models es52-7b es56-7b es066-7b 7 speed transmission
Contents
1. SECTION X 4 Place the caged needle bearing and 3rd speed gear onto the shaft The gear hub should point toward 2nd 3rd speed synchronizer Position the lock ball into the shaft and slide the thrust washer into place 5 Note that the lock ball keeps the thrust washer form rotating on the shaft Wearing safety glasses Continue by A installing the snap ring with the rounded side toward the thrust washer 6 Continue by placing two caged needle bearings wider one first on the shaft Slide 4th speed gear on the shaft A with the clutching teeth up Also install 4th 5th speed clutch gear Secure it with a snap ring The rounded side of the snap ring should face the clutch gear Tech Support 1 800 401 9866 REASSEMBLY 5 3 7 Lubricate then Install the 4th bth speed synchronizer 9 Install two caged needle bearings and either the overdrive gear for the overdrive version or the 6th speed gear for the direct version The clutch teeth should face up Install the 6th 7th speed clutch gear and secure it with the spiral snap ring 8 Next install the two caged needle bearings and 5th speed 10 Press the bearing onto the end of the shaft The gear The gear hub should face the synchronizer chamfered side of the bearing should face the 6th A Put the lock ball into place Then install the thrust A 7th speed clutch gear washer and snap ring Tech Support 1 800 401 9866 35 1 Press the2. D This Spicer transmission can be repaired with ordinary mechanics tools However if your transmission has mainshaft intermediate nut rather than a snap ring vehicle downtime can be minimized with the use of this special socket It is available through Sealed Power Corporation part number OEM6599 To order contact Division Sealed Power Corporation O E M Sales 655 Eisenhower Drive Owatonna MN 55060 Phone 800 533 6127 Fax 800 283 8665 Tech Support 1 800 401 9866 GENERAL DISASSEMBLY Important Procedure To locate and correct unit power or auxiliary transmission troubles a systematic procedure should be followed Road test whenever possible Mechanics usually get second or third hand reports of trouble experienced with the unit These reports do not always accurately describe the actual conditions Sometimes symptoms seem to indicate trouble in the transmission while actually the problem is with the axle driveshaft universal joints engine or clutch This is especially true of noise complaints Therefore before removing the transmission or related components to locate trouble road test to check the possibility of trouble in other closely associ ated units Road testing is most effective when the mechanic drives the vehicle However riding with the driver can be very informative Check Functioning Prior to Disassembly If a remote control is used a careful check of the remote and connecting lin
3. OIL TROUGH oe SCREW BEARING PLATE SPRING PLUNGER Ze COVER SCREW Tech Support 1 800 401 9866 21 Clutch Housing amp Shift Forks Exploded Drawing DRIVE GEAR BEARING 1st AND REVERSE FORK AND BAR DRIVE GEAR BEARING CAP 2nd and 3rd FORK AND BAR CLUTCH HOUSING BUSHING OVERDRIVE SHIFT BAR OVERDRIVE SHIFT FORK HAND HOLE Q gt o ZS ff sui SHIFT FORK SHOE SNAP RING MOUNTING BRACKET PIN Nae MOUNTING BRACKET 5 22 Tech Support 1 800 401 9866 MAIN CASE DISASSEMBLY 1 Remove case bolts 2 Begin main case disassembly by removing the housing Use a chain hoist 3 Lift the mainshaft from the case with the help of a hoist It may be necessary to tilt the countershaft to the side for clearance Note that the 2nd 3rd and 4th 5th speed forks lift out of the housing with the mainshaft Tech Support 1 800 401 9866 23 SECTION VI 4 Remove the forks from the mainshaft 5 Tilt the countershaft and lift it from the housing 6 Slide the synchronizer away from the fork clips MAIN CASE DISASSEMBLY 7 The overdrive fork is pictured here It is not necessary to remove this fork although the technician may wish to do so 8 The direct shift fork shown at left also could be removed at this time 9 If the overdrive shift bar is worn simply remove the snap ring and pin Replace the bar and secure it with the
4. Wrong lubricant in unit Seals defective wrong type or omitted from bearing cap d Transmission breather omitted or plugged internally Capscrews loose omitted or missing from remote control shifter tower bearing caps PTO or covers f Oil drain back openings in bearing caps or case plugged with varnish or dirt g Gaskets shifted or squeezed out of position broken gaskets with pieces still under the shift tower h Cracks or holes in castings Loose drain plug Oil leakage from engine K Loose speedometer adaptor or connections SECTION XIV Walking or Jumping Out of Gear If the units are walking out of gear it could be caused by a b External interference such as the floorboard opening preventing full engagement or An internal malfunction such as worn clutching teeth allowing the transmission to shift out of position If a remote control is being used make sure it is functioning properly before the transmission is blamed for the problem Note whether the unit walks out of gear under drive while pulling a load or on a coast load Also notice whether the gear hop occurs on smooth roads or only on rough roads Items that would prevent full engagement of gears are a Improperly positioned forward remote control which limits full travel forward and backward from the remote neutral position Improper length shift rails or linkage that limits travel of forward remote fr
5. and power chisels It may also be created within the unit during service from raking teeth These chips produce small indenta tions in balls and races When these hard particles jam between the balls and races it may cause the inner race to turn on the shaft or the outer race to turn in the housing Fatigue All bearings are subject to fatigue and must be replaced eventually Your own operating experience will dictate mile age replacement of bearings showing only normal wear TROUBLESHOOTING Corrosion Water acid and corrosive materials formed by deterioration of lubricant will produce a reddish brown coating and small etched holes over outer and exposed surfaces of the race Corrosive oxides also act as lapping agents Shaft Fits Bearing fits on rotating shafts are usually specified as tight Excessive looseness even 001 under a load produces a creeping or slipping of the inner race on the rotating shaft The result is that surface metal of the shafts scrub or wear off The force causing the inner race to rotate disappears when the bearing fits properly Installation and Removal of Bearings Improper installation or removal of bearings especially ham mering the bearing on the shaft with off center blows can result in brinelling Since such damage is seldom visible it does not become known until after failure or complete disas sembly The correct drivers preferably under an arbor press and pullers should be use
6. 3 000 43 Engine Types 5 9 Liter Diesel 76 Simple Shift Pattern ES52 7B 520 Ibs ft 704 nm ES56 7B 560 Ibs ft 758 nm ESO66 7B 660 lbs ft 894 nm 10 1 Gears 2 7 35 clutch housing mounting face to washer seat face 454 Ibs 206 kg SAE No 2 13 or 14 single or 2 plate push or pull 1 3 4 10 spline or 1 1 2 10 spline 22 pints 10 4 liters Provision for mechanical and electronic 6 bolt right amp left countershaft rear 34 tooth 18 right hand helix 17 50 pressure angle of engine RPM ES52 7B 48 8 ES56 7B 48 8 ES066 7B 65 8 INFORMATION SECTION I TORQUE SPECIFICATIONS FOR NUTS AND CAP SCREWS Nom Size Dia Part Name Wrench Torque ft Ibs Inches mm Min Max Oil trough 16 x 750 Intermediate shift bar support 16 x 1 00 Front mainshaft bearing cap 16 x 1 00 Overdrive linkage 16 x 1 00 Rear mainshaft bearing cap 16 x 1 125 Rear countershaft bearing cap 16 x 1 125 Clutch housing to main case 16 x 1 25 Front shift bar support 16 x 2 250 Rear mainshaft brake cap 14 x 1 25 Shift tower trunnion 6 bolt PTO aperture cover Mainshaft output nut Intermediate mainshaft spanner nut Backup light switch Tech Support 1 800 401 9866 GENERAL INFORMATION How to Shift the Spicer Easy Shift 7 Speed Transmissions Synchronizer Information The purpose of a synchronizer is to simplify shifting and help deliver clash free shif
7. 11 Using pullers in the milled slots remove the rear mainshaft bearing E 3 9 Next remove the speedometer signal gear 12 Remove bolts from housing Tech Support 1 800 401 9866 12 DEASSEMBY SECTION V 13 Next place pry bars in the slots provided in the rear case Break the seal A 14 Then use a chain hoist to remove the rear housing 17 Notice that the 1st reverse shift fork support bracket also T stays in the housing This bracket shoud not be removed unless it is broken and is going to be replaced 15 Using a plastic mallet tap the rear countershaft out of the 18 Tap the reverse idler shaft out of the housing rear of the case Tech Support 1 800 401 9866 13 DEASSEMBy SECTION V 19 Remove the reverse idler gear and bearings 22 Next remove the rear mainshaft 20 Continue by removing the thrust washer reverse gear 23 To remove 1st gear from the mainshaft first remove the and the caged needle bearings snap ring Always wear safety glasses to protect A your eyes when servicing transmissions 21 Unbolt the rear shift bar support bracket Lift the 1st 24 Remove the thrust washer and lock ball next reverse fork and collar assembly from the housing 14 Tech Support 1 800 401 9866 DEASSEMBY 25 Remove 1st gear and the bearing from the shaft The 27 Lock the transmission into two gears Remove the snap clutch gear is a par
8. CLUTCH COLLAR 10 Tech Support 1 800 401 9866 DISASSEMBLY 1 After removing the transmission from the vehicle drain the 4 The backup light switch can be removed if it is going to be oil Let the unit cool down first Otherwise hot replaced Otherwise it does not have to be removed during A transmission fluid could cause burns servicing 2 Remove the interlock retaining drive screws Next remove 5 If the driver has experienced shifting problems check the the gaskets and interlock retainer plate crossgate plunger and spring at this time Replace them if they are worn or damaged If no problems have occurred it is not necessary to remove the plunger and spring 3 The four springs and plungers should be removed now If 6 Attach a bracket or lift hooks to the rear case Secure the reason for the teardown was a shifting problem closely with bolts which are at least hand tightened Lift the examine the springs and plungers for wear or damage Re transmission with a hoist and set it on end on a place them if they are worn or damaged workbench that contains a hole for the drive gear Tech Support 1 800 401 9866 11 DISASSEMBLY SECTIONV 7 Remove the nut washer and end yoke or flange 10 Remove the countershaft bearing cap and shims Note Some models have a rear countershaft PTO option In this situation the countershaft will come out with the rear case when it is removed
9. bearing into place and install snap ring Then 4 Install the oil baffle Then coat the drive gear bearing cap use a suitable press to push the oil ring into place with purple Loctite 515 or the equivalent aligning the lubrica A A brass hammer can also be used for this tion holes Torque the cap screws to 25 41 ft Ibs procedure 2 Install the drive gear into the clutch housing 5 Place the clutch housing drive gear face down on the workbench S Ki d 3 Place a protective sleeve over the shaft before installing 6 Install the overdrive fork if it was removed earlier Secure it the bearing cap See the warning on the inside front with bolts Torque the bolts to 25 41 ft lbs If working on a A cover of this manual Also notice the position of the direct drive model install the 6th 7th speed fork lubrication hole The bearing cap lubrication hole must be aligned with this housing lubrication hole Tech Support 1 800 401 9866 36 MAIN CASE REASSEMBLY 7 Next lubricate then install the 6th 7th speed synchronizer Shift it down toward the drive gear This will aid alignment 8 The countershaft is installed next Tilting the countershaft toward the mainshaft is the easiest way to do this Notice that there aren t any timing marks on the gears There is no need to time the countershaft to the mainshaft 9 Lift the mainshaft with a hoist While it is in the air install 2nd 3rd and 4th 5th speed forks i
10. if any of these conditions exist Gears Examine for broken or cracked operating and clutching teeth Also check for any unusual wear patterns If any of the preceding exists replace the gear If a gear must be replaced also remember to replace its mating gear Tech Support 1 800 401 9866 SECTION IX Thrust Washers Check for flatness excessive face wear cracks scoring or signs of heat damage Replace if any one of these conditions exists Snap Rings New snap rings are recommended with every rebuild Mainshaft Check for signs of twisting or misalignment Also check for worn or damaged splines Replace the shaft if any of these conditions exists Bearings New bearings are recommended with every rebuild See General Disassembly Bearings for further information Housings Inspect the housing sections for cracks If cracks exist replace that section of the housing Also inspect the shift bar support bracket for cracks or worn slots Replace if either of these conditions exists MAINSHAFT REASSEMBLY 1 Lubricate all bearings with oil before beginning reassembly Continue by placing the caged needle bearing and 2nd speed gear hub toward clutch gear on the shaft Position the thrust washer on the shaft then press the bearing race into place 2 Place the assembly in a vise or holding fixture 3 Lubricate the 2nd 3rd speed synchronizer with oil then slide it onto the shaft Shift it into 2nd gear
11. splines provide increased torque are positioned correctly capacity 4th speed gear recessed ID faces 3rd gear 3rd gear is part of the shaft Spacer e 5th speed gear Overdrive gear or 6th speed gear on a direct shift unit Part number faced 5th speed gear e 7th speed gear hub faces overdrive gear or 6th speed gear on a direct shift unit 32 Tech Support 1 800 401 9866 CLEANING amp INSPECTION PROCEDURES Cleaning Prior to reassembly wash all parts thoroughly Use a petroleum based solvent Refer to the solvent manufacturer s safety precautions to pre vent personal injury or transmission damage Do not use water or steam to clean internal components If you do it could cause corrosion of these components Do not use gasoline to clean parts Gasoline can explode causing serious physical injury Dry the parts immediately with compressed air Coat them with lubricant if they are to be reassembled immediately If the parts are to be stored coat them with a rust inhibitor and wrap them to keep contamination out Inspect parts thoroughly for wear or damage Parts damaged or worn from previous service must be replaced to insure maximum rebuild life Suggested inspection procedures in clude the following Inspection Clutch Collars Both the internal and external teeth must have sharp edges Check for chipped or broken teeth or teeth with rounded corners Also examine fork slots for wear Replace collars
12. the snap ring groove Install the snap ring If the unit is secured with a nut install the nut on the mainshaft using the special socket listed in the tool reference Torque the nut to 300 325 ft Ibs Tech Support 1 800 401 9866 45 REAR CASE SECTION XII REASSEMBLY OPTI RAIL 7 If the trough was removed earlier check now to make sure there is proper clearance between it and 1st gear 9 Next install the caged bearing and reverse gear The gear hub should face the bearing Also install the thrust washer with the tapered side up 10 Assemble the bearings and gear onto the idler shaft and install the assembly Make sure the bearings are packed with Moly 2 lubricant A n a Ne uc 11 The straight edge on the end of the idler shaft must be positioned as shown here Tap it into the case so the top portion of the shaft is flush with the case or not more than 030 below the case surface The lower portion of the idler shaft will extend about 1 4 above the case 12 Coat the case sealing surface with purple Loctite 515 or the equivalent Then install the rear case with the A aid of a chain hoist Secure with capscrews Torque them to 25 41 ft lbs If a new 1st reverse shift bar support was installed in the rear case make sure the 1st reverse bar is shifting properly Tech Support 1 800 401 9866 REASSEMBLY OPTL RAIL SECTION XII 13 Next install the rear mainshaft beari
13. will avoid another teardown on the unit in the near future Also at this time make the recommended changes or modifications to bring the transmission up to date and increase the service life of the unit Tech Support 1 800 401 9866 GENERAL DISASSEMBLY Read this section before starting the detailed disassembly proce dures Follow each procedure closely in each section making use of both text and pictures Rebuild Facilities A suitable holding fixture or overhaul stand with a hole for the input shaft is desirable For easier working conditions table height should be 28 30 inches A light chain hoist should be used to handle the mainshaft and countershaft during removal and reassembly procedures Cleanliness Transmissions should be steam cleaned prior to disassembly Seal all openings before steam cleaning to prevent entry of dirt and water which can damage serviceable parts Dirt is abrasive and will cause premature wear of bearings and other parts TTC suggests that mechanics have a wash tank available to clean parts just prior to reassembly Bearings When a transmission is removed at relatively low mileage bearings should be removed with pullers designed for this purpose Wrap the bearings to keep out dirt Clean inspect and lubricate all bearings just prior to reassembly If accumu lated mileage is over 150 000 miles we suggest that all bearings be replaced If bearings are worn or damaged always replace th
14. your transmission PUSH SLEEVE OVER END OF SHAFT TN INSTALL BEARING CAP ASSEMBLY d AFTER RED SLEEVE IS IN PLACE E INSTALL SEAL DRY L SCH iN d HYDRODYNAMIC LIP SEAL MUST BE INSTALLED SO THAT HYDRODYNAMIC LIP FACES TOWARD INSIDE OF TRANSMISSION REMOVE SEAL CARDBOARD SHIPPING TUBE OR PLASTIC INSTALLATION SLEEVE JUST PRIOR TO INSTALLING BEARING CAP ASSEMBLY TO TRANSMISSION SHIFT TOWER erter DISASSEMBLY 1 Shift Tower Disassembly 1 Begin disassembly by cutting the two tie cables which secure the boot 2 Slide the boot off the shift lever HANDLE 3 Remove the two trunnion screws 4 Lift the lever from the tower UPPER TIE CABLE 5 To remove the shift yoke from the lever simply press out the pivot pin 6 Wash all parts Inspect them thoroughly for damage Replace parts as necessary LOWER TIE CABLE SHIFT LEVER PIVOT PIN YOKE SHIFT TOWER SCREW TRUNNION SCREW Tech Support 1 800 401 9866 DISASSEMBLY SECTONV Rear Case Exploded Drawing CAP SCREW MAINSHAFT REAR BEARING CAP BEARING CAP SCREW REAR CASE LIFT HOOK DOWEL PIN PLUG COUNTERSHAFT REAR BEARING CAP BEARING CUP Tech Support 1 800 401 9866 Rear Case Gears Exploded Drawing EAR MAINSHAFT MAINSHAFT NUT WASHER END YOKE LE BEARING 7 THRUST WASHER SNAP RING NEEDLE BEARING 1st AND REVERSE
15. 1 9866 REANW ePFATIALALVI REASSEMBLY OPTI RAIL SECTION XII 25 Install gasket and interlock retaining plate 28 Temporarily install the shift tower and bench shift the unit to make sure all forks are shifting properly Before A removing shift tower assembly shift the transmission into direct gear This will aid in the installation of transmission into the vehicle 26 Install the interlock on top of interlock retaining plate Top surface of interlock should be flush with the retaining plate 27 Install final gasket and note the position of the interlock plate This photograph shows the correct position Tech Support 1 800 401 9866 49 SHIFT TOWER REASSEMBLY 1 To reassemble the tower first position the yoke onto the shift lever The yoke has a boss which must align with the tower side that has boss clearance Secure the yoke by pressing the pivot pin into position 2 Place the lever assembly into the tower housing The raised boss on the yoke must be placed next to the side of the tower that contains the casting number stamp 3 Install the two trunnion screws Torque to 100 125 ft Ibs 4 Slide the boot into place Secure it with two tie cables being careful not to cut into the boot SHIFT LEVER PIVOT PIN SHIFT TOWER SECTION XIII HANDLE EI S I vp Per TIE CABLE h 4 LOWER CABLE SHIFT TOWER SCREW TRUNNION SCREW Tech Support 1 800 401 9866 50
16. 2 Remove the spiral snap ring from the groove The 5 Remove the snap ring thrust washer and lock ball easiest way to do this is to place a screwdriver under The lock ball prevents the thrust washer from A one end and work it around the snap ring A turning on the shaft Also remove 5th speed gear and the two caged needle bearings 3 Attach a puller to the 6th 7th speed clutch gear Remove 6 Remove the 4th 5th speed synchronizer from the shaft the gear and the drive gear bearing together 30 Tech Support 1 800 401 9866 MAINSHAFT DISASSEMBLY 7 Wearing safety glasses remove the snap ring and 4th 5th speed clutch gear Also remove 4th speed A gear and the two caged needle bearings Notice that one bearing is wider than the other This will be important during reassembly 1 i 8 The snap ring thrust washer and lock ball can be removed Also remove 3rd speed gear and the A caged needle bearing 9 Remove the 2nd 3rd speed synchronizer Tech Support 1 800 401 9866 31 SECTION VII 10 Then remove the thrust washer 2nd speed gear and the caged roller bearing 11 Disassembly of the mainshaft is complete COUNTERSHAFT DISASSEMBLY amp REASSEMBLY SECTION VIII bth ES52 7B Poa Overdrive Head End ES066 78 5066 7 1 The countershaft gears easily pressed off and on this 2 When assembling this countershaft make sure the gears shaft The rolled involute
17. BLY 19 Set the transmission in normal operational position 20 Install the backup light switch if it was removed earlier Torque it to 25 41 ft Ibs 21 Next install the plungers and springs 44 SECTION XII 22 Bench shift the unit to make sure all forks are shifting properly 23 Install a gasket the interlock plate and the final gasket Note the position of the interlock plate This photograph shows its correct position Next shift into direct and install the transmission into the vehicle Install the shift tower Secure it with cap screws torqued to 25 41 ft Ibs Tech Support 1 800 401 9866 REASSEMBLY OPTI RAIL SECTION XII 1 Remove zip tie with needle nose pliers and discard housing Do not use gaskets or sealing compounds on either cap because it could prevent proper lubrication to the unit Torque the cap screws to 25 41 ft lbs Q has a groove that lines up with the lubrication hole in the 2 Slide rear support on to the end of the rail channel secure 5 Next install the bearing and 1st gear onto the rear mainshaft with bolts Torque to 21 45 ft Ibs Also install the lock ball thrust washer and snap ring 3 Install the snap rings on the intermediate bearings Lock the 6 Use Moly 2 lubricant to coat the mainshaft splines Then transmission into two gears If the unit is to be secured by a install the rear mainshaft A snap ring lift up on 4th gear to expose
18. ECTION IX CLEANING amp INSPECTION PROCEDURES 33 SECTION X MAINSHAFT REASSEMBLY senem 34 SECTION MAIN CASE REASSEMBLY 36 MAIN CASE REASSEMBLY OPTI RAIL a 38 SECTION XII REAR CASE REASSEMBLY 41 REAR CASE HEASSEMBLY OPTI RAIL 45 SECTION XIII SHIFT TOWER REASSEMBLY 50 SECTION XIV TROUBLESHOOTING cece eee ee eee eeeeeeeeeeeeeeesseeeeeeaneeeeenes 51 Tech Support 1 800 401 9866 GENERAL INFORMATION Gear Ratios ES52 7B ES066 7B ES56 7B Ratio Ratio 8 99 6 10 09 7 5 98 4 3 72 2 2 56 1 1 81 1 1 35 1 1 00 Specifications Torque Capacity SIA NES Lube Capacity Speedometer Power Take Off PTO Speeds Tech Support 1 800 401 9866 90 34 00 074 SECTION General Application Guidelines On Highway Use ES56 7B ES52 7B ES066 7B GVW 50 000 Ibs 65 000 Ibs 66 HP Range 155 210 HP 185 250 HP 48 RPM Range 1 800
19. MBLY OPTI RAIL SECTION V 7 Remove the nut washer and end yoke or flange 9 Next remove the speedometer signal gear Tech Support 1 800 401 9866 17 10 Remove the countershaft bearing cap and shims Note Some models have a rear countershaft PTO option In this situation the countershaft will come out with the rear case when it is removed i E k NM P ER d d Es B k i 1 EI A mui Z Ki we i amp E L x A s i A LE a Es j s f b 4 e ar TSN kus i L E EN A D Kb m Pr 11 Using a puller in the milled slots remove the rear mainshaft bearing 12 Remove bolts from housing REAR CASE 93 e FATIALAIU DISASSEMBLY OPTI RAIL SECTION V 13 Next place pry bars in the slots provided in the rear case Break the seal 14 Then use a chain hoist to remove the rear housing 17 Notice that the 1st reverse shift fork support bracket also stays in the housing This bracket should not be removed unless it is broken and is going to be replaced 15 Using a plastic mallet tap the rear countershaft out of the 18 Tap the reverse idler shaft out of the housing rear of the case 18 Tech Support 1 800 401 9866 REARCASE 3 DISASSEMBLY OPTI RAIL SECTION V 19 Remove the reverse idler gear and bearings 20 Continue by removing the thrust washer reverse gear 23 Remove
20. MODELS ES52 7B ES56 7B ES066 7B 7 SPEED TRANSMISSION TRANSMISSION b TECHNOLOGIES Corporation Service Manual Bulletin No 2366 Revised August 2002 Technology in Motion TABLE OF CONTENTS SECTION GENERAL INFORMATION TION rp 1 TOBROUE a ml 67 1 EE 2 DIED LR Ce H e cc 9 SECTION MAINTENANCE Mr P 2 4 ues cidicse 5 SECTION Ill GENERAL DISASSEMBLY a 6 SECTION IV SHIFT TOWER DISASSEMBLY 8 SECTION V REAR CASE DISASSEMBLY REAR CASE EXPLODED DRAWING menm 9 REAR CASE GEARS EXPLODED DRAWING esee 10 REAR CASE DISASSEMBLY esses nennen nnne nennen nnns nnns 11 REAR CASE DISASSEMBLY OPTI RAIL a 16 SECTION VI MAIN CASE DISASSEMBLY MAIN CASE EXPLODED DRAWING cicius intera nent ait 21 CLUTCH HOUSING amp SHIFT FORKS EXPLODED DRAWING 22 MAIN CASE DIGAS E EE 23 MAIN CASE DISASSEMBLY TOF E E 26 SECTION VII MAINSHAFT DISASSEMBLY MAINSHAFT EXPLODED DRAWING E 29 Wee e THREE EE 30 SECTION VIII COUNTERSHAFT DISASSEMBLY amp REASSEMBLY 32 S
21. NTENANCE Lubrication peratures in this unit the proper lubricants must be used Correct oil levels must be main tained TTC recommends using only lubricants produced by reputable well known suppliers If you want to use a lubricant not specified below please contact your local truck dealer to determine whether the lubricant is suitable for your purposes Q To insure proper lubrication and operating tem Recommended Lubricants The lubricants listed below are recommended for use in all Spicer mechanical transmissions auxiliaries and transfer cases Oil Changes For off highway use TTC recommends that the oil be changed after the first 24 hours of service but before 100 hours of service have been completed Many factors influence the following oil change periods There fore a definite mileage interval is not specified here In general a drain and flush should be scheduled at 50 000 miles or one year intervals If synthetic oil is used a drain and flush should be scheduled at 500 000 miles or 5 year intervals Off highway uses usually require an oil change every 1 000 hours The oil level in the transmission should be checked every 5 000 Above O F 18 C SAE 30 or 40 Below 0 F 18 C SAE 30 Above O F 18 C SAE 90 Below 0 F 18 C SAE 80 All CD SAE 50 CD SAE 30 SECTION 11 miles 8045 km on highway or every 40 hours in off highway operation When it is necessary to add oil TTC recommends tha
22. TROUBLESHOOTING Noisy Operation Noise is usually a very elusive problem and is generally not the fault of the transmission Mechanics should road test the vehicle to determine if the driver s complaint of noise is actually in the transmission In numerous instances where drivers have insisted noise was coming from the transmission investigations revealed it was caused by one of the following conditions a Fan out of balance or blades bent h Loose or broken engine mounts b Defective vibration dampers c Crankshaft out of balance d Flywheel out of balance e Loose flywheel mounting bolts fr Rough engine idle producing rattle in gear train g Clutch assembly out of balance Power take off engaged Worn universal joints AC Driveshaft out of balance P om Universal joint angles out of phase or at excessive angles 3 Center bearings in driveline dry not mounted properly Wheels out of balance Tire treads humming or vibrating at certain speeds Gos Air leaks on suction side of induction system especially with turbo chargers Mechanics should try to locate and eliminate noise by means other than a transmission removal or an overhaul However if the noise appears to be in the transmission try to determine what position the gear shift lever is in when the noise occurs If the noise is evident in only one gear position the problem is ge
23. d Removing bearings is more difficult than installing them In most cases it is necessary to remove the bearing by pulling on the outer race which can damage the balls or races There fore itis a good idea to replace bearings during an overhaul to prevent problems However if a bearing is not going to be replaced avoid removal during low mileage rebuilds 54 SECTION XIV Interchangeability All ball bearings whether manufactured here or abroad are interchangeable in regard to standardized dimensions toler ances and fits However for a given shaft size there are standard bearings for light medium and heavy duty service Numbers and symbols stamped on inner and outer races of bearings designate size and type Note that the numbering systems of different bearing manufacturers have not been standardized Consult interchangeable tables and use the proper bearings for replacement parts Clutch Troubleshooting Faulty clutch operation interferes with proper shifting of gears in any transmissions The two following paragraphs describe the most common problems encountered with clutches a If the clutch slips or does not engage properly first check the internal clutch adjustment If adjustment does not remedy the situation check for weak pressure springs lack of free pedal and worn or oily clutch facings and binding release mechanism If the clutch drags or does not release properly check the internal clutch adjustm
24. d prevent proper lubrication to the unit Torque the cap capscrews to 25 41 ft Ibs 4 Use Moly 2 lubricant to coat the mainshaft splines Then install the rear mainshaft 5 If the trough was removed earlier check now to make sure there is proper clearance between it and 1st gear 3 Next install the bearing and 1st gear onto the rear mainshaft Also install the lock ball thrust washer and snap ring Tech Support 1 800 401 9866 6 Install the fork and 1st reverse shift collar When the shift bar won t drop further push in on the fork bars at the shift tower opening while pushing the fork bar bracket down This will aid alignment UID Zem m i L E P ker WT A 5 P r r Al D n si A m h w a A s ar ual 7 Secure the bracket with cap screws Torque the cap screws 10 The straight edge on the end of the idler shaft must be to 25 41 ft Ibs positioned as shown here Tap it into the case so the top portion of the shaft is flush with the case or not more than 030 below the case surface The lower portion of the idler shaft will extend about 1 4 above the case 8 Next install the caged bearing and reverse gear The gear 11 Coat the case sealing surface with purple Loctite 515 or hub should face the bearing Also install the thrust washer the equivalent Then install the rear case with the with the tapered side up A aid of a chain hoist Sec
25. ed on transmissions and auxiliaries require separate lubrication b No lubrication in or grease fittings on u joints or swivels of remote controls c Lack of lubricant or wrong lubricant used causing buildup of sticky varnish and sludge deposits on splines of shaft and gears d Badly worn or bent shift fork e Improper adjustment on shifter linkage f Sliding clutch gears tight on splines of shaft g Clutch teeth burred over chipped or badly mutilated because of improper shifting h Binding or interference of shift lever with other objects or rods inside the cab or near the remote control island i Clutch dragging j Free running gears seized or galled on either the thrust face or diameters Sticking in Gear a Clutch not releasing Also check remote units such as hydraulic or air assist Note On some units employ A ing a full air control for clutch release air pressure of approximately 60 lbs or more must be secured before the clutch can be released Do not leave these vehicles parked in gear Sliding clutch gears tight on splines Chips wedged between or under splines of shaft and gear d Improper adjustment excessive wear or lost motion in shifter linkage Tech Support 1 800 401 9866 SECTION XIV Bearing Failures The service life of most transmissions main and auxiliary is governed by the life of the bearings The majority of bearing failures can be a
26. em regardless of mileage Front Bearing Retainer amp Seal When installing the front bearing Q retainer and seal in the transmis sion use the red plastic sleeve to prevent serious damage to the oil seal Failure to use the seal sleeve will void the seal warranty Tech Support 1 800 401 9866 SECTION Ill End Yokes and Flanges Do not hammer on end yokes and flanges to remove or install them It is not only destructive to the yoke or the flange itself but can also cause serious internal damage Hammering destroys or mutilates the pilot diameters and warps or bends the flange Hammering on end yokes will close in the bearing bores or misalign yoke lugs This will result in early failures of journal needle bearings Serious damage can be done internally to bearings thrust faces and washers pilot bearings etc by hammering on external parts In most designs when the yoke flange locknuts are tightened and secure the internal bearings and gears are in proper location When the yoke flange is driven on the shaft however two conditions can exist a If the bearing fit is tight on the shaft usually the bear ings will brinell as they must absorb the pounding force b If the bearing fit is loose the shaft will keep moving inward until it is stopped by the internal parts such as the pilot bearing thrust washers Power Take Offs Refer to your owner s manual and installation procedures when installing any PTO on
27. ent Some other causes for clutch drag are an intermediate plate sticking on drive pins or drive lugs the pressure plate not retracting a distorted or warped driven disc worn splines on the main drive gear of the transmission a damaged clutch release bearing or the bushing in the release sleeve dragging on the trans mission drive gear Tech Support 1 800 401 9866 14700 Helm Court Plymouth MI 48170 800 401 9866 or 734 456 3770 ice Fax 734 456 3739 TECHNOLOGIES Corporation www ttcautomotive com k automotriz Group Company
28. kages and their adjustment must be made The remote unit must be in good working order if the transmis sion is expected to shift satisfactorily Many times the answer to the trouble is apparent when the unit is inspected prior to disassembly But this evidence is often lost when the parts are separated If possible check the unit prior to disassembly Bear in mind that a careful inspection of the unit should be made as each disassembly step is performed SECTION Inspect Thoroughly During Disassembly It is poor practice to disassemble a unit or the complete transmission as quickly as possible without examining the parts The mechanic may completely dissemble a unit and fail to find the cause of the trouble unless he examines the parts After the transmission is disassembled check the lubricant for foreign particles This is a source of trouble often overlooked during the disassembly Repair or Replace Worn Parts Many times the parts or critical adjustments causing the trouble are not replace or corrected because the mechanic only inspects and replaced parts that have failed completely All pieces should be carefully examined because broken parts are often just the result not the cause of the problem All parts that are broken or worn and no longer meet specifications should be replaced Also parts that are worn to the extent that they do not have a long service life remaining should be replace Replacing these parts now
29. m RPM of the shaft A whine or boom may be heard at this point Metallic rattles These noises within the transmission usually result from a variety of conditions Engine torsional vibrations are transmitted to the transmission through the clutch In heavy duty equipment clutch discs with vibration dampers are not used so a rattle particularly in neutral is common with diesel equip ment In general engine speeds should be 600 RPM or above to eliminate objectionable rattles and vibration during the idle A defective or faulty injector would cause a rough or lower idle speed and possibly a rattle in the transmission A rattle can also be caused by excessive backlash between the PTO input gear and the transmission output gear TROUBLESHOOTING Noise in Neutral Possible Causes Misalignment of transmission Worn flywheel pilot bearing O lt Worn or scored countershaft bearings Sprung or worn countershaft D Excessive backlash in gears Scuffed gear tooth contact surface H 7 Insufficient lubrication ES o EN ui 27 Use of incorrect grade of lubricant Noise in Gear Possible Causes a Rough chipped or tapered sliding gear teeth b Noisy speedometer gears Excessive end play of countershaft gears em tmm 0o O 2 Refer to conditions listed under Noise in Neutral Oil Leaks Possible Causes Oil level too high S
30. nerally traceable to the operating gears Next try to catego rize the noise into the following classifications a Growling humming and grinding These noises are caused by worn chipped rough or cracked gears As gears continue to wear the grinding noise will be noticeable particularly in the gear position that throws the greatest load on the worn gear A lack of lubricant or use of improper lubricant can also result in growling and grinding noises This is because there is insufficient lubricant to cool and cover the gears which allows metal to metal contact b Hissing thumping and bumping Hissing noises can be caused by bad bearings As bearing wear and retainers start to break up the noise could change to a thumping or bumping Tech Support 1 800 401 9866 54 SECTION XIV Gear whine This is usually caused by lack of backlash between mating gears Improper PTO shimming is the big offender here Vibration Today s improved highways mean entire power trains are cruising at higher RPMs These higher speeds mean damage caused by driveline vibration is more obvious than in the past When the maximum RPM of a shaft is reached it begins to bow A resonant hum can be heard and a vibration will be set up This type vibration can cause gear seizures broken synchronizer pins bearing failures brinelling and corrosion During acceleration and deceleration the shaft may pass through half critical vibration half the maximu
31. ng using the proper driver 16 Install the signal gear and the mainshaft bearing cap and to avoid bearing damage Also install the countershaft and the gasket Make sure the bearing cap oil passage lines up with the countershaft bearing race oil passage in the transmission housing 14 Coat the countershaft bearing cap with purple Loctite 515 17 Secure the bearing cap with cap screws Torque them 2 the equivalent Do not put sealant in the oil to 25 41 ft Ibs groove because it could prevent proper unit lubrication 15 Secure the cap with cap screws Torque them to 25 18 Remove the PTO cover and position a dial indicator as 41 ft lbs shown Use a pry bar to lift up on a gear End play should measure between 001 008 If end play is correct replace the PTO cap and torque the cap screws to 25 41 ft Ibs If end play is not correct add or subtract shims under the rear countershaft bearing cap Tech Support 1 800 401 9866 47 REASSEMBLY OPT RAL SECTION XII 19 Install the flange or yoke Secure with a nut Torque to 300 22 Check the alignment of the shift rails and shift rail channel 325 ft Ibs 20 Set the transmission in normal operational position 21 Install the backup light switch if it was removed earlier 24 Install cross slide between the shift rails making sure all 4 Torque it to 25 41 ft Ibs rails are aligned in neutral and the cross slide is sitting flat 48 Tech Support 1 800 40
32. nto place Tech Support 1 800 401 9866 SECTION XI 10 Oil the pocket bearing race then slide the mainshaft assembly into place It may be necessary to tip the counter shaft away from the mainshaft to do this Make sure the shift bars line up with the shift bar support in the case 11 Coat the clutch housing sealing surface with purple Loctite 515 or the equivalent Lower the case into place A with the help of a chain hoist Secure it with bolts Torque to 25 41 ft Ibs HEASSENBLY OPTI RAIL SECTION XI 1 Press the bearing into place and install snap ring Then 4 Install the oil baffle Then coat the drive gear bearing cap use a suitable press to push the oil ring into place A with purple Loctite 515 or the equivalent aligning the lubrica A brass hammer can also be used for this tion holes Torque the cap screws to 25 41 ft lbs procedure 2 Install the drive gear into the clutch housing 5 Place the clutch housing drive gear face down on the workbench and install front bar support secure with bolts and torque to 25 41 ft Ibs s A 3 Placea protective sleeve over the shaft before installing 6 Next lubricate then install the 6th 7th speed synchronizer the bearing cap See the warning on the inside of Shift it down toward the drive gear This will aid alignment this manual Also notice the position of the lubrica tion hole The bearing cap lubrication hole must be aligned with this housing lub
33. om neutral position Loose bell cranks sloppy ball and socket joints Shift rails cables etc too spongy or flexible or not secured properly at both ends Worn or loose engine mounts if forward unit is mounted to frame Forward remote mount too flimsy or loose on the frame Setscrews loose at remote control joints on shift forks inside remote Shift fork pads or groove sliding gear or collar worn excessively Transmission and engine out of alignment either vertically or horizontally A few items which could move the gear or shaft out of proper position particularly on rough roads are a b d e A Use of heavy shift lever extensions Broken shift rail poppet springs Worn shift rail poppet notches Bent or sprung shift rails Excessive end play in drive gear or countershaft caused by worn bearings or retainers Worn or missing thrust rings Tech Support 1 800 401 9866 TROUBLESHOOTING Hard Shifting An improperly operating clutch will interfere with the proper shifting of gears in any transmission It is also important that the hydraulic air or similar release mechanism is in proper working order If full and complete clutch release is being made the following could be a few of the possible causes for hard shifting complaints a No lubricant in remote control unit Note The forward remote is isolated and is often overlooked Many remote controls us
34. retaining bolts and rear shift bar support and the caged needle bearings 21 Remove retaining bolt from 1st reverse shift fork Remove 24 To remove 1st gear from the mainshaft first remove the 1st reverse shift fork and collar from output shaft snap ring Always wear safety glasses to protect A your eyes when servicing transmissions Tech Support 1 800 401 9866 19 REAR CASE p I A3 33 DISASSEMBLY OPTI RAIL SECTION V Y d FL Ta E T c ee 4 i A L Mie C a 25 Remove the thrust washer and lock ball next 28 Lock the transmission into two gears Remove the snap ring or mainshaft intermediate nut depending on which com ponent your unit contains If your unit contains the mainshaft intermediate nut the easiest way to remove it is to use the special socket pictured on the tool reference page E Tw GNE UN I I li t H 26 Remove 1st gear and the bearing from the shaft The 29 Use pry bars to remove the mainshaft and countershaft clutch gear is a part of the shaft 27 Continue by removing the two intermediate bearing caps The large oil trough connected to the housing doesn t have to be removed 20 Tech Support 1 800 401 9866 DISASSEMBLY SECTION VI Main Case Exploded Drawing INTERLOCK N Ll BACKUP LIGHT SWITCH 22 BREATHER SPRING POPPET PLUNGER POPPET INSERT N
35. rication hole 38 Tech Support 1 800 401 9866 MAIN CASE REASSEMBLY OPTI RAIL SECTION XI m 7 The countershaft is installed next Tilting the countershaft toward the mainshaft is the easiest way to do this Notice that there aren t any timing marks on the gears There is no need to time the countershaft to the mainshaft 8 Oil the pocket bearing race then slide the mainshaft assembly into place It may be necessary to tip the countershaft away from the mainshaft to do this 4 9 Lubricate the 2nd 3rd synchronizer with oil then slide it onto the shaft Continue by placing the caged needle bearing and 2nd speed gear hub toward synchronizer on the shaft Position the thrust washer on the shaft Tech Support 1 800 401 9866 10 Slide the 2nd 3rd shift fork onto the 2nd 3rd synchronizer The part 01 66 14 stamped on shift fork should be facing up Slide the 4th 5th shift fork onto the 4th 5th synchronizer The part 4101 66 17 stamped on shift fork should be facing down Slide the 6th 7th shift fork onto the 6th 7th synchronizer The part 4101 66 16 stamped on the shift fork should be facing up Overdrive Attach the 6th 7th shift fork assembly to the clutch housing torque bolts to 25 41 ft los On direct models slide 6th 7th shift fork onto synchronizer D 11 Install the rail channel from the top through the shift forks and down into the front bar support 12 Ga
36. shift fork mounting pin and snap ring 24 SECTION VI 10 If the overdrive shift fork clips or the direct dirve shift fork shoes are worn they must be removed and replaced 11 Next tip the clutch housing up Remove the four drive gear bearing cap capscrews 12 Use the milled slot to pry the bearing cap away fromt the housing Tech Support 1 800 401 9866 EE SECTION V 13 Remove the cap and oil baffle Then tap the drive gear out 14 Continue by removing the snap ring and oil ring Also of the clutch housing remove the bearing Countershaft Exploded Drawing 4th SPEED COUNTERSHAFT GEAR SPACER HEAD END COUNTERSHAFT DRIVE GEAR GEAR FOR ES52 7B 7th SPEED COUNTERSHAFT SNAP RING GEAR FOR ES066 7B lt gt BEARING Tech Support 1 800 401 9866 25 DISASSEMBLY OPTI RAIL SECTION VI 1 Remove case bolts 4 Remove rail channel from shift forks and front bar support 2 Begin main case disassembly by removing the housing 5 Remove 2nd 3rd shift fork 4th 5th shift fork Overdrive mod Use a chain hoist els remove shift fork assembly retaining bolts from clutch housing Direct models remove 6th 7th shift fork 3 Remove shift rails from rail channel 6 Remove 2nd speed gear assembly and 2nd 3rd synchronizer 26 Tech Support 1 800 401 9866 DISASSEMBLY OPTI RAIL SECTIONVI 7 Remove main shaft 10 Remove retaining bolts and front shift bar
37. support 8 Remove countershaft tilting the countershaft is the easiest 11 Next tip the clutch housing up Remove the four drive gear way to do this bearing cap capscrews 9 Remove 6th 7th synchronizer 12 Use the milled slot to pry the bearing cap away from the housing Tech Support 1 800 401 9866 27 DISASSEMBLY OPTI RAIL SECTION VI 13 Remove the cap and oil baffle Then tap the drive gear out 14 Continue by removing the snap ring and oil ring Also of the clutch housing remove the bearing Countershaft Exploded Drawing 4th SPEED COUNTERSHAFT GEAR HEAD END COUNTERSHAFT DRIVE GEAR GEAR FOR ES52 7B 7th SPEED COUNTERSHAFT SNAP RING GEAR FOR 5066 7 lt gt Gu Tech Support 1 800 401 9866 DISASSEMBLY SECTION VII Mainshaft Exploded Drawing 5th SPEED MAINSHAFT GEAR NEEDLE BEARING THRUST WASHER SNAP RING eth SPEED MAINSHAFT GEAR NEEDLE BEARING BALL IF SNAP RING PRESENT I 3rd SPEED MAINSHAFT GEAR SPANNER NUT OR SNAP RING THRUST WASHER Z IF SPANNER NUT OR PRESENT AL THRUST WASHER IF SNAP RING PRESENT NEEDLE BEARING 2nd and 3rd MAINSHAFT SYNCHRONIZER Tech Support 1 800 401 9866 29 BE SECTION VII 1 Place the shaft in a vise with protective jaws or a holding 4 Next remove the overdrive gear in an overdrive unit or 6th fixture speed gear in a direct drive unit There are two caged needle bearings in the gear
38. t of the shaft ring or mainshaft intermediate nut depending on which com ponent your unit contains If your unit contains the mainshaft intermediate nut the easiest way to remove it is to use the special socket pictured on the tool reference page 26 Continue by removing the two intermediate bearing caps 28 Use pry bars to remove the mainshaft and countershaft The large oil trough connected to the housing doesn t have to bearings be removed Tech Support 1 800 401 9866 15 DISASSEMBLY OPT RAL SECTION V 1 After removing the transmission from the vehicle drain the 4 The backup light switch can be removed if it is going to be oil Let the unit cool down first Otherwise hot replaced Otherwise it does not have to be removed during transmission fluid could cause burns servicing 2 Remove the interlock retaining drive screws Next remove 5 If the driver has experienced shifting problems check the the gaskets and interlock retainer plate crossgate plunger and spring at this time Replace them if they are worn or damaged If no problems have occurred it is not necessary to remove the plunger 3 Remove the detent springs and detent balls 6 Attach a bracket or lift hooks to the rear case Secure with bolts which are at least hand tightened Lift A the transmission with a hoist and set it on end on a workbench that contains a hole for the drive gear 16 Tech Support 1 800 401 9866 REAR CASE DISASSE
39. t types and brands of oil not be mixed The correct oil level in this transmission is established by the filler plug opening Refill First remove all dirt around the filler plug Then refill the transmission with now oil Use the grade recommended for the existing season and prevailing service The lubricant should be level with the oil fill plug located on the right side of the transmission case Overfilling Do not overfill the transmission This usually results in oil breakdown due to excessive heat and aeration form the churning action of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on splines and bearings Heavy duty engine oil meeting MIL L 2104 D or MIL L 46152 B API SF or API CD MIL L 2104 B amp C or 46152 are also acceptable Straight mineral gear oil R amp O type API GL 1 Synthetic engine oil meeting MIL L 2104 D or MIL L 46152 B API SF or API CD Do not use extreme pressure additive such as those found in multi purpose or rear axle type lubricants These additives are not required for this unit and my in some cases create transmission problems Multi purpose oils as a group have relatively poor oxidation stability a high rate of sludge formation and a greater tendency to react on or corrode the bronze parts in this transmission Tech Support 1 800 401 9866 MAINTENANCE SECTION Tool Reference M rai
40. the vehicle road conditions and type of service When 2nd gear is desired declutch and move the shift lever toward that gear The synchronizer will pick up 2nd gear and synchronize its speed to the mainshaft speed When synchro nized the lever moves easily into 2nd gear Continue in the same manner to top road speed Notice that as you approach top road speed you must accelerate close to the governed speed before allowing the engine to drop to the next gear shift point This is because air resistance at higher speeds requires more of the available horsepower to get adequate performance Maximum performance and horse power are achieved at governed speed Downshifting To begin downshifting form top gear declutch and move the shift lever steadily toward 6th gear and speed it up to the vehicle speed This will allow a clash free shift from 7th to 6th gear After the shift reengage the clutch while accelerating the engine to keep the vehicle moving at the desired speed If further downshifts are required continue in a similar manner Remember that 1st gear isn t synchronized Therefore shift ing into gear will require a double clutch operation to complete a clash free shift Towing Do not tow vehicles without first pulling the axles 2 or disconnecting the driveshaft If you tow the vehicle without doing this you can damage drive train components because the system lubrication is inad equate when the vehicle is towed MAI
41. ther all 4 shift rails and put them in order from left to right 1st reverse 2nd 8rd 4th 5th and 6th 7th REASSEMBLY OPTI RAIL SECTION XI 14 Coat the clutch housing sealing surface with purple Loctite the rail channel When properly installed in the rail channel the tabs on 215 or equivalent Lower the case into place with the bottom ofthe shift rails will line up with the appropriate shift fork Also the help of a chain hoist Secure it with bolts there are indentations on rails 2 3 4 5 and 6 7 If the rails are installed Torque to 25 41 ft Ibs properly the indentations will descend from left to right After insuring proper installation temporarily secure shift rails with a zip tie 13 Slide the shift rails into the front bar support and in place between 40 Tech Support 1 800 401 9866 REAR CASE REASSEMBLY SECTION XII 1 Install the snap rings on the intermediate bearings Lock the transmission into two gears If the unit is to be secured by A a snap ring lift up on 4th gear to expose the snap ring groove Install the snap ring If the unit is secured with a nut install the nut on the mainshaft using the special socket listed in the tool reference Torque the nut to 300 325 ft Ibs 2 Install the intermediate bearing caps The mainshaft bearing cap has a groove that lines up wtih the lubrication hole in the 2 housing Do not use gaskets or sealing compounds on either cap because it coul
42. ts Only 1st and reverse gears aren t synchronized To shift the driver depresses the clutch and moves the lever toward the desired gear When the synchronizer ring makes contact with the desired gear blockers automatically prevent the shift collar from completing the shift until the gear and mainshaft speeds are matched When the speeds are matched the synchronizer allows the shift to be completed without clashing Steady pressure on the shift lever helps the synchronizer do its job When speeds are synchronized the lever moves into gear smoothly and easily If the driver jabs or teases the synchronizer the synchronizer can t do its job It is possible to override a blocker if the lever is forced into gear However this defeats the purpose of the synchronizer and can shorten the life of the transmission Driver Instructions Upshifting To drive a vehicle containing this transmission first depress the clutch and wait for complete release Next move the shift lever into 1st gear and engage the clutch Accelerate to an RPM that will allow enough momentum to select the next higher gear and still have vehicle acceleration after complet ing the shift into 2nd gear This is known as the progressive shift technique Using this shift technique saves fuel There is usually no reason to go all the way to the governor before you shift to Tech Support 1 800 401 9866 SECTION I 2nd gear This method can vary depending on the GVW of
43. ttributed to vibration and dirt Some other prominent reasons for unit bearing failures are a Fatigue of raceways or balls b Wrong type or grade of lubricant c Lack of lubricant d Broken retainers brinelled races and fretting caused by vibration e Bearings set up too tight or too loose 7 Improper installation resulting in brinelled bearings Improper fit of shafts or bore h Acid etching due to water in lube 2 EE omm EE enn oi Em Vehicle overload or too large an engine for the transmission resulting in overload Dirt More than 90 ol all ball bearing failures are caused by dirt which is always abrasive Dirt may enter the bearings during assembly of units or may be carried into the bearing by the lubricant while in service Dirt also may enter bearings through seals the breather or even dirty containers used for addition or change of lubricant Softer material such as dirt or dust usually forms abrasive paste of lapping compounds within the bearings The pres sure between the balls and raceways makes a perfect pulver izer the rolling motion tends to entrap and hold the abrasives As the balls and raceways wear the bearings become noisy The lapping action tends to increase rapidly as the fine steel from the balls and rollway adds to the lapping material Hard coarse material such as metal chips may enter the bearings during assembly from tools such as hammers drifts
44. ure with capscrews Torque them to 25 41 ft lbs If a new 1st reverse shift bar support was installed in the rear case make sure the 1st reverse bar is shifting properly 9 Assemble the bearings and gear onto the idler shaft and 12 Next install the rear mainshaft bearing using the proper driver install the assembly Make sure the bearings are packed with Moly to avoid bearing damage Also install the countershaft 2 lubricant and the countershaft bearing race 42 Tech Support 1 800 401 9866 13 Coat the countershaft bearing cap with purple Loctite 515 16 Secure the bearing cap with cap screws Torque them or the equivalent Do not put sealant in the oil to 25 41 ft Ibs groove because it could prevent proper unit lubri cation 14 Secure the cap with cap screws Torque them to 25 17 Remove the PTO cover and position a dial indicator as 41 ft Ibs shown Use a pry bar to lift up on a gear End play should measure between 001 008 If end play is correct replace the PTO cap and torque the cap screws to 25 41 ft lbs If end play is not correct add or subtract shims under the rear countershaft bearing cap 15 Install the signal gear and the mainshaft bearing cap and 18 Install the flange or yoke Secure with a nut Torque to 300 gasket Make sure the bearing cap oil passage lines up with the 325 ft Ibs oil passage in the transmission housing Tech Support 1 800 401 9866 43 REAR CASE REASSEM
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