedure for Ta pered Bearings Note Make sure capscrews are properly torgued Note Make sure the input shaft rotates 245 0
166. sary remove the spring and O ring from the bores in the left housing lt D 5 T D N D E o co J ba o o cD 2 ba cD 9 lf necessary remove the springs O ring and sleeve from the bores in the right housing 71 In Vehicle Service Procedure How to Assemble Roadranger Valve A 4900 Special Instructions None Special Tools e Typical service tools Component Nomenclature and Auxiliary Countershaft Sectional View 1 Medallion 17 Screw 2 Spring 12 O Ring 3 Retainer 13 Spring 4 Housing 14 5 32 Ball 5 Spring 15 Spring 6 Washer 16 Ball 7 O Ring 17 Seal 8 Range Selector 18 Detent 9 Pin 19 Splitter Button 10 Cover 20 Old Style Shift Knob 72 In Vehicle Service Procedure Procedure 1 Refer to the drawing for proper reassembly Use a very small amount of silicone lubricant on the O rings to avoid clogging the ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Install the control valve on the gear shift lever and tighten the jam nut 3 Attach the air lines and install the bottom cover lt D 5 T D N D E o co J ba o o cD 2 ba cD 3 In Vehicle Service Procedure How to Remove the Air Lines and Hoses Special Instructions Before removing the air lines and hoses label or record their location If you are unsure of their location after yo
167. se so the sensor can be reinstalled to the same depth If the sensor is a push in type remove the hold down capscrew and pull the sensor out of the bore Remove the speedometer rotor seal sleeve and the o ring Pry the seal out using a large screwdriver or prybar in the metal groove of the seal Note The seal will be damaged during removal and must be replaced 8 Remove seal slinger from the speedometer rotor seal sleeve using a brass drift and hammer Inspect all parts of the seal surface for wear scratches burrs or other damage Note Replace the seal surface if it is worn or damaged Do not attempt to salvage the seal mating surface with crocus Cloth filing etc In Vehicle Service Procedures 109 a lt 5 T co N cD Lu T cD J ba o cD 2 uu cD 7 In Vehicle Service Procedures How to Install the Oil Seal Magnetic Speedometer Special Instructions To prevent oil leaks do not touch the seal lip and make sure the seal driver is clean Special Tools e See Tool Information see Table 8 e Oil seal driver e Oil seal slinger driver Procedure 1 Place a seal on the oil seal driver and drive the new seal into the rear bearing cover The seal is fully installed when the flange on the seal is flush with the shoulder in the bore 2 Install the new slinger on speedometer rotor seal sleeve us ing a slinger driver 3 lf previously removed install the o ring over t
168. shift blocks 5 From the middle yoke bar remove the shift yoke and shift block As the neutral notch in the bar clears the rear boss remove the small interlock pin from the notch bore 6 Remove the actuating plunger from the center top bore boss 7 From the bottom yoke bar remove the two 2 shift yokes 142 Transmission Overhaul Procedures Bench Service 8 As the shift bar clears the last boss two 2 3 4 interlock balls drop from the bottom rear boss bore 9 If damaged from the 1st and reverse shift yoke remove the plug spring and plunger JneuI9A0 UOoISSIUISUOJ 0 o cD 2 Lm cD o CO o 5 N Lu T cD 10 Inspect the yoke or block parts replace the worn parts 143 Transmission Overhaul Procedures Bench Service How to Assemble the Forward Shift Bar Housing Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The Sealant should be applied so at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the way of any part Keep yoke bars in neutral while assembling Special Tools e Vise with brass jaws
169. sponding forward or reverse gear ratio is obtained See the Operating instructions and power flow charts found in this section for specific details Shift Patterns A shift pattern decal that explains how to properly shift the transmission should be in your vehicle Figure 2 1 If it has been lost a replacement may be obtained from any Eaton parts distributor RTO 11707LL RTO 11707DLL RTO 13707MLL RTO 13707DLL RTO 11708LL RTO 14708LL RTX 11 06LL RTX 14709LL RTO 11908LL RTO 14908LL RTO 16908LL Eaton Fuller Roadranger SPEED 08 Lo L0 Aro Transmissions DEEP ee SELECTOR SELEC LOLO PRE SELECT ALL RANGE SHIFTS MOVE RANGE SELECTOR BEFORE MOVING SHIFT LEVER PSHIFTING START WITH RANGE SELECTOR DOWN SHIFT LO 1 2 3 RAISE RANGE SELECTOR SHIFT 4 5 6 DOWNSHIFTING SHIFT 7 8 8 4 MOVE RANGE SELECTOR DOWN 00 NOT CHANGE RANGE WHILE MOVING IN REVERSE EE TRANSMISSION IN NEUTRAL amp AwarNinG EEE AG Eaton Fuller Roadranger 8 SPEED L0 amp LO LO RTO UPSHIE TN SELECTOR BEFORE MOVING SHIFT LEVER Transmissions SELECTOR HI 4 LO UN Es Ry PRE SELECT _ ALL RANGE SHIFTS eal dhe RANGE SELECTOR DOWN Neutral SHIFT LO 1 2 3 4 RAISE RANGE SELECTOR SHIFT 5 6 ic 5 DOWNSHIFTING 7 SHIFT 8 7 6 5 MOVE RANGE SELECTOR DOWN SHIFT 4 7 2 LO DO NOT CHANGE RANGE WHILE MOVING IN REVERSE PUT TRANSMISSION IN NEUTRAL 8 AWARNING Eaton Fuller Roadranger BSPEED a Transmissions DEEP REDUCTION SELECTO
170. t Knob transfers this air to the insert valve at the deep reduction cylin der cover 3 When air is applied to the Insert Valve the valve will shut off the constant air to the rear of the deep reduction piston The air on the rear of the deep reduction piston will exhaust through the insert valve and out a hole in the cylinder cover Constant air on the front of the deep reduction piston will move the deep reduction piston bar yoke and sliding clutch rearward to engage the deep reduction gear 45 46 Air system 4 To shift out of deep reduction the button on the shift knob is moved rearward The air on the SP is shut off and exhausted at the shift knob This results in the insert valve supplying air to the rear side of the deep reduction piston Supply air is present on both sides of the deep reduction piston however due to the greater piston surface area on the rear Side the piston moves forward This forward movement shifts the deep reduction yoke bar yoke and sliding clutch out of the deep reduction ratio Cylinder Assembly Air to Housing Port BO l E No Air li N RS AN UD Sad FEL UL Nagi SNE See Vehicle iii Wl a source IDA CZ eal a Deep Reduction cum A SI i ET Air Filte
171. tallation of the bottom shift bar as the bar passes the bosses install the two 2 bottom shift yoke assemblies Install the shift yoke lockscrew torque to 35 45 Ib ft 47 45 61 01 Nem Lockwire securely Place the actuating plunger in the top center bore Place one 3 4 interlock ball in the interlock bore against the bottom bar Holding the middle bar notched end start installation As the bar passes the rear boss position the shift block As the bar passes the center boss position the shift yoke on bar long hub to the housing front dust prior to inserting notched end of bar in rear boss install the small interlock pin vertically in the neutral notch bore Install the shift block and shift yoke lockscrews torque to 39 45 lb ft 47 45 61 01 Nem Lockwire securely Place one 3 4 interlock ball in the interlock bore against the middle bar 139 TATE EDDIE JneuI9A0 UOoISSIUISUOJ Transmission Overhaul Procedures Bench Service 140 19 16 17 18 19 Holding the top bar notched end start installation As the bar passes the rear boss position the shift block As the bar passes the center boss position the shift yoke on the bar long hub to the housing rear Install the shift block and shift yoke lockscrews torque to 35 45 lb ft 47 45 61 01 Nem Lockwire securely Install the oil trough Torque the retaining capscrews to 8 12 Ib ft 10 85 16 30 Nem
172. tching teeth down position the next gear on the 16 17 18 19 20 mainshaft engaging with spacer external splines With clutching teeth up install the next gear on shaft against the previously positioned gear Position another spacer against the previously positioned gear engaging the spacer external splines with gear clutch ing teeth With washer flat side down position the tolerance washer against the spacer Rotate the washer until the washer Splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft Insert two large screwdrivers between the two gears Apply Slight downward pressure to spread the gears evenly Be tween the gear hub and mainshaft spacer insert 0 006 feel er gauge and 0 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer Refer to informa tion before stepped procedures for further information 21 22 23 24 20 26 2 28 Transmission Overhaul Procedures Bench Service Align the sliding clutch missing internal spline with the mainshaft key and install the reverse speed sliding clutch With the flat side up place a washer blue or white in the next available groove Rotate the washer until the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft Against the tolerance washer position reverse speed gear spacer Install reverse gear on the
173. the gasket and clean the area the replacement gas ket will contact 90 In Vehicle Service Procedure How to Install the Gear Shift Lever Remote Shift Control Special Instructions Remote control housings are installed the same way as gear shift levers For standard and forward shift bar housings make sure the detent springs and balls are in the shift bar housing top bores Make sure the shift block and yoke notches are aligned in the neutral position Special Tools e Typical service tools Procedure F lt D T D 7 D Lu 1 o cp J mm o o cD mm cD 1 Thoroughly clean mounting surface 2 Position a new gear shift lever shift control housing gasket on the gear shift lever mounting surface 3 Install the detent springs 4 Install the shift lever shift control housing Make sure the tip finger of the gear shift lever fits into the slots in the shift block 1 5 Apply Eaton sealant 771205 or equivalent to the retaining capscrews 2 6 Install the retaining capscrews torque to 35 45 lb ft 47 45 61 01 Nem 3 Note Make sure the capscrews are properly torqued Note Make sure you can shift the transmission 1 Housing 2 Capscrew 3 Gasket 91 In Vehicle Service Procedure How to Adjust the Remote Shift Control LRC Type Special Instructions The following is a typical adjustment procedure for an LRC type slave control It is recommended that the OEM Chassis S
174. the vise and lay on its side Install the front sliding clutch into position 207 J La o Ur cD 2 ba D o co D o N D E eh T cD JneuI9A0 UOISSIUISUOJ Transmission Overhaul Procedures Bench Service How to Assemble the Mainshaft Assembly with Low Force Gearing Special Instructions The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft It still utilizes Non Selective Non Adjustable Tolerance Washers but the 1st and reverse gears and sliding clutch have been redesigned In this configuration the 1st reverse sliding clutch rides on a clutch hub and the 1st and reverse gears have been redesigned to accommodate this change The proper mainshaft key must always be used with the proper design mainshaft washers If necessary refer to the parts manual for your specific model to confirm the proper parts Special Tools e A piece of 5 32 air line 1 long e Vise with brass jaws 208 Procedure 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with brass jaws or wood blocks 2 If previously removed install the roll pin in keyway 3 With mainshaft pilot end down install offset washer flat surface up Rotate the washer until the washer splines and mainshaft splines align 4 Start at the mainshaft bottom and install a plastic line in the marked keyway to lock the washer in place 5 With clutching teeth down p
175. to Assemble the Mainshaft Assembly with Non Selective Non Adjustable Tolerance WaSllel a Y a hia a 205 How to Assemble the Mainshaft Assembly with Low Force Gearing e e 208 How to Prepare the Main Case for Assembly 211 How to Assemble the Countershaft Assemblies 212 How to Assemble the Lower Reverse Idler Gear Assembly 214 How to Install Countershaft Assemblies 21 How to Install the Lower Countershaft Bearings 218 How to Install the Input Shaft and Main Drive Gear 220 How to Install the Mainshaft Assembly 222 How to Install the Upper Countershaft Bearings 224 How to Assemble the Upper Reverse Idler Gear Assembly 221 How to Install the Auxiliary Drive Gear Assembly 230 How to Install the Clutch Housing ccce 233 How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube n 234 How to Assemble the Integral Oil Pump without Auxiliary Oil Tube ccce 23 How to Remove the Integral Oil Pump 240 How to Install the Integral Oil Pump uu 242 How to Install the Auxiliary Section with Tapered Bearings niesen 244 Shim Procedure without a Shim Tool for Tapered Bearings uuuueueeeueuun 246 Table of Contents Introduction Purpose and Scope of Manual This manual is designed to provide information necessary to service and repair the Fuller transmissions
176. u remove the air lines and hoses see the Air System Troubleshooting Guide TRTSO920 Special Tools e Typical service tools e For push to connect fittings the Eaton service tool kit K 2394 is recommended The kit contains the release tool and the tubing cutter Procedure 1 Disconnect all air lines and hoses 2 Inspect the air lines and hoses 74 In Vehicle Service Procedure 3 Inspect air fittings and remove if damaged Air Line Fitting Types 1 1 8 tube 1 8 NPTF 2 Push to connect 3 5 32 tube 1 8 NPTF gt lt D T D N D Lu 1 o cp J mm o o cD 2 Lm cD 19 In Vehicle Service Procedure How to Install the Air Lines and Hoses Special Instructions Make sure air lines and hoses are not damaged Install the air lines and hoses at their proper location All externally threaded 1 8 or 5 32 air lines and pipe fittings that are not coated with pre applied thread sealant must be coated with Eaton Sealing material 771209 or equivalent for at least 5 complete and consecutive threads All externally threaded 1 4 air fittings that are not coated with pre applied thread sealant must be coated with Eaton sealing ma terial 71209 or equivalent for at least 3 complete and consecutive threads For the 1 4 I D air hoses install the fixed nut end first To install the air lines and hoses the air filter regulator must be in position If you are unsure of the ai
177. ubricate and install plunger pin spring and sleeve into case 3 Install any necessary air hoses at this time 4 Install new gasket 5 Apply Eaton sealant 71205 or equivalent to the retaining capscrews 6 Install the retaining capscrews torque to 8 12 Ib ft 10 85 16 30 Nem Note Make sure the retaining capscrews are properly torqued In Vehicle Service Procedure Air Line Fittings Plunger Spri a Sta de Retaining Capscrews 89 91np9201d 991M9S 9J31U9A U In Vehicle Service Procedure How to Remove the Gear Shift Lever Remote Shift Control Special Instructions The air lines must be disconnected from the transmission or from the Roadranger valve Different detent springs are available to increase or decrease shifting effort Note and record specific locations for specific springs In some cases a Stiffer spring is installed in the top rail position Remote control housings are removed the same way as gear shift levers Special Tools e Typical service tools Procedure 1 From the gear shift lever base shift control housing remove the four 4 retaining capscrews i miisi 2 Capscrew 3 Gasket 2 To break the gasket seal lightly jar the gear shift shift con trol housing Wal vt l NO CW 3 Remove the gear shift lever housing A CAUTION Make sure the detent springs do not fall into the transmis sion 4 Remove detent springs as needed 5 Remove
178. uding from the case under the slave valve The pin should extract when the transmission is shifted into gear and retract when shifted into neutral Actuating plunger pin moves freely If air system has been tested and found to operate satisfactory the auxiliary section must be removed to inspect for mechanical problem Remove auxiliary section and inspect for Binding of range yoke bar or piston Damaged or defective range yoke Damaged or defective range syn chronizer Cracked c s weld resulting in gear turning on shaft Damaged or defective range sliding clutch Auxiliary section gearing out of time What to do next 3 Check for a plugged or dirty filter in the filter regulator assembly 4 Check for a pinched or obstructed 1 4 rubber air line between the filter regulator and slave valve 5 Check for a pinched or obstructed air line between the slave valve and the S port on the shift knob 6 If all are good replace the shift knob Go to step I 1 Remove actuating plunger pin and check for damage 2 Check for missing or broken Spring Repair or replace slave valve and check for proper range operation Air System Procedure 6 Symptom No or Slow Range Shift into High Normal Operation When the range selector on the shift knob is moved down to select low range air pressure will flow through the shift knob to the P port on the slave valve The slave valve will direct air press
179. up to lock the washer on the mainshaft With clutching teeth down position the next proper gear on the mainshaft Position the flat washer against the gear Rotate the washer until the washer splines and mainshaft splines align 15 20 21 22 23 24 20 Transmission Overhaul Procedures Bench Service With clutching teeth up install next gear on the shaft against previously installed gear Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main shaft splines align Push the air line up to lock the washer on the mainshaft With the missing internal splines aligned with the plastic line install the reverse sliding clutch Install the reverse gear offset washer in the last groove From the mainshaft rear install the mainshaft key into the Spline with the air line Pull the air line from the spline while installing the key Install the reverse gear Spacer washer with external spline teeth over the mainshaft rear and against the offset washer Note Some models the reverse gear offset washer has a large chamfer machined in the backside This special offset washer must be used in this position The large chamfer faces rearward From the rear install the reverse gear over the sliding clutch teeth Install the snap ring in the mainshaft groove Note Some models do not use a snap ring at this position Remove the mainshaft from
180. ure spray may is only a weep and it is not force contamination into the area of concern and considered to be detrimental temporarily disrupt the leak path to the life of the transmission i Clean area with a clean dry cloth or mild 4 Repair is complete soluble degreaser and fill the transmission to the proper lube level OR ii Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level Step 2 Operate vehicle to normal transmission operating temperature and inspect the area for oil leak s visually or if tracer dye was introduced use an UVL Ultraviolet Light to detect the tracer dye s point of origin Note When inspecting for the origin of the leak s make sure the assumed leak area is not being contaminated by a source either forward or above the identified area such as the engine shift tower Shift bar housing top mounted oil cooler etc Step 3 Once the origin of the leak is identified repair the oil leak using proper repair procedures from the designated model service manual Step 4 After the repair is completed verify the leak is repaired and operate the vehicle to normal transmission operating temperature Inspect repaired area to ensure oil leak has been eliminated If the leak s still occurs repeat steps or contact the Roadranger Call Center at 1 800 826 4357 20 Power Flow Power Flow Diagrams An understanding of the e
181. ure through the low range 1 4 rubber supply hose to the range cylinder to shift the range There will be a brief burst of air at the slave valve as the high range side of the range piston exhausts Likewise when high range is selected the air pressure in the P will be exhausted at the shift knob This will cause the slave valve to direct air to the rear side of the range cylinder piston The air pressure on the low range side will be exhausted at the Slave valve Possible Causes e _ Incorrect air line hook up e Insufficient air supply to transmission e Plugged filter e Incorrect regulator pressure e Damaged or defective shift knob master valve e Damaged or defective slave valve e Damaged or defective range cylinder ep cb e cD Lm o gt h i Lu o i e Damaged or defective range yoke or yoke bar e Damaged or defective range synchronizer e Damaged or defective gearing in auxiliary section of transmission a rr ee O Place the shift lever in neutral Check Constant air leak is detected Go to the above corresponding for constant air leakage at the shift symptom first See beginning of Air knob slave valve and transmission system Troubleshooting section case breather when both low and high range have been selected No constant leak is detected Go to step B Place shift lever in neutral Move Air flows from the high range port Remove range cylinder cover and range selector down t
182. uxiliary housing gasket surface Measure and record the gap at two capscrew locations Average the two feeler gauge measurements by adding the measurements together and dividing by 2 as shown in Ex ample Shim Chart Gap 1 060 Gap 2 050 Average 110 2 055 Total Gap 060 050 110 Select yellow shim as indicated in the shim chart at the end of this selection Locate the feeler gauge average measurement in the shim chart to determine the required shim and color code Note The oil pump shim is used when an auxiliary oil pump or PTO is mounted on the countershaft The oil pump shims have a smaller outside diameter Remove the countershaft rear bearing cover and gauging shim Place the selected shim on the rear countershaft bearing race Position a new gasket on countershaft rear bearing cover mounting surface Position the countershaft rear bearing cover over the new gasket 247 v cD n Lm cD P 5 cD oD cD Lu oD cD jneuI9A0 UOISSIUISUOJg Transmission Overhaul Procedures Bench Service 14 Apply Eaton Fuller thread sealant 71205 or equivalent to the auxiliary countershaft rear bearing cover capscrews and auxiliary countershaft rear bearing cover 15 Install the auxiliary countershaft rear bearing cover and se cure it with the capscrews Make sure the shim is in the proper location and is not pinched between the co
183. ve Compression Type Fittings 18 How to Install Compression Type Fittings 19 How to Remove Push To Connect Type Fittings 80 How to Install Push To Connect Type Fittings 81 How to Remove Rubber 1 4 Air Hoses 82 How to Install Rubber 1 4 Air Hoses csc 83 How to Remove the Air Filter Regulator 84 How to Install the Air Filter Regulator 85 How to Remove a Roadranger Valve cssc 86 How to Install a Roadranger Valve c eee 87 How to Remove a Slave Valve e e eueeeeeueeuun 88 How to Install a Slave Valve woo eeceesssesessseeseeees 89 How to Remove the Gear Shift Lever Remote Shift Control 90 How to Install the Gear Shift Lever Remote Shift Control 91 How to Adjust the Remote Shift Control LRC Type 92 Neutral Switch Operation and Testing 9 94 How to Remove the Neutral Switch 95 How to Install the Neutral Switch e9 9 9 96 Reverse Switch Operation and Testing 97 How to Remove the Reverse Switch 98 How to Install the Reverse Switch 99 How to Remove the Shift Bar Housing 100 How to Install the Shift Bar Housing 102 How to Remove the Oil Seal Mechanical Speedometer a ioa 104 How to Install the
184. ve Maintenance Check Points Note Transmission appearance may differ however the procedure is the same Preventive Maintenance Air System and Connections e Check for leaks worn air lines loose connections and capscrews Clutch Housing Mounting e Check all capscrews of clutch housing flange for looseness Clutch Release Bearing Not Shown e Remove hand hole cover and check radial and axial clearance in release bearing e Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches Clutch Pedal Shaft and Bores e Pry upward on shafts to check wear e f excessive movement is found remove clutch release mechanism and check bushings on bores and wear on Shafts See OEM literature Lubricant e See Lubrication Manual TCMT0021 Oil Filter e Oil Filter Inspection during vehicle PM schedule Inspect oil filter for damage or rust Replace as necessary Inspect oil filter adapter for damage or leakage Replace as necessary e Oil Filter Replacement Replace every 100 000 miles and top off fluid Every transmission fluid change Filler and Drain Plugs e Remove filler plugs and check level of lubricant at specified intervals Tighten fill and drain plugs securely Capscrews and Gaskets e For applicable models check all capscrews especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage e Check PTO opening and rear bearing covers f
185. ver and the housing Tighten the capscrews to 40 45 Lb ft 54 61 Nm Note Use a thick grease to hold the shim in position when installing the cover 16 Repeat this procedure for the remaining countershaft Note Make sure capscrews are properly torqued Note Make sure the input shaft rotates Shim Table eeler Gauge Average Shim Thickness Standard Shim Part Oil Pump Shim Part Num Color Code Gap Number ber LLEN ES EN fee fare 036 0385 069 070 21685 21687 249 This page intentionally left blank Copyright Eaton Corporation and Dana Limited 2009 Eaton and Dana hereby grant their customers vendors or National Institute for distributors permission to freely copy SELLE E reproduce and or distribute this document CELLENC in printed format lt may be copied only in its Ys entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES For spec ing or service assistance call 1 800 826 HELP 4357 or visit our web site at Roadranger www roadranger com In Mexico call 001 800 826 4357 ETN p Roadranger Eaton Dana and other trusted partners providing the best products and services in the industry ensuring more time on the road 2009 Eaton Corporation All rights reserved Eaton Corporation Truck Components Operations PO Box 4013 e Kalamazoo MI 49003 U S A e www roadranger com Printed in USA
186. ver to twist between the spring and hous ing forcing the spring from under the housing lugs one coil at a time From inside the housing tower remove the tension spring washer and gear shift lever In models so equipped from the housing bore remove the nut and washer From the housing tower spade pin bore remove and inspect the spade pin discard if damaged From the housing tower inside groove inspect the O ring discard if damaged Tran How to Assemble the Gear Shift Special Instructions Inspect tension spring and washer for wear smission Overhaul Procedures Bench Service Lever Apply Eaton rust preventative lubricant 71212 or equivalent to the shift lever pivot ball A rust preventative lubricant film should cover all surfaces between and including the pivot ball Seat the tension spring one coil at a time Special Tools e Vise with brass jaws or wood blocks e item T4 Tension Spring Driver 3 z o 8 1 0 lt gt i ta Sn 2 i v4 A hy i A pis D p _ E ae 12 1 a ay Mu a S 5 u a ry Ss 6 T i Pay me ae SS Che a 8 a ta pW Ss 184 j WN a E x i 7 9 g gt ie 1 Pin 2 Bushing 3 Upper Lever 4 Snap Ring 5 Rubber Boot 6 Spade Pin Housing 8 Capscrew 9 Gasket 10 O Ring 11 Washer 12 Lower Lever 13 Stepped Washer 14 Tension Spring 129 v m
187. vice tools Procedure 1 Remove 2 screws retaining wire terminals 2 Remove the switch using a 7 8 deep well socket or box end wrench In Vehicle Service Procedure 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft a gt E a r y W oF lt lt gt gt PES ate os aS P A Fi ca lt amp kK mE gt en Pi 7 Fd gim g rW ll o dan gt N cw af PEM I DD fm A A a a gt Mr sr Nr a a FM y yr LA g a A a pE y aE E N rd Pr GK OSA Se cae a S oO A cr v A ME opa n on LS co gt SS as rs f Sea Ao gt a y Ed ym y y Med 5 See eee A A N my pmi E Bex ms o 2S ee at ae MO Pm AS yr LS 4 ma a ao 1 e y My lt lt r gt 3 y E Go ymar Ge ry oe A TF ne pp i gam 2 2 a ZZ gt oe e P Pa Za io y y gt gt rr pE w A Te a H we ut ao it a Ao 7 Oe y tl SAS Sec Sa Yon OA SUP X en omy Ea a AA s a p ZA a i bL a a m rf Yn UU we Ai CE fe 9 95 F lt D T D N D Lu 1 o cp J mm o o cD 2 mm cD In Vehicle Service Procedure How to Install the Neutral Switch Special Instructions None Special Tools e Typical service tools Procedure 1 Install a new gasket 2 Install the neutral switch torque to 15 20 lb ft 20 34 27 12 Nem 3 Connect the wi
188. w threads and install the six 6 capscrews Torque the capscrews to 35 45 Lbeft Slide the auxiliary dirver gear over the mainshaft splines In Stall the rear snap ring in the mainshaft groove Note For the snap ring to install fully it may be necessary to slide the mainshaft assembly rearward If the snap ring cannot be installed in the groove the reverse gear Spacer washer may be improperly positioned the chamfer in the washer must face rearward Transmission Overhaul Procedures Bench Service How to Install the Clutch Housing Special Instructions Installation of the clutch housing is done in the horizontal position Special Tools e Typical service tools Procedure 1 Position a new gasket on the housing mounting surface with beads toward case 2 Install the clutch housing on the front box pilot it on the six Studs and drive gear bearing cover 3 Install the nuts with washers or lock washers on the studs tighten to 180 190 Lb ft of torque 4 Install the capscrews with lock washers tighten to 90 100 Lb ft of torque Note Make sure the capscrews are properly torqued 233 0 Ur cD 2 Lm D o co D l N D E eh co cD jneuI9A0 UOISSIUSULIL Transmission Overhaul Procedures Bench Service How to Disassemble the Integral Oil Pump without Auxiliary Oil Tube Special Instructions None Special Tools e Typical service tools e Avise with brass jaws or wood
189. ward Ath Gear Deep Reduction Sliding Clutch Forward Sliding Clutch Forward Range Sliding Clutch Forward 6th Gear Deep Reduction Sliding Clutch Forward Sliding Clutch Rearward Range Sliding Clutch Forward 8th Gear 32 Deep Reduction Sliding Clutch Forward Range Sliding Clutch Forward Sliding Clutch Rearward 5th Gear Deep Reduction
190. ws are snug 9 Drive the two dowel pins forward and remove them 10 Remove all but one capscrew that secure the auxiliary sec 118 tion to the main section Leave one capscrew to secure the housing until it is ready to be removed Note Capscrews are different lengths Note their locations for reassembly purposes A WARNING Use the proper equipment with safety chains attached to re move the auxiliary section The auxiliary section can slide rearward and could fall causing you serious injury and or damage to the auxiliary section Attach a chain and lifting device to the auxiliary section hanger or attach the support jack to the auxiliary section as shown in the pictures to the left With the support device in position remove the remaining capscrew lf necessary 3 capscrews can be installed into the three threaded holes in the auxiliary section flange When threaded in they will push the auxiliary section rearward Clean the holes of rust paint and other debris by threading a 3 8 16 tap into each hole Thread each capscrew in evenly to prevent damage to the auxiliary housing A CAUTION The weight of the auxiliary section must be supported during removal to avoid damage to internal transmission parts Support the weight of the auxiliary section with a lifting de vice or Support jack and move the auxiliary section rearward until it is free from the front section of the transmission In Vehicle Service Procedu
191. y changes between 58 63 PSI and 0 at the gauge Pressure does not change rapidly at gauge Air flows from the disconnected line No air flow from the disconnected line Air flows from this port No air flow from this port The gauge responds slowly Air System What to do next Replace the filter regulator and check for proper range operation Go to step E Air system appears to be operating satisfactory Go to step R 1 Check for a plugged or dirty filter in the filter regulator assembly 2 Check for a pinched or obstructed 1 4 rubber air line between the filter regulator and slave valve uoneunioJu je1eUa4 3 Check for a pinched or obstructed 1 4 rubber air line between the slave valve and the test gauge 4 If all are satisfactory Go to step F 1 Confirm that the air lines are con nected to the correct ports at the shift knob 2 If the lines are correct replace the shift knob Go to step G Replace the slave valve Continue to step H 1 Check for a restricted line between theshiftknobandslavevalve 2 Check for a restricted exhaust port on the shift knob of Air system Step Step R 08 Procedure Result The gauge rapidly moves between 58 63 PSI and 0 PSI Actuating plunger pin does not move freely If possible leave air lines attached to slave valve Unbolt the slave valve from transmission side Check for free movement of the plunger pin protr

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