Service Manual
Contents
1. 2 9 Brake Adjusting End 1 26 Brake Support Stud Nut Lockwasher 2 10 Brake Draw Rod Clevis Pin Cotter 1 27 Brake Support Stud eee 1 11 Brake Spacer LinKk ccscccnccennns 2 28 Brake Band Locating Screw 1 12 Spacer Link Clevis Pin Cotter 2 29 Compression Spring ooocccccnnnnncnnnnnnncco 1 ECH el te Dl essa 1 30 Brake Band Facing Rivet 26 14 Brake Cam Lever Shoe 2 1 31 Brake Band Facing 1Brake Drum 15 Brake Band amp Facing Assembly Inc items 32 Brake Drum to Flange Bolt 4 30 4 31 1 16 Companion Flange co 1 17 Companion Flange to Brake Drum Lock washer4 280V SERIES ASSEMBLY INSTRUCTIONS When screws with pre applied thread locking compound Hand spin idler gear and countershaft assemblies after are removed after initial assembly clean thread locking each is installed on their bearings in trans case Both compound are removed after initial assembly clean must spin freely and smoothly threads thoroughly and apply Loctite 262 Thread Lock before re installation Unless otherwise specified Tighten all capscrews 20 25 Lbs Ft 27 2 33 8N m Check all mainshaft constant mesh gears to make sure they rotate freely on mainshaft Apply a thin coat of Loctite 510 Gasket Eliminator to the O D of all oil seals before Check mainshaft 1st amp Reverse sliding gear to make sure2. 1 al parta i K u d la m ri u d a y Figure 44 Install 4th 5th shift fork to shift rod roll pin move rod to neutral Figure 42 Install clutch housing and tighten stud nuts 60 to 80 ft Ibs torque Remove drive gear bearing cap and main drive gear 12 Figure 45 Install two interlock balls between 4th A 5th Figure 47 Install 2nd amp 3rd shift fork to shift rod roll and 2nd amp 3rd shift rods pin Move rod to neutral Figure 46 Install 2nd amp 3rd shift rod through shift sup Figure 48 Install two interlock balls between the 2nd amp port Install over shift spacer shift fork and interlock 3rd and 1st amp Reverse shift rods cross pin 13 MAINSHAFT REASSEMBLY F AF ond I 8 j ul al W i H Figure 49 Install 1st amp reverse rod through support and Figure 51 Install 2nd speed gear retainer ring locating into lug washer and 2nd speed gear on mainshaft NOTE clutch ing teeth are up Figure 50 Install 1st amp reverse lug lockscrew and lock wire to prevent loosening Figure 52 Install 2nd gear retainer ring 14 MA di a L i i RRE D CN IT AR Figure 53 Install 2nd amp 3rd shift hub sleeve and sleeve Figure 55 Install 3rd speed gear with clutching teeth retainer ring down Install 3rd gear locating washer Figure 54 Install 2nd amp 3rd synchronizer assembly Figure 52 Install 3rd gear retainer ring
3. Figure 97 Remove ist amp reverse shift fork and rail assembly Figure 100 Remove ist amp reverse shift rail 25 Figure 103 Remove 1st reverse rocker arm Figure 104 Remove reverse latch plunger spring retain ing plug Figure 105 Remove reverse latch plunger spring and plunger SEE CLEANING AND INSPECTION PROCEDURE PAGES 10 11 26 DIECAST CONTROL REASSEMBLY Figure 106 If fork bushings are worn secure fork in a vise equipped with soft jaws and remove worn bushings with a drift Install new bushings in fork Turn fork over on anvil of vise and secure bushing in fork using a prick punch and upsetting bushing metal on outside of fork Figure 110 Install mesh lock poppet balls quantity 4 Note 1st amp reverse shift fork rail poppet ball in pocket Figure 107 Install reverse latch plunger spring and retaining plug Tighten plug securely Figure 111 Align one tapered interlock cross pin with hole in 1st amp reverse shift rail Position rail on poppet ball with rail in neutral position Figure 108 Position 1st amp reverse rocker arm on pivot pin as shown 21 Figure 112 Note position of tapered interlock cross pin in relation to rail Figure 113 Install interlock cross pin in 2nd amp 3rd shift rail Figure 114 Position 2nd amp 3rd shift rail on poppet ball in neutral position with interlock pin aligned with 1st interlock tapered pin
4. install bearing cap and bolts Tighten bolts 15 to 20 ft Ibs torque 20 4 27 1 N m ZA Figure 74 Install mainshaft rear bearing Figure 76 Press a new oil seal in mainshaft rear bearing cap with lip of seal down Coat a new gasket on both sides with a grade 2 multi purpose grease Position gasket on mainshaft rear bearing cap use caution as not to cover oil return grooves in bearing cap Install bearing cap with oil grooves lined up with oil holes in case Tighten bolts 35 to 45 ft Ibs torque 47 5 61 0 N m 20 Figure 77 Install drum and flange assembly brake Figure 79 Install anchor clip spring and brake band on locating bracket and anchor support bar anchor support bar Figure 78 Install companion flange nut and tighten 400 Figure 80 Install brake release springs and cam lever to 500 ft Ibs torque 542 3 610 0 N m shoe as shown 21 Figure 83 Install anchor clip screw BRAKE BAND ADJUSTMENT Adjust brake band anchor screw to give clearance of 010 Figure 81 With spacer link and cam lever in position between brake drum and band Adjust brake band locat install adjusting bolt washer and nut ing screw and adjusting bolt to give a 010 clearance around the entire drum After adjustment lockwire ee ote sl anchor clip screw Figure 84 With transmission shifted into neutral install shift control assembly 2nd amp 3rd and 4th amp 5th shift forks set over shift hubs 1st a
5. 15 Figure 59 Turn mainshaft assembly over and install 1st Figure 57 Install 4th gear with clutching teeth up Note amp reverse sliding gear with shift fork slot down chamfer on 4th amp 5th shift hub sleeve Chamfer must go down Install bottom cup of 4th amp 5th synchronizer on Ath speed gear clutching teeth before installing 4th amp 5th shift hub sleeve Install sleeve retainer ring REASSEMBLY OF TRANSMISSION Figure 58 Install 4th amp oth synchronizer on shift hub Figure 60 Coat countershaft pilot bearing needles with sleeve heavy grease to hold in place until countershaft is installed 16 Figure 61 Tip rear of countershaft down and into trans Figure 63 Drive rear bearing on countershaft and rear mission case Feed rear of countershaft through rear bearing bore NOTE Countershaft drive gear must be countershaft bearing bore Move countershaft forward supported on each side with a Y flat bar to prevent dam and into pilot bearing CAUTION Do not disrupt counter age to countershaft pilot bearing Shaft needle bearing Figure 62 Position rear bearing oil slinger as shown and Figure 64 Install countershaft rear bearing retainer ring Start rear bearing 17 Figure 65 Coat a new gasket on both sides with a grade 2 multi purpose grease Position Figure 67 Insert two reverse idler gear bearings in idler gear Figure 66 Use heavy grease on reverse idler thrust washers
6. eseeeereereerreen 4 Clutch Housing CLARK 280V SERIES CONTROL PARTS GROUP Stamped Cover ITEM Description 1 oO co N O ow A W N oO OO N N N N N N N N N NO ech eck ek sch sch sch sch sch sch o ch O OO O N OO FO A O N O O O N QO ON A WO N lt O QTY Gear Shift Lever Dust Cover Gear Shift Lever Pivot Pm Control Top Gear Shift Lever Gear Shift Lever Support Washer Support Spring Control Top asko iodo Shift Rod Cover Shift Rod Cover Gasket nennen Shift Rod Support Shift Rod Support Screw and Lockwasher 1st amp Reverse Shift Fork Lockscrew 1st amp Reverse Shift Fork ccnn Shift Fork Lock bm 4th A oth Shift Fork Assembly Inc Items 16 17 1 Shift Fork Bushing Shift Fork Bushing Shift Fork Bushing Shift Fork Bushing SHINE FORK LOCKE IM EE 2nd amp 3rd Fork Assembly Inc Items 18 amp 19 1 2nd Speed Overshift Gpacer Reverse shift Lug Reverse shift Lug Lock ee MES ROO een Mesh Lock Ball Interlock Cross bm 2nd amp 3rd Shift Rod 1st amp Reverse Shift Rod Mesh Lock Spring Mesh Lock Spring ITEM Description 32 39 34 30 36 37 30 39 40 41 Reverse Latch Plunger Reverse Latch Plunger Retainer Washer Reverse Latch Plunger Spring 1st 4 Reverse Rocker Reverse Latch Plunger Nut Reverse
7. 28 Figure 115 Install 2nd interlock tapered pin Align pin with interlock cross pin hole Figure 116 Position 4th amp 5th shift fork and rail on pop pet ball in neutral Figure 117 Slightly raise rear of 4th amp 5th shift rail and align 2nd interlock tapered pin with cross hole in 4th amp 5th shift rail Figure 121 Install rail support capscrews and washers Tighten capscrews slightly Figure 118 Note position of tapered interlock pins and shift rails Figure 122 Install interlock tapered pin supports Tap 4th A 5th shift fork to the rear 4th speed position Figure 119 Install 1st 4 reverse shift fork and rail assembly on poppet ball in a neutral position Align 1st amp reverse rocker arm in notch at rear of rail as shown y a d r ETT Figure 123 Position front rail support and install cap Figure 120 Position rear rail support screws and washers 29 Figure 124 Tighten front and rear support capscrews 20 to 25 ft Ibs torque 27 2 33 8 N m Tap 4th amp 5th shift fork and rail assembly forward to a neutral position Figure 125 With transmission in neutral position con trol cover over gears aligning shift forks in shift cover with gear shift hubs If control cover is in neutral and transmission is in neutral transmission drive gear should turn without brake drum or output shaft turning Figure 126 Install center rear capscrews first and tighten 20 t
8. Latch Plunger Nut Backup Switch Hole Plug Cotter Backup Switch Hole Plug Gasket Welch Plug Control Top Screw amp Lockwasher CLARK 1 2 10 11 12 13 14 15 280V SERIES CONTROL PARTS GROUP Diecast Cover Fabricate Rails ITEM Description Gear Shift Lever Dust Cover Gear Shift Lever Pivot Pin COMO TOP aan Gear Shift LEVET sun ta Gear Shift Lever Support Washer Support Spring oeeie Control Top or Remote Control Gasket CONT Ol CO usara iaa 1st amp Reverse Rocker Am QTY 1st amp Reverse Shift Fork amp Rail Assembly Rear Rail Support nesnese Rear Rail Support Capscrew Lockwasher Rear Rail Support Capscrew Front Rail Support Capscrew Front Rail Support Capscrew Lockwasher ITEM Description QTY 16 Front Rall SUDO rasa aras 1 17 2nd amp 3rd 4th amp Sth Shift Fork Bushing 4 18 4th 5th Shift Fork amp Rail Ass y Includes Item 17 1 19 2nd amp 3rd Shift Fork amp Rail Ass y Includes Item 17 1 20 tenio GROSS Mco 1 21 Interlock Tapered Pin Support 2 22 Interlock Tapered PiD ooon connninnnininnnnicicnnrananinaracinccnrn occ 2 A RA O A 1 24 Mesh Lock Poppet RallS oooooomoo
9. Lock Ball ooooooooooooo 1 37 1st amp Reverse Latch Plunger Plug Gasket 1 16 1st amp Reverse Mesh Lock Spring 1 38 1st amp Reverse Latch Plunger Stop 1 17 1st amp Reverse Shift Fork oo 1 39 1st amp Reverse Latch Plunger Spring 1 18 1st amp Reverse Shift Fork Rail Lock Pin 1 40 1st amp Reverse Latch Plunger 1 19 1st amp Reverse Shift Fork Rail 1 41 Control Top Lockwasher ccce 4 20 Shift Fork BUSNING i 2 42 Control Top OC LOW za ee 4 21 SHIEEFOrKBUSHINGe 2 ae 2 22 4th amp 5th Shift Rail eee eres 1 CLARK 280V SERIES BRAKE PARTS GROUP ITEM Description QTY ITEM Description QTY 1 Brake Support Capscrew cccee 2 18 Companion Flange to Brake Drum Bolt Nut4 2 Brake Support Lapsgcreuw 2 19 Anchor Clip Screw ooonncccccnnnonccccnanncnnos 1 3 Brake Locating Bracket 1 20 Brake Compression Spring Washer 1 4 Brake Band Locating Screw Nut 2 21 Brake Adjusting Bolt Nut 2 5 Brake Release Spring 2 22 Brake Adjusting Bolt Nut Lockwasher 1 6 Brake Spacer Link Clevis Pin 2 23 Brake Anchor Support Bar 1 7 Brake Draw Rod Clevis Pin 1 24 Brake Anchor Clip SprinQ 1 8 Brake Cam Lever 2 25 Brake Support Stud Nut
10. ON On On gt O N ch Aa Aa BWW WWW WWW 0 QQ NN N NN NN NN N NN NN N NM HA sch sch eck sch sch ch SS ch sch N zk O O DAN OTA BW PO OO O GOAN OT On oO O ON OT Sw PE Oo 280V Series Transmission Description QTY Shift Rod KEE 14 Shift Rod Cover Screw LockWwaSher sesser 14 Control Cover Stamped vergion 1 Control Cover GASKket oononnnnnnnnnninnicinninrncrarcconrnna ran ncranancnos 1 Mainshaft 5th Speed Synchronizer Cup 1 Mainshaft 4th amp 5th Synchronizer Assembly 1 Mainshaft 4th Speed Synchronizer Cup 1 Mainshaft 4th 5th Shift Hub Sleeve Retainer Ring 1 Mainshaft 4th 5th Shift Hub Sleeve cnnn 1 Mainshaft 4th Speed Gear 1 Mainshaft 3rd Gear Retainer RINg nn 1 Mainshaft 3rd Gear Locating Wacher 1 Mainshaft 3rd Speed Gear oo coonnncconocicinnconacacinnnnaranacinn ona 1 Mainshaft 3rd Speed Synchronizer Cup 1 Mainshaft 2nd amp 3rd Synchronizer Assembly 1 Mainshaft 2nd 3rd Shift Hub Sleeve Retainer Ring 1 Mainshaft 2nd 3rd Shift Hub Sleeve co 1 Mainshaft 2nd 3rd Shift Hub Sleeve Retainer Ring 1 Mainshaft 2nd Speed Gear 1 Mainshaft 2nd Speed Gear Locating Washer 1 Mainshaft 2nd Speed Gear Retainer Himg oeccsccccccnren 1 Mansia asar taa lada 1 Mainshaft 1st amp Reverse Gent 1 Countershaft Rear Bearing CapSCreW iseer 4 Countershaft Rear Bearing Cap Lockwasher eenn 4 C
11. Service Manual Fuller Mid Range Transmissions TRSMO194 October 2007 E BACKED BY Powering Business Worldwide Roadranger SUPPORT Caution Before towing the vehicle be sure to lift the rear wheels off the ground or dis connect the driveline to avoid damage to the transmission during towing FOREWARD This manual has been prepared to provide the customer and the maintenance personnel with information and instruc tions on the maintenance and repair of the CLARK Transmission Extreme care has been exercised in the design selection of materials and manufacturing of these units The slight out lay in personal attention and cost required to provide regular and proper lubrication inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the transmission its principle of operation troubleshooting and adjustments it is urged that the service person study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of components parts is required only Clark approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment The Clark Equipment Company does not warrant repair or replacemen
12. a no rancia nos 12 Mainshaft Rear Bearing capscrew Lockwasher 1 Mainshaft Rear Bearing CapSCrew oisinn 1 Speedometer Driven Gear cccecsessesessessseessseessseeessseeesees 1 Speedometer Tube Nut oo onnnnninnicnonicinanccinrnccnncnaranananos 1 Reverse Idler Shaft Lock crew 1 Reverse Idler Shaft LOCK oo ooonnnccnnnccnnncccnanicinnrccrnnnanas 1 A an 1 Reverse Idler Thrust Wacher 2 Reverse Idler Bearing cccccccssssssssssssessseessseesseeesecseneeseess 2 Reverse Idler G ar ccsscssccssssssscsssssessseessseessseeesecseeeeseens 1 Mainshaft Spigot Bearing ooooccccnocccnoncccnoncnononaninnnnonananonanos 1 Main Drive esmas alain iia 1 Main Drive Gear Bearing Oil Slmger 1 Main Drive Gear Bearing ocoocccccccnncccnooccnnonnnononaninncrnnnonononos 1 Main Drive Gear Bearing Retainer RINng ooo 1 Main Drive Gear Bearing Cap Oil Gel 1 Main Drive Gear Bearing Cap Gacket 1 Main Drive Gear Bearing Lan 1 Main Drive Gear Bearing Capgcrgouw 4 Clutch Housing Stud NUT Sean ae ee ne 4 Clutch Housing Stud Nut Lockwaeher essercene 4 Gluten Housing A taderends 4 Countershaft Pilot Bearing 1 Pedal Shaft Grease Fitting eeeeeeeeneeerrerrere 2 Clutch Housing Clutch Housing Clutch Housing Inspection Plate Bolt 2 Inspection Plate Lockwasher 2 Inspection Plate 1 Clutch Pedal Shaft Bushing
13. arily prevent further movement of the shift lever and the pressure exerted by the driver to complete the movement is transferred by the blockers to the synchronizer providing the force neces Sary to synchronize the gears being engaged When the engaging gears have reached the same speed the blockers automatically disengage permitting the gear shift lever movement to be completed Therefore to properly shift a syn chronized transmission a steady and continuous pressure must be applied by the driver to the shift lever until the shift is completed Under normal conditions this action is instantaneous sometimes difficulty is experienced in shifting a synchronizer when the vehicle is standing still This is caused by the fact that the disengagement of the blockers requires relative rotation and with the vehicle at rest and with the engine clutch released there may be at times no relative rotation of the engaging gears Under these conditions the same con tinuous pressure should be applied to the shift lever and at the same time the clutch should be engaged slightly This will give sufficient rotation to unblock the synchronizer and allow the shift to be completed without difficulty RECOMMENDED LUBRICANTS FOR CLARK MANUALLY SHIFTED TRANSMISSIONS Mil L 2105C Extreme Pressure Lubricant or API classifica tion GL 5 of the SAE viscosity recommended in the chart at Prevailing Ambient the right is preferred All lubricants should be backed by the Te
14. assembly it slides freely on mainshaft bh When screws with pre applied thread locking Hand spin idler gear and countershaft assemblies compound are removed after initial assembly after each is instalted on their bearings in clean threads thoroughly and apply Loctite trans case Both must spin freely and smoothly 262 Thread Lock before re installation Untess otherwise specified make sure they rotate freely on mainshaft Apply a thin coat of Loctite 510 Check mainshaft 1st amp Rev sliding gear to make Gasket Eliminator to the O D of all oil seals before assembly sure it slides freely on mainshaft Tighten 4 screws 35 to 45 Lbs Ft 47 5 61 0 N m These gaskets installed dry Coat gasket on both sides or coat both mating surfaces with Grade 2 Multi Purpose Grease before assembly Tighten 4 screws 15 to 20 Lbs Ft 20 4 27 1 N m Tighten 60 to 70 Lbs Ft 81 4 94 9 N m 4 nuts Tighten 4 screws 60 to 80 Lbs Ft 81 4 108 4 N m Coat gaskets on both sides or coat both mating surfaces with Grade 2 Multi Purpose Grease Tighten 2 screws to maximum torque of 5 Lbs Ft 6 7 N m l Tighten P T O cover screws 6 each side 10 to 15 Lbs Ft 13 6 20 3 N m These screws must not be over tightened to avoid cover amp gasket damage When installing control assembly install amp tighten center rear screw first center Bu ss front screw second amp then remaining
15. case hardening is worn through or cracked replace with new gear Small nicks may be removed with suitable hone Inspect shafts to make cer tain they are not sprung bent or splines twisted and that Shaft are true 11 Housing Covers Etc Inspect housings covers and bearing caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures MAIN DRIVE GEAR DISASSEMBLY AND REASSEMBLY Figure 40 Remove main drive gear bearing retainer ring Press bearing and oil slinger from main drive gear Replace gear or bearing and install as shown Install retainer ring CLUTCH HOUSING OR COUNTERSHAFT STAMPED CONTROL REASSEMBLY FRONT BEARING REPLACEMENT Figure 41 If countershaft front bearing is to be replaced Figure 43 Install 4th 4 5th shift rod through support remove clutch housing and drive front bearing from and into 4th amp 5th shift fork transmission case Apply a light coat of permatex No 2 on the outher diameter of the new bearing Install in transmission case as shown with end of bearing 001 to 007 below the face of case Install main drive gear andearing assembly in transmission case Install main drive gear bearing cap on drive gear kan HB el F o S e HN TTT wm E P Za a SEAN ULC i with LL RI E 7 A
16. cionncicicncccrnccoso 4 25 POPDC TOONS unid 4 26 Reverse Latch Plunger cecceccessccssseceseeecrseeessseessnesesaeens 1 27 A Tu DEEN 1 28 Plunger Spring Retaining Plug essenin 1 Control Top or Remote Control Capscrew4 CLARK ah on mb co 280V SERIES CONTROL PARTS GROUP Diecast Cover Round Rails ITEM Description QTY ITEM Description QTY 1 Gear Shift Lever Dust Cover 1 23 Rear Rail Support 1 2 Gear Shift Lever Pivot Pin 2 24 Rail Support SCreW NENNEN 6 A Rene Ne tek ee nt eR ane 1 25 Front Rail Support taa 1 4 GEARSNIH Lever nee 1 26 210 Rob gt EE 1 5 Gear Shift Lever Support Washer 1 27 Inter Lock Cross Pm 1 0 SUPPO SPNO eren E 1 28 1st Gear Shift Stop Space wide 1 7 Control Top or Remote Control Gasket 1 29 1st amp Gear Shift ug 1 8 WEICH Alias 1 30 ist Gear Shift Stop Spacer narrow 1 9 Shift Rail Housing a nn 1 31 1st 4 Reverse Shift bal 1 10 1st Reverse Rocker Lug 1 32 Mesh amp Inter Lock Ball H 11 Shift Fork Ried EEN 4 33 Mesh Lock Spring 3 12 1st amp Reverse Rocker Am 1 34 Back up Switch Hole Plug Gasket 1 13 4th amp 5th Shift Fork ooomonccocinco o 1 35 Back up Switch Hole Plug 1 14 2nd 3rd Shift Fork NK 1 36 1st 4 Reverse Latch Plunger Springer Plug 1 15 Mesh
17. d to avoid inhalation of vapors and skin rashes when using alkali cleaners All parts cleaned must be thoroughly dried immediately by using moisture free compressed air or soft lintless absorbent wiping rages free of abrasive materials such as metal filings contaminated oil or lapping compound INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts Showing indication of wear or stress will eliminate costly and avoidable failures at a later date Bearings Carefully inspect all rollers and balls for wear chipping or nicks to determine fitness of bearings for further use After inspection dip bearings in clean oil and wrap in clean lintless cloth or paper to protect them until installed Oil Seals Gaskets Etc Replacement of spring load oil seals gaskets and snap rings is more economical when unit is disassembled that premature overhaul to replace these parts at a future time Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing members should be handled carefully particularly when being installed Cutting scratching or curling under of lip of seal Seriously impairs its efficiency Gears and Shafts If magno flux process is available use process to check parts Examine teeth on all gears carefully for wear pit ting chipping nicks cracks or scores If gear teeth Show spots where
18. itoin 1st amp reverse fork should not shift If it does inter lock cross pin or interlock cross over balls were not assembled correctly Disassemble cover and correct cross over See illustration Figure 13 A NOTE Install control cover capscrews in sequence explained in Figure 126 1 TROUBLESHOOTER S TRANSMISSION CHECKLIST NOISE ARISING IN NEUTRAL Misalignment of transmission Worn transmission bearings scuffed gear tooth contact surfaces on gears Worn mainshaft gear bushings Worn or rough reverse idler gear Sprung or work countershaft Excessive backlash in constant mesh gear Work mainshaft pilot bearing Incorrect lubricant Low lubricant level Noisy main drive gear bearing NOISE ARISING IN GEAR Worn or rough mainshaft rear bearing sliding gear teeth rough chipped tapered Excessive end play on mainshaft gears Noisy speedometer gears See Conditions under 1 NOISE ARISING OUTSIDE Out of balance fan Defective torsional dampener Out of balance crankshaft Out of balance flywheel Out of balance clutch assembly Loose engine mountings Worn universal joints U joints improperly installed Misaligned or sprung driveshaft Incorrect driveshaft assembly Out of balance driveshaft DIFFICULT SHIFTING Improperly operating clutch sliding gear or shift hubs tight on mainshaft splines Damaged chamfer on sliding gear teeth Burred mainshaft splines Misaligned mainshaft Damaged or worn synchronizer assembly Imp
19. made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www eaton com roadranger In Mexico call 001 800 826 4357 Roadranger Eaton and trusted partners providing the best products and services in the industry ensuring more time on the road Eaton Corporation Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA A BACKED BY E TeN Roadranger Powering Business Worldwide SUPPORT
20. mp reverse fork enters slot on 1st amp reverse gear Tighten bolts 20 to 25 ft Ibs torque 27 2 33 8 N m Position three mesh lock balls and Springs in Support housing Figure Install band locating screw as shown with threaded end up install nut 22 E E RR d H i A i N I ii j TE Fa e IE EE iw F pT j i y FF Ke k Figure 87 Install remove control or shift control top tighten bolts 20 to 25 ft Ibs torque 27 2 33 8 N m USE FOLLOWING PROCEDURE FOR DIECAST COVER DISASSEMBLY AND REASSEMBLY Fabricated Rails Figure 86 Tighten shift support cover bolts 20 to 25 ft Figure 88 Remove remote control or shift tower from Ibs torque 27 3 33 8 N m control cover Remove control cover capscrew and lock washers 23 Figure 89 Remove control cover assembly from trans Fi 92 R i 7 mission Remove backup switch igure 92 Remove front rall support Figure 90 With control cover in neutral pry 4th amp 5th Figure 93 Remove interlock tapered pin supports shift fork to 4th speed position toward the rear of cover Figure 91 Remove front rail support capscrews Figure 94 Note position of interlock tapered pins for reassembly 24 Figure 98 Remover 4th 5th 2nd amp 3rd shift fork and rail assembly See Caution in Figure 99 Figure 99 Use caution as not to lose interlock cross pin interlock tapered pins or mesh lock poppet balls
21. mperature reputation of a well know supplier It is important to specify m EN EP lubricants of the MIL L 2105C type only or of a API clas D 8 sification GL 5 e E X Do not use extreme pressure lubricants other than MIL L m T 2105C or of a API classification GL 5 mi m Many EP lubricants contain highly active chemical com sil pounds that have been formulated to perform satisfactorily in a specific types of applications Severe corrosion residual E ti g deposits and inadequate lubrication may result from HA Sri A MIL L 2105C improper application Use of EP lubricants other that MIL L try i Grade 80 90 2105C or of a API classification GL 5 may result in failure A lor Of a API and or impaired operation x en x as DRAINING ECONOMY The object in draining the transmis Sa x sion oil periodically is to eliminate possible bearing surface A ain d a abrasion and attendant wear Minute particles of metal the da i Su Kei product of normal wear in service are deposited in and circu e 7 PF MIL L 21056 75W late with the transmission oil The oil changes chemically a Eh due to its repeated heating and cooling also the terrific e churning it undergoes in the presence of air It is desirable to m f x drain out this used oil after the first 1 000 miles 1609 0 Km Lem of service regardless of type of service Subsequent drains ha should be made every 24 000 miles 38616 0 Km or six 6 Gem Va months whichever comes fi
22. o 25 ft Ibs torque 27 2 33 8 N m Install center front screw second and tighten 20 to 25 ft Ibs torque 27 2 33 8 N m Tighten remaining capscrews 20 to 25 ft Ibs torque 27 2 33 8 N m SHIFT CONTROL DISASSEMBLY Round Rails Figure 4 Remove 2nd amp 3rd shift fork and rail assembly CAUTION Do not loss interlock cross pin Figure 5 Remove 1st amp reverse shift fork rail and lug assembly Figure 3 Remove the 4th and oth shift fork and rail assembly Figure 6 Using a small magnet remove the 1st and reverse shift fork rod lock pin 31 Figure 7 Remove first amp reverse shift fork and rail assembly Figure 9 Remove mesh lock spring and lock ball 3 each Remove crossover interlock balls 4 each Ee Figure 10 If the second third fourth or fifth shift fork bushing is to be replaced remove worn bushings from fork Install new bushing and bend bushings tab over top and bottom of fork Figure 11 Remove reverse latch plunger pin and spring See Cleaning and Inspection Section Page 10 REASSEMBLY Figure 12 Install reverse latch plunger spring pin and plunger spring plug Figure 13 Position crossover interlock balls in cover cross bores Two balls in cover cross bore between 1st amp reverse rail groove and 2nd amp 3rd rail groove and two balls in cover cross bore between 2nd amp 3rd rail groove and 4th amp 5th rail groove See cross sec
23. ountershaft Rear Bearing Lan 1 Countershaft Rear Bearing Cap Gasket o n 1 Countershaft Rear Bearing Cap Retainer Ring 1 Countershaft Rear Bearing o ocncninnncinnnnninncninanicinaracinn caos 1 Countershaft Rear Bearing Oil Glmger 1 BOuntelsh ll ns kn en 1 Countershaft Gear Key ooooooncccccccccocnccoconocanoncnononcnonoconanonanonnos 1 Countershaft 4th Speed Gear 2 Countershaft Drive Gear cic scsssscsssesssesssssressseussseeeseees 1 Countershaft Drive Gear Heianerbmg ecscsercscccenrrrrn 1 AMERO EE 1 Magnetic Drain Plug EE 1 A erg 1 Flange to Drum Bolt Nut o oonnconncninnnaninanininanininaninnancnos 4 Flange to Drum Bolt Lockwasher nenn 4 compamon Fange ana ea 1 un een 1 item 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 Description QTY Brake Drum to Flange Bolt 4 Mainshaft Rear Oil Gel 1 Mainshaft Rear Mainshaft Rear Mainshaft Rear Bearing CADSCIEW NENNEN 3 Bearing capscrew Lockwasher 3 A A ddd aiid 1 Mainshaft Rear Bearing Cap Gasket o e 2 Speedometer Drive Gear ooo nnnnicinnnccnnnnicnnnnnanininaracino conan 1 Mainshaft Rear Bearing eseeseseeeresrrerrrerrrrrrrrerrerrrrrren 1 Transmission GAS 0 aia 1 P T O Cover Plate Gasket 2 REO COMO Plate nata 2 P T O Cover Plate SCrew oonnonnnicninncicornccaraccnnn nn rar
24. puller remove reverse idler shaft Figure 18 Remove mainshaft assembly Figure 20 Remove reverse idler gear bearings and two thrust washers Figure 21 Pry countershaft to the rear to expose rear bearing Figure 22 Remove countershaft rear bearing and oil Figure 24 Remove mainshaft 1st amp reverse sliding gear Slinger Set mainshaft up as shown and remove 4th amp 5th syn chronizer assembly NOTE Bottom synchronizer cup may stay on mainshaft Figure 25 Remove 4th oth shift hub sleeve retainer ring Figure 26 Remove 4th amp 5th shift hub sleeve and 4th Speed gear Figure 28 Remove 3rd speed gear and locating washer Figure 30 Remove 2nd amp 3rd shift hub sleeve retainer ring Figure 31 Remove 2nd amp 3rd shift hub sleeve Figure 32 Remove 2nd gear retainer ring Figure 33 Remove 2nd gear and locating washer Figure 35 Remove 1st amp Reverse shift fork rod and lug from shift rod support STAMPED CONTROL DISASSEMBLY See Page 23 for Diecast Cover Fabricated Rails See Page 31 for Diecast Cover Round Rails Figure 34 Remove 1st amp Reverse shift lug lockscrew Figure 36 Using a small pin or drift remove 2nd amp 3rd Shift fork roll pin Figure 37 Remove 2nd amp 3rd shift rod CAUTION Do not lose interlock cross pin or 2nd speed overdrive Spacer Figure 34 Remove 4th amp oth shift fork roll pin 10 Figure 39 Remove 4th amp 5
25. roper linkage adjustment Worn or sprung shift fork 35 9 STICKING IN GEAR Improperly operating clutch sliding gear or shift hubs tight on mainshaft splines Misaligned mainshaft Improper linkage adjustment SLIPPING OUT OF DIRECT Misaligned of transmission on engine Worn pinion gear teeth Worn clutching teeth on shift hub Insufficient tension on detent balls Improper linkage adjustment Excessive shift lever whip action SLIPPING OUT OF FIRST OR REVERSE First or reverse sliding gear splines worn Sliding gear teeth worn or tapered Worn mainshaft splines Worn countershaft first speed gear Partial engagement Improper linkage adjustment SLIPPING OUT OF OTHER SPEEDS Excessive clearance between mainshaft gear and mainshaft Excessive end play of mainshaft gear on mainshaft Worn clutching teeth Weak detent ball springs Improper linkage adjustment Copyright Eaton Corporation 2012 Eaton hereby grant their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been
26. rst for highway service and every 8 000 to 10 000 miles 12872 0 16090 0 Km or six 6 months whichever comes first on off highway and pick up and delivery types of service Do this only when the transmission is thoroughly warm FLUSHING After draining flushing is desirable Replace the drain plug and fill the transmission to the proper level with a light flushing oil Drive the transmission for a short period at fast idle in such a manner that the gears in the transmis sion are rotating without load This washes out the old oil clinging to the interior of the gear case covers and shifter rails BE SURE TO DRAIN OUT ALL of the flushing oil before attempting to refill with new oil This flushing procedure is most important after first drain REFILL First removal all dirt around the filler plug Then refill with new oil of a grade recommended for the existing Season and prevailing service Fill to the bottom of the level testing plug positioned on the side of the transmission DO NOT OVERFILL as the excess quantity will serve no useful purpose If the oil level is too high it will cause excessive oil churning and high oil temperature and possible leakage INSPECTION Oil level inspection should be made every 6 000 miles 9654 0 Km which usually coincides with the vehicle manufacturers chassis lube procedure Always clean around filler plug before inspection Add sufficient oil to maintain correct level CLARK Item oO
27. screws When parts list calls for only 3 studs Tighten drain tube to 7 10 Lbs Ft 9 5 13 5 N m when required OVERHAUL OF TRANSMISSION ASSEMBLY The instructions contained herein cover the disassembly CAUTION Cleanliness is of extreme importance and an and reassembly of the transmission in a sequence that absolute must in the repair and overhaul of this unit would normally be followed after the unit has been Before attempting any repairs the exterior of the unit removed from the machine and is to be completely over must be thoroughly cleaned to prevent the possibility of hauled dirt and foreign matter entering the mechanism DISASSEMBLY OF THE TRANSMISSION Figure 1 Remove control top or remote control assembly Figure 3 Remove shift rod cover Figure 2 Remove shift rod cover capscrews NOTE See Page 23 for Diecast Cover Disassembly Figure 4 Remove shift rod support assembly Figure 11 Remove brake drum es W m Bee gt pa j Figure 10 Lock transmission in two gears and remove Figure 12 Remove mainshaft rear bearing cap and brake drum speedometer drive gear Figure 14 Remove countershaft rear bearing retainer Figure 16 Remove main drive gear Use caution as not to ring drop mainshaft spigot bearing rollers in transmission case Figure 17 Pry mainshaft to the rear to expose rear bear Figure 19 Remove reverse idler shaft lockscrew and ing Remove bearing lock Using a suitable
28. t parts nor failures resulting from the use thereof which are not supplied by or approved by the Clark Equipment Company IMPORTANT Always furnish the Distributor with the transmission serial and model number when ordering parts THE CLARK SYNCHRONIZER AND HOW IT WORKS FOR YOU The Clark split pin synchronizer prevents the clashing of the gears and increase the speed of shifting In a conventional transmission which does not have synchronizers the absence of gear clashing is dependent entirely on the skill of the truck driver By double clutching and split second timing of engine speeds with the gear shifting movement a driver can synchronize the speeds of the engaging gears and thereby prevent the damage to gears by clashing when a fast shift The splint pin sychronzier performs the same function with or without the double clutching operating even though the driver does not accurately time his gear shifting movements It also mechanically prevents the driver from completing the shift to the point of gear engagement until the engaging gears have reached the same or synchronous speeds This is known as the blocking action of the synchronizer and it is this action that makes the oper ation of shifting a transmission having synchronizers different from one which does not have synchronizers Upon shifting gears in these synchronized transmissions the first part of the gear shift lever movement brings the blockers into contact The blockers moment
29. th shift rod and fork CLEANING AND INSPECTION CLEANING Cleaning all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in clean ing fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners Bearings Remove bearings from cleaning fluid and strike against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream across bearing to avoid Spinning Do not spin bearings when drying Bearing say be rotated slowly by hand to facilitate drying process Housings Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercise
30. tion illustration Figure 13 A MESH LOCA BALLS 3 INTERES INTERLOCK SHL CROSS PIN 1 SPRINGS 3 THREE BALLS ADDED FOR BACK UP SWITCH ONLY Figure 13 A Figure 14 Position the mesh lock spring and ball three each in spring pockets See cross section illustration Figure 13 A 33 Figure 16 Install 1st amp reverse shift fork and rail assem bly in control housing Install shift rail lock pin to position rail in control housing Figure 17 Install 1st amp reverse shift lug rocker lug shift rail and spacers in rail groove over mesh lock ball and spring NOTE Position widest spacer between shift lug and front support The narrower spacer between the shift lug and center support Figure 18 Install interlock cross pin in 2nd 3rd shift rail Position 2nd amp 3rd shift rail and fork assembly in rail groove over mesh lock ball and spring Make certain cross pin is in position in rail See Figure 13 A Figure 19 Position 4th 5th shift rail and fork assem bly in rail groove over mesh lock ball and spring 34 Figure 20 Position front rail support shift rails and install capscrews Position rear support over rails and install capscrews Figure 21 Tighten support capscrews 20 to 25 ft Ibs torque 27 2 33 8 N m Test Cover for Double Shift Pry 4th amp 5th shift fork and rail out of neutral position Try to pry 1st amp reverse shift fork and rail out neutral pos
31. to hold in place 18 Figure 68 Install reverse idler gear as shown Insert idler shaft through case and idler gear NOTE Idler shaft lock groove must line up with lock bolt hole Drive shaft into position Install shaft lock and bolt Tighten bolt 20 to 25 ft Ibs torque 27 2 33 8 N m Figure 69 Install mainshaft assembly into transmission case as shown Figure 70 Assemble the pilot bearing in the main drive gear as follows 1 Ifa new pilot bearing is used it comes from the fac tory with a plastic sleeve Stand drive gear on end Set bearing and sleeve over bearing pocket in drive gear Slide bearing rollers and cage from plastic sleeve into bearing pocket 2 Ifold pilot bearing is used set rollers in bearing cage and hold in place with a rubber band Slide bearing rollers and cage from rubber band into bearing pocket 19 a i Ka i i a Figure 71 Install main drive gear assembly in transmis sion case Clutching teeth on main drive gear must enter oth speed synchronizer cup without binding Figure 72 Press oil seal into drive gear bearing cap with lip of seal up Coat a new gasket on both sides with a grade 2 multi purpose grease Position gasket on drive gear bearing cap Use caution as not to cover oil return groove in bearing cap Figure 75 Install speedometer drive gear Figure 73 With bearing cap oil return groove lined up with oil hole in transmission case
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