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SPEC FLYER -CEMT18 (AUG92).

1. Manual Forward Speeds Multi Mesh Gearing x 100 Nominal Torque Capacity D Torque Converter IMPORTANT All Fuller Transmissions are identified by model and serial number This information is stamped on the transmission identification tag and affixed to the case DO NOT REMOVE OR DESTROY THE TRANSMISSION IDENTIFICATION TAG 18 Speed Transmission On Off Highway Relative Speed 3 Gear Ratios PTO Gear Oil Cap To Input R P M Pints is es ra ah 55 om 75 86 Reverse Piom Boom ttes amose 18 in fiano 734 826 378 2 0 194 39 Loolesona rit 696 596 55 Gu RTLO 1118 4858 CHART NOTES 1 Lengths measured from face of converter housing to front bottoming surface of companion flange or yoke 2 Weight Listed weights are with torque converter and include standard controls Weight of standard controls is approximately 10 lbs 4 5 kg All weights are approximate 3 Oil Capacities are approximate depending on inclination of engine and transmission Always fill transmission with proper grade and type of lubricant to level of filler opening See LUBRICATION Proper Lubrication the Key to long transmission life Proper lubrication procedures are the key to a good all around maintenance program If the oil is not doing its job or if the oil level is ignored all the maintenance procedures in the world are not going to keep the transmission running or assure
2. REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING H Removal of Hydraulic Pressure Valves 3 The filter by pass valve is located inside the hydraulic 1 The pressure relief valve is located in the torque Vili We be NE housi il i p CONVENE AEUR Ds PAPSUND ales SERVICABLE and replacement is required 2 To service the pressure relief valve reach into the oil filter mounting adapter and remove the valve The valve is NON SERVICEABLE Replacement is required DISASSEMBLY AUXILIARY SECTION SPLITTER CYLINDER ASSEMBLY CYLINDER COVER CAPSCREW GASKET SHIFT YOKE i SPLITTER CYLINDER 0 N a AND PISTON GASKET UG N E i INSERT VALVE v P v O RING QUA WA SEARG YOKE BAR l LOCKSCREW Note Use lock wire at this position Cut 6441 3 87 A Removal and Disassembly Rear Auxiliary Drive Gear and Yoke 1 Cut the lockwire on the splitter yoke retaining bolt and 2 Remove the retaining bolt splitter yoke and sliding loosen the bolt clutch assembly from the auxiliary section DISASSEMBLY AUXILIARY SECTION AUXILIARY MAINSHAFT ASSEMBLY SYNCHRONIZER LO SYNCHRONIZER HI ROLL PIN CAPSCREW SLIDING CLUTCH SPRING SLIDING REAR AUXILIARY CLUTCH DRIVE GEAR Cut 6593 L 4 87 3 Temporarily install an output yoke on the output shaft 4 Break loose the 15 16N retaining capscrew on the front and secure it by placing a bar through the
3. TOOL REFERENCE 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 But 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 all that is needed to successfully disassemble and reassemble any Fuller Transmission The specialized tools listed below can be obtained from a tool supplier or made from dimensions as required by the individual user Detailed Fuller Transmission Tool Prints are available upon request by writing Eaton Corporation Transmission Dept Technical Service Dept P O Box 4013 Kalamazoo Michigan 49003 PAGE TOOL HOW OBTAINED 45 Countershaft Retaining Strap Made M a ECCO 45 Auxiliary Section Hanger Bracket Made ides d x 55 Jaw Puller and Bearing Separator Tool Supplier 72 Snap Ring Pliers Tool Supplier 75 Impact Puller 1 2 13 Threaded End Tool Supplier 91 Countershaft Support Tool Made from Fuller Transmission Print T 22247 109 Torque Wrench 1000 Lbs Ft Capacity Tool Supplier Lubrication Change Procedure Draining Oil Drain transmission while oil is warm To drain oil remove the two 2 drain plugs at the case bottom and oil pan Clean the drain plugs and flush cooler circuit before re installing
4. NOTE If equipped with a shift lever the gear shift lever housing assembly can now be removed from shift bar housing by removing the four capscrews from the tower NOTE The Roadranger valve mounted in the cab can De emoved AS SNOWN 5 Loosen the jam nut and turn the valve and nut from gear shift lever Remove the valve cover air lines sheathing and O rings from lever DISASSEMBLY SHIFTING CONTROLS B Removal of Air Filter Regulator Assembly 6 Remove retaining capscrews on the shift bar housing which hold wiring harness clamps left Disconnect input speed sensor and engine speed sensor at wiring harness connectors right Tdrn out the two capscrews and remove the air filter regulator assembly 7 Disconnect the 1 4 air hose at the inertia brake solenoid also disconnect the remaining air hose to the splitter NOTE For disassembly and reassembly of Air Filter cylinder left Remove the air hose at the inertia brake Regulator Assembly see Page 26 housing also disconnect the hydraulic valve wiring harness connector right T amp n out the four retaining capscrews and remove slave 8 Remove the wiring harness and inertia brake air hose m valve from transmission case from the transmission DISASSEMBLY SHIFTING CONTROLS 3 If necessary remove the air line fittings from slave valve NOTE For disassembly and reassembly of piston type Slave Valve Assembly see Page 26 DISASSEMBLY
5. tate reassembly Keep the internal splined washers and external splined spacers with the gear from which they were removed There is ONLY one limit washer and one spacer belonging to each gear 6 Remove the LO Reverse speed sliding clutch from mainshaft DISASSEMBLY FRONT SECTION 8 Remove each remaining gear limit washer spacer and sliding clutch from mainshaft in the same 7 Using a small screwdriver turn the limit washer in hub of LO speed gear to align its splines with those of the mainshaft Pull the LO speed gear manner previously detailed And if necessary re from rear of mainshaft to remove limit washer move the snap ring from I D of each gear spacer and gear If necessary remove the snap ring from I D of gear inset DISASSEMBLY FRONT SECTION INPUT SHAFT DRIVE GEAR Cut 5390B 10 88 E Input Shaft Removal 2 Use a soft mallet to drive the input shaft toward the rear of the transmission Pull the shaft forward and repeat as necessary 1 Remove the input bearing snap ring from shaft DISASSEMBLY FRONT SECTION 3 Use pry bars to complete the input shaft bearing removal left Remove spacer from input shaft right 5 Inspect the input shaft bushing for wear and replace if necessary 6 The main drive gear can be removed from the case this time 4 Push input shaft through the drive gear and remove the input shaft from case NOTE
6. 4 SHIFT LEVEF 5 8 18 Threads Use Lockwashers HOUSING CAPSCREWS 35 45 Lbs Ft 3 8 1 4 SLAVE AIR VALVE CAPSCREWS Threads Apply Loctite 242 to Threads 8 12 Lbs Ft 1 4 20 Threads Apply Loctite 242 to Threads 1 REVERSE SIGNAL SWITCH PLUG 35 5C Lbs Ft 9 16 18 Threads ai 2 SUPPORT STUD NUTS 170 185 Lbs s Ft 5 8 18 Threads Use Lockwashers Prim is N O SAC ok EN O Ovid lt e o ia 1 ay SA E d UL FHEEEEEELE TEE ELE HELL BLA LLLI 1 OIL DRAIN PLUG 45 55 Lbs Ft 3 4 Pipe Threads 6 MAINSHAFT REAR BEARING RETAINER CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Secure with Lockwire 2 REVERSE IDLER SHAFT NUTS 50 60 8 LARGE P T O COVER CAPSCREWS 50 65 Lbs Ft 5 8 18 Threads Lbs Ft 7 16 14 Threads Apply Loctite 242 to 6 SMALL P T O COVER CAPSCREWS 35 45 Threads Lbs Ft 3 8 16 Threads Apply Locite 242 to 2 COUNTERSHAFT FRONT BEARING RETAINER Threads CAPSCREWS 90 120 Lbs Ft 5 8 Threads 3 OIL FILTER HOUSING CAPSCREWS Lbs Ft 4 TORQUE CONVERTER HOUSING CAPSCREWS 70 3 8 16 Threads 75 Lbs Ft 1 2 13 Threads Use Lockwashers 20 OIL PAN RETAINING CAPSCREWS TORQUE RECOMMENDATIONS AUXILIARY SECTIONS 2 AIR FILTER REGULATOR MOUNTING APSCREWS 8 12 Lbs Ft 1 4 20 Threads pply Loctite 242 to Threads 1 RANGE CYL
7. FRONT SECTION 3 Using inside jaw pullers or impact puller remove the 5 Remove the pipe plug from rear of idler shaft and use auxiliary countershaft front bearing race from left an impact puller 1 2 13 threaded end to remove shaft reverse idler gear bore If necessary repeat the from case bore inset procedure for removing the auxiliary countershaft front bearing race from right reverse idler gear bore P i eA igen i 6 As the idler shaft and idler plate are moved to the rear 4 Loosen the nut on the idler shaft inset Remove the remove the thrust washer and gear from case If nec stop nut and washer from front of idler shaft essary remove the inner race from bearing and remove needle bearing from idler gear DISASSEMBLY FRONT SECTION C Removal of Countershaft Bearings NOTE In the following instructions the front and rear bearings from BOTH countershafts are removed For removal of the mainshaft assembly from case it is necessary to remove the bearings from right countershaft ONLY 3 Loosen and remove capscrew from retaining plate on upper countershaft front 4 Use a soft bar and maul to drive each countershaft to the rear as far as possible This partially unseats the front bearings NOTE The soft bar should have a flattened end that is large enough so damage to the countershaft end does not occur 2 From inside the case use a soft bar and maul to drive the coun
8. If the transmission fails to shift or shifts too slowly to or from the split position the fault may be in the Splitter Shift Air System or related components of the Range Shift Air System To locate the trouble the following checks should be made with normal vehicle air pressure supplied to the system but with the engine off NEVER WORK UNDER A VEHICLE A WARNING WHILE ENGINE IS RUNNING as personal injury may result from the sudden and unin tended movement of vehicle under power Always place transmission in the neutral position NOTE It is assumed that correct PSI readings were obtained from the air filter regulator and all air lines have been checked for leaks 1 Air Supply See Air System Schematics With the gear shift lever in neutral select HI or LO RANGE and loosen the connection at the S Port of the Roadranger Valve until it can be deter mined that AIR is supplied to valve Reconnect air line If there is NO AIR check for a restriction in the air line between the Roadranger valve and slave valve Make sure this line is connected to fitting at the supply Port of slave valve 2 Roadranger Valve See Page 27 and Air System Schematics With the gear shift lever in neutral disconnect the air line at the Left Port of splitter cylinder cover making sure this line leads from the SP Port of the Roadranger Valve A WHILE IN HI or LO RANGE move the Splitter Control Button FORWARD There should be AIR flowing
9. Refilling The operational level should always be within the appropriate temperature bands on the dipstick The exact amount of oil depends on the transmission inclination and model Insufficient oil damages the pump and other components and can affect the function and reduce the life of the transmission DO NOT OVERFILL This causes overheating and loss of fuel economy When adding oil types and brands of oil should not be mixed because of possible incompatibility Use clean oil and clean containers when filling transmission Containers that have been used for anti freeze or water should not be used for transmission oil 1 Remove the dipstick and slowly add seven 7 gallons of the prescribed oil through the fill tube 2 Place the transmission in neutral position and apply the parking brakes Start the engine and let it idle for five 5 minutes this allows oil to fill the converter main case and cooling system add oil as needed to obtain a level at the proper temperature range Total oil quantity needed at this time should be approximately 10 gallons this varies depending on the cooling system 3 Increase the engine idle slowly to 1500 RPM for five 5 minutes Now recheck the oil level at normal idle speed in neutral again adding oil to obtain a level at the proper temperature range 4 Replace the dipstick and tighten securely Hydraulic System Flush Procedure A complete hydraulic circuit flush should be completed when efir
10. The input shaft is a NON SERVICABLE assembly excluding the sealing rings and should be replaced if damaged NOTE Input shaft can be serviced without removing the main shaft Remove the snap ring and input shaft bearing remove the internal snap ring from the drive gear and remove the input shaft DISASSEMBLY FRONT SECTION COUNTER SHAFT KEY BEARING ASSEMBLY COUNTERSHAFT PTO GEAR RETAINER COUNTERSHAFT DRIVE GEAR CAPSCREW Cut 6346L 3 87 BEARING F Removal and Disassembly of Countershaft Assemblies NOTE Except for the PTO gears the left and right countershaft assemblies are identical and disas sembled in the same manner 1 Move the right countershaft assembly to the rear as far as possible so front of shaft can be removed from Case 2 Remove the drive gear retaining snap ring from front of bore and moved to the center of the case Lift the Bach countershatt assembly from case and repeat the procedure for left countershaft assembly NOTE The left and right reverse idler gear assemblies are identical and disassembled in the same manner If removal and disassembly of this assembly is neces sary refer to Part B of this section DISASSEMBLY FRONT SECTION 3 Use the rear face of 3rd speed gear as a base press the drive gear PTO gear and 3rd speed gear from each countershaft This removes the front bearing inner race from the countershaft IMPORTANT NEVER USE THE PTO GEAR AS A PRESSING
11. between the slave valve and range cylinder the transmission gearing will not correspond with the range se lection A LO RANGE selection will result in a HI RANGE engagement and vice versa 2 AIR LEAKS With the gear shift lever in neutral coat all air lines and fittings with soapy water and check for leaks moving the control that provides range se lection UP and DOWN A f there is a steady leak from the exhaust port of control valve O rings and or related parts of the control valve are defective B If there is a steady leak from breather of slave valve an O ring in valve is defective or there is a leak past O rings of range cylinder piston C If transmission fails to shift into LO RANGE or is slow to make the range shift and the case is pressurized see Check No 7 of this section D Tighten all loose connections and replace de fective O rings and parts 3 AIR FILTER REGULATOR See illustration Page 26 With the gear shift lever in neutral check the breather of air filter regulator assembly There should be NO AIR leaking from this port The complete assembly should be replaced if a steady leak is found Cut off the vehicle air supply to the air filter regulator assembly disconnect the air line at fit ting in Supply OUTLET and install an air gage in opened port Bring the vehicle air pressure to nor mal Regulated air pressure should be 57 5 to 62 5 Psi DO NOT ADJUST SCREW AT BOTTOM OF REGU LATOR TO O
12. from disconnected line Move the button REARWARD to shut off air flow and re connect air line B If the preceding conditions do not exist the Roadranger valve is defective or there is a re striction in the air lines 3 Splitter Cylinder Refer to the following illustra tion If any of the seals in the splitter cylinder as sembly are defective the splitter shift will be af fected The degree of air lost will govern the degree of failure from slow shifting to complete shift failure A Leak at O ring A results in a slow shift to engage rear auxiliary drive gear pressurizing of transmission case auxiliary gearing can be dis engaged AIR SYSTEM B Leak at O ring B results in slow shifting or 4 Insert Valve See Page 30 complete failure to engage and disengage Any constant flow of air from exhaust port of cyl front or rear auxiliary drive gearing steady inder cover usually indicates a faulty insert valve flow of air from exhaust port of Roadranger Exhaust should occur ONLY BRIEFLY when Split valve and or cylinder cover when Splitter Con ter Control Button is moved REARWARD WHILE trol Button is in the REARWARD position IN LO and HI RANGE C Leak at gasket C results in a slow shift to dis A faulty insert valve leaking at the O rings of engage rear auxiliary drive gear steady flow valve O D or from inner seals results in constant of air to atmosphere air leak and shift failure Two indications of defec tiv
13. hois to the output shaft NOTE The front box sliding clutches must be in the neutral position 4 Remove the countershaft straps Make sure a 0 125 countershaft rear bearing shim is installed Be sure the countershaft rear bearing races are seated in the bear ing bores 2 With the transmission set in the vertical position block under the torque converter housing to prevent damage to the torque converter position the new gasket on the transmission case Lower the auxiliary assembly on the front case rear IMPORTANT Shift the reduction sliding clutch into deep reduction before installing the auxiliary L 5 Install two clean 3 8 x 1 capscrews without washers directly across from each other in each bearing cover Tapped holes in auxiliary case must be free of thread adhesive 3 Install the retaining capscrews in the housing flange and tighten to the recommended torque INSTALLATION CLUTCH HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE b 8 Remove the countershaft rear bearing covers and gauging shims 6 Tighten the capscrews to 7 in Ibs of torque DO NOT INSTALL THE COUNTERSHAFT REAR BEARING COVER GASKET 9 After the correct shim has been selected place the 7 Rotate the output shaft six times in the clockswise direc shim on the rear countershaft bearing race install the tion then six times counterclockwise to seat the coun countershaft rear bearing cov
14. simplify reassembly and reduce the possibility of losing parts SNAP RINGS Remove snap rings with pliers de signed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose INPUT SHAFT The input shaft can be removed from transmission without removing the coun Inspection tershafts mainshaft or main drive gear Special procedures are required and provided in this man ual CLEANLINESS 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 good practice to clean the outside of the unit before starting the planned disassembly WHEN USING TOOLS TO MOVE PARTS Always apply force to shafts housings etc with restraint Movement of some parts is restricted Never apply force to the part being driven after it stops solidly The use of soft hammers bars and mauls for all disassembly work is recommended Before reassembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Fuller Transmission parts to assure continued performance 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 reus ing a questionable part which could lead to additional repairs and expe
15. stamped with an O for easy identification A highly visible color of toolmakers dye is recommended for making timing marks 1 Place the left countershaft assembly into position in case making sure that the L marked assembly has the larger 47 tooth PTO gear Place the right counter shaft assembly into position in case making sure that the R marked assembly has the smaller 45 tooth PTO gear REASSEMBLY FRONT SECTION F Bearing Installation of Left Countershaft Assembly 1 Move the left countershaft assembly to the rear 3 Center the front of left countershaft in bearing and and insert countershaft support tool or blocking move the assembly forward to center shaft in rear case bore 2 Use a flanged end bearing driver to start the 4 Use a flanged end bearing driver to completely bearing in case bore seat front bearing or bearing outer race in case bore NOTE The inner race of roller type front bearing is pressed on front of countershaft REASSEMBLY FRONT SECTION F Reassembly Installation and Timing of Main Drive Gear Assembly 5 Position the retainer plate on front of left countershaft 1 Install the snap ring in I D of main drive gear roll pin in hole at end of shaft and secure with capscrew tightening to recommended torque 6 Remove countershaft support tool or blocking 2 Mark the main drive gear for timing purposes from rear case bore and install the left counter Mark any two adj
16. the output shaft to driveline as HI RANGE 5th gear Mud Te d 58 POWER FLOW Auxiliary Section Power Flow HI RANGE OVERDRIVE 7 The front auxiliary drive gear splits torque between the 9 Torque is transferred to output shaft through the sliding two auxiliary countershaft drive gears clutch 8 Torque is delivered along both auxiliary countershaft 10 Output shaft delivers torque to driveline as HI Range to mating countershaft gears of engaged rear auxiliary 5th gear OVERDRIVE drive gear HI RANGE OVERDRIVE TIMING Timing Procedures All Models It is essential that both countershaft assemblies of the front and auxiliary sections are timed This as sures proper tooth contact is made between main shaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that distribute the load evenly If not properly timed serious damage to the transmission is likely to result from unequal tooth contact causing the mainshaft gears to climb out of equilibrium Timing is a simple procedure of marking the appro priate teeth of a gear set prior to installation and placing them in proper mesh while in the transmis sion In the front section it is necessary to time only the drive gear set And depending on the model only the LO range deep reduction or splitter gear set is timed in the auxiliary section Front Section A Marking countershaft drive gear teeth 1 Prior
17. three sets of ten sion springs and balls from the housing bores DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING k b 3 Secure the assembly in a vise with the plunger 5 Move the 1st 2nd speed shift bar to the housing side up The front of the housing will be to the rear removing the yoke and block from the bar As left For models so equipped cut the lockwire the neutral notch in the bar clears the rear boss and turn out the retaining capscrews to remove remove the small interlock pin from the bore the oil trough from the housing NOTE Start with the upper shift bar move all bars to the right and out the rear boss bore Cut the lockwire and remove the lockscrews from each bar just before their removal EJ 4 Move the 3rd 4th speed shift bar to the housing 6 Remove the actuating plunger from the center rear removing the yoke and block from the bar boss bore DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING B Reassembly of the Shift Bar Housing Assembly 7 Move the short LO Reverse speed shift bar to the 1 housing rear remove the yoke from the bar As the shift bar is removed from the housing two 3 4 in terlock balls will drop from the rear boss bottom bore If previously removed install the reverse stop plunger in the LO Reverse shift yoke making sure the plunger is fully seated in the yoke slot bore 8 If necessary remove the plug spring and reverse stop pl
18. to placing each countershaft assembly into case clearly mark the tooth located directly over the keyway of drive gear as shown This tooth is stamped with an O to aid identification Tooth on Countershaft directly over Keyway marked for timing Cut 7300 H11 86 B Marking main drive gear teeth 1 Mark any two adjacent teeth on the main drive gear 2 Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear As shown below there should be an equal number of unmarked gear teeth on each side between the marked sets Dive gear teeth correct y marked for timing Cut 7300G 11 86 C Meshing marked countershaft drive gear teeth with marked main drive gear teeth After placing the mainshaft assembly into case the countershaft bearings are installed to com plete installation of the countershaft assemblies 1 When installing the bearings on left counter shaft mesh the marked tooth of countershaft drive gear with either set or two marked teeth on the main drive gear 2 Repeat the procedure when installing the bearings on right countershaft making use of the remaining set of two marked teeth on the main drive gear to time assembly Countershaft gear teeth meshed with drive gear teeth for correct timing Cut 7300 F 1 1 86 Auxiliary Section A Timing the auxiliary countershaft and LO range gear 1 Mark any two adjacent teeth on the LO range gear of set to be time
19. verse gear limit washer on mainshaft flat side of washer up Rotate washer in the 5th groove of mainshaft to align the splines of washer with those of the mainshaft and reinsert key in key way to lock washer in place 19 Install the spacer on shaft against washer 20 Install reverse gear on mainshaft Engage the clutching teeth of gear with splines of spacer and sliding clutch and move the reverse gear against the LO speed gear NOTE DO NOT REPLACE REVERSE GEAR IN TERNAL SNAP RING AT THIS STEP 21 Remove the mainshaft assembly from vise Align the missing internal spline of 3rd 4th speed slid ing clutch with key in mainshaft and install on front of shaft engaging the external splines of sliding clutch with clutching teeth of 3rd speed gear REASSEMBLY FRONT SECTIO rt l CUD AT 1 TULLE l wm p ff ua mu ddr m LJ gt mr a oo m 22 Block the right countershaft assembly against case wall and lower the mainshaft assembly into position with the reverse gear held against LO speed gear and rear of shaft moved into case bore l TIL fl mi j y Iu ill iL ILE IH i ULL HDI ral E ALLTEL 24 With the reverse gear remaining against LO speed gear mesh the corresponding forward speed gears of left countershaft assembly Check to make sure that marked t
20. yoke of the output shaft DISASSEMBLY AUXILIARY SECTION AUXILIARY COUNTERSHAFT ASSEMBLY BEARING BEARING SPACER COUNTERSHAFT ASSEMBLY Cut 6503M 11 91 B Removal of the Auxiliary Countershaft Assemblies 1 Secure the auxiliary housing in a vise Remove the auxiliary countershaft retaining straps or rear bearing covers shim and rear bearing race Th haft will fall in th A WARNING e countershaft will fall loose in the auxiliary section but will not fall out of auxiliary section 2 Use a soft bar and maul to partially drive the output shaft forward DISASSEMBLY AUXILIARY SECTION C Removal Rear Auxiliary Drive Gear Assembly 3 Remove the auxiliary countershaft from the auxiliary section case 1 Remove the 15 16 retaining capscrew retainer and auxiliary drive gear from the auxiliary section 4 If necessary secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing separator and jaw pullers DISASSEMBLY AUXILIARY SECTION RANGE CYLINDER ASSEMBLY CAPSCREW CAPSCREW AUXILIARY CYLINDER EON ha LOCK SCREW TOREBAR Note Use lockwire at Cut 6427 5 83 this position D Removal and Disassembly of Range Cylinder Assembly 1 Remove the capscrews range cylinder cover and 9 Remove nut from yoke bar gasket DISASSEMBLY AUXILIARY SECTION 3 Cut the lockwire
21. 00 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly LO Air from Vehicle Source Air to Cover Port HI RTO 15618 and RTLO XX618 Models HI Range H A 5013 Roadranger Valve Slave Valve Identification Up E n T A 5000 Valve o HG oO J leno lo Ot O o 19470 Valve OLH 1 lop a 19470 or A 5000 Slave Valve THIELE For all questions concerning removal and Air Filter Regulator Splitter Cylinder Range Cylinder Assembly replacement Assembly Assembly Sp refer to Eaton Service and Parts Literature No Air Air from Vehicle Source Air to Cover Port HI DISASSEMBLY SHIFTING CONTROLS AIR SYSTEM 3 Turn out the two mounting screws in the Roadranger Te valve cover A Removal of Air Controls 1 Disconnect the two air lines at the S or Supply Port and P or End Port of the slave valve on the transmission case Disconnect the three 1 4 rubber lines from the slave valve 4 Slide the cover down to expose the valve ports and disconnect the three air lines 2 Remove the air line at the splitter cylinder cover A Then remove the three 3 1 4 rubber lines at the range cylinder B
22. 1206 silicone lubricant or its equivalent to O rings and cylinder walls Install valve in bore with flat surface to the outside When install ing the special valve retaining nut apply Fuller 71204 adhesive sealant or its equivalent to threads and tighten See TORQUE RECOMMENDATIONS Travel of the small insert valve piston is only sne As shown in the illustrations below when NO AIR is applied to the top side of valve piston CONSTANT AIR supplied from the regulator passes to the FRONTSIDE of cylinder piston moving the yoke bar backward to engage the REAR AUXILIARY DRIVE GEAR LO RANGE DIRECT AND HI RANGE DIRECT The piston moves up to cut off air to the back side of the cylinder piston This air is exhausted out the oyl inder cover as the piston moves rearward When AIR is applied to top side of valve piston through signal line the piston moves down passing air through the bottom of insert valve to the front and backside of the cylinder piston moving the yoke bar FORWARD engaging the FRONT AUXILIARY DRIVE GEAR LO RANGE OVERDRIVE AND HI RANGE OVERDRIVE OVERDRIVE AIR APPLIED THROUGH SIGNAL LINE PUSHES INSERT VALVE PISTON DOWN THIS SECTION SEALED OFF TO BACK SIDE OF AT THIS POINT PISTON YOKE BAR FORWARD PISTON YOKE BAR TO FRONT SIDE OF X FORWARD CONSTANT AIR Cut 7450F 11 87 Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature RTO 1
23. 421475 RED TAN 046 0485 084 086 21452421456 21472421476 RED ORANGE 043 0455 087 089 21452421457 21472421477 RED YELLOW 040 0425 090 092 21452421458 21472421478 RED GREEN 038 0395 093 095 21452421459 21472421479 RED LT BLUE If the transmission is equipped with an auxiliary countershaft oil pump use the fourth column to identify the oil pump shim Copyright Eaton and Dana Corporation 2002 EATON AND DANA CORPORATION National Institute for hereby grants its customers vendors or AUTOMOTIVE distributors permission to freely copy SERVICE reproduce and or distribute this document EXCELLENCE in printed format THIS INFORMATION IS NOT INTENDED FOR SALE OR RE O SALE AND THIS NOTICE MUST REMAIN ON ALL COPIES E T N One Great Drivetrain from Two Great Companies Roadranger The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced most trouble free drivetrain in the industry And it s backed by the Roadrangers the most experienced most expert most accessible drivetrain consultants in the business For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800 826 HELP 4357 for more time on the road Or visit our web site at www roadranger com TRSM 0011 08 92 PDF Printed in USA
24. 5618 and RTLO XX618 Models LO Range L A 5013 Roadranger Valve Slave Valve Identification Down N n A 5000 Valve o HO o e Oj o H 19470 Valve Eu Dnm 19470 or A 5000 Slave Valve Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly c OF A No Air Air to Housing Port LO Air from Vehicle Source A 3 Hag 2 Zz J RT0 15618 and RTLO XX618 Models LO Range H A 5013 Roadranger Valve Slave Valve Identification Down A 5000 Valve O H oO 1 fe B o OL O o V 19470 Valve o H 1 lo 5 3 lo 1 o Air Filter Regulator Splitter Cylinder Range Cylinder Assembly Assembly Assembly SP Air to LO Housing Air from Port Vehicle D Source m e LE SEE THIELE For all questions concerning removal and replacement refer to Eaton Service and Parts Literature Schematic For all questions concerning removal and replacement refer to Eaton Service and Parts Literature RT0 15618 and RTLO XX618 Models HI Range L A 5013 Roadranger Valve Slave Valve NN Identification Up zd b n mi A 5000 Valve o THO3 o FEAE 19470 Valve Lo t o 19470 or A 50
25. AND REASSEMBLY SHIFT BAR HOUSING SHIFT BAR HOUSING ASSEMBLY STEELBALL SPRING PLUG iiA CAPSCREW NX i V STEEL BALL LOCKWASHER V gasker i im COVER iii j PLUG GASKET T pe Las NQGASKET PIPE PLUG Se SS MN CAPSCREW ge US Se ED Ge BREATHER REDUCER go TM 277 g PIPE PLUG GASKET Ban AIR VALVE SHAFT PLUNGER PRING SHIFT YOKE s LO REVERSE 7 LOCK SCREW CAPSCREW LIFTING E SHIFT BAR HOUSING YOKE BAR PIN SHIFT BLOCK PIPE PLUG GASKET REVERSE 314 3RD 4TH MERMERE GY STELBAL AJ LOCKSCREW NOTE Use Lockwire at these positions during reassembly Cut 6233D 1 84 Cut 6278 9 80 2ND 3RD de SCREW es YOKE BAR c J 0 LOCK SCREW SHIFT YOKE 1ST 2ND Ka HN SHIFT YOKE 3RD 4TH A Removal and Disassembly of the Shift Bar Housing Assembly For models equipped with an Oil Pump and or Cooler Assemblies make sure t disconnect the lube line at the fitting on the shift bar housing before doing the followin instructions 1 Turn out the retaining capscrews Jar the top to break the gasket seal and lift the shift bar housing from the transmission case Remove the gasket NOTE During disassembly lay all parts on a clean bench in order of removal from the housing to make reassembly easier Shift bars not being re moved must be kept in the neutral position or the interlocking parts will lock the bars 2 Tilt the assembly and remove the
26. AUXILIARY SECTION AND TORQUE CONVERTER HOUSING 4 Loosen and remove the three retaining capscrews from the oil filter housing Change the oil filter as recommended Service the sealing ring if required 2 Remove the stator support and gasket F Removal of the torque converter housing 1 Loosen and remove the six 6 retaining capscrews from the stator support NOTE The staor support bay be set in place a soft face mallet or pry bay may be required to loosen the staor support The staor support is a NON SERVICABLE assembly REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING 7 Loosen and remove the two 2 retaining capscrews from the oil pump assembly Left Remove the oil pump from the torque converter housing Right NOTE The oil pump is a NON SERVICABLE assembly and should be returned for service The two 2 oil pump o rings can be serviced at this time if necessary 4 Jar the torque converter housing to break the seal remove the torqueconverter housing and gasket from the transmission case G Removal of the Inertia Brake 1 Loosen the six 6 retaining capscrews form the Inertia Brake Housing 5 Block the oil pump drive gear to loosen retaining nut from oil pump shaft COSE T 2 Remove the retaining capscrews from the assembly 6 Remove the oil pump drive gear and retaining nut from and remove from the transmission case the torque converter housing
27. BASE The narrow face width of this gear makes it very susceptible to breakage 4 Disassembly is complete at this point due to the welded countershaft design Replacement of reverse low first and 2nd speed gears will be completed as an assembly gears are not available separately G Removal and Disassembly of Right Reverse Idler Gear Assembly NOTE To remove the right reverse idler gear assembly see section B The right and left reverse idler gear assemblies are disassembled in the same manner DISASSEMBLY FRONT SECTION H Disassembly Auxiliary Drive Gear Assembly 1 Remove the retaining ring from the front of the auxiliary 3 If necessary remove the O rings from hub O D of drive gear left remove the snap ring from the auxiliary front auxiliary drive gear drive gear hub right 2 Using the rear face of retainer ring as a base Dress the drive aear throuah bearina REASSEMBLY FRONT SECTION A Reassembly of Auxiliary Drive Gear Assembly NOTE If previously removed install the O rings on extended front hub of front auxiliary drive gear 2 Start the front auxiliary drive gear bearing on front hub bearing snap ring facing groove in retainer ring Use both hands press the bearing on gear with snap ring in groove of retainer ring inset 1 Install the retainer ring on front auxiliary drive gear snap ring groove facing front hub and away from gear teeth 3 Install the snap ring into i
28. BTAIN CORRECT READINGS The air regulator has been PREADJUSTED within the correct operating limits Any deviation from these limits especially with regulators that have been in operation for some time is likely to be caused by dirt or worn parts If replacement or cleaning of the filter element does nothing to correct the air pressure readings replace the complete as sembly as the air regulator is nonserviceable 4 RANGE VALVE See Page 27 With the gear shift lever in neutral select HI RANGE and disconnect the air line at the OUT LET or P Port of control valve AIR SYSTEM 5 A When LO RANGE is selected a steady blast of air will flow from opened port Select HI RANGE to shut off air flow This indicates the control valve is operating properly Reconnect air line B If control valve does not operate properly check for restrictions and air leaks Leaks in dicate defective or worn O rings HI RANGE OPERATION With the gear shift lever in neutral select LO RANGE and disconnect the 1 4 I D air line at the port of range cylinder cover Make sure this line leads from the HI Range or H Port of slave valve A When HI RANGE is selected a steady blast of air should flow from disconnected line Select LO RANGE to shut off air flow B Move the shift lever to a gear position and se lect HI RANGE There should be NO AIR flow ing from disconnected line Return the gear shift lever to the neutral position Th
29. INDER SHIFT BAR NUT 73 70 85 Lbs Ft 5 8 18 Threads 2 RANGE SHIFT YOKE CAPSCREWS 0 65 Lbs Ft 1 2 20 Threads secure with Lockwire C N ES E SN 7 7 1 CAPSCREW REAR AUXILIARY RETAINING NUT 90 120 Lbs Ft 3 8 18 Threads 1 SPLITTER SHIFT YOKE LOCKSCREW 35 45 Lbs Ft 7 16 20 Threads Secure with Lockwire 19 AUXILIARY HOUSING CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads 1 OUTPUT SHAFT NUT 450 500 Lbs Ft 2 16 Threads Oiled at Vehicle Installation 6 MAINSHAFT REAR BEARING COVER CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads 4 RANGE CYLINDER MOUNTING CASPCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads 4 RANGE CYLINDER COVER CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads Jg V er Ji M Tm um Ter A E EU O OIL PAN RETAINING CAPSCREWS 14 20 Lbs Ft 5 16 18 Threads 1 RETAINING NUT PLUG 40 50 Lbs Ft 5 8 18 Threads 4 SPLITTER CYLINDER COVER CAPSCREWS 20 25 Lbs Ft 5 16 18 Threads Apply Loctite 242 to Threads 8 COUNTERSHAFT REAR BEARING COVER CAPSCREWS 35 45 Lbs Ft 3 8 16 Threads Apply Loctite 242 to Threads 1 SPEEDOMETER HOUSING PLUG 35 50 Lbs Ft 13 16 20 Threads Apply Loctite 242 to Threads HYDRAULIC VALVE CAPSCREWS 26 32 Lbs Ft 3 8 16 Threads
30. INSTALLATION SHIFTING CONTROLS 6 Connect the red air line to the S or Supply Port and 8 Connect the blue air line to the splitter cylinder cover the black air line to the P or End Port of the slave Tighten fittings securely valve Tighten fittings securely j 9 Position valve cover on Roadranger valve and secure um by tightening the two mounting screws in cover 7 Connect the red air line to the S or Supply Port and the black air line to the P Port and the blue line to the SP on the roadranger valve SHIMMING CHART Average the feeler gauge measurement and match the measurement to the Feeler Gauge Average Gap in the left column Follow the column to the right to identify the Shim Thickness Part Number and Color Code to be used TE E nie treme ob rine Ra cocon con 088 089 042 043 21454 21474 BROWN 085 0875 045 046 21455 21475 TAN 082 0845 048 049 21456 ORANGE 079 0815 051 052 21457 YELLOW 076 0785 054 055 21458 GREEN 073 0755 057 058 21459 LIGHT BLUE 070 0725 060 061 21460 LAVENDER 067 0695 063 064 21461 WHITE 064 0665 066 067 21684 21686 BLACK 061 0635 069 070 21685 21687 SILVER 058 0605 072 074 21452421452 21472421472 RED RED 055 0575 075 077 21452421453 214724214783 RED PINK 052 0545 078 080 21452 21454 21472421474 RED BROWN 049 0515 081 083 21452421455 21474
31. LINDER Refer to the following illustration If any of the seals in the range cylinder assembly are defective the range shift will be affected A Leak at either O ring A results in complete failure to make a range shift steady flow of air from breather of slave valve in both ranges B Leak at gasket B results in a steady flow of air to atmosphere while in HI RANGE C Leak at O ring C results in a slow shift to LO RANGE pressurizing of transmission case ides LO RANGE AIR PORT COVER NN LE XM Cut 7420 5 87 Range Cylinder Assembly All Models AIR SYSTEM AIR FILTER REGULATOR ASSEMBLY END CAP FILTER ELEMENT j The air filter contains a replaceable filter element which can be removed by turning out the end cap This ele ment should be cleaned at each oil change or more often under high humidity conditions Replace if necessary SLAVE VALVES POPPET TYPE PLUNGER PIN GASKET SPRING PLUNGER PIN ley e SPRING Q i SEAL 7 7 0 RING WASHER SPRING PLUG SLEEVE SLAVE VALVE ASSEMBLY SPRING SEAL cap GASKET SLAVE VALVE ASSEMBLY CAP CAPSCREW Refer to the drawing for disassembly and reassembly of the piston type slave valve assemblies Should the pop pet type slave valve assembly prove to be defective replace the complete assembly as it is non serviceable The actuating components used with these valve assemblies are non interchangeable Fail
32. ON FORWARD For OVERDRIVE REARWARD For DIRECT UP for HIGH RANGE ige Preselection Lever Ls t DOWN For LOW RANGE POWER FLOW The transmission must efficiently transfer the engines power In terms of torque to the vehicle s rear wheels Knowledge of what takes place in the transmission during torque transfer is essential if troubleshooting or repair becomes necessary Parts Identification HYDRAULIC FRONT AUXILIARY SECTION SECTION SECTION L E i E LOCKUP MAIN DRIVE i PERI GEAR l T l INTERRUPT CLUTCH TORQUE CONVERTER ER DRIVE SPLINE SYNCHRONIZ AUXILIARY TORQUE DRIVE CONVERTER SLIDING GEAR CLUTCHES TURBINE HYDRAULIC TORQUE BUMP CONVERTER IMPELLER POWER FLOW Torque Converter Mode Power Flow LO Range see figure A 1 Power torque from the vehicle s engine is transferred to the torque converter s drive spline 2 The impeller spins directing oil to the torque converter turbine 3 The oil flow hits the turbine causing the turbine to rotate The power is related to the speed difference between the impeller and the turbine 4 The turbine is connected to the interrupt clutch housing The interrupt clutch inner hub is splined directly to the transmission input shaft 5 When the interrupt clutch is activated the housing and the inner hub are connected to complete t
33. Remove the two 3 4 yoke lock 5 screws inset 4 Pull the yoke bar from the cylinder housing bore 6 Remove the range piston from the cylinder bore If necessary remove the O rings from the position I D and O D inset DISASSEMBLY AUXILIARY SECTION 7 Remove capscrews and range cylinder housing 8 If necessary remove the small O ring from the range cylinder housing bore DISASSEMBLY AUXILIARY SECTION 1 SYNCHRONEIZER Place the larger LO range synchronizer ring on the bench Cover the assembly with a shop rag to pre vent losing the three springs released from the high range synchronizer at the pin locations Pull the HI range synchronizer from the blocker pins SYNCHRONIZER 2 Remove the sliding clutch from the synchronizer ring LO range pins DISASSEMBLY AUXILIARY SECTION F Removal and Disassembly Output Shaft and Rear Bearing Assemblies 1 Use a soft bar and maul to drive the output shaft forward and through the rear bearing assembly 3 Use the front face of the reduction gear as a base press the output shaft through the bearing and gear This frees the bearing LO range gear and the splined washer 2 Remove the bearing inner spacer from the output shaft 4 Remove the stepped washer LO range gear and splined washer from the shaft DISASSEMBLY AUXILIARY SECTION G Removal Splitter Cover 5 Remove the rear bearing retaining capscrews rear bearing c
34. Roadranger Eaton Fuller Automated Transmissions lt Dana gt E T N One Great Drivetrain from Two Great Companies CEMT 18 Speed Service Manual TRSM 0011 August 1992 For the most current information visit the Roadranger web site at www roadranger com TABLE OF CONTENTS FOREWORD MODEL DESIGNATIONS AND SPECIFICATIONS LUBRICATION OPERATION POWER FLOW TIMING TORQUE RECOMMENDATIONS TOOL REFERENCE LUBRICATION CHANGE PROCEDURE HYDRAULIC SYSTEM FLUSH PROCEDURE HOW TO CHANGE OIL SUMP PAN STRAINER OIL FILTER TRANSMISSION OIL FILTER CHANGE PROCEDURE PREVENTIVE MAINTENANCE CHECKS PRECAUTIONS DISASSEMBLY INSPECTION REASSEMBLY CHANGING INPUT SHAFT AIR SYSTEM RANGE SHIFT AIR SYSTEM SPLITTER SHIFT AIR SYSTEM AIR SYSTEM SCHEMATICS DISASSEMBLY SHIFTING CONTROLS DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING DISASSEMBLY AUXILIARY SECTION REASSEMBLY AUXILIARY SECTION DISASSEMBLY FRONT SECTION REASSEMBLY FRONT SECTION INSTALLATION TORQUE CONVERTER HOUSING AUXILIARY SECTION AND OUTPUT YOKE INSTALLATION SHIFTING CONTROLS SHIMMING CHART FOREWORD This manual is designed to provide detailed information necessary to service and repair the Fuller Transmissions listed on the cover As outlined in the Table of Contents the manual is divided into 3 main sections a Technical information and reference b Removal disassembly reassembly and installati
35. Torque converter assembly is Non Servicable Do not attempt to disassemble It will be returned for service and replaced as a complete assembly D Removal of the Hydraulic Valve NOTE If not previously removed the transmission dip stick and tube can be removed from the oil pan at this time 4 Remove the torque converter snap ring from the input shaft LIS L osen and remove the ten 10 retaining capscrews from the hydraulic valve assembly Note the location of the two 2 allen head capscrews for reassembly REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING E Removal of oil pan oil pick up and screen and oil filter assembly 2 Remove the hydraulic valve assembly form the torque converter housing Left Separate the 2 gaskets and mounting plate from the hydraulic valve Right 1 Disconnect and remove the oil sump return line from the oil pan a P p 2 Loosen and remove the retaining cap screws from the oil pan Left Remove the oil pan from the bottom of the NOTE The hydraulic valve is a NON SERVICABLE torque converter housing Right assembly DO NOT DISASSEMBLE it will be returned for service 3 If necessary the electronic solenoids can be removed from the hydraulic valve at this time 3 Remove the two 2 retaining capscrews from the oil pick up Remove the pick up and screen and oil pan gasket from the torque converter housing REMOVAL OUTPUT YOKE
36. acent teeth on drive gear and re shaft rear bearing with larger I D lead chamfer to peat the procedure for the two adjacent teeth the front of shaft and install the snap ring in directly opposite the first set marked A highly vis groove at rear of left countershaft ible color of toolmakers dye is recommended for making timing marks REASSEMBLY FRONT SECTION f gt E 5 Place two lifting eyes with capscrews over bearing snap ring to temporary secure bearing in transmission bore 3 Mesh the marked tooth of left countershaft drive gear with either set of two marked teeth on main drive gear Slide the input shaft through the main drive gear inset a 6 Use a soft bar and maul to drive the input shaft through bearing Remove front bearing cover 4 Install drive gear spacer Install the bearing on the input shaft with external snap ring to the outside inset Set input shaft bearing into the bore of the case front 7 Install bearing retainer snap ring to secure input shaft in case bore Remove the two capscrew and lifting eyes REASSEMBLY FRONT SECTION H Reassembly and Partial Installation of Mainshaft Assembly If previously removed install the corresponding snap rings in I D of mainshaft gears 1 e a Secure the mainshaft in a vise equipped with brass jaws or wood blocks pilot end of shaft down If previously removed install the roll pin in keyway Install the 3rd speed
37. aft timing of the auxiliary will be checked at this time The single marked tooth of each countershaft must align with the two teeth marked on each side of the LO range gear REASSEMBLY AUXILIARY SECTION E Reassembly Range Cylinder 5 Heat the rear output shaft bearing cone and install the bearing on the shaft taper side down NOTE Do not heat the bearing above 275 F 136 C 1 Install O ring in slot of small bore in cylinder Apply silicone to all O rings inset 6 Install the rear bearing cover on the auxiliary housing The nylon collar and brass washer are installed in the chamfered hole on the lower right side of the cover 2 If previously removed install the O rings in the I D and O D of the range position NOTE Because the collar becomes distorted when compressed DO NOT REUSE OLD NYLON COLLAR REASSEMBLY AUXILIARY SECTION F Reassembly and Installation of Splitter Cylinder Assembly 3 Position new gasket on housing Install range cylinder piston yoke piston and retaining nut into housing Tighten retaining nut to recommended torque Install 4 capscrews into range cylinder housing and tighten to recommended torque 1 If previously removed install the small O ring in the cylinder housing bore 4 Place range cylinder cover and new gasket on range 2 If removed install the O ring on the piston O D left cylinder install 4 capscrews and tighten to recom Insert the yoke ba
38. all splined washer on mainshaft splines behind of mainshaft Use a flanged end driver and maul to set auxiliary drive gear bearing in case bore T Align the six capscrew holes in retainer with the tapped 9 Install the snap ring in groove at end of mainshaft holes in case and install capscrews Tighten to recom mended torque ratings and lockwire the capscrews in groups of three INSTALLATION TORQUE CONVERTER HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE A Installation of Torque Converter Housing Note The transmission rear must be blocked so the two aligning pins on the transmission rear case are not damaged If the auxiliary section has been installed the transmission can be placed vertically on a stand using an output flange or half round yoke affixed to a large plate Care must be taken when placing the CAUTION transmission in the vertical position Always use safety chains on the transmission Assure that the transmission is stable in the vertical position before removing the safety chains B Installation of the Inertia Brake Place the inertia brake gasket and six 6 retaining capscrews on the transmission case left Tighten the six 6 retaining capscrews to required torque specifications C Installation of the Torque Converter Housing 1 If the pressure relief valve was replaced check for proper seating and secure the valve left After replacing the filter by pass val
39. ansmission for proper torque E Installation of the Hydraulic Valve 2 Place the oil pan gasket on the mounting surface and install the pick up screen assembly in place with the three 3 retaining capscrews 1 If the electronic solenoids were removed place them back on the hydraulic valve and secure them with their retaining nuts left Place the two 2 gaskets and mounting plate on hydraulic valve right NOTE Gaskets to hydraulic valve are marked for proper installation The mounting plate should be checked for proper alignment INSTALLATION TORQUE CONVERTER HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE 2 Install the hydraulic valve on the torque converter housing and align mounting holes left Install the ten 10 retaining capscrews into the hydraulic valve Note two 2 of the retaining capscrews are allen head capscrews check their location right NOTE The transmission dipstick tube can be reinstalled on the transmission at this time i ul 2 After the torque converter is properly seated exposing F Installation of the Torque Converter the snap ring groove install the snap ring 3 Install the torque converter pilot into the torque converter and properly seat the converter pilot left Install the eight 8 retaining capscrews into the converter pilot and properly torque the capscrews right 1 Install two 2 lifting eyes into the converter pilot capscrew h
40. arance of gears Where excessive clearance is found check gear snap ring washer spacer and gear hub for excessive wear Maintain 005 to 012 axial clearance between mainshaft gears C SPLINES 1 Check splines on all shafts for abnormal wear If sliding clutch gears companion flange have worn into the sides of the splines replace the specific shaft affected D TOLERANCE WASHERS 1 Check surfaces of all tolerance washers Washers scored or reduced in thickness should be replaced E REVERSE IDLER GEAR ASSEMBLIES 1 Check for excessive wear from action of roller bearings F GRAY IRON PARTS 1 Check all gray iron parts for cracks and breaks Replace or repair parts found to be damaged G SHIFT BAR HOUSING ASSEMBLY 1 Check for wear on shift yokes and blocks at pads and lever slot Replace excessively worn parts 2 Check yokes for correct alignment Replace sprung yokes 3 Check lockscrews in yokes and blocks Tighten and rewire those found loose 4 If housing has been disassembled check neutral notches of shift bars for wear from interlock balls H GEAR SHIFT LEVER HOUSING ASSEMBLY 1 Check spring tension on shift lever Replace tension spring and washer if lever moves too freely 2 If housing is disassembled check spade pin and corresponding slot in lever for wear Replace both parts if excessively worn I BEARING COVERS 1 Check covers for wear from thrust of adjacent bearing Repla
41. boade HCA ETRE orie con eRer hone nate Brevet with the mainshaft sliding clutches inset Use a large d saa y i a q Yi B as b breaker bar to turn the output shaft nut from the output aede e UM ca hee aR cr cae calc ra shaft completed in the horizontal position 2 Pull yoke straight to the rear and off the output shaft 2 Remove the four capscrews and the auxiliary countershaft rear bearing cover gasket and rear bearing shim REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING Auxiliary Countershaft Retaining Straps CAUTION may be installed to hold countershaft in place Auxiliary can be removed without straps use caution 3 Install an Auxiliary Countershaft Retaining Strap with 3 3 8 x 1 clean capscrews Place a flat washer under the strap to prevent damage to the rear auxiliary countershaft bearing Do not use an air gun Tighten b AWARNING D ES hand until the capscrews are snug 4 Repeat Steps 2 and 3 for the remaining auxiliary countershaft T A 2 95 b a n 5 Remove the nineteen capscrews that hold the auxiliary section to the transmission case NOTE There are three lengths of capscrews note their location 6 Insert three capscrews in the tapped holes of housing flange Tighten evenly to move auxiliary section to the rear and just far enough from front section to break gasket seal 7 Remove capscrews and attach a chain hoist to auxiliary sec
42. ce between the gears REASSEMBLY FRONT SECTION 10 Install the 1st 2nd speed sliding clutch aligning 12 Install spacer and 1st speed gear on the main the missing internal spline of sliding clutch with shaft clutching teeth down and engaged with en key in mainshaft ternal splines of spacer l C 11 Remove the key from keyway and install the 1st 13 Install the LO speed gear on shaft against 1st speed gear limit washer on mainshaft flat side of speed gear clutching teeth up washer up Rotate washer in the 2nd groove of mainshaft to align the splines of washer with those of the mainshaft and reinsert key in key way to lock washer in place REASSEMBLY FRONT SECTION 16 Check axial clearances and make adjustments if necessary between the LO and 1st speed gears as described in No 9 of this section 14 Install the spacer in LO speed gear engaging the external splines of spacer with clutching teeth of 17 Install the LO Reverse speed sliding clutch aligning the missing internal spline of sliding clutch with key in mainshaft 15 Remove the key from keyway and install the LO speed gear limit washer on mainshaft flat side of washer down and against spacer Rotate washer in the 4th groove of mainshaft to align the splines of washer with those of the mainshaft and reinsert key in keyway to lock washer in place REASSEMBLY FRONT SECTION 18 Remove the key from keyway and install the re
43. ce covers damaged from thrust of bearing outer race 2 Check bores of covers for wear Replace those worn oversize J SLIDING CLUTCHES 1 Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat 2 Check engaging teeth of sliding clutches for partial engagement pattern K SYNCHRONIZER ASSEMBLY 1 Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles 2 Check blocker pins for excessive wear or looseness 3 Check synchronizer contact surfaces on the auxiliary drive and low range gears for excessive wear L O RINGS 1 Check all O rings for cracks or distortion Replace if worn PRECAUTIONS Reassembly Make sure that interiors of case and housings are clean It is important that dirt and other foreign materials be kept out of the transmission during reassembly Dirt is an abrasive and can damage polished surfaces of bearings and washers Use certain precautions as listed below during reassembly 1 GASKETS Use new gaskets throughout the transmission as it is being rebuilt Make sure all gaskets are installed An omission of any gasket can result in oil leakage or misalignment of bearing covers CAPSCREWS To prevent oil leakage use Loctite 242 thread sealant on all capscrews For torque ratings see TORQUE RECOMMENDATIONS O RINGS Lubricate all O rings with silicone lu bricant ASSEMBLY Refer to the il
44. cessive wear on the splines Except for removal of the shift bar housing assembly the input shaft can be removed without further disassembly of the transmission Removal of the torque converter housing is required NOTE The following illustration and instructions pertain to changing the input shaft ONLY To change the main drive gear complete disassembly of the front section is required BEARING SNAP RING SPACER INPUT SHAFT DRIVE GEAR Cut 5390B 10 88 Disassembly Reassembly 1 Remove the gear shift lever housing assembly or re 1 If necessary install bushing in pocket of input shaft mote control assembly from shift bar housing and the E 2 Install new input shaft in lin f main dri r shift bar housing assembly from transmission case 3 Inte Splines oimai arive gga just far enough to expose snap ring groove in I D of 2 Remove the bearing retaining snap ring from groove in drive gear gnait 3 Install snap ring in snap ring groove inside drive gear 3 Push down on input shaft to cock bearing in bore Drive input shaft toward rear of transmission through bearing ee anstall Give dear spacer ondnpgEsnart as far as possible Pull input shaft forward to expose 5 Install drive gear bearing on input shaft and into case snap ring of bearing Use pry bars to complete removal of bearing 5 Remove drive gear spacer and snap ring Pull input shaft forward and out of drive gear and case b
45. d Then mark the two ad jacent teeth located directly opposite the first set marked as shown in lllustration B 2 Prior to placing each auxiliary countershaft as sembly into housing mark the tooth stamped with an O on gear to mate with timed main shaft gear as shown in Illustration A 3 Install the LO range gear on the out put shaft and into the auxiliary case Seat the auxiliary countershaft bearings Install the rear bearing cover and tighten to recommended torque 6 Place the auxiliary countershaft assemblies into position and mesh the marked teeth of the mating countershaft gears with the marked teeth of the LO range gear as shown in illustra tion C gm TORQUE RECOMMENDATIONS Correct torque application is extremely important to assure long transmission life and dependable performance Over tightening or under tightening can result in a loose installation and in many instances eventually cause damage to transmission gears shafts and or bearings Use a torque wrench whenever possible to attain recommended lbs ft ratings Do not torque capscrews dry FRONT SECTION ALL MODELS 6 STATOR SUPPORT CAPSCREWS 1 NEUTRAL SIGNAL SWITCH PLUG 35 45 Lbs Ft 3 8 16 Threads 35 50 Lbs Ft 3 4 16 Threads Apply Loctite 242 to Threads 5 SHIFT BLOCK AND YOKE LOCKSCREWS 6 TORQUE CONVERTER HOUSING NUTS 35 45 Lbs Ft 7 16 20 Threads Secure with Lockwire 180 190 170 175 Lbs Ft 16 SHIFT BAR HOUSING AND
46. e 1 If previously removed install the air line fittings 3 Install the hat type alignment sleeve in bore of on slave valve slave valve 2 Install the spring on shank of actuating pin and in 4 Position gasket on valve mounting surface inset sert in bore of transmission case and install the slave valve on case inserting the end of actuating pin into alignment sleeve Secure the valve to case with four capscrews tighten evenly to recommended torque rating INSTALLATION SHIFTING CONTROLS 3 Connect the 1 4 air line from the inertia brake to the air filter regulator at solenoid Also connect the two 2 air lines from the slave valve to the range cylinder LO range connects to the front of the cylinder and HI range connects to the rear left Connect the 1 4 air line to the TCB 6 air fitting also connect the hydraulic valve wiring harness at connector right 1 Place the inertial brake air hose and wiring harness on the transmission 4 Connect the wiring harness clamps to the shift bar housing capscrews left Connect the input speed sensor and engine speed sensor at each connector as shown 2 Install the two capscrews into the air filter regulator and tighten to proper torque 5 Install the Roadranger valve cover and slide three airlines through cover Install the jam nut on the shift lever Thread the Roadranger valve on shift lever and secure by tightening jam nut against valve
47. e O rings or seals are A CONSTANT AIR flowing from exhaust port of cylinder cover B CONSTANT AIR flowing from Exhaust Port E of control valve WHILE SPLITTER CON TROL BUTTON IS REARWARD OR FORWARD providing the control valve is operating pro perly The three O rings in position on valve O D can be replaced However if an inner seal is damaged the complete assembly MUST be replaced COVER ASSEMBLY LEFT SIDE PORT SIGNAL LINE FROM ROADRANGER VALVE Z b A SS A NCATE YOKE BAR EXHAUST PORT INSERT VALVE NN NS S el 4 PISTON BACON an mud RIGHT SIDE PORT CONSTANT AIR Cut 7450D 8 86 AIR SYSTEM INSERT VALVE EQUIPPED WITH ROADRANGER VALVE A 5013 The insert valve is a self contained 1 3 16 valve as sembly located in the splitter cylinder cover It CAN PORT SIGNAL LINE FROM CONTROL VALVE SP PORT RETAINING NUT L INSERT VALVE NS ENS STU SSE KN Cut 7441A 11 87 SUPPLY PORT LOW RANGE AND HIGH RANGE DIRECT NO AIR ON SIGNAL LINE FROM CONSTANT AIR BACK SIDE SEALED OFF AT THIS POINT OF PISTON TO FRONT SIDE OF PISTON YOKE BAR i BACK A Cut 7450E 11 87 CONSTANT AIR NOT be disassembled except for the three O rings on outer diameter The O rings provide a stationary seal and do not move in cylinder When installing the insert valve in bottom edge of cover apply Fuller 7
48. e rear on mainshaft and use a screwdriver to engage sliding clutches with all forward speed gears A sliding clutch that will not engage with a gear indicates the gear set is not in proper mesh The bearings of the right countershaft would then need to be removed and the drive gear set retimed NOTE Do not engage sliding clutches with more than one gear at the same time This will lock the gearing and prevent the mainshaft and countershaft assemblies from rotating REASSEMBLY FRONT SECTION 1 Reassembly and Installation of Left Reverse Idler Gear Assembly NOTE Since the left and right reverse idler gear assemblies are identical reassembly and installation of the left reverse idler gear assembly should be performed at this time as described in Part C of this section J Completed Installation of Mainshaft and Auxiliary Drive Gear Assemblies E 3 Install the snap ring in hub of reverse gear and move the reverse gear forward on mainshaft and into proper position in case 1 Move the reverse gear to the rear as far as possible meshing teeth of gear with those of the reverse idler gears 2 Align the external splines of spacer with clutching teeth of reverse gear and move spacer forward on the 5 Install splined washer on mainshaft splines behind re mainshaft and into reverse gear verse gear REASSEMBLY FRONT SECTION i L3 6 Reinstall the front auxiliary drive gear assembly on rear 8 Inst
49. er and gasket Check for tershaft rear bearings Use a feeler gauge as close to proper shim alignment if misaligned rear bearing cover one capscrew location as possible and measure the may be damaged when proper torque is applied Posi gap between the countershaft rear bearing cover and tion a new gasket on each countershaft rear bearing the auxiliary case Record the measurement Using the cover mounting surface and install both rear bearing average measurement refer to page 115 in this Ser vice Manual Select the numbers in the left column that compare to the avereage measurement recorded from the countershaft rear bearing cover Follow the column to the right to identify the proper shim to be used in the countershaft shim bores Duplicate this procedure for the other countershaft rear bearing cover covers Install and tighten the capscrews to the recom mended torque INSTALLATION SHIFTING CONTROLS A Installation Shift Bar Housing 3 Install the thirteen capscrews in shift bar housing and tighten to recommended torque rating position Install shift bar housing gasket in position NOTE There are two sizes of capscrews The 11 2 capscrews are used with lifting eyes 4 With all three shift yokes in the neutral position install the shift bar housing assembly on case fitting the shift yokes into the slots of the corresponding sliding clutches INSTALLATION SHIFTING CONTROLS C Installation of Slave Valv
50. ere should now be a steady flow of air from dis connected line Select LO RANGE to shut off air flow and reconnect air line C If the air system does not operate accord ingly the slave valve or actuating components of the shift bar housing assembly are defec tive IMPORTANT RANGE PRESELECTION The plunger pin located in case bore between the slave valve and actuating plunger of shift bar housing prevents the slave valve from operating while the shift lever is in a gear position When the lever is moved to or through the neutral po sition the pin is released and the slave valve be comes operational 6 na LO RANGE OPERATION With the gear shift lever in neutral select HI RANGE and disconnect the 1 4 I D air line at the fitting on range cylinder housing Make sure this line leads from the LO Range or L Port of slave valve A When LO RANGE is selected a steady blast of air should flow from disconnected line Se lect HI RANGE to shut off air flow B Move the shift lever to a gear position and se lect LO RANGE There should be NO AIR flo wing from disconnected line Return the gear shift lever to the neutral position There should now be a steady flow of air from dis connected line Select HI RANGE to shut off air flow and reconnect air line C If the air system does not operate accord ingly the slave valve or actuating components of the shift bar housing assembly are defec tive RANGE CY
51. etween the two countershaft drive gears Torque is delivered along both countershaft to mating countershaft gears of engaged mainshaft gear The following cross section views illustrate a 1st 5th speed gear engagement Internal clutching teeth in hub of engaged mainshaft gear transfers torque to mainshaft through sliding clutch 10 Mainshaft transfers torque directly to rear auxiliary drive gear The rear auxiliary drive gear splits torque between the two auxiliary countershaft drive gears Torque is delivered along both auxiliary countershaft to the engaged reduction gear on output shaft Torque is transferred to output shaft through sliding clutch Output shaft delivers torque to driveline LO RANGE DIRECT POWER FLOW Auxiliary Section Power Flow LO RANGE OVERDRIVE The front auxiliary drive gear splits torque between the 9 Torque is transferred to the output shaft through sliding clutch 7 two auxiliary countershaft drive gears Torque is delivered along both countershaft to 10 Torque is delivered to driveline as LO RANGE 1st gear engaged LO RANGE gear on range mainshaft or OVERDRIVE output shaft LO RANGE OVERDRIVE da 3 4 5 6 7g Auxiliary Section Power Flow HI RANGE DIRECT 7 The rear auxiliary drive gear transfers torque directly to the output shaft through engaged sliding clutch HI RANGE DIRECT 8 Torque is delivered through
52. gear limit washer on main shaft flat side of washer up Rotate washer in the 1st or bottom groove of mainshaft to align the splines of washer with those of the mainshaft in stall the key in mainshaft keyway to lock washer in place 4 5 Install the spacer on shaft against washer Install the 3rd speed gear on mainshaft clutching teeth down and engaged with external splines of spacer NOTE Gear limit washers are internally splined and locked to mainshaft by the key Gear spacers are externally splined to engage with clutching teeth in gear hubs There is one limit washer and one spacer for each gear in the mainshaft as sembly REASSEMBLY FRONT SECTION Setting Correct Axial Clearances For Mainshaft Gears Axial Clearance End Play Limits Are 005 012 for all mainshaft gears Washers are used to obtain the correct limits six thicknesses are available as follows LIMITS INCH COLOR CODE 248 250 WHITE 253 255 GREEN 258 260 ORANGE 263 265 PURPLE 268 270 YELLOW 2793 275 BLACK PLUS RED TOLERANCE WASHER NOTE New style tolerance washers come in a full range of tolerances as corresponding colors listed above plus red Example Orange plus red limit washer has an inch limit thickness of 258 260 Refer to lllustrated Parts Lists for washer part num bers Always use the 248 250 tolerance washer White or white plus red in the reverse LO and 2nd speed
53. gear positions as shown at right IMPORTANT REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST SPECIFIED BY MODEL SE IES TO ENS URE THAT TRANSMISSION TOLERANCE WASHER TOLERANCE Cut 6324G 11 87 REASSEMBLY FRONT SECTION 6 Install the 2nd speed gear on shaft against 3rd speed gear clutching teeth up 7 Install the spacer in 2nd speed gear engaging the external splines of spacer with clutching teeth of gear 8 Remove the key from keyway and install the 2nd speed gear limit washer on mainshaft flat side of washer down and against spacer Rotate washer in the 2nd groove of mainshaft to align the splines of washer with those of the mainshaft and reinsert key in keyway to lock washer in place inset Insert two large screwdrivers between the 2nd and 3rd speed gears to check axial clearances Apply slight downward pressure on screwdriver handles to spread gears evenly Making sure the gear hubs are parallel insert a feeler gage between hubs Correct axial clearance is less than the minimum 005 to 012 If the clearance is less than the minimum 005 tolerance the limit washer in the 2nd speed gear should be replaced by a thinner limit washer This will increase the axial clearance between the gears If the clearance checked is greater than the maximum 012 tolerance a thicker limit washer should be installed in the 2nd speed gear This would decrease the axial clear an
54. he mechanical link and transfers power to the input shaft 6 Input shaft splines engage the internal splines in the main drive gear hub 7 Torque is split between the two countershaft drive gears Lockup Mode see figure B 1 Power torque from the vehicle s engine is transferred to the torque converter s drive spline 2 The drive spline is connected to the lockup clutch 3 The lockup clutch is splined directly to the interrupt clutch outer hub When the lockup clutch is activated the interrupt clutch is driven directly from the engine 8 Torque is delivered along both countershaft to mating countershaft gear of the engaged mainshaft gear 1st gear in this example 9 The internal clutching teeth in the engaged mainshaft gear hub transfers torque to the mainshaft through the sliding clutch 10 The mainshaft transfers torque directly to the auxiliary drive gear 1 The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 2 Torque is delivered along both countershaft to the engaged LO range gear on the range mainshaft or output shaft 3 Torque is transferred to the output shaft through a sliding clutch 4 Torque is delivered to the driveline as LO RANGE 1st 4 The interrupt clutch inner hub is splined directly to the transmission input shaft 5 When the interrupt clutch is activated the torque is transmitted directly from the engine to the input shaft from
55. ifications Install the transmission converter housing oil pan drain plug and tighten to 14 to 20 Lb ft of torque Install the transmission main case drain plug rear bottom and tighten to 45 to 50 Lb ft of torque Remove the transmission dipstick and slowly pour 7 gallons of Dexron Il fluid into the transmission Apply the vehicle parking brakes and place the transmission lever in neutral Start the engine and let is idle for five minutes Check the dipstick periodically while the engine is idling adding oil at needed to obtain a level that is in the cold band on the dipstick Total quantity added at this time should be approximately 10 gallons With the transmission still in neutral increase the engine idle speed to 1500 RPM and retain at this speed for five minutes Now check the oil level at normal engine idle speed in neutral again adding oil as required for a level 1 1 2 below the add hot mark on the dipstick Total oil quantity added at this time should be approximately 11 gallons Transmission temperature F 180 to 220 Oil level between the add hot and full hot marks Below 100 Oil level at the cold fill mark How to Change Oil Sump Pan Strainer Oil Filter NOTE To prevent oil leakage and loosening use Fuller thread sealant adhesive 71205 on all Capscrews 1 Install a new gasket 2 Using the 2 screws install the oil filter transfer tube Tighten the screws to 14 20 Lb ft of torque 3 Check the
56. ion In addition to the various components of the Range Shift Air System the Splitter Shift Air System utilizes a splitter cylinder and the Roadranger Valve A 5013 See Air System Schematics CONSTANT AIR from the air filter regulator assembly is supplied to the splitter cylinder at the port on right side of cylinder cover The Insert valve installed in cover see Page 30 provides the proper air flow needed to move the splitter piston in the cylinder rearward to engage rear auxiliary drive gear for operation in direct forward to engage the front auxiliary drive gear for operation in overdrive WHILE IN HI OR LO RANGE AIR needed to make the splitter selection and complete the shift is supplied to the Roadranger valve from the fitting at the S Port of slave valve When the overdrive selection is made the AIR passes through the Roadranger valve and is supplied to the Left Port of cylinder cover With Splitter Control Button in the DIRECT REARWARD position the SP Port of the Roadranger valve is CLOSED and NO AIR is supplied to the Left Port of the Splitter cylinder cover Button REARWARD SP Port CLOSED aed While in HI or LO Range the button can be moved FORWARD to operate in OVERDRIVE The SP Port of valve is OPENED when overdrive is selected sup plying AIR to the Left Port of the Splitter cylinder cover Fuller Transmissions j Button FORWARD SP Port OPENED Trouble Shooting
57. ite the first set marked There 2 PI li h haft shoul should be the same number of teeth between ooo APINGA WARNEN Sigurt SNAN elena facing up as shown the markings on each side of the gear dius REASSEMBLY AUXILIARY SECTION 3 Install the LO Range gear on the output shaft i 5 Using a heat lamp or hot plate and oil heat the out clutching teeth engaged with the splines down to put shaft rear bearing and install on output shaft engage the washer splines Seat the bearing securely on shaft Bearing can also be installed using the appropriate driver NOTE DO NOT HEAT BEARING ABOVE 2759F 136 C 4 Install the LO Range gear rear washer on output r shaft and against gear with chamfer side facing 9 Install the bearing inner spacer on the output up shaft REASSEMBLY AUXILIARY SECTION 7 Place the auxiliary housing on a flat bench and install ee de e et SPLIRUS IN DOTES EU Kange SyHOUro the 2 bearing cups and spacer in the rear bearing bore the cup with a lip seats next to the rear of the auxiliary case B Reassembly Synchronizer Assembly 3 Place the HI range synchronizer ring over pins of LO speed synchronizer ring seating springs against pins m4 1 Place the larger LO range synchronizer ring face down on bench with pins up Place the sliding clutch re cessed side up on pins of LO range synchronizer NOTE Pins on LO range synchronizer must line up with chamfered holes on bo
58. itter shift yoke into splitter sliding clutch slot Install assembly onto auxiliary section engaging the sliding clutch teeth into the auxiliary drive gear clutching teeth and splitter yoke onto yoke bar align lockscrew tighten to recommended torque and lockwire DISASSEMBLY FRONT SECTION RETAINER GEAR AUXILIARY DRIVE RETAINER N A 7 SNAP RING SNAP RING Cut 6416 8 92 A Removal Front Auxiliary Drive Gear 1 Remove snap ring from mainshaft rear groove 2 Remove the splined washer from inside front auxiliary drive gear assembly DISASSEMBLY FRONT SECTION 3 Remove six capscrews from the auxiliary bearing re 5 Remove the spline d washer from the mainshaft also tainer ring Insert three puller screws in the specially remove the front auxiliary drive gear retaining snap ring tapped holes of retainer ring Tighten screws evenly to from the mainshaft pull the front auxiliary drive gear assembly from case bore 4 Remove front auxiliary drive gear from mainshaft DISASSEMBLY FRONT SECTION IDLER SHAFT GEAR IDLER WASHER CENE THAUST WASHER IDLER PLATE Cut 6382 9 80 B Removal and Disassembly of Left Reverse Idler Gear Assembly 1 Move the mainshaft reverse gear as far to the rear 2 Move the reverse gear forward and against the LO as possible and remove the snap ring from I D of speed gear engaging the splines of mainshaft gear sliding clutch DISASSEMBLY
59. long transmission life Eaton Fuller Transmissions are designed so that the internal parts operate in an oil bath circulated by the motion of the gears and shafts Thus all parts are amply lubricated if these procedures are closely followed 1 Maintain oil level Inspect regularly 2 Change oil and filters regularly eUse the correct grade and type of oil Buy oil from a reputable dealer Additives and friction modifiers are not recommended for use in Eaton Fuller Transmissions Operating Temperatures An external oil cooler is required on the converter enhanced transmission in order to maintain proper operating temperatures Transmission oil temperature is sensed from the torque converter outlet port before the oil enters the cooler Normal operating temperature when sensed from the torque converter outlet port should be below 250 F however intermittent operating temperatures to 300 F do not harm the transmission A dash light will signal high oil temperatures 250 F or higher On vehicles equipped with two transmission oil temperature gauges one gauge required senses torque converter oil as mentioned above while the other gauge optional reads oil temperature from the transmission sump The sump temperature represents oil that has circulated through the cooler This temperature is normally below 225 F however intermittent sump temperatures to 250 F do not harm the transmission When the average temperature of the transmis
60. lustrations provided in the detailed disassembly instructions as a guide to reassembly INITIAL LUBRICATION Coat all limit washers and splines of shafts with Lubriplate during reas sembly to prevent scoring and galling of such parts 6 T AXIAL CLEARANCES Maintain original axial clearances of 005 to 012 for mainshaft gears BEARINGS Use of flanged end bearing drivers is recommended for the installation of bearings These special drivers apply equal force to both bearing races preventing damage to balls rollers and races while maintaining correct bearing align ment with bore and shaft Avoid using a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races See TOOL REFERENCE UNIVERSAL JOINT COMPANION FLANGE OR YOKE Pull the companion flange or yoke tightly into place with the output shaft nut using 450 500 foot pounds of torque Make sure the speedome ter drive gear or a replacement spacer of the same width has been installed Failure to pull the com panion flange or yoke tightly into place will permit the output shaft to move axially with resultant damage to the rear bearing IMPORTANT REFER TO THE APPROPRIATE ILLUSTRATED PARTS LIST SPECI FIED BY MODEL SERIES TO ENSURE THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION CHANGING INPUT SHAFT Special Procedure In some cases it may become necessary to replace the input shaft due to ex
61. nd reassembled in the same manner NOTE Reverse low 1st and 2nd speed gears are part of the shaft and are note serviceable J M It 4 Install the OUTER RACE of auxiliary countershaft front bearing into case bore NOTE The bearing INNER RACE is installed on front of auxiliary countershaft and never with outer race 1 Press the 3rd speed gear on the countershaft long hub of gear to countershaft front REASSEMBLY FRONT SECTION mmm 4 Install the drive gear retaining snap ring in groove on front of each countershaft 2 Start the PTO gear onto countershaft bullet nose side of teeth facing up and toward rear of shaft Align key way of drive gear with key in countershaft and press BOTH gears onto shaft long hub of drive gear against PTO gear NOTE The left countershaft assembly has a 47 tooth PTO gear the right countershaft assembly has a 45 tooth PTO gear 5 Use a flanged end driver to install bearing inner race on countershaft shoulder of race against shoulder of coun tershaft 3 To avoid confusion during installation mark the end of left countershaft with an L the end of right counter shaft with an R REASSEMBLY FRONT SECTION E Partial Installation of Countershaft Assemblies IMPORTANT Mark the countershaft drive gear for timing purposes On the drive gear of each countershaft assem bly mark the tooth aligned with keyway of gear and
62. nse soon after initial reassembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the units history mileage application etc Recommended inspection procedures are provided in the following checklist A BEARINGS 1 Wash all bearings in clean solvent Check balls rollers and raceways for pitting discol oration and spalled areas Replace bearings that are pitted discolored or spalled 2 Lubricate bearings that are not pitted discol ored or spalled and check for axial and radial clearances 3 Replace bearings with excessive clearances 4 Check bearing fits Bearing inner races should be tight to shaft outer races slightly tight to slightly loose in case bore If bearing spins freely in bore however case should be replaced B GEARS 1 Check gear teeth for frosting and pitting Frosting of gear tooth faces present no threat of transmission failure Often in continued operation of the unit frosted gears will heal and not progress to the pitting stage And in most cases gears with light to moderate pit ted teeth have considerable gear life remain ing and can be reused But gears with advanced stage pitting should be replaced 2 Check for gears with clutching teeth abnor mally worn tapered or reduced in length from clashing in shifting Replace gears found in any of these conditions PRECAUTIONS Inspection cont d 3 Check axial cle
63. nstall the small interlock pin VERTICALLY in the neutral notch bore Install the block and yoke lockscrews tighten and lockwire securely NOTE It is necessary that the interlock pin re main in a vertical position during reassembly as rotation of the bar causes the pin to jam in the ten sion spring bores 8 Install the other 3 4 interlock ball inthe rear boss top bore This ball rides between the 1st 2nd and the 3rd 4th speed shift bars 10 While holding notched end of the bar install the 3rd 4th speed shift bar in the housing boss upper bore position the shift block on the bar between the front and center bosses long hub to the housing rear Install the block and yoke lock screws tighten and lockwire securely For models so equipped install the oil trough on the housing Tighten the capscrews and lockwire securely DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING C EE TET a 11 Remove the assembly from the vise Install the 12 Install the three tension springs one over each three tension balls one in each bore on the hous ball in the housing bores ing top REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING B Removal of the Auxiliary Section 2 5625 2 5625 A Removal of the Output Yoke r 40625 3 Drilled Holes Bar Stock 3 8 x 1 Tool Print T 65853 1 Place the transmission in the vertical position Put 1 Lock transmission by engaging two mainshaft gears
64. oles Attach a lifting chain to lifting eyes lower torque onto the input shaft into the torque converter housing NOTE The torque converter may not seat itself completely on the shaft Care must be taken during installation Do not force the torque converter onto the input shaft as damage to internal splines will occur The splines on the input shaft must match those internal to the torque converter interrupt clutch splines Not matching these splines will not allow the torque converter to properly slide onto the input shaft INSTALLATION CLUTCH HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE G Installation of Output Yoke NOTE Replacement of seal and slinger must be completed prior to yoke or flange installation 3 Install washer and output nut onto the output shaft NOTE It will be necessary to temporarily lock the trans mission in two gears by moving sliding into gear for final torque procedure 1 Install speedometer gear or spacer on output shaft 4 Complete installation process by torquing the output 2 Place output yoke or flange onto the output shaft shaft nut to recommended torque INSTALLATION CLUTCH HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE H Installation of the Auxiliary Section and Shimming Procedure 1 Tighten the middle bolt on each countershaft strap until the countershaft are snug Shift the reduction sliding clutch into reduction Attach a chain
65. on The format of the manual is designed to be followed in its entirety if complete disassembly and reassembly of the transmission is necessary But if only one component of the transmission needs to be repaired refer to the Table of Contents for the page numbers showing that component For example if you need to work on the Shifting Controls you will find instructions for removal disassembly and reassembly on page 35 Instructions for installation are on page 111 Service Manuals Illustrated Parts Lists Drivers Instructions and other forms of product service information for these and other Fuller Transmissions are available upon request You may also obtain Service Bulletins detailing information on product improvements repair procedures and other service related subjects by writing to the followi ng address EATON CORPORATION TRANSMISSION DIVISION Technical Service Department P O Box 4013 Kalamazoo Michigan 49003 61 6 342 3344 Every effort has been made to ensure the accuracy of all inf ormation in this brochure However Eaton Transmission Division makes no expressed or implied warranty or representation based on the enclosed information Any errors or omissions may be reported to Training and Publications Eaton Transmission Division PO Box 4013 Kalamazoo MI 49003 MODEL DESIGNATIONS AND SPECIFICATIONS Nomenclature Letter Designations Roadranger Twin Countershaft Low Inertia Mainshaft Overdrive
66. ooth on left countershaft drive gear has remained in mesh with marked set of teeth on main drive gear 23 Move the pilot end of mainshaft into pocket bushing of input shaft 25 Center rear of mainshaft in case bore and install the auxiliary drive gear assembly on shaft par tially seating the bearing in bore DO NOT COM PLETE INSTALLATION AT THIS TIME REASSEMBLY FRONT SECTION H Bearing Installation and Timing of Right Countershaft Assembly IMPORTANT The left countershaft assembly MUST remain in time with main drive gear when timing right countershaft assembly 3 Position the front countershaft bearing in front bearing bore Use the proper bearing driver to set the bearing in bore left Install retainer washer and capscrew Make sure to match roll pin in retainer with inner bearing hole right 1 Remove blocking from right countershaft as sembly and place it parallel to mainshaft as sembly Mesh the marked tooth of right countershaft drive gear with remaining set of two marked teeth on main drive gear 4 Tighten capscrew to the recommended torque 2 Insert countershaft support tool or blocking in rear bearing bore REASSEMBLY FRONT SECTION 5 Position the countershaft rear bearing in rear bearing 6 With bearing installation complete install the snap ring bore Use the proper bearing driver to seat bearing in in right countershaft rear groove bore 7 Move the reverse gear to th
67. ore Install bearing retainer snap ring To facilitate proper reinstallation of the shift bar housing assembly on case make sure mainshaft sliding clutches are placed in the neutral position Reinstall the shift bar housing assembly the front bearing cover and all other parts and assemblies previously removed making sure to replace the gaskets used AIR SYSTEM ROADRANGER VALVE AIRLINES RANGE NS CYLINDER AIR FILTER N SLAVE 4 LD AIR LINES AIR SYSTEM RANGE SHIFT AIR SYSTEM Operation The Range Shift Air System consists of the air filter regulator slave valve a Range Control Valve or Mas ter Control Valve range cylinder fittings and connecting air lines See Air System Schematics CONSTANT AIR from the air filter regulator is sup plied to the S or Supply Port of slave valve and passed through to the INLET or S Port of control valve WHILE IN LO RANGE the control valve is OPEN and AIR is returned to slave valve at the P or End Port This signals the valve to supply AIR in line be tween the LO Range or L Port of slave valve and the LO Range Port of range cylinder housing AIR re ceived at this port moves the range piston to the rear and causes the auxiliary LO RANGE gear to become engaged WHILE IN HI RANGE the control valve is CLOSED and NO AIR is returned to the slave valve This signals the slave valve to supply AIR in line between the HI Range or H Po
68. over and gasket from the auxiliary housing l j The rear bearing cone drops from the housing bore 1 Remove the capscrews from the splitter cylinder cover when the cover is removed If necessary remove the and remove the splitter cylinder cover and gasket from the auxiliary section case oil seal from the cover inset 4 2 If necessary turn out the insert valve retaining nut and remove insert valve from bore 6 Remove the two bearing cups and spacer from the bearing bore DISASSEMBLY AUXILIARY SECTION 3 Pull the yoke bar from cylinder housing If necessary If h Il O ring f h lind remove the Oing ront piston O D Insel 4 If necessary remove the small O ring from the cylinder housing bore REASSEMBLY AUXILIARY SECTION AUXILIARY HOUSING ASSEMBLY PLUG MAGNETIC OIL B PLUG SPEEDO DAPSEH EU ANAL 5 PIA SLINGER CAPSCREW PTIONAL SE OM PLUG MECHANICAL EL ECTRONIC d ET m Y j BEARING GASKE REAR BEARING COVER MECHANICAL AND s ELECTRONIC SPEEDO ur B CE Codd me i LIFTING EYE REAR HOUSING EAR EARING COVER Cu S576 ugr l A Reassembly and Installation of NOTE Make sure magnetic plugs preinstalled in auxiliary housing 1 IMPORTANT Mark timing teeth on the LO Range gear A highly visible color of toolmaker s dye is recommended a Mark any two adjacent gear teeth on LO Range gear front side b Then mark the two adjacent teeth which are directly oppos
69. r in the cylinder housing bore right mended torque REASSEMBLY AUXILIARY SECTION 3 If previously removed install the insert valve flat end the outside and the valve retaining nut in the bottom bore of the cylinder cover Tighten to recommended torque ratings NOTE Prior to installation of the insert valve make sure the three O rings on the valve O D are not defec tive Replace if necessary 4 Place the new splitter cylinder gasket splitter cylinder assembly new splitter cylinder cover gasket and split ter cylinder cover onto the auxiliary housing Install 4 capscrews into the assembly and tighten to recom mended torque G de to Reassembly of Auxiliary Rear Bearing Assembly Place the rear bearing cone over the bearing and into the rear bore Align the 125 shim over the cone and install the rear bearing cover with four 4 capscrews tighten only till snug right Retaining straps may also be used at this time they are required for horizontal installation Complete assembly by installing remaining rear bearing cover left Installation of Range Yoke Capscrews and Recommended Torque of Auxiliary Drive Gear Nut 1 Install the 2 capscrews into the range yoke and tighten to recommended torque right Tighten auxiliary drive gear retaining nut to recommended torque left REASSEMBLY AUXILIARY SECTION 1 Installation of Splitter Sliding Clutch and Yoke 1 Place spl
70. ricant and filter Normal off highway use Recommended Lubricant Fahrenheit Ambient Temperature Dexron Il Above 0 F Oil Dipstick A WARNING Before working on a vehicle place the transmission in neutral set the parking brakes and block the wheels Maintaining Oil Level nm TS za a Dol ee abo COLD FULL 3 COLD 60 120 F USE C3 FLUID PER MILL 2104D x x M dE AD gt AOT FULL 1 HOT 180 220 F CHECK AT IDLE IN NEUTRAL Iz Different Views of the Oil Dipstick Make sure oil is within dipstick marks for the corresponding oil temperature Oil should be checked at idle speed in the neutral position using the corresponding temperature band Cold checks can be performed when the oil temperature is 60 120 F The oil level should be within the dipstick cold band Additional checks can be made with the transmission at operating temperature by using the hot band on the opposite side of the dipstick The hot band temperature range is 180 220 F OPERATION 18 Speed Transmission Shift Lever Patterns and Shifting Controls SHIFT LO 1 2 3 4 IN LO RANGE a RANGE SHIFT AND SHIFT 5 6 7 8 IN HI RANGE OVERDRIVE WHILE IN LO AND HI RANGE Ratios can be split by moving the splitter Control Button to the forward position ROAD RANGER VALVE A 5013 SPLITTER CONTROL BUTT
71. rt of valve and the HI Range Port of range cylinder cover AIR received at this port moves the range piston forward to engage the aux iliary drive gear with sliding clutch and bypass the LO RANGE gear set Range shifts can be made ONLY when the gear shift lever is in or passing through neutral Thus the range desired can be PRESELECTED while the shift lever is in a gear position As the lever is moved through neutral the actuating plunger in the shift bar housing releases the slave valve allowing it to move to the selected range position Trouble Shooting If the transmission fails to make a range shift or shifts too slowly the fault may be in the Range Shift Air System or actuating components of the shift bar housing assembly To locate the trouble the following checks should be made with normal vehicle air pressure applied to the system but with the engine off NEVER WORK UNDER A VEHICLE A WARNING wuiLE ENGINE IS RUNNING as personal injury may result from the sudden and unin tended movement of vehicle under power Always place transmission in the neutral position 1 INCORRECT AIR LINE HOOK UPS See Air System Schematics With the gear shift lever in neutral move the con trol that provides range selection UP and DOWN A If the air lines are crossed between control valve and slave valve there will be CON STANT AIR flowing from the exhaust port of control valve WHILE IN HI RANGE B If the air lines are crossed
72. sion oil exceeds the temperature limits as stated above more frequent oil changes may be needed The following conditions in any combination can cause the recommended transmission oil temperatures to be exceeded 1 operating the transmission in a stall condition while in the converter ratios i e extended operation while in gear with the vehicle stopped or slowly moving 2 high density of starts and stops at slow operating speed 3 minimal cooler capacity and or restricted air flow to the transmission oil cooler 4 exhaust system too close to the transmission 5 improper oil level incorrect oil Proper Lubrication Levels as Related to Transmission Operating Angles If the transmission operating angle is more than 12 improper lubrication can occur A special kit may be required for sustained operation on grades greater than 12 Lubrication Change and Inspection First 1 000 to 1 500 miles Flush hydraulic system and change transmission oil filter on new units Every 2 500 miles Inspect lubrication level Check for leaks Every 50 000 miles or 1 year Change transmission lubricant and filter OFF HIGHWAY USE First 30 hours Flush hydraulic system and change transmission oil filter on new units Every 40 hours inspect lubrication level Check for leaks Every 500 hours Change transmission lubricant and filter where severe dirt conditions exist Every 1 000 hours Change transmission lub
73. st 1 000 to 1 500 miles for highway use or 30 hours for off highway use a catastrophic failure has occurred Assumption The transmission is at ambient 65 F 20 temperature 1 co ON DO n Begin draining the transmission from the two drain locations 1 At the transmission main case drain plug rear amp bottom 2 At the converter housing oil pan drain plug Disconnect the transmission cooler supply line between the transmission outlet and the oil cooler not between the cooler and the transmission oil pan With 80 PSI clean dry air from a hose and nozzle use a rubber stopper or clean rag to seal the air hose to the converter outlet hose Apply air to the converter outlet for approximately two minutes to backfush oil into the transmission oil pan Disconnect oil lines and dipstick tube from the sump pan Remove and clean the sump pan Remove the oil strainer tube from the torque converter housing Remove the oil strainer from the tube and clean Assemble the oil strainer on the tube 10 Position a new gasket and install the oil strainer tube A CAUTION Use the proper tool to tighten the retaining capscrews on the sumppan damage can occur 11 12 13 14 15 16 17 18 Install the sump pan Tighten the retaining capscrews to 14 to 20 Lb ft of torque Connect oil lines and dipstick tube Connect the hose between the transmission and cooler Tighten to vehicle manufacturer s spec
74. strainer for contaminants If needed wash the strainer in clean solvent 5 Install the return hose tube 4 Position the oil sump pan Install the retaining capscrews in oil sump pan Tighten the capscrews to 14 20 Lb ft of torque Transmission Oil Filter Change Procedure Transmission oil must be drained before proceeding 1 Remove the retaining capscrews 2 Remove the filter housing 3 Replace the oil filler and housing O ring gasket 4 Position the filler housing on the transmission 5 Install the capscrews and tighten to 26 to 32 Lb ft of torque NOTE To prevent oil leakage and loosening use Fuller thread sealant adhesive 71 205 on all capscrews Note Item numbers refer to the illustration Preventive Maintenance Checks 1 Lubricant and Filter Change at specified service intervals eUse only the types and grades recommended eCheck lubrication lines and cooling circuit for leaks Use only genuine Eaton Fuller filter elements when servicing filter Air System eAnnually replace the filter regulator element If excessive contamination is present service vehicle air dryer system The MT 18 Speed requires clean dry air for proper operation Check vehicle air dryer system regularly for proper operation Dipstick e Monitor oil level Add oil if necessary e Tighten dipstick securely Drain Plugs e Tighten the drain plugs securel
75. tershaft rear bearings to the rear and from case bores NOTE This procedure will damage the bearings and should not be attempted unless replacement of the bearings is planned DISASSEMBLY FRONT SECTION 5 From the rear of the countershaft drive the shaft 6 Use a bearing puller or pry bars to remove the forward to unseat the front bearing from the front case countershaft front bearings pele 10 expose tno pganng snapTing NOTE The front roller bearing inner race will remain pressed on the front countershaft DISASSEMBLY FRONT SECTION SLDING CLUTCH WASHER SPACER sone 4TH AT MAINSHAFT OD RTOIRTX ASHEI SLIDING CLUTCH Cat Edd baa la D Removal and Disassembly of Mainshaft Assembly F s p e 1 Block the right countershaft assembly against 2 Remove the 3rd 4th speed sliding clutch from case wall and pull the mainshaft assembly to the mainshaft front rear to free pilot from input shaft pocket Tilt front of mainshaft up and lift the assembly from case inset Use caution as the reverse gear is free and can fall from shaft DISASSEMBLY FRONT SECTION 3 Remove the reverse gear and spacer from main shaft rear 5 Turn the reverse gear limit washer to align its splines with those of the mainshaft and remove washer u eoo ade AR 4 From mainshaft rear pull the key from mainshaft key way NOTE When removing limit washers spacers and gears note their location on mainshaft to facili
76. the lockup clutch The losses from the slippage in the torque converter are eliminated in this manner Auxiliary Section Power Flow HI Range see figure C 6 Input shaft splines engage the internal splines in the main drive gear hub 7 Torque is split between the two countershaft drive gears 8 Torque is delivered along both countershaft to mating countershaft gear of the engaged mainshaft gear 9 The internal clutching teeth in the engaged mainshaft gear hub transfers torque to the mainshaft through the sliding clutch 10 The mainshaft transfers torque directly to the auxiliary drive gear 11 The auxiliary drive gear transfers torque directly to the range mainshaft or output shaft through the engaged sliding clutch 12 Torque is delivered through the output shaft to the driveline as HI RANGE 5th POWER FLOW POWER FLOW The transmission must efficiently transfer the engine s power in terms of torque to the vehicle s rear wheels Knowledge of what takes place in the transmission during torque transfer is essential when troubleshooting and making repairs Front Section Power Flow LO Range Direct 1 Power torque from the vehicle s engine is transferred to the transmission s torque converter Splines of input shaft engage internal splines in hub of main drive gear Torque is split b
77. tion Move the assembly to the rear until free of front section and remove gasket REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING C Removal Torque Converter NOTE The transmission rear must be blocked so the two aligning pins on the transmission rear case are not damaged If the auxiliary section is not being removed the transmission can be placed vertically on a stand using an output flange or half round yoke affixed to a large plate CAUTION Care must be taken when placing the transmission in the vertical position Always use safety chains on transmission Assure that transmission is stable in vertical position before removing the safety chains 8 The auxiliary section can also be removed with the transmission set in the vertical position Remove the retaining capscrews from the housing flange and lift the assembly from the front section Remove the gasket Rerhove the retaining capscrews from the convertor pilot Us ihe two 2 threaded capscrew holes to separate the converter pilot form the torque converter Left Remove the converter pilot from the torque converter Right REMOVAL OUTPUT YOKE AUXILIARY SECTION AND TORQUE CONVERTER HOUSING 3 If required the pilot o ring or hydraulic seals can by Snstall 2 lifting eyes into the converter pilot capscrew serviced at this time holes attach lifting chain and remove converter straight up form the converter housing NOTE
78. ts groove left place the outer retainer ring and seat with the proper driver right REASSEMBLY FRONT SECTION CASE ASSEMBLIES NOTE Before starting reassembly make sure the three magnetic discs are solidly in place at bottom of case These can be secured to disc mounting surfaces with Scotch Grip Rubber Adhesive or equivalent adhesive C Reassembly and Installation of Right Reverse Idler Gear Assembly 2 Install the bearing inner race on idler shaft and insert shaft into case bore threaded end of shaft to the front As the idler shaft is moved forward install the reverse idler gear on shaft long hub to the front and seating on bearing inner race Position the thrust washer on shaft between the gear and support boss in case and con tinue with movement of idler shaft forward into bore of Support boss 1 If previously removed thread pipe plug in rear of re 7 k had verse idler shaft and tighten Install the thrust washer to l the end of the idler shaft NOTE If previously removed replace the needle bear ing into bore of reverse idler gear 3 Making sure that the reverse idler shaft is seated in bore of support boss and forward as far as possible install the washer and stop nut on front of shaft Tighten nut to recommended torque rating REASSEMBLY FRONT SECTION C Reassembly of Countershaft Assemblies NOTE Except for the PTO gears the left and right countershaft assemblies are identical a
79. ttom of sliding clutch REASSEMBLY AUXILIARY SECTION C Installation of Auxiliary Driver Gear a 4 Apply downward pressure to the HI range synchronizer ring WHILE TWISTING COUNTER CLOCKWISE to compress the springs and fully seat ring on blocker pins 1 Place auxiliary drive gear retainer and 15 16 capscrew on of LO range synchronizer It is suggested that a shop output shaft assembly Secure capscrew on shaft till towel be placed over the synchronizer to prevent injury tight recommended torque will be applied during final to your hands assembly pg 67 D Reassembly of Auxiliary Countershaft Assemblies and Timing gt gt 5 Install synchronizer assembly to front of output shaft To make reassembly of the auxiliary section easier you can assembly make this auxiliary section fixture out of a section of 2 x 12 REASSEMBLY AUXILIARY SECTION NOTE Auxiliary countershaft bearings will be installed 3 Install the range yoke into the synchronizer sliding at this time if replacement was required clutch slot offset side facing down 1 Mark each countershaft for correct timing Locate the O stamped on the countershaft and mark the tooth with highly visible toolmakers dye or paint 4 Place the auxiliary housing over countershaft assem blies and output shaft assemblies 2 Place the countershaft in fixture or on a flat surface for reassembly Locate output shaft assembly between countersh
80. unger from the LO Reverse speed shift yoke bore 2 Install the spring in the yoke bore and on the plunger shank DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING 3 Install the plug and tighten to compress the spring left Back the plug out 1 1 1 2 turns and stake the plug through the small hole in the yoke right 5 While holding the plunger shank install the ac tuating plunger in the center boss bore H 4 Secure the shift bar housing in a vise Hold the 6 Install one 3 4 interlock ball in the rear boss top notched end of the short LO Reverse speed shift bore This ball rides between LO Reverse and 1st bar install the bar in the lower bore of the shift bar 2nd speed shift bars housing bosses Install the yoke lockscrew tighten and wire securely NOTE Start with the lower shift bore of the rear boss and move to the left front of the housing Keep bars in the neutral position during installa tion DO NOT EXCEED the recommended torque ratings for the yoke lockscrews as over tightening may distort the shift bars DISASSEMBLY AND REASSEMBLY SHIFT BAR HOUSING While holding the notched end of the bar install the 1st 2nd speed shift bar in the housing boss middle bore Position the shift block on the bar be tween the center and rear bosses and the yoke on the bar between the front and center bosses long hub to the housing front Just before inserting the notched end of the rear boss bar i
81. ure to use the correct plunger pin spring and alignment sleeve during installation on the transmission will cause hard shifting in LO Range gears AIR SYSTEM ROADRANGER VALVE A 5013 SPRING ae SP RETAINER MEDALLION ACTUATOR DETENT e nau Saut O RING LEVER Cut 6148A 11 87 Removal and Disassembly 1 Remove two screws holding bottom cover to valve and slide cover down gearshift lever to expose air line fittings Disconnect air lines 2 Loosen jam nut and turn control valve from gear shift lever 3 Pry medallion from recess in top cover 4 Turn out the two screws to remove the top cover from valve housing 5 Turn out the two screws in side of valve housing to separate the housing 6 Remove the Range Preelection Lever from left housing and the position balls and guide from lever SPRING 7 If necessary remove the spring and O ring from bores in left housing 8 If necessary remove the springs O ring and sleeve from bores in right housing Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Install control valve on gear shift lever and tighten jam nut 3 Attach air lines and install bottom cover AIR SYSTEM SPLITTER SHIFT AIR SYSTEM Operat
82. ve the valve should be properly seated and secured right 2 Place the oil pump on the torque converter housing opening left Install the two retaining capscrews and properly torque the capscrews right 3 Install the oil pump drive gear on the pump shaft and thread retaining locknut in place left Block the oil pump drive gear and tighten lock nut to proper torque 7 08 4 Place the torque converter housing gasket and torque converter housing onto the front of the main case left Install the four 4 retaining capscrews and six 6 retaining nuts and properly torque each retainer right 5 Install the sta tor support and gasket over the input shaft down into the torque converter housing left Install the six 6 retaining capscrews and properly torque capscrews INSTALLATION TORQUE CONVERTER HOUSING OUTPUT YOKE AUXILIARY SECTION AND SHIMMING PROCEDURE D Installation of Oil Pan Pick Up and Screen and Oil Filter Assembly ee ELE 3 Place the oil pan over pick up and screen onto the torque converter housing left Secure the oil pan to the torque converter housing with the retaining capscrews right ad 1 Install the oil filter o ring seal oil filter and oil filter housing onto the torque converter housing and tighten three 3 retaining capscrews to required torque 4 Install the oil sump return tube to the oil pan Check the fittings at the oil pan and tr
83. y Tighten the main case drain plug to 45 50 Lb ft of torque Tighten oil pan plugs to 14 20 Lb ft of torque Capscrews and Gaskets eCheck all capscrews especially those on the PTO covers and rear bearing covers for looseness which can cause oil leakage Tighten capscrews to 35 45 Lb ft of torque Check PTO opening oil sump pan strainer and rear bearing covers for oil leakage due to faulty gaskets PRECAUTIONS Disassembly It is assumed in the detailed disassembly instructions that the lubricant has been drained from transmission the necessary linkage and air lines disconnected and the transmission has been removed from vehicle chassis Removal of the gear shift lever housing assembly or remote control assembly is included in the detailed in structions Disassembly and Reassembly Shifting Controls however this assembly MUST be detached from shift bar housing before transmission can be removed FOLLOW CLOSELY EACH PROCEDURE IN THE DETAILED INSTRUCTIONS MAKING USE OF THE TEXT iLLUS TRATIONS AND PHOTOGRAPHS PROVIDED 1 BEARINGS Carefully wash and relubricate all reusable bearings as removed and protectively wrap until ready for use Remove bearings planned to be reused with pullers designed for this pur pose ASSEMBLIES When disassembling the various assemblies such as the mainshaft countershaft and shift bar housing lay all parts on a clean bench in the same sequence as removed This pro cedure will

SPEC FLYER -CEMT18 (AUG92).

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