transmission - Discount Truck Transmissions
Contents
1. trem 551442 244 HET Smad prr 8 Position 1st reverse bar assembly the housing as 10 Position the 41h Sth yoke assembly in the housing sembly as shown assembly as shown NOTE Position spacers as shown Ea _ a 9 Install the 2nd 3rd yoke assembly interlock pin inset 11 Place the shift yokes in and install two Position the 2nd 3rd yoke assembly in the housing asser retainers and the four capscrews as shown Tighten the bly as shown capscrews fo the recommended torque Shift 4th Sth yoke assembly into 4th speed position DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Assembly cont 12 Install the remaining two capscrews and tighten capescr ws t recammanded torque REMOVAL YOKE AND CLUTCH HOUSING Yoke and Clutch Housing WEAR OPARA s S 01 SPEEDO DRIVE DEAF v ui SNAP RAI __ TEN c 2 REARING CUP M 7 4 47 FLATE CAPSCREW 4 s CABRIT sy ont 25 v 5 Pe REAR BEARING a COVER r CLLITCM OSG WASHER oe i we 9p _ FID COVER CAP CHEN a i J F ALA AING2. ag CM NOR Or GOES Re eoe ul caca UR GR aa 12 INSPECTION xui ze Scie te da Rocha Deas e dure es Sane us a M UE 12 REASSEMBEY ERE tears e tae ac Cece Nae nine m EUR AR D 14 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS GEARSHIFT LEVER HOUSING ASSEMBLY 5 25 ELE mache x Rode a x Rma eR Dn 15 SHIFT BAR HOUSING ASSEMBLY RU EO KOC rd RR AUREUS be es 18 REMOVAL YOKE AND CLUTCH HOUSING 27 DISASSEMBLY TRANSMISSION 29 REASSEMBLY TRANSMISSION 43 INSTALLATION CLUTCH HOUSING 57 INSTALLATION SHIFTING CONTROLS 58 OPTIONS soe eps ees sates 59 1 FOREWORD This manual is designed to provide detailed information necessary to service and repair the Eaton Fuller Transmission listed on the cover outlined in the Table of Contents the manual is divided into 3 main sections a Technical information and reference b Removal disassembly reassembly and installation c Options 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 compo nent of the transmission needs to be repaired see the Table of Contents for the
3. PLUG Cu BEAL A BE HOLE COVER pn WASHER Cal 8196 887 1 Lack ihe transmission by engaging two mnainshalt gears 2 Remove the yoko from the output shati as shown Use adarge breaker bar t turn the retaining nut from the output shaft REMOVAL YOKE AND CLUTCH HOUSING 427 dite 2 Jar clutch housing witha rubber mallet and pull fram the transmission case 28 DISASSEMBLY TRANSMISSION Input Shaft Assembly SNAP POG 4 2 Y U ROLLER BEARINGS BEARINGS RETAINONG ANG INPUT SHAFT AND DAVE GEAR BEARING CUP A Remova E CILE 2 Remove the input shaft assembly fram the transmis 1 Remove the four capscrews from the front bearing cover and remove the cover and shims The front bearing sion cover shims can came of with the front bearing cover If necessary remove the oil seal fram the cover inset DISASSEMBLY TRANSMISSION 3 necessary remove the retention snap fing and the 5 Use a chisel to remove the bearing cage and rollers bearing retention ring install bearing puller and remove the bearing race from the input shaft 4 if necassary ramove the 14 roller bearings from tha main drive g ar bearing pocket DISASSEMBLY TRANSMISSION IPED C AVWOHPOMIZTER amp TH STH ASSEMBLY gt SYNOHAOMLZER
4. 17 Install mainghatt 3rd speed gear bearing 18 Install mainshafl 3rd amp poed gear clutching tenth facing 20 Install mainshatt 3rd speed paar retaining snap ring in down ihe snap ring groove REASSEMBLY TRANSMISSION Reassembly of Mainshaft cont 21 Install mainahaft 4th gear bearing 23 install mainshalt 4m 5r speed clutch hab machined lacing up 22 Install mainshaft dih gear clutching teeth facing 24 instali hrust beanng and bearing race the main up shati 4ih 6ih clutch hub 52 REASSEMBLY TRANSMISSION Reassembly of Mainshaft cont 25 Install 4th Sth speed synchronizer and cups aver tha 27 previousty removed install 14 roller bearings in the 46 545 clutch hub main drive gear bearing pocket Install the retention snap ring and retention ring inst lubricate the bearings with Tisi 26 Remove the mainshaft the vice and wrap 28 Heat the input shaft bearing and install the bearing on or rope around end 3ed synchronizer Use ahaistto install the input shaft iha mainshaft assembly in transmission case CAUTION Do not heat bearing above 275 F 138 C I possible use a heal lamp as the source REASSEMBLY TRANSMISSION 28 Install the input shaft by aligning clutching teeth 31 Install input shaft bearing cover gasket and cap drive gear with t
5. prp SET SCREWS 1 4 THREAD 4 COUTNERSHAFT REAR BEARING COVER CAPSCREWS 20 30 LBS FT 3 8 16 THREAD USE PLAIN FLAT WASHERS OIL DRAIN PLUG 20 25 LBS FT 3 4 PIPE THREAD APPLY LOCTITE 262 TO THREADS OF ALL CAPSCREWS BEFORE INSTALLING Adobe 0003 2 88 PREVENTIVE MAINTENANCE 10 PREVENTIVE MAINTENANCE Preventive Maintenance Check Chart CHECKS WITHOUT PARTIAL DISASSEMBLY OF CHASSIS OR CAB 1 Clutch Housing Mounting a Check all capscrews of clutch housing flange for looseness 2 Clutch Release Bearing Not Shown a Remove hand hole cover and check radial and axial clearance in release bearing b Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches 3 Clutch Pedal Shaft and Bores a Pry upward on shafts to check wear b If excessive movement is found remove clutch release mechanism and check bush ings in bores and wear on shafts 4 Lubricant a Change at specified service intervals b Use only the types and grades as recom mended See LUBRICATION 5 Filler and Drain Plugs a Remove filler plug and check level of lubricant at specified intervals Tighten filler and drain plugs securely 6 Capscrews and Gaskets a Check all capscrews especially those on PTO covers front and rear bearing covers for looseness which can cause oil leakage See TORQUE RECOMMENDATIONS b Check PTO opening and rear bearing covers for oil
6. Drain transmission while oil is warm To drain oil remove the drain plug at case bottom Clean the drain plug before re installing Refilling Clean case around filler plug and remove plug from case side Fillthetransmissiontothe level ofthe filler opening Ifthe transmission has two filler openings fill to the level of both openings The exact amount of oil depends on the transmission inclination and model Do not over fill this causes oil to be forced out of the case through the front bearing cover When adding oil types and brands of oii should not be mixed because of possible incompatibility LUBRICATION Operating Temperatures With Eaton Roadranger CD50 Transmission Fluid Heavy Duty Engine Oil and Mineral Oil The transmission should not be operated consistently at temperatures above 250 F 120 C However intermittent operating temperatures to 300 F 149 C do not harm the transmission Operating temperatures above 250 F increase the lubricant s oxidation rate and shorten its effective life When the average oper ating temperature is above 250 F the transmission can require more frequent oil changes or external cooling The following conditions in any combination can cause operating temperatures of over 250 F 1 operating consistently at slow speeds 2 high ambient tempera tures 3 restricted air flow around transmission 4 exhaust system too close to transmissio
7. FS 5005B with soft FS 5005C with short se fourth and 2 speed axle fourth and 2 speed axle Adobe 0001 2 88 General Information FS 5005 transmissions have five forward speeds and one reverse and are shifted as you would shift any synchro nized manual transmission following the simple 5 speed shift pattern Driving Tips Always use the clutch when making upshifts or downshifts Premature synchronizer failure can result from not using the clutch Always select a starting gear that provides sufficient reduction for the load and terrian Never downshift at road speed too high Never slam or jerk the shift lever to complete gear engagement Never coast with the transmission in neutral and the clutch dis engaged POWER FLOW The transmission must efficiently transfer the engine s power in terms of torque to the vehicle s rear wheels Knowl edge of what takes place in the transmission during torque transfer is essential when troubleshooting and making repairs Power torque from the engine is transferred to the input shaft and drive gear Torque is transferred to the countershaft drive gear Torque is delivered along the countershaft to all countershaft gears Torque is transferred to engaged mainshaft gear The cross section illustrates 1st speed gear position Engaged mainshaft gear internal clutching teeth transfers torque to mainshaft through synchronizer a
8. TRANSMISSION Mainshaft Disassembly cont 11 Remove the Sed speed g ar 13 Remove the 3rd gear synchronizer cup and synchro nizar assembly 12 Remove the 3rd gear bearing 14 Reposition mainshatt in the vise so rear bearing is up DISASSEMBLY TRANSMISSION Mainshaft Disassembly cont 16 OE ES SEL EET 18 Remove the 151 gear Use caution so not to lose bearing rollers under the 151 gear inset DISASSEMBLY TRANSMISSION Mainshaft Disassembly cont 221 52 21 Aemove tha 151 reverse sliding clutch 19 Remove the bearing rollers and spacers 22 Remove the shit hub 20 15t reverse shift hub snap ring 36 gt 2 5 lt d D Mainshaft Disassembly cont 25 Remove 2nd gear split washer retainer ring ersg gear Remove the rev 23 28 Remove the 2nd gear washer and iocating ball inset 24 Remove the reverse gear bearing DISASSEMBLY TRANSMISSION Mainshaft Disassembly DISASSEMBLY TRANSMISSION ountershaft Assembly 4TH SPEED DRIVE SNAP RING EAR 4 HEARING cur BEARING CONE Reverse Idler Assembly SEARING ROLLER pn SPACER C and Disassembly of Countershaft and Reverse idler 1 Romove tha Tour capscrews and the eauntershalt rear bearing caver and gasket 2 Remove t
9. 5 m EL LIN gu WASHER pide p BETAINER THRUST BEAMING GALL SPEED GEAR REF AINE i L A ND JRD BYMCHRONUER bI 2 mt SPACER 4 F 24 je COME EYNCHFONIZER m 27 ASHEA CuP REVERSE LJ ST SPEED GEAR B Removal and Disassembly of Mainshaft i HE DN 1 Remove the four retaining nuts and lockwashers and 2 Remove speedomelor drive gear inset the remove the raat bearing cover If necessary remove ihe front of the main shaft jo move the mainshalt rearward oil seal trom cower inset about 1 4 Use pry bars to remove the rear bearing cup and locating snap ring a DISASSEMBLY TRANSMISSION 3 Wrap a sling ar around the end 3rd synchronizer 5 Remove the thrust bearing and bearing race Use a hoist to remove the mainshalt assembly trom the transmission case 4 Install the mainshaft assembly ina vise equipped with B Remove 41h 5th speed cluteh hub jaws ar wood shat rant facing up Remove ihe 4th Sih soeed synchronizer and cupa DISASSEMBLY TRANSMISSION Mainshaft Disassembly cont 9 Remove 3rd speed gear retaining snag ring 7 Remove the 4th speed gear 10 Remove 3rd speed gear thrust washer Remove the focaling ball 41h gear pearing DISASSEMBLY
10. is equal to the limit of 12 degrees If you have a 0 degree mounting angle the transmission can be operated on a 12 degree 21 percent grade Anytime the transmission operating angle or 12 de grees is exceeded for an extended period of time the transmission should be equpped with an oil pump or cooler kit to insure proper lubrication Note on the chart the effect low oil levels can have on safe operating angles Allowing the oil level to fall 1 2 below the filler plug hole reduces the degree of grade by approximately 3 degrees 5 5 percent Proper Lubrication Levels are Essential 12 10 19 10 13 9 16 5 48 Limitations for Proper Lubrications Percent of Grade Percent Grade Converted to Degrees 0 1 2 4 5 6 7 Transmission Mounting Angle Dotted line showing 2 Quarts Low is for reference only Not recommended OPERATION Gear Shift Lever Pattern and Shifting Instructions Follow the simple 5 speed shift pattern Simple progressive shift pattern 1005 300 43850 a M 2 4H 2H 4H R au R 2 4 4 oe pie P A PA S a A N i So oe Pens M sce ua EO Ou d Neutral Neutral JE 7 N pax N piden ZU 2 Neutral 4 1 x 1H 3H 5H m 1L 3L V IL 3b 5L H EV T p NL E i 1 3 5 js e
11. it 4 H 1 RM i 4 Hissquapetturertet eque gpl 4 Remove the 4th 5th yoke assembly DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Disassembly cont 4 137 5 Remove 2nd 3rd yoke assembly and interlock pin insat shift bar Haemove istraverse bar assembly necessary B Remove the 1st reverse lack pin from the 18t reverse remave the front spacer from 15t reverse shift bar inset shift yoke assembly Remove the 1st reverse shift yoke inset DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Disassembly cont 1114 1211 B Remove the Tst reverse actuator 11 Remove the reverse plunger retaining plug and gasket from ihe shift bar housing 10 Remove the four interlock balls the three detent balls 12 Remove the reverse plunger spring the three back up light switch balls and the three springs fram the shift bar housing 21 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Disassembly cont 1 TCU E 4 13 the reverse plunger stop 15 If the yoke pads are to be replaced remove warn pad tram shift yoke install now pad and bend tabs over tap and bottom of yoke 15 necessary blocks and shift yokes can removed by driving lockpen trom shift bar with a punch and hammer as shown DI
12. 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 15 Instructions for installation are on page 58 Service Manuals Illustrated Parts Lists Drivers Instructions and other forms of product service information for these and other Eaton Fuller Transmissions are available upon re quest A Product Literature Order Form Service Bulletins detailing information on product improve ments repair procedures and other service related subjects can be obtained by writing to the following address EATON CORPORATION TRANSMISSION DIVISION Technical Service Department P O Box 4013 Kalamazoo Michigan 49003 616 342 3344 Every effort has been made to ensure the accuracy of all information in this brochure However Eaton Transmis sion Division makes no expressed or implied warranty or representation based on the enctosed information Any errors or omissions may be reported to Training and Publications Eaton Transmission Division P O Box 4013 Kalamazoo MI 49003 MODEL DESIGNATIONS AND SPECIFICATIONS Nomenclature F S 5 0 0 5 Number Designations Letter Designations Ratio Group Forward Speeds Fuller Synchronized Design Level x 100 Nominal Torque Capacity IMPORTANT All Eaton Fuller Transmissions are identified by the model and serial number This information is stamped on
13. these procedures are closely followed 1 Maintain oil level Inspect regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy from a reputable dealer Lubrication Change and Inspection Eaton Roadranger CD50 Transmission Fluid HIGHWAY USE First 3 000 tc 5 000 miles Factory fill 4827 to 8045 Km initia orais Every 10 000 miles Check fluid level 16090 Check or ieaxs Every 250 000 miles Change transmission 492336 Km OFF HIGHWAY USE Factory fl First 30 hours initial drain Every 40 hours Inspect fluic evel Check for leaks Cnange transmission luic where severe dirt conditions exist Change transm ss o fluid Norma off n ghway use Every 500 hours Every 1 009 Heavy Duty Engine Lubricant or Mineral Gear Lubricant HIGHWAY USE First 3 900 to 5 200 miles Faccory fill 4827 to 8045 Km initial Every 70 000 miles Inspect lubricant level 116990 Cneck for eexs Every 50 900 mles Change transmission 60450 lubricart OFF HIGHWAY USE Change transmission First 39 hours lubricant cn new units Every 40 purs Inspect lubricant eve Checa for ieaks Change transmissior lubricant where severe dirt conditons exist Change transmission lubricant Norma off highway use Every 500 hours Every 1 000 hours Recommended Lubricants Fahrenheit
14. Celsius Grade Ambient SAE Temperature Eaton Roadranger CD50 Transmission All Fluid Heavy Duty Engine Oi Mli L 2104B C or D or Above 10 t F API SF or AP CD Above 10 F Previous API designacions Below 10 F acceotab 12 126 12 C Mneral Gear Ol w h rust and oxization inhibitor API GL Above 19 F i 72 C Below 0 F 2 C Theuse of mild EP gear oil or multi purpose gear oil is not recommended but if these gear oils are used be sure to adhere to the following limitations Do not use mild EP gear oil or multi purpose gear oil when operating temperatures are above 230 F 110 C Many of these gear oils particularly 85W140 break down above 230 F and coat seals bearings and gears with deposits that can cause premature failures If these deposits are observed especially a coating on seal areas causing oil leakage change to Eaton Roadranger CD50 transmission fluid heavy duty en gine oil or mineral gear oil to assure maximum compo nent life and to maintain your warranty with Eaton Also see Operating Temperatures Additives and friction modifiers are not recommended for use in Eaton Fuller Transmissions Proper Oil Level Improper Oil Level Proper Oil Level Make sure oil is level with the filler opening Because you can reach oil with your finger does not mean oil is at proper level One inch of oil level is about one gallon of oil Draining Oil
15. Housing and Gear Shift Lever 1 1 Place the Eransrission in neutral and install the gasket 3 Install the remaining capscrews and tighten to the Piace the shift bar housing in neutral and install on casa recommended torque make sura the shift yokes align with corresponding gyri chronizers and sliding clutch 2 Apply Loctite 8262 to Ihreads ol capscrews Install teo 4 Goat the retaining capscrews threads pctite 262 capacrews into shill bar housing alignment holes and and install Tighten the capscrews to the recommended tighten to the recommended torque tanque OPTIONS REMOTE SHIFT ARM SHIFT FINGER WASHER OPTIONAL CAPSCREW SA SPRING OPTIONAL Cut 727 8 87 REMOTE CONTROL HOUSING ASSEMBLY BREATHER BUSHING CAPSCREW HOUSING BUSHING Cut 728 6 87 Copyright Eaton Corporation 2012 Eaton hereby grant their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION 15 NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contain
16. Inspection Before reassembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Eaton Fuller Transmission parts to assure continued performance and extended life from your unit Since the cost of a new part is generally a small fraction of the total cost of downtime and labor avoid reusing a questionable part which could lead to additional repairs and expense soon after reassembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the unit s history mileage application etc Recommended inspection procedures are provided in the following checklist A BEARINGS B GEARS 1 Wash all bearings in clean solvent Check balls 1 Check gear teeth for frosting and pitting Frost rollers and raceways for pitting discoloration ing of gear teeth faces present no threat of and spalled areas Replace bearings that are transmission failure Often in continued opera pitted discolored spalled or damaged during tion of the unit frosted gears heal and do not disassembly progress to the pitting stage In most cases gears with light to moderate pitted teeth have 2 Lubricate bearings that are not pitted discol considerable gear life remaining and can be ored or spalled and check for axial and radial reused but gears with advanced stage pitting clearances should be replac
17. SASSEMBLY AND REASSEMBLY SHIFTING CONTROLS 119 Reassembly of Shift Bar Housing 1 Place the shift bar housing on its side shown and 3 Install he reverse plunger gasket and plug Tighten the install the reverse plunger reversa plunger plug to the recommended torque 2 Install mese plunger sping inset and fhe reverse plunger stop 4 if shift blacks or shift yokes were removed align shift yoke or black wit alignment hole in the shift bar and inseri lock pan NOTE previously removed install two spacers on 18t reverse shift bar betone installing both shift blocks inset DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Assembly cont 5 Install intariock balls detent balls and springs in the 3rd detent spring and ball Position 2 balls in adjacent following sequence position 3 balls in the reverse light cross bore and install 4th 5th detent spring and switch bore and install 131 reverse detent spring and NOTE Balis and springs can be used interchangeably Position 2 balls in adjacent cross bare and install 2nd 6 Seal the 1si reverse actuator in the shift bar housing 7 Position 1st reverse yoke assembly in the shift bar over ihe actuator pivot pin as shown housing inset Install the 1st reverse lock pin in the yoke assembly 2 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Assembly cont
18. Service Manual Fuller Mid Range Transmissions TRSMO130 October 2007 FS 4005A FS 4005B FS 4005C FS 4205A FS 4205B FS 4205C FS 5005A FS 5005B FS 5005C ETN Powering Business Worldwide BACKED BY Roadranger SUPPORT For parts or service call us Pro Gear amp Transmission Inc 1 877 776 4600 407 872 1901 parts eprogear com 906 W Gore St Orlando FL 32805 A WARNING Before starting a vehicle always be seated in the drivers seat place the transmission in neutral set the park ing brakes and disengage the clutch Before working on a vehicle place the transmission in neutral set the park ing brakes and block the wheels Before towing the vehicle place the transmission in neutral and lift the rear wheels off the ground or discon nect the driveline to avoid damage to the transmission during towing TABLE OF CONTENTS FOREWORD wee Kis deeds dA Rep da teens 2 MODEL DESIGNATIONS AND SPECIFICATIONS 3 XS Rast Y san nca De acu y dicata die RERO QE 4 OPERATION RR on Re EATUR RR een 6 POWER FEOW eua asa re se Me QoS E S aci na ocn odi e E M RR 7 TORQUE RECOMMENDATIONS 8 PREVENTIVE MAINTENANCE 1 6494 e ECRIRE REOR RR ER ed mim 10 PRECAUTIONS DISASSEMBLY
19. Y MODEL SERIES TO ENSURE THAT PROPER PARTS ARE USED DURING REASSEMBLY OF THE TRANSMISSION DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Gearshift Lever Housing Assembly LEVER GRIP em COVER ix gt DUE HOUSING f a Eum D a SHIFT LEVER WASHER 1 Turn aut four capscraws and ramowe the tower assem 2 Remove the shift lever grip and boot from the shift lever bly and gasket tram the shift bar housing assmbly ina vise with the housing bottom up Use a lange screwdriver to twist between spring and housing forcing the spring from under the housing lugs Do at a tima DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Gearshift Lever Housing Assembly cont s ini 5 Remove the spade pins from housing hore 4 Remove the washer and gearshift laver from the housing Remove the boot from the gear shift lavar 16 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS B Reassembly of Gearshift Lever Housing Assembly 1 Secure the gearshift lever housing in vise install the 3 Use a spring driving tool to install the tension spring spade pins in housing bare under the housing lugs seating one at a time T 2 2 Position gearshift lever in housing with the spade pins 4 Remove assembly the vise and install the rubber in ihe lever ball shat and install the tension spring washer boot over th
20. a gearshilt laver and against tha housing over the ball dished side up Install tha shift lever grip 17 DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS Shift Bar Housing Assembly CAPSORE WY LIFTING EVE PLUG Dr JAK I L REVERSE STOP a 1 REVERSE PLUNGER REVERSE 7950 e LICHT SWITCH LUE Fil BOCK 1aT AEVERSE WORE BAR SPACER REAR LOCK PIN REVERSE BLOCK y rs GM a 2 SPAGER FRONT S YOKE RAR Y e 4TH STH TORE dTH 5TH YORE p Jj De IFTAINERB ss 1 Lia USING GASKET gt 5 ACTUATOR LOCK PIN BALL THO 3HD YOKE Eg BPRING 157 HEVERSE YERE 15T REVERSE WORE al VI DISASSEMBLY AND REASSEMBLY SHIFTING CONTROLS C Removal and Disassembly of Shift Bar Housing 1 Shift the transmission inta neutral position rama the capscraws and lift the shiit bar housing and gasket from the casa inse 2 Lay the shii bar housing on the work bench Remove two capscrows as shown and shift 4th Sin yoke assembly inta 4th spaed position with a screwd rbver 3 Remove tha rest ol tha capscrews and the two retain ers riii 1 aod ER P ata 2 Ah
21. all 4th and Sth spond gear keys in the countershaht 3 insta ring in the countershatt iront snap ring heyways inset Align 41 speed cauntershaft key groave way to shaft key Press 4th gear on the countershatt long hub to shaft front 2 Press Sth speed countorshalt gear on lang hubo shaft 4 Heat and install the front countershaft bearing iar CAUTION Do not heat the bearing above 275 F 136 C possdye use a heat lamp ihe source REASSEMBLY TRANSMISSION Reassembly Countershaft and Reverse Idler cont ikbal 44 5 and install the rear cauntershaft bearing CAUTION Donat heat the bearing above 275 F 136 C if possible use a heat lamp as the source T Use grease on the two reverse idler thrust washers 1 hald in place Install reverse idier gear with tangs of wash ers in housing groove with the small reverse idler gear to the rear B If previously removed install the snap ring cauntershaft front bearing race from inside of case and front case bore plug Coat the outer diameter of bore plug with Loctite 510 before installing B Insert the reverse idler shaft through the case and idler gear needle bearings Install the reversa idler retainer and capserew inset Make sure the idler shalt locking groove lines up with the capscrew hole Tighten the capecrew to the recommended torque REASSEMBLY TRANSMISSION Reassembly Countershaft and Reverse I
22. dler cont 8 Carelully lower the countershaft into the transmission 12 Temporaniy install new shima into the bearing retainer inset Install the retainer and bohtan these screws to the recommended Larque 10 Position the transmission case on end as shown Position ihe countershalr assembly inta the front bearing REASSEMBLY TRANSMISSION bly Co Reassem prse untershaft and Reverse Idler cont 13 Rolate the countershalt to seat the bearings and races Position ihe dial indicator as shown lift tha cauntershaft witha screwdriver to measure the end play End play must be set al 002 008 0 05 0 20 mm Add shims for more end play and remove shims lar less end play NOTE Once end play is correct remove the retainer and apply a light coat of Loctite 510 to each side of the shims and iha retainer face Goat sat screw threads with Loctite 262 and tighten to the recommended torgue 14 Install the countershaft rear bearing cover and gasket Coat capscrew threads with Loctite 262 and tighten to the recommended tarque 46 REASSEMBLY TRANSMISSION B nsn and Installation Mainshaft 1 install the masnshaft in a vise equipped with wood Install locating ball inset and 2nd gear spiri washer brass jaws rear facing up Lubricate and install the split rings join at the locating ball manehan 2nd speed gear baaring mg 2 Ins
23. ds 2 Check pedal shafts Replace those worn at bushing surfaces H SHIFT BAR HOUSING ASSEMBLY 1 Check for wear on shift yokes and finger as sembly at pads and lever slot Replace exces sively worn parts 2 Check yokes for correct alignment Replace sprung yokes 3 Check lockscrews in yoke assembly retainer plates Tighten those loose GEAR SHIFT LEVER HOUSING ASSEMBLY 1 Check spring tension on shift lever Replace tension spring if lever moves too freely 2 If housing is disassembled check gear shift lever bottom end and shift finger assembly for wear Replace both gears if excessively worn J BEARING COVERS 1 Check covers for wear from thrust of adjacent bearing Replace covers damaged from thrust of bearing outer race 2 Check cover bores for wear Replace those worn oversized K OIL SEALS 1 Check oil seal in input shaft and rear bearing cover If sealing action of lip has been de stroyed replace seal L 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 loose ness 3 Check synchronizer contact surfaces on the synchronizer cups for wear PRECAUTIONS Reassembly Make sure that case interiors and housings are clean t is important that dirt and other foreign materials are kept out of the transmission during reassembly Dirt is an abrasive and can damage pol
24. ed Replace bearings with excessive clearances 2 Check for gears with clutching teeth abnormally worn tapered or reduced in length from clash 3 Check bearing fit Bearing inner races should ing in shifting Replace gears found in any of be tight to shaft outer races slightly tight to slightly loose in case bore If bearing spins freely in bore case should be replaced 12 these conditions PRECAUTIONS Inspection cont 3 Check axial clearance of gears Where exces sive clearance is found check gear snap ring split washer clutch hub and gear hub for ex cessive wear C SPLINES 1 Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub have worn into the sides of the splines replace the specific shaft affected D WASHERS 1 Check surfaces of all 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 Heavy castings may be welded or brazed pro vided the cracks do not extend into the bearing bores or bolting surfaces When welding never place the ground so current passes through the transmission G CLUTCH RELEASE PARTS 1 Check clutch release parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pa
25. ed within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www eaton com roadranger In Mexico call 001 800 826 4357 Roadranger Eaton and trusted partners providing the best products and services in the industry ensuring more time on the road Eaton Corporation Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA Roadranger Powering Business Worldwide SUPPORT For parts or service call us Pro Gear amp Transmission Inc 1 877 776 4600 407 872 1901 parts eprogear com 906 W Gore St Orlando FL 32805
26. eeth in mainshaft Sth speed synchronizer screws The ront bearing cover lubrication pil groove must cup beatthetop Apply Loctite 262 to threads of capscsrews and tighten to recommended torque NOTE Baaring cover is marked for proper installation 32 Install tna speedometer driva gear or rator an the output shaft 30 Coat the outer diameter of the input shalt bearing cover oil seal with Loctite 4510 Install the oil seal an the front bearing cover with a bearing driver as shown Install the input bearing race in the front bearing cover with the proper bearing driver REASSEMBLY TRANSMISSION Installation of Mainshaft cont 33 Install the main shaft rear outer bearing race in the oulpul shat bearing bore 34 Il a new ol seal is required install using a flanged driver Coal tha oll seal outer diameter with Loctite 510 35 Coat both sides of a new rear bearing cover gasket with Loctite 510 and position the gasket on the rear bearing cover Install the rear bearing cover positon the lubrication oil groove with case hale NOTE Rear bearing cover is marked for proper installa tion 36 Tighten the rant bearing cover capscrews to 30 im Ibs at torque Using two feelar gages at Ihe capscrew loca recard tha gap between the iront bearing cover and the transmission case Average the two recorded meas uramerts and add 0 016 This total gives you shim pack thickness Lo start the and play measur
27. ement Combine the shims to aqual the total shim pack measurement Irem the above procedura Remova the front bearing cover and install the shim pack Replace the front bearing cover and four retaining capscraws lighten capscrews 1o recom mended torgue REASSEMBLY TRANSMISSION Installation of Mainshaft cont ond i 1 Im EU 37 Place transmission in a vertical position as shown Install yoke ard nut Tightenthe yoke nut to recommended torque Rotate the input shaft six times in each direction to seal the bearings and races 38 Position dial indicator as shown on the output shan Pry on thu output flange and read the dial indicator io gui the mainshalt end play End play must be between 008 012 0 20 0 30 mm Add shims to the front bearing cover for more end play or ramove shims for less and play After the correct and play 15 set remove the front bearing cover and shims beth sides of tha shima with a light coal Loctite 610 Install the shims and the front bearing cover on the transmission case Coat the trant bearing cover cupscrews with Loctite 252 install in the front bearing cover and tighten to the recommended tongui INSTALLATION CLUTCH HOUSING 1 Position the transmission as shown Place the clutch housing onthe transmission case Install the four retaining bolts and tighten to the recommended torque INSTALLATION SHIFTING CONTROLS A Installation of Shift Bar
28. he two sot screws inset Remove tha bearing retainer outer race and shine NOTE Countershaft may slide to the rear and out of the DISASSEMBLY TRANSMISSION Countershaft and Reverse Idler Disassembly cont 3 the countershait assembly the rear HM it 5 Using a wedge bar remove the reverse idler from the transmission case 3 s its E M 4 the reverse iter retaining capscrew and ihe 6 Remove the reverse idler bearings spacer and retainer thrust washers 40 DISASSEMBLY TRANSMISSION 7 It tha countershaft front bearing race is to be replaced B Lisa a screwdriver and snap rina pilers to move the snap drive the bore plug through the front of the transmissison ring aut of snap ring groove and against the bearing back and drive tha race to the rear toward the case s inside 8 Position gear puller and clamp behind the rear counter 10 Use the countershalt drive gear rear face as a base shalt bearing and remove ihe bearing then press the drive gear snap ring and bearing fram the countershaf 41 DISASSEMBLY TRANSMISSION Countershaft 7 288 11 Remove ihe 5th gear key from countershafi 13 Remove Ath gear key from the countershaft 12 Remove countershalt 4th gear REASSEMBLY TRANSMISSION A Reassembly and Installation of Countershaft and Reverse 1 Inst
29. ished surfaces of bearings and washers Use certain precautions as listed below during reassembly 1 GASKETS Use new gaskets throughout the 5 INITIAL LUBRICATION Coat all thrust washers transmission as it is being rebuilt Make sure all synchronizers and bearings with transmission gaskets are installed An omission of any gasket lubricant during reassembly to prevent damage can result in oil leakage or misalignment of during initial start up bearing covers 6 AXIAL CLEARANCES Maintain origina 2 CAPSCREWS To prevent oil leakage and clearances for mainshaft gears loosening use Loctite 262 thread sealant on all capscrews For recommended torque ratings 7 BEARINGS Using a sleeve type driver that see TORQUE RECOMMENDATIONS contacts the bearing inner race prevents damage to the rollers and cage 3 SHIMS Apply a light coat of Loctite 510 to both sides of shims before final installation to prevent 8 UNIVERSAL JOINT COMPANION FLANGE OR leakage YOKE Pull the companion flange or yoke into place with the output shaft nut using 300 350 4 ASSEMBLY See the illustrations provided in the Ibs ft 407 475 Nm of torque Make sure the detailed disassembly instructions as a guide to speed ometer drive gear or a replacement spacer reassembly has been installed Failure to properly torque the nut can result in damage to the mainshaft rear bearing IMPORTANT SEE THE APPROPRIATE ILLUSTRATED PARTS LIST SPECIFIED B
30. leakage 7 Gear Shift Lever a Check for looseness and free play in hous ing If lever is loose in housing proceed with Check No 8 8 Gear Shift Lever Housing Assembly a Remove the gear shift lever housing assem bly from transmission b Check tension spring and washer for set and wear c Check gear shift lever bottom end for wear of Slots Also check finger assembly for wear CHECKS WITH DRIVE LINE DROPPED 9 Universal Joint Companion Flange or Yoke Nut a Check for tightness Tighten to recom mended torque rating 10 Output Shaft Not Shown a Pry upward against output shaft to check radial clearance in mainshaft rear bearing CHECKS WITH UNIVERSAL JOINT COM PANION FLANGE OR YOKE REMOVED NOTE If necessary use solvent and shop rag to clean sealing surface of companion flange or yoke DO NOT USE CROCUS CLOTH EMERY PAPER OR OTHER ABRASIVE MATERIALS THAT WILL MAR SURFACE FINISH 11 Splines on Output Shaft Not Shown a Check for wear from movement and chucking action of the universal joint companion flange or yoke 12 Mainshaft Rear Bearing Cover a Check oil seal for wear PRECAUTIONS Disassembly It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission the necessary linkage disconnected and the transmission has been removed from vehicle chassis Removal of the gear shift lever housing assembly is included in the detailed instructions Di
31. n 5 high horsepower overdrive operation External oil coolers are available to reduce operating temperatures when the above conditions are encoun tered Transmission Oil Coolers are Recommended Wlith engines of 350 and above with overdrive transmissions Required MWith engines 399 and above with over drive transmissions and GCW s over 90 000 Ibs With engines 399 H P and above and 1400 lbs ft or greater torque With engines 450 and above With EP or Multipurpose Gear Oil Mild EP gear oil and multipurpose gear oil are not recommended when lubricant operating temperatures are above 230 F 110 C In addition transmission oil coolers are not recommended with these gear oils since the oil cooler materials can be attacked by these gear oils The lower temperature limit and oil cooler restriction with these gear oils generally limit their success to milder applications Proper Lubrication Levels as Related to Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication can occur The operat ing angle is the transmission mounting angle in the chassis plus the percent of upgrade expressed in degrees The chart below illustrates the safe percent of upgrade on which the transmission can be used with various chassis mounting angles For example if you have a 4 degree transmission mounting angle then 8 degrees or 14 percent of grade
32. sassembly 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 ILLUSTRATIONS AND PHOTOGRAPHS PROVIDED 1 BEARINGS Carefully wash and relubricate all reuseable bearings as removed and protectively wrapped until ready for use Remove bearings planned to be reused with pullers designed for this purpose 4 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 2 ASSEMBLIES When disassembling the various assemblies such as the mainshaft counter 5 shafts and shift bar housing lay all parts on a WHEN USING TOOLS TO MOVE PARTS Always apply force to shafts housings etc with clean bench in the same order as removed This procedure simplifies reassembly and reduces the possibility of losing parts restraint Movement of some parts is restricted Never apply force to the part being driven after it stops solidly The use of soft hammers bar and mauls far all disassembly work is recommended 3 SNAP RINGS Remove snap rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose
33. ssembly Mainshaft transfers torque directly to driveshaft through rear yoke Oar an Tie y n ha Ui 777 m 2 7 7 TORQUE RECOMMENDATIONS Correct torque application is important to assure long transmission life Over or under tightening of fasteners can resull in a loose installation and in many instances can eventually cause damage to the transmission Use a torque wrench to obtain recommended torque ratings Do not torque capscrews dry 4 SHIFT LEVER HOUSING 9 SHIFT RAIL RETAINER CAPSCREWS CAPSCREWS 20 25 LBS FT 20 25 LBS FT 4 FRONT BEARING 3 8 16 THREAD 3 8 16 THREAD COVER CAPSCREWS 15 20 LBS FT 17 SHIFT BAR HOUSING CAPSCREWS 20 25 LBS FT 3 8 16 THREAD 5 16 18 THREAD 4 CLUTCH HOUSING CAPSCREWS 145 155 LBS FT 5 8 16 THREAD 2 HAND HOLE OUTPUT SHAFT NUT COVER CAPSCREWS 300 350 LBS FT 5 LBS FT 11 4 18 THREAD WITH 1 4 12 THREAD NYLON LOCKING INSERT OILED AT VEHICLE INSTALLATION Adobe 0002 2 88 TORQUE RECOMMENDATIONS 4 MAINSHAFT REAR BEARING COVER NUTS 60 70 LBS FT 1 2 32 THREAD USE LOCKWASHERS T 2607 1 C S2 A Ko RA iN OIL FILL PLUG 20 25 LBS FT 3 4 PIPE THREAD 14 PTO COVER CAPSCREWS 10 15 LBS FT S A 2 COUNTERSHAFT REAR 3 8 16 THREADS X
34. tall masnshatt 2nd gear 4 install 2nd gear washer retainer ring AT 7 Install mainshaft 1st reverse speed clutch hub haft cont Ins M al O z 2 2 E gt 2 J tr 5 Install mainshaltt reversa gear bearing Reassembly of Ma B Install 151 gear sliding clutch 6 Install mainshaft reverse gear REASSEMBLY TRANSMISSION 11 install m gear over the two rows ol needis bearings with clutching teeth down Be careful not to 10 Coat the 18 gear position with a high quality 12 install a locating on the mainshaft Install 151 grease Lay a row of needia bearings around the main speed gear washer so the split rings join at the shaft 44 naedie bearins Place a spacer rig over the tap locating ball Of tha bearings Lay a second row of 44 needle bearings around the mainshah on top of the spacer ring Install a spacer fing over the top the second row of needle bearings REASSEMBLY TRANSMISSION Reassembly of Mainshaft cont Imm 13 Install the split washer retainer ring over the split rings 15 Reposition mainshat in vise so front is up Install tha mainshaft 3rd speed gear synchronizer assembly 14 Using a bearing driver install mainshaft rear bearing 16 Install the mainshaft 3rd speed gear synchronizer cup as shown as shown 50 REASSEMBLY TRANSMISSION Reassembly of Mainshaft cont
35. the transmission identifi cation tag and affixed to the case DO NOT REMOVE OR DESTROY THE TRANSMIS SION IDENTIFICATION TAG Specifications jd ve Soeed 5 Gear Ratios PTO Gear 9 Capacity Ne R P M ters Model Speecs FS 5005A 2 54 FS 5005B E 30 515 219 556 0 FS 5005C 515 21 9 556 0 1 Lengths measured from clutch housing face to speedo gear rear 2 Weights include shift bar housing clutch housing less tower assembly and clutch release parts For more information on available clutch housings see the transmission s Illustrated Parts List or the Super Parts Book 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 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 long transmission life Eaton Fuller Transmissions are designed so that the internal parts operate in an oil circulating bath by the motion of the gears and shafts Thus all parts are amply lubricated if
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