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Transmission - Hansen Web Design

1. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 ors Z 00 4 OO PWN AACA AMAT 45 44 43 42 4 40 49 48 Main drive gear bearing retainer Retainer gasket Main drive gear Mainshaft pilot bearing spacer Sliding clutch synchronizer ring Mainshaft clutch sleeve Clutch poppet ball Selector lever assembly Clutch poppet spring Second speed gear lock ring Second speed gear Transmission cover Shift lever assembly Shift lever setscrew Mainshaft adapter Second speed gear lock ring Mainshaft Mainshaft sliding gear low and reverse Transmission cover gasket Rear bearing retainer gasket Mainshaft rear bearing Speedometer drive gear Mainshaft rear bearing retainer Oil seal PRINTED IN UNITED STATES OF AMERICA 3 emnes Y X SKK E GE pi 29 30 3l 32 A 21744 Description FIange Lockwasher Nut Oil slinger Speedometer gear spacer Countershaft Countershaft thrust washer bronze Countershaft thrust washer steel Countershaft roller bearing Transmission case Countershaft gear cluster Countershaft bearing spacer Drain plug Countershaft roller bearing Countershaft thrust washer Second speed gear thrust washer Clutch sleeve second and high Clutch hub second and high Main drive gear ball bearing Bearing lock ring Mainshaft pilot bearing Idler shaft snap r
2. Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section B L LINE MOTOR TRUCK SERVICE MANUAL Page 2 TRANSMISSIONS MODEL T 87 D The Model T 87 D transmission is of syn chro mesh type with remote controls having three speeds forward and one reverse Fig 2 illustrates the shift diagram A 21987 Fig 2 Shifting Diagram T 87 D DISASSEMBLING AND REASSEMBLING The assembly is simply the reverse ofdis assembling with the exception of a few minor details Therefore the following disassembly instructions will also serve as referencefor assembling Figure numbers in parantheses throughout this section will refer to Fig 1 which illustrates construction details of this transmission l Clean outside of transmission especially around the control and bearing covers 3 21 2 Shift selector lever 12 into neutral position Remove capscrews and lockwashers holding cover assembly 5 to case 39 and lift off the cover assembly 3 disassemble the control cover assembly a Clip lockwire and remove lockscrew from low and reverse speed shift fork 14 Tap shift rail 16 toward rear of cover driving out expansion plug 18 Pull out shift rail 16 releasing poppet spring and ball 10 and shift fork 14 CAUTION Do not lose poppet springs and balls b To remove second and third speed shift fork 11 rail expansion plug poppet spring and balls 10 follow the
3. a b c Main shaft sliding clutch After locking gears by engaging two speeds the countershaft rear bearing nut 32 is removed from end of counter shaft Remove rear bearing retainer 33 Slide off speedometer gear 35 and remove key Drive mainshaft assembly toward rear of case sufficiently to expose rear bearing 34 snap ring Install suit abie puller and pull bearing 34 from mainshaft 40 By tilting the main shaft assembly front end upward the entire unit comes out easily leaving sliding gears 46 43 inside case After shaft assembly is removed the sliding gears may then be lifted out of case To disassemble the mainshaft slide the sliding clutch 17 from front end of shaft Remove gear retaining washer key Fig 5 Main shaft gear Main shaft A 22941 Fig 4 After removing key rotate gear re lainer washer until its inside lugs line up with grooves in the shaft and then PRINTED IN UNITED STATES OF AMERICA 5 remove The bushed gears 18 47 and sleeve are removed by using rear gear 47 to start the sleeve Also remove the sleeve key from shaft To disassemble main drive gear a Remove four capscrews from main drive gear bearing retainer 15 The main drive gear 16 bearing 14 and lock nut assembly can then be with drawn through front of case Remove peened over material from slots in drive gear shaft 16 and turn off drive gear bearing lock nut
4. 29 and sleeve gear 24 are held together by poppet springs 28 and balls 26 The clutch hub 29 can be removed from sleeve 24 by supporting the outside diameter and pressing on the hub Use care when disassembling as poppet springs and balls are under spring tension and may fly out when sleeve is removed It is suggested that a cloth be wrapped around the assembly to guard against this TRANSMISSION REMOVAL L 160 SERIES When it becomes necessary to remove the transmission on the above series trucks it is necessary to disconnect and move to one side the front propeller shaft mit removal of the transmission This will per Proceed as follows a Remove the bolts from the front end of the front propeller shaft at the joint flange Spicer joints used Remove the brake drum retainer bolts and slide the brake drum out of the brake band onto the propeller shaft This will provide maximum clear ance for the end of the propeller shaft to permit its being moved to one side Carefully pry the shaft end towards the rear and over the transmission main shaft flange and nut to permit the shaft to clear the flange Securely wire the shaft to one side to keep it out of the way while proceed ing with transmission removal Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL o TRANSMISSI
5. Drain plug Mainshaft Counter shaft Countershaft low speed drive gear Countershaft rear bearing Countershaft rear bearing lock nut Countershaft rear bearing retainer Snap ring Snap ring Speedometer drive gear PRINTED IN UNITED STATES OF AMERICA 33 34 35 A 23189 Description Nut Cotter pin Washer Mainshaft rear grease seal Mainshaft rear bearing Rear bearing cover and speedometer housing Gasket Shifter shaft rear cover Shifter shafts Mainshaft low and reverse sliding gear Shifter fork low and reverse Shifter fork 2nd and 3rd speed Mainshaft 2nd and 3rd speed sliding gear Poppet ball Poppet spring Mainshaft 3rd speed constant mesh gear Shifter shaft lock screw Mainshaft gear lock key Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section G Page 2 TRANSMISSION MODELS F 54 and F 54 B The Model F 54 transmission 5 A 620 is constructed having five forward speeds and one reverse Fifth speed is overdrive Fig 2 illustrates the shift diagram 20 4 zen cn l A 22884 Fig 2 Shifting Diagram F 54 The Model F 54 B transmission 5 A 62 is constructed having five speeds forward and two reverse Fifth speed is direct Fig 3 illustrates the shift diagram A 22885 Fig 3 Shifting Diagram F 5u 8 L LINE MOTOR TRUCK SERVI
6. NOISSINSNY L TIVOANVAW SOIAYSS AONYL YOLOW 3NIFT I JN m SEI E o gt dE d Za Donated by John amp Susan Hansen For Personal Use Only L LINE MOIOR IRUCK SERVICE MANUAL TRANSMISSION General Page l TRANSMISSIONS Driving Downhill A safety rule to follow by all good drivers is to use the same or next lower transmission gear when going downhill as would be used in climbing the same hill If necessary the vehicle speed can then be easily controlled tothe maximum road speeds for that particular gear by snubbing down with the brakes This practice will not only prevent damage to the engine but will also effect a saving on the brakes CAUTION Do not coast down hill even for a very short distance with the clutch disengaged If the clutch is engaged while the truck is coasting the sudden acceleration of the engine s speed will result in a shock to the gears an excessive strain and ultimate failure of the driving parts Overdrive Some transmissions have an over drive speed This gearing is for maintaining in creased road speed with reduced engine speed Overdrive should be used only when conditions are favorable to high road speeds Overdrive should never be used at low road speeds or for lugging Usually for overland hauling the minimum road speed for overdrive is 30 m p h Overload The transmissions installed in International trucks are engineered to the rated
7. T 98 Models L 150 L 153 L 160 L 163 L 164 L 165 LC 160 L 170 L 173 L 174 L 175 LF 170 Disassembling and reassembDling ech ee 9 ORES X wow OTHE 1 5 4 9 Gear shill diata X 4 x O amp O OES e SH 2 Transmission Pernovals SE HEROES we 3 SECTION E 51 AND 51 Models L 170 L 173 L 174 L 175 LF 170 L 180 L 183 L 184 L 185 LC 180 Disassembling and reassembling ee ee eae o o t o senses 1 2 3 2 Gear shift dagram T LITT n n PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL SECTION EI F 52 AND F 52 C Models L 190 L 193 L 194 L 195 LF 190 LC 190 L 200 L 204 LC 200 Disassembling and reassembling ce eee ee coe eo ot o on n Gear shiit ssi o4 4 9 o X Ade 00 di E Oe SECTION F 54 AND F 54 B Models L 200 L 204 L 205 LC 200 L 210 LF 210 Disassembling and reassembling onbe cb esse E EE o s Gear SHIT RR ew SECTION H FULLER AUXILIARY TRANSMISSION Model 2 A 45
8. same procedure as in step a c Remove snap rings from shifting shaft 13 located on each side of shift lever 12 thus releasing shaft assembly 13 spring shift lever 12 and key d Interlock plunger 9 may be removed by pulling 3 8 tapered plug located on left side transmission cover 5 directly below poppet spring and ball NOTE When reassembling the top cover assembly 5 to case make sure that shift forks 11 14 are not sprung and engaged properly with sliding gears To disassemble the mainshaft assembly a Lock transmission and remove com panion flange nut 26 Remove cap screws four in number holding main drive gear bearing retainer 3 to case 39 and five capscrews hold ing mainshaft assembly rear bearing retainer 21 b Lift off main drive gear retainer 3 revealing snap rings 2 and bearing 42 Remove mainshaft rear retainer 21 revealing speedometer drive gear 27 snap ring 22 and bearing 23 NOTE When reassembling the front bearing retainer 3 see that oil drain in retainer is located at bottom c With the mainshaft rear bearing re tainer 21 removed slip speedometer drive gear 27 from mainshaft 25 Remove mainshaft rear bearing 23 and oil retainer washer 20 CAUTION Exercise care in driving off bearing to prevent damage d Pull main drive gear 1 and bearing 42 out through front of case until drive gear contacts countershaft gear Slide mainshaf
9. Disassembling e ws Sek es OS AE 9 9 XE X ox y ee A POE Rod A BReassembbDNHP a c amp Wok e u ho 28 Te De E e de Wo 284 SECTION T BROWN LIPE AUXILIARY TRANSMISSION Model 553 DisasseniDILOE s sa 4 465 x 65 o RECO E ED OG EENG 42666 4 0 m 19069 ODS Oe Re SECTION BROWN LIPE AUXILIARY TRANSMISSIONS Models 6231 and 6231 Disease x 14 amp o BOR we ee Boum Eo i EUR E ee IG3SSOIMDDEHD Loa 09e ORI INEO e CR DOS ROS SECTION BROWN LIPE AUXILIARY TRANSMISSIONS Models 8031 C and 8031 G 4 9 Se eR EEE SOE HS D ReEGSSEMDNNS L3 40 4 3 x SSE OES A 4e WR USO WOO SE DUX M CEDAR HER ee 9 8 e I d A VV Page ei v2IH3HMY 4O 531715 NI OALNING Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION SPECIFICATIONS TRANSMISSION MODELS 1H T 87 D H 41 B T 98 F 51 F 51 C F 52 C F 54 F 54 B Transmission make IH Warner Warner Warner Fuller Fuller Fuller Fuller Fuller Manufacturer s model 5 4 87 AS 74 T 9 ASA T 98 5 A 33 5 A 430 5 A 43 5 A 620 5 A 62 sess Synchro Synchro Direct Synchr
10. NOTE Nut is left hand threaded Press bear ing 14 from main drive gear 16 To disassemble countershaft and reverse idler gear a b c To disassemble reverse idler gear re move capscrew and lock plate from groove in idler A simple method of pulling idler shaft use a short piece of pipe a long bolt having threads the same size as those tapped in end of shaft Using a flat piece of steel with a hole in the center sufficiently large to permit passage of bolt The nut is turned on the bolt close up to the head The bolt is then passed through plate and pipe in order named and screwed into idler shaft The nut is then tightened against the plate with the result that the pulling action is exerted against the shaft with the case acting as a base through the pipe and plate After with drawing reverse idler shaft the gears 50 51 are lifted from case and bear ings removed from idler gear With the countershaft rear bearing lock nut 32 removed drive countershaft assemblytoward rear of case sufficiently to install suitable puller to remove rear bearing 31 By tilting the front end upward the countershaft assembly is easily removed through top of case Also remove front bearing thrust washer To disassemble countershaft remove retaining snap ring from countershaft Countershaft gears 23 24 25 26 should be pressed off one at a time and keys 20 removed from shaft CAUTION In reassembling new sna
11. Press off countershaft rear bearing 7 Remove capscrews from countershaft 30 Remove countershaft rear bearing front bearing cover washer 8 Remove countershaft front bearing 3l Remove countershaft front bearing cover and gasket from case 9 Remove countershaft rear bearing cover capscrews B Assemble Transmission 10 Remove countershaft rear bearing cover and gasket l Install countershaft front bearing in case 11 Lock transmission gears 2 Install countershaft rear bearing washer 12 Remove countershaft front bearing on shaft lock nut 3 Press on countershaft rear bearing 13 Remove capscrews from main drive gear cover 4 Install countershaft rear bearing lock nut and washer 14 Remove main drive gear bearings and cover as a unit 5 Install countershaft in position by in serting through rear bore in case 15 Press main drive gear from cover and bearing assembly 6 Install countershaft underdrive gear gear spacer countershaft drive gear 16 Remove capscrews from main shaft and front bearing spacer washer as rear bearing cover shaft progresses 17 Remove rear bearing cover and gasket 7 Install main shaft underdrive gear sleeve and key on shaft 18 Remove main shaft rear bearing 8 Install main shaft underdrive gear sleeve 19 Remove rear bearing spacer washer on shaft Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL W INTERN
12. a With the main drive gear bearing 3 removed from drive gear 5 it is lifted out through top of case 6 To disassemble the mainshaft assembly a b c Remove snap ring holding third and di rect speed clutch assembly and main shaft third speed gear 18 and slide clutch assembly and bushed gear from mainshaft Remove first and second speed hub retainer snap ring 36 and slide off synchronizer assembly Remove mainshaft second speed gear snap ring 54 releasing thrust washer 53 needle bearing 50 thirty four in number second speed gear 22 and spacer 49 To disassemblethe countershaft assembly a b Remove capscrew 41 and lock plate 40 locking countershaft 39 and re verse idler shaft 42 Using a brass drift drive countershaft out through rear of case and lift the gear cluster 48 out through top of case NOTE The countershaft gear cluster turns on four sets of roller bearings 37 52 which are loose in the bore of the countershaft gear There are twenty two rollers in each bearing set totaling eighty eight bearings separated by spacer washers and spacer 46 These rollers will probably inter mingle with the main drive gear pilot bearing rollers 56 in bottom of case when the countershaft gear is removed Countershaft rollers 37 52 are slightly smaller than pilot bearing rollers 56 Be sure to pick up front thrust washer 51 rear thrust washer 38 and spa
13. b Remove setscrews from shift forks and slide shift bar toward rear of case L LINE MOTOR TRUCK SERVICE MANUAL Use shift bar to tap out bar thimbles dust plugs With the removal of shift bar the shift fork is lifted out through top of case c Remove interlock plunger retainer capscrew to release interlock plunger from case CAUTION In reassembling trans mission be sure to insert interlock plunger poppet springs and balls d Remove low and reverse shift bar and fork in the same manner as described in paragraph b P Fr rrr SE Shift fork Poppet spring and ball retaining plug oi Transmission case A 14055 Fig 3 Sectional View of Shifting Bars Poppet Springs and Balls and Shifting Forks 5 Removing main drive gear assembly a Lock transmission and remove com panion flange 25 Remove capscrews three in number from mainshaft rear bearing retainer 23 Lift off retainer and gasket 20 revealing oil deflector 28 speedometer drive gear 22 and spacer 29 b Drive out countershaft 30 toward rear of case permitting countershaft gear cluster 35 to drop down in case allowing clearance for removal of main drive gear c Remove capscrews four in number from the main drive gear bearing re tainer 1 Remove retainer 1 re vealing main bearing 43 and retaining ring 44 NOTE When reassembling see that oil drain in retainer 1 is located at
14. drift With the countershaft removed the gear cluster 36 can be lifted out through top of case Be sure to pick up the bronze thrust washer 37 at front and bronze washer 28 and steel washer 29 at rear in bottom of case Countershaft bearings 38 and spacer 40 can also be removed from gear cluster 7 Removal of reverse idler gear and shaft a Reverse idler shaft 33 can be re PRINTED IN UNITED STATES OF AMERICA moved by driving out through rear of case May also be removed by placing a pinch bar in lock plate slot and pulling out shaft With the idler shaft 33 removed the idler gear 35 can be lifted out of case NOTE When re assembling be sure to position properly slots in countershaft 30 and idler shaft 33 to take lock plate 31 8 disassemble mainshaft clutch assembly a The mainshaft clutch hub and sleeve are held together by two retaining springs located on each side of clutch hub The clutch sleeve 8 can be re moved from clutch hub 43 by removing the retaining springs and supporting the outside diameter of sleeve 8 and pressing on hub 43 Use care when dis assembling not to lose the three shifting plates 7 The blocker rings 4 are supported by the main drive gear hub and second speed gear hub and are dis assembled with the removal of the mainshaft assembly CAUTION In reassembling the clutch be sure to place end of each retaining spring in the same shifting
15. plate with the loose ends located in same position on both sides to equalize the tension on all three shifting plates 7 Also index etched marking on hub and sleeve Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL ub vd age TRANSMISSION H 41 B 11 38 12 37 13 36 14 35 15 34 VS HA Ga Se nd EM le 33 z d I i WAAR Sie m 77 1 X v EE v7 i 30 17 y 29 7 See lt a 7 8S NS SX IPN WY RS 25 21 22 28 24 m Fig H UI B 1 Shift lever Main drive gear Mainshaft gear low and 2 Retainer Main drive gear second 3 Retainer washer Main drive gear bearing Mainshaft rear bearing 4 Spring Mainshaft gear 3rd and Spacer 5 Fulcrum ball direct Speedometer drive gear 6 Pin Countershaft thrust Mainshaft 7 Control cover washer Washer 8 Poppet spring Countershaft gear cluster Cotter pin 9 Poppet ball Drain plug Nut 10 Interlock pin Bearing spacer Grease seal 11 Shifter shaft Countershaft bearing Rear bearing retainer 12 Shift fork 3rd and direct Reverse idle gear Grease slinger Counter shaft Expansion plug Shifter fork lock screw Shift fork 1st and 2nd 14 M drive gear brg retainer PRINTED IN UNITED STATES OF AMERICA Donated by J
16. shaft Re verse idler gear can then be lifted out through top of case NOTE When reassembling be sure to position slot in shaft properly to take lock plate When reassembling the top cover assembly make sure that the shifter forks are not sprung and engaged properly with sliding gears Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION 98 15 16 10 D IL Si 9 26 27 28 NE 29 d CLA D E TF LLL LL LES AS Nw wm ce ZZZ d 74 b zl 1 ia ial TER i NES 55 E CEP NE A 54 I 7 CSS AN 53 52 em 42 A 43 KISS 44 SS 50 49 4 8 47 46 45 SS SS A 21747 Fig Main drive gear bearing Tv ou blocking ring 40 Lock plate Mainshaft 154 and 2nd Lock plate capscrew retainer 2 Snap ring speed gear Reverse idler shaft 3 Main drive gear bearing Shift fork lst and 2nd Reverse idler gear 4 Snap ring speed Transmission case 5 Main drive gear Poppet ball Drain plug 6 Synchronizer blocking ring Expansion plug Countershaft bearing 7 Shifting plate Poppet spring spacer 8 Expansion plug Clutch hub 154 and 2nd P T O openi
17. 5 can be removed from control lever 1 by driving out pin 6 with a suitable punch Clip lockwire from first and second speed shift fork 38 and remove lock screw 38 Drive shift rail 11 to ward rear of cover driving out expan sion plug 37 With the expansion plug removed pull shift rail 11 out and lift shift fork 13 out of cover CAUTION Do not lose poppet spring 8 and ball 9 Continue disassembly operation re moving third and direct shift fork 12 reverse shift block stop pin spring rails poppet balls and springs and inter lock pins and stops CAUTION In reassembling the control cover care should be exercised to see that all parts are replaced in their correct positions and none of the small inter locking parts are lost or omitted To remove mainshaft assembly Lock transmission by engaging two speeds and remove flange nut 32 Remove five capscrews holding main shaft rear bearing retainer 35 to case Lift bearing retainer off mainshaft revealing gasket speedometer drive gear 29 spacer 28 and mainshaft rear bearing 27 Hold mainshaft sliding gears 18 26 in position Mainshaft 30 and bearing 27 can now be removed through rear of case If necessary use a brass drift against washer 31 and nut 32 Lift out mainshaft third and direct gear 18 and low and second gear 26 through top of case Donated by John amp Susan Hansen For Personal Use Only L LINE MO
18. ATIONAL V AUXILIARY TRANSMISSION Section H Page 4 9 Install main shaft sliding clutch gear in position 10 Press main shaft pilot bearing into position on shaft 11 Install main shaft rear bearing in position in rear bore in case 12 Insert main shaft assembly previously prepared through front bore in case and move toward the rear Install rear bearing washer and main shaft underdrive bushed gear as shaft pro gresses 13 Install main drive gear bearing in position on main drive gear 14 Install main drive gear bearing spacer 15 Install main drive gear outer bearing 16 Install main drive gear and bearing assembly in position in case 17 Install main drive gear and bearing cover and gasket 18 Install capscrews in main drive gear bearing cover 19 20 21 23 24 29 26 Zt 28 29 30 341 32 Install main shaft rear bearing spacer Install speedometer drive gear and key Install main shaft rear bearing spacer Install main shaft rear bearing Install rear bearing cover and gasket Install rear cover capscrews Install shifter bar through shifter fork hub of shifter fork toward the rear Insert poppet spring and ball in position Push shifter fork into position Install poppet spring retainer screw Install shifter fork lock screw Install side cover or power take off and gasket Install capscrews holding cover or power take off Fill transmission
19. CE MANUAL INTERNATIONAL Fig 1 illustrates construction details of the F 54 and F 54 B transmissions and figure num bers in parentheses throughout this section will refer to this illustration Item 27 on Fig 1 will be referred to as mainshaft fifth speed gear although due to change in diameter on F 54 B direct in fifth transmission it is used as fourth speed gear DISASSEMBLING AND REASSEMB LING With a few minor exceptions the assembling is simply the reverse of disassembling There fore the following disassembling instructions will also serve as reference for assembling 1 Clean the outside of transmission particu larly around the control and bearing covers 5 13 8 47 38 2 Place shift lever to neutral position and remove the holding capscrews and lift off control cover assembly 8 CAUTION Do not try to force the cover off as you may spring the shifting yoke and cause gear interference 3 To disassemble control cover assembly Remove four capscrews 6 and lift shift lever assembly 5 from control cover assembly 8 b Remove shift lever ball from shiftlever 1 and also dust cover 2 Remove nut and lockwasher from pivot pin Place cover in a vise grasp lower end of control lever spring 4 with a large pliers and twist it from its lugs Spring may also be removed by use of a pinch bar and forcing over the retainer lugs With the spring removed relea
20. Donated by John amp Susan Hansen For Personal Use Only MIN TRANSMISSION INTERNATIONAL L LINE MOTOR TRUCK SERVICE MANUAL Index UA Page I SPECIFICATIONS Page SPECIFICATIONS TRANSMISSIONS 64 E RO E 1 SPECIFICATIONS AUXILIARY TRANSMISSIONS 2 GENERAL INFORMATION Driving downhill 245644464 Ae EKG AK ES De 1 OVerdrive zm e e TT TP TTC rr 1 OVerload 644 464 65 og he Sh ao X See rud ee ee 9 8 Shii ng ete ban ee be BE Oe ae eee EE EE ew ow ee Ow amp EK XEOX e 9 X ee Ow Ce XO ed OP RUE Qoia ENEE SECTION HDS Models L 110 L 120 Disassembling and reassembling T rTTTET Se e oy wg Gear shift VOU EERE ROSES EE BE e 2 SECTION T 87 D Models L 110 L 120 LM 120 L 130 LM 150 Disassembling and reassembling e Tm a ree ee KE Gear shift xd o SES Ko o EDS SECTION H 41 B Models L 130 L 150 L 153 Disassembling and reassembling Tr TP lj 2 Gear shift dlagram A o wo CX E EUR decis d REO 4 SECTION D
21. ONS F 51 AND F 51 C 10 9 8 29 30 31 7 32 6 33 5 34 aa LL DELLE E 35 X 36 1 SS Zb 37 783 us 738 39 53 N 24 43 SS ECK 51 50 49 48 47 46 45 44 A 21746 Fig Ue and F 5l C Countershaft rear bearing l Main drive gear Reverse idler roller 2 Drive gear bearing nut bearing lock nut 3 Front bearing retainer Reverse idler gear Drain plug capscrew Reverse idler shaft Countershaft gear lst 2nd 4 Main drive gear bearing Shifter fork 2nd amp 3rd amp reverse retainer speed Countershaft 3rd speed 5 Retainer gasket Mainshaft 2nd amp 3rd speed gear 6 Shift rail thimble gear Countershaft 5th speed 7 Interlock pin Shifter fork low amp reverse gear 8 Poppet ball Mainshaft low amp reverse Mainshaft 5th gear washer 9 Poppet spring gear Mainshaft 5th speed gear 10 Control cover Mainshaft key 11 Shifter fork lockscrew Control cover gasket Countershaft drive gear 12 Shifter fork 4th amp 5th Rear bearing cover gasket Spacer speed Speedometer drive gear Key 13 Shifter fork lockwire key Countershaft snap ring 14 Spring Speedometer drive gear Countershaft front bearing 15 Retainer Rear bearing retainer washer 16 Dust cover Mainshaft rear bearing Countershaft front bearing 17 Shift lever and ball grease seal Countershaft front bea
22. TOR TRUCK SERVICE MANUAL TRANSMISSION Section C Page 3 5 To disassemble the mainshaft a Remove nut 32 companion flange then remove rear bearing retainer 35 speedometer drive gear 29 spacer 28 and bearing 27 Remove main drive gear a Remove four capscrews holding main drive gear bearing retainer 14 to case b Remove retainer 14 revealing gasket and bearing 17 NOTE When re assembling be sure to locate oil drain at bottom c Main drive gear 15 and bearing 17 can now be removed from front of case If necessary use babbit or rawhide hammer to tap main drive gear 15 Removing the countershaft assembly a Remove countershaft and reverse idler shaft lock screw and plate Drive out countershaft 25 toward rear of case using a brass drift PRINTED IN UNITED STATES OF AMERICA b Remove cotter pin from reverse idler gear shifter fork shaft Drive shaft toward rear of case with a brass drift and remove idler shifter fork c Lift countershaft gear cluster 20 with bearings 23 and spacer 22 through top opening of case Tilt gear cluster slightly through rear bore in case to facilitate removal d Remove roller bearings 23 and spacer 22 from cluster 20 Be sure to pick up countershaft thrust washers one each end from bottom of case Removing the reverse idler gear and shaft assembly a Insert screwdriver or pinch bar in lock plate groove and pry out
23. aft assembly to obtain 000 to 003 loose bearing adjustment Install companion flange nut and cotter key tighten securely Install transmission cover assembly being sure that the shifting forks engage clutch collars and tighten all cap screws securely Fill with specified lubricant per lubri cation section Capacity 8 pints
24. ansmission 5 A 43 is constructed having five speeds forward and one reverse Fifth speed is direct Fig 4 illustrates the shift diagram A 22883 Fig 3 Shifting Diagram F 52 C L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL ER AT VW Fig lillustrates construction details of the F 52 and F 52 C transmissions and figure numbers in parentheses throughout this section will refer to this illustration Item 18 on Fig 1 will be referred to as mainshaft fifth speed gear although due to change in diameter on F 52 C direct in fifth transmission it is used as fourth speed gear DISASSEMBLING AND REASSEMB LING With a few exceptions the assembly is simply the reverse of disassembly There fore the following disassembly instructions will also serve as reference for assembly 1 Clean the outside of transmission particu larly around the control and bearing covers 15 8 5 35 2 Place shift lever 1 to neutral position then remove the holding capscrews and lift off the control cover assembly CAU TION Do not try to force the cover off as it may spring the shifting yokes and cause gear interference A slight manipu lation will free it 3 Disassemblingthe controlcover assembly a Remove four capscrews and lift shift lever cover assembly 5 from control cover assembly 8 b Remove shift lever ball from shift lever 1 and also dust cover 2 Re move nut and lockwasher from pivot
25. ar speed and thereby prevent clashing of gears When the truck is equipped with a governor the maximum engine speed is controlled If however it is desired to shift at lower road speeds than those shown the shifts should be made at correspondingly lower engine speeds Since the governor does not operate at the lower engine speeds determination of the proper lower engine speed at which to shift is a matter of judgment that comes with practice When the operator becomes accustomed to the sound of the engine at various engine speeds and has become experienced at double clutching he should be able to shift from a high to a lower gear very rapidly and without clashing the gears CAUTION When shifting avoid injury to the gear teeth by making it a practice to shift gears with as little clashing as possible Starting When starting new unit or one which has been exposed to cold weather allow sufficient time for the lubricant to circulate and coat all contacting surfaces Do not stay in any one gear for any length of time The metal to metal contact between some of the working parts due to insufficient lubrication will result in damage which may not appear immediately but will eventually develop into serious trouble Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section A L LINE MOTOR TRUCK SERVICE MANUAL Ge age TRANSMISSION HDS
26. bottom d Main drive gear 3 and bearing 43 can now be removed from case 34 by driv ing toward front of case CAUTION Exercise care not to damage bearing 43 when driving from case A UN INTERNATI ONAL Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION Section A Page 3 6 Removal of mainshaft assembly a With companion flange 25 and main shaft bearing retainer 23 removed slip off oil deflector 28 speedometer drive gear 22 and spacer 29 from mainshaft assembly Remove mainshaft rear bearing 21 CAUTION Exercise care in driving off bearing to prevent its being damaged Mainshaft assembly can then be lifted out through top of case NOTE Main drive gear assembly 3 must be removed first as outlined in paragraph 5 Removal of countershaft cluster gear a As countershaft 30 has already been removed for disassembly of main drive gear 3 the countershaft gear cluster 35 is merely lifted out through top of case Be sure to remove the bronze washer 39 at front and bronze washer 31 and steel thrust washer 32 at rear in bottom of case Countershaft bearings 38 and spacer 36 can also be removed from gear cluster Removal of reverse idler gear and shaft a Reverse idler shaft 47 can now be removed by driving shaft toward rear of case and this will permit lifting idler gear 48
27. capacity of the trucks An ample safety factor well above normal requirements has been provided but neither the transmission nor any other part of the truck will give maximum performance and long wear if continued to load it beyond its rated capacity Shifting Probably one of the most distinguishing characteristics of a good driver is his ability to shift gears from a high to a lower trans mission speed A knowledge of the maximum obtainable road speeds in the various gears is helpful in deter mining the maximum road speed at which a shift from a high to a lower gear can be made For example in shifting fourth speed to third speed the maximum road speed at which this change can be made is at approximately PRINTED IN UNITED STATES OF AMERICA thirty three miles per hour since that is the maximum available road speed for this truck in third gear Gear changes from a higher to lower gear speeds should be made as follows 1 Ease off on accelerator and disengage clutch 2 Move gear shift lever to neutral position and engage clutch At same time accelerate engine to governed speed 3 Disengage clutch ease off on accelerator and move gear shift lever to next lower transmission gear position 4 Engage clutch and depress accelerator sufficiently to pick up load The above procedure known as double clutching is necessary to bring about an equal ization or synchronization of engine speed and transmission ge
28. cing washer from bottom of case To disassemble the reverse idler gear assembly a Remove reverse shifting arm and drive reverse idler shaft 42 out through rear of case and lift idler gear 43 out through top of case NOTE When reassembling be sure to position slot in shaft properly to take lock plate To disassemble the third and direct speed clutch assembly a The mainshaft clutch hub and sleeve are held together by two retaining springs located on each side of clutch hub The clutch sleeve can be removed from clutch hub by removing the retaining springs and supporting the outside diameter of sleeve and pressing on PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL 10 TRANSMISSION Section D Page 3 hub Use care when disassembling not to loose the three shifting plates 7 The blocker rings are supported by the main drive gear hub and third speed gear hub and are disassembled with the removal of the mainshaft assembly CAUTION In reassembling the clutch assembly be sure to place end of each retaining spring in the same shifting plate 7 with the loose ends located in same position on both sides to equalize the tension on all three shifting plates 7 and also index etched marking on hub and sleeve To disassemble first and second speed synchronizer unit 2 The mainshaft first and second speed clutch hub
29. e of pipe a long bolt having threads the same size as those tapped in end of shaft Using a flat steel plate with a hole in the center sufficiently large to permit passage of bolt The nut is turned on the bolt close up to the head The bolt is then passed through plate and pipe in order named and screwed into idler Shaft The nut is then tightened against the plate with the result that the pulling action is exerted against the shaft with the case acting as a base through pipe and plate After withdrawing the idler shaft or shafts from case the idler gears are lifted out through top of case and bearings removed from idler gears With the countershaft rear bearing lock nut 37 removed drive counter shaft assembly toward rear of case sufficiently to install suitable puller to remove rear bearing 36 By tilting the front end upward the countershaft assembly is easily removed through top of case Also remove front bearing thrust washer 22 To disassemble countershaft remove re taining snap ring from countershaft Gears 24 26 28 29 should be pressed off one at a time and keys 25 removed from shaft CAUTION Inreassembling NEW snap rings should be used throughout the unit When reassembling mainshaft as sembly always replace lock key and washer and make sure the gears are neither tight nor loose after they are assembled Make sure that all gears in ihe unit are replaced in their proper position Donated by Jo
30. en For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL BROWN LIPE AUXILIARY TRANSMISSION MODELS 6231 AND 6231 A FOR TEAR DOWN ILLUSTRATIONS SEE SHOP TALK No 38 f 37 38 39 1 3 4 5 6 36 EB TELE My 7 23 AY iy 8 22 I Kf A D 7 Ee SIE LZ SE Ch gt s p SEN 5 NE a irre 4 SE m ON d Mind BS ioci o ANE es SAT EG y EL L7 Vi SS e FF a AV AN Y ei nz EE gt e SY gt gt LA LAE C HE n p f i d ES E TR GEN i a 31 d Geer ZA e 230 We j ens EA Ze 7 LA Ss AN 80 ES SS SUN A SW PFD P AVE s sg Ad ve 28 T 16 a is 97 NS 17 E S ERN SSYSSSSSSSSES 18 26 uocis 25 24 99 a 90 19 B 3668 Fig Mainshaft overdrive gear 1 Cover tainer 2 Shift bar Countershaft rear bearing Needle bearings 47 3 Shift fork Counter shaft Mainshaft pilot bearing 4 Underdrive gear Countershaft rear bearing Sleeve oil dam 5 Needle bearings 47 retainer Clutch gear 6 Clutch collar Power take off opening Mainshaft outer bearing 7 Clutch gear Drain plug front 8 Inner bearing rear Countershaft underdrive Sleeve 9 Outer bearing rear gear Mainshaft inner bearing 10 Slinger Power take off gear front 11 Mainshaft Co
31. following instructions will be found helpful in servicing the unit and it will be noted that the procedure is best handled in sections A Dismantle Transmission l Drain transmission 2 Remove shifter housing capscrews and housing 3 Remove companion flange nut front 4 Remove companion flange nut rear 5 Remove companion flange front 6 Remove companion flange rear 7 Remove power take off covers and gaskets 8 Remove countershaft rear bearing cover and shims 9 Remove countershaft front bearing cover and shims 10 Drive countershaft toward rear of housing forcing rear bearing cup from position 11 Drop countershaft assembly to bottom of case 12 Remove main shaft rear bearing cover 13 Force main shaft assembly toward rear of case 14 Remove main shaft rear bearing 15 Tilt main shaft assembly and lift out through top of case 16 Remove drive gear and bearing from top of case 17 Remove countershaft assembly B Dismantle Countershaft Assembly 1 Remove countershaft front bearing cone 2 Remove countershaft rear bearing cone 3 Remove snap ring from front of counter shaft 4 Press off countershaft drive gear and remove key 5 Press off countershaft overdrive gear and remove key 6 Press off countershaft power take off gear and remove key C Dismantle Main Shaft Assembly 1 Remove underdrive clutch gear collar 2 Remove underdrive clutc
32. h gear 3 Remove main shaft underdrive gear 4 Remove direct and overdrive clutch gear collar 5 Remove direct and overdrive clutch gear 6 Remove direct and overdrive gear 7 Remove main shaft snap ring D Dismantle Shifter Housing Assembly 1 Remove lockwires from shifter rail setscrews 2 Remove shifter rail setscrews 3 Remove poppet retaining plugs and springs 4 Remove overdrive shifter rail poppets and springs and shifter fork 5 Remove underdrive shifter rail poppets and springs and shifter fork 6 Remove shifter rail packing glands and covers E Dismantle Main Drive Gear Assembly 1 Remove pocket bearing 2 Press off main drive gear bearing F MA WA Dismantle Main Shaft Front Bearing Cover Assembly 1 Remove front bearing oil seal 2 Remove front bearing oil slinger 3s Remove inner bearing race Assemble Countershaft Assembly l Press countershaft power take off gear into place after installing holding key Ba Press countershaft overdrive gear and key into place 3 Press countershaft drive gear and key into place 4 Install countershaft gear lock ring 5 Install countershaft front bearing cone 6 Install countershaft rear bearing cone Assemble Main Shaft Assembly 1 Install main shaft snap ring in place on shaft 2 Install main shaft underdrive gear with clutch gear to rear of shaft 3 Install main shaft underdrive clutch gear w
33. haft Main shaft sliding clutch Main shaft ear J gear Main shaft 22222 B A Key Washer ER A 22941 Fig u b Remove fifth speed gear key 48 from groove in mainshaft 30 Rotate fifth PRINTED IN UNITED STATES OF AMERICA 6 T Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION Section E Page 3 speed gear washer 47 on mainshaft to index lugs with splines of shaft and then remove Figure 4 Slide main shaft fifth speed gear 20 sleeve 19 and washer 21 from shaft To disassemble main drive gear a Remove peened over material from slots in main drive gear and turn off drive gear bearing nut 2 NOTE Nut is left hand threaded Press bearing 58 from main drive gear 1 To disassemble countershaft and reverse idler gear a Remove peened over material from slots and remove countershaft rear bearing nut 42 from countershaft 44 b Remove capscrew and lockwasher from reverse idler shaft lock plate and re move from slot in idler shaft 25 Drive idler shaft 25 toward rear of case and lift idler gear 24 and roller bearings 23 from case c Drive countershaft assembly 44 toward rear of case sufficiently to expose rear bearing 41 attach puller and remove rear bearing from countershaft Lift countershaft assembly through top of case lifting front end upward and til
34. he ridge of the oil sleeve toward inside of the retainer casting Be sure to locate oil sleeve holes in proper location The sleeve permits building up a reservoir of oil to assure front bearing lubrication Press in outer bearing cup Press inner bearing cone on the main drive gear and install spacer and shims Slide main drive gear shaft through retainer assembly and install outer cone Place suitable tubing over end of main drive gear shaft and against outer bear ing cone Press against tubing to seat the bearings and shims Approximately 30 tons pressure against sleeve will suffice to firmly seat the bearings Bearing adjustment must be 000 to 002 tight Install spacing washer andoil retainer on outer end of drive gear shaft retainer Install companion flange and nut draw down tight Install mainshaft pilot bearing in main drive gear G Assemble countershaft assembly H I l Press countershaft power take off gear into place after installing holding key Press countershaft overdrive gear into place after installing holding key Press countershaft drive gear into place after installing holding key Install countershaft gear snap ring Install countershaft front and rear bear ing cones Assemble mainshaft assembly l Place mainshaft underdrive gear on flat surface and insert a little non soap viscous type low melting point grease in the bore of the gear Insert one row of ro
35. here fore the following disassembly instructions will also serve as reference for assembling 1 Clean the outside of the transmission particularly around the control and bearing covers 4 10 35 A Place shift lever 17 to neutral position Remove nine capscrews and lockwashers from control cover 10 and lift cover assembly and gasket 31 from top of case 3 disassemble the control cover assembly a Cut lockwire 13 at fourth and fifth speed shift fork 12 and remove shift fork lockscrew 11 Drive shift rail out to ward front of cover driving out shift rail thimble 6 and remove shift fork 12 Do not lose poppet ball 8 and spring 9 b Remove interlock ball and pin retainer plug located on left outside of cover directly below the poppet spring and ball housing releasing interlock ball and pin 7 c Continue disassembly operation re moving low and reverse and second and third speed shift forks 26 28 shift block step pin spring and rails Do not lose shift rail poppet balls 8 and springs 9 or interlock pin 7 and balls d Remove shift lever ball 18 from shift lever 17 Remove lever dust cover 16 and also nut and lockwasher from control lever pivot pin Place cover 10 in a vise grasp lower end of con trol lever spring 14 with a large pliers and twist it from its retaining lugs Spring may also be removed by use of a pinch bar and forcing spring over the retaining l
36. hn amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AUXILIARY TRANSMISSION Section H Page 1 FULLER AUXILIARY TRANSMISSION MODEL 2 A 45 c SS NS A 46 45 44 43 50 49 48 47 AN 7 T SG 38 37 36 35 34 un 7777 ASIN Pe TH 4 b ei PNN PZN lh e ZINS eue lt A gt Aq EE NS SY gt Sie A m A ao G S L 44 09 1 12 gt s Z ALR n 7 T SS EZ 29 30 CAT ANZ LZ Yu H 13 1 17 0 SS u 14 77 15 26 16 9 ANOS SS 25 SEH 4 2 S 18 Ii B 24 in RANN 19 20 21 22 23 B 4758 ep esee Te Description l Transmission case washer Mainshaft 2 Cork seal Countershaft drive gear Speedometer gear spacer 3 Cork seal retainer Countershaft gear spacer Rear bearing cover and 4 Shifting bar Countershaft low speed speedometer housing 5 Shifting bar eyebolt gear Breather pipe 6 Main drive gear Countershaft rear bearing Cotter pin 7 Cotter pin Spacer Breather pipe cap 8 Nut Countershaft rear bearing Rear support stud 9 Oil seal washer Oil retainer thimble 10 Mainshaft bearing washer Countershaft beari
37. iners shims gasket and speedometer 3 drive gear 8 Remove seven main drive gear and 4 bearing retainer assembly capscrews and lockwashers De 9 Lift off main drive gear and retainer assembly leaving pilot bearing in the drive gear 10 Remove clutch collar from front of D mainshaft L ll Support mainshaft underdrive gear on blocks inside of front face of trans mission case Press mainshaft out of 2 rear bearings underdrive clutch gear L LINE MOTOR TRUCK SERVICE MANUAL V collar and underdrive gear NOTE Do not lose any of the loose needle bearings located in the underdrive gear There are 47 rollers in each row of bearings The mainshaft assembly can then be removed out through front of case and underdrive gear lifted out through top of case Press out mainshaft rear outer bear ing cup and use a brass drift and care fully drive out mainshaft front bearing cup Tap forward end of countershaft with soft hammer to drive out countershaft rear bearing cup Lift countershaft assembly out through top of case and then remove countershaft front bearing cup B Dismantle countershaft assembly Remove countershaft rear and front bearing cones Remove snap ring from front end of countershaft Press off countershaft drive gear and remove key Press off countershaft overdrive gear and remove key Press off countershaft power take off gear and remove key Dismantle the mainshaft a
38. ing Reverse idler shaft Reverse idler gear Reverse idler gear bushing Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section A Page Z TRANSMISSION MODEL HDS The Model HDS transmission is of synchro mesh type with remote control having three speeds forward and one reverse Fig 2 illus trates the shift diagram A 21987 Fig 2 Shifting Diagram HDS DISASSEMBLING AND REASSEMBLING With a few minor exceptions the assembly is simply the reverse of disassembling Therefore the following disassembly instructions will also serve as reference for assembling Fig 1 illustrates construction details of this transmission and figure numbers in parentheses throughout this section will refer to this illu stration 1 Clean outside of transmission particularly around the control and bearing covers l 12 23 2 Shift selector lever 8 and shift lever 13 to neutral position Remove cotter pin and breather cap from hold down bolt Re move four capscrews and lockwashers from control cover 12 and lift off control cover assembly 3 To disassemble the control cover assembly a Remove outer selector lever setscrew releasing both outer and inner levers 8 b Remove shift lever setscrew 14 and this will release the shaft spring and shift lever 13 4 Disassembling shift forks and shafts a Remove poppet ball and spring retainer plugs releasing balls and springs
39. ith flat face toward rear of shaft 4 Install main shaft underdrive clutch gear collar with hub toward rear of shaft 5 Install main shaft direct and overdrive gear with clutch gear to front of shaft 6 Install main shaft direct and overdrive clutch gear with flat face toward front of shaft 7 Install main shaft direct and overdrive gear clutch gear collar with clutch teeth toward the front Assemble Transmission Shifter Housing Assembly Install direct and overdrive shifter rail shifter fork poppet ball and spring in place in housing cover Shifter fork must be installed with hub toward the rear Install shifter rail interlock 3 Install underdrive shifter rail shifter fork poppet ball and spring in place in housing Shifter fork must be in PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AUXILIARY TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL Section I Page 3 stalled with hub toward the front Lock underdrive shifter fork in place with setscrew Lock direct and overdrive shifter fork in place with setscrew Install lockwires through shifter fork setscrews Install poppet spring retaining plugs Install packing glands and covers for shifter rails J Assemble Transmission E 2 10 L1 13 14 15 16 Install countershaft front bearing cup in position in front of case Install countershaft front bea
40. ller bearings 47 rollers and turn gear over and insert spacer Insert second row of bearings 47 rollers Note that when all bearings are in place there is a space wide enough for another roller Do not place another roller in the bearing row The space is left to provide rolling clearance for all the rollers in that particular row Repeat roller installation as outlined in paragraphs 1 amp 2 with the mainshaft overdrive gear Slide overdrive gear on shaft being careful not to disturb the rollers Place clutch gear on mainshaft with flat face of gear toward front of shaft and install gear retaining snap ring Carefully place mainshaft underdrive gear with bearings on shaft with clutch teeth on gear toward rear and install clutch collar Assemble transmission shifter housing assembly 15 Install direct and overdrive shift rail shift fork poppet ball and spring in place in housing cover Shift fork must be installed with hub toward rear Install shift rail interlock pin Install underdrive shift rail shift fork poppet ball and spring in place in hous ing Shift fork must be installed with hub toward front Donated by John amp Susan Hansen For Personal Use Only AUXILIARY TRANSMISSION Section J Page 4 4 Lock shift forks in place with set Screws and install lockwires through setscrews 5 Install poppet springs balls and retainer plugs 6 Install shift rail seals J Assemble tran
41. mbling Fig l illustrates construction details of this transmission and figure numbers in parentheses throughout this section will refer to this illu stration l Clean outside of transmission particularly around the control and bearing covers 1 11 30 2 Place control lever 13 into neutral position Remove capscrews and lockwashers holding cover 11 to case 44 and lift control cover assembly off transmission CAUTION Do not force the control cover assembly off the transmission Forcing may spring the yokes and cause partial engagement or gear interference A slight manipulation will free the cover 3 To disassemble the control cover assembly a Cut lock wire on reverse shift block and remove shift block lockscrew Drive shift rail 10 out toward rear of cover driving out expansion plug 27 and remove shift block b Pull tapered plug located on left out side of cover directly below poppet Spring and ball and remove interlock plunger 19 and third and direct speed shift rail interlock pin c Continue disassembly operation in the same manner as described in para graph a removing third and direct speed shift fork 12 and first and second speed shift fork 25 rails ex pansion plugs poppet springs balls and interlock plunger CAUTION In reassembling the control cover assembly care should be exer cised to see that all parts are replaced in their correct positions and none of the small in
42. ng 9 Sleeve 3rd and direct speed Countershaft gear cluster 10 Shift rail Mainshaft rear bearing 2nd speed gear bearing 11 Transmission cover retainer Spacer 12 Shift fork 3rd and direct Mainshaft rear bearing 2nd speed gear roller 13 Control lever Rear bearing retainer bearing 14 Control housing cap seal Countershaft thrust 15 Fulcrum ball Mainshaft flange nut washer front 16 Controllever spring Mainshaft Countershaft roller 17 Control lever ball Speedometer drive gear bearing 18 Mainshaft 3rd speed gear Snap ring 2nd speed gear thrust 19 Interlock plunger Countershaftroller bearing washer 20 Poppet spring Countershaft thrust washer Snap ring 21 Poppet ball rear Clutch hub 3rd and direct 22 Mainshaft 2nd speed gear Counter shaft Mainshaft pilot bearing PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section D Page 2 L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION MODEL T 98 The Model T 98 transmission is of synchro mesh type having four speeds forward and one reverse Fig 2 illustrates the shift diagram q UP I A 22937 Fig 2 Shifting Diagram T 98 DISASSEMBLING AND REASSEMBLING With a few minor exceptions the assembling is simply the reverse of disassembling There fore the following disassembly instructions will also serve as reference for asse
43. ng nut Mainshaft low speed gear Front bearing spacer Front bearing cover Gasket Counter shaft Countershaft bearing nut Countershaft front bearing cover 17 Gasket 18 Drain plug Countershaft front bearing Countershaft rear bearing cover Gasket Gasket Mainshaft washer Key Cotter pin Nut Mainshaft Oil seal PRINTED IN UNITED STATES OF AMERICA sleeve Key Mainshaft low speed gear bushing Mainshaft low speed gear Mainshaft low speed gear washer Shifting yoke Shifting yoke Oil deflector Donated by John amp Susan Hansen For Personal Use Only AUXILIARY omes L LINE MOTOR TRUCK SERVICE MANUAL Page 2 POWER TAKE OFF FOR FULLER MODEL 2 A 45 TRANSMISSION 1 2 a 7 16 VY 4 15 4 ZZ las 14 13 12 24 e 4 TAARTEN A 4 i s tse E EE 6 N INV ZTE SE E ZR SE en X ANE ISPS e KASS ns 10 7 8 8 A 23182 11 Fig 2 Description Gasket Front bearing cover Countershaft bearing nut Bearing spacer Key Bushing Gear sleeve washer Gasket Cotter pin Nut Mainshaft Oil seal e Rear bearing cover Mainshaft sliding clutch Donated by John amp Susan Hansen For Personal U
44. o Direct O D in Direct O D in Direct mesh mesh in 4th mesh in 5th 5th in 5th 5th in 5th Overdrive 4 43995 AN NL e No No No No No Yes No No Number of forward speeds 1 1 1 1 1 1 1 2 Reductions First low 3 058 1 3 714 1 6 40 1 6 398 1 7 35 1 8 03 1 Second 1 481 1 1 871 1 3 09 1 3 092 1 4 30 1 4 61 1 Third amp 4 1 000 1 1 000 1 1 69 1 1 686 1 2 52 1 2 46 1 Fourth ee e a a a e a 1 00 1 1 42 1 1 41 1 Fifth cece cece cere 22777 lee 1 000 1 1 000 1 High reverse m vi m emm em wm mmm T m wg gp u mm eg emm wb S Z E D ES zs C Le Un CS lt gt 2 C gt Low reverse secrvreccece 3 707 1 4 588 1 7 82 1 7 820 1 Number of P T O opening 1 1 Lubricant capacity pints 3 6 5 8 SNOI LVOLdAIOWdS NOISSIINSNY UL 2824 Donated by John amp Susan Hansen For Personal Use Only AUXILIARY TRANSMISSION SPECIFICATIONS MODEL 2 A 45 553 6231 6231 A 8031 C 8031 G Brown Lipe Brown Lipe Brown Lipe Brown Lipe Brown Lipe Number of speeds Number of bearings Type of bearings 6 Ball 2 Ball 1 Ball Ball 3 Ball 3 Ball l Roller 4 Roller 6 Roller 6 Roller 3 Roller 3 Roller Ratios 1 00 to 1 Underdrive Overdrive o0 o e Lubricant capacity Summer pints Winter pints 7 SNOILLV 21 4104 dS
45. ohn amp Susan Hansen For Personal Use Only TRANSMISSION Section C Page 2 TRANSMISSIONS MODEL H 41B The Model H 41 B transmission is of sliding gear type having four speeds forward and one reverse Fig 2 illustrates the shift diagram a b c A 22887 Fig 2 Shifting Diagram H UI B DISASSEMBLING AND REASSEMBLING With a few minor exceptions the assembling is simply the reverse of disassembling There 4 fore the following disassembly instructions will also serve as reference for assembling Fig 2 illustrates construction details of this transmission and figure numbers in paren theses throughout this section will refer to this illustration a b 1 Clean the outside of the transmission particularly around the control and bearing covers 7 14 35 c 2 Place shift lever 1 in neutral position Remove the six holding capscrews and lift off the control assembly 7 CAUTION Do not force the control cover off the transmission Forcing may spring the yokes of alignment and cause partial engagement or gear interference If bind ing occurs a slight manipulation will free it d L LINE MOTOR TRUCK SERVICE MANUAL 4 A INTERNATIONAL J d if d 1 3 To disassemble the control cover assembly Remove control lever retainer 2 from top of cover 7 Lift out control lever 1 retainer 2 washer 3 and spring 4 and fulcrum ball 5 Fulcrum ball
46. out through top of case NOTE When reassembling be sure to position shaft so that recess will take rear bearing retainer properly Disassembly of mainshaft clutch assembly a Mainshaft clutch and sleeve are held together by poppet springs 9 and balls 7 Mainshaft clutch can be removed from sleeve by supporting outer diameter of sleeve and pressing on clutch Use care when disassembling as poppet balls are under spring tension and may fly out when sleeve is removed It is suggested that a cloth be wrapped around the assembly to guard against this A special tool SE 920 is available which if used will facilitate disassembly and reassembly If you do not have this tool on hand follow instructions out lined in paragraph b PRINTED IN UNITED STATES OF AMERICA b Cotter pin Sleeve Ball To reassemble insert clutch partially in sleeve and install springs and balls Then insert cotter pins 1 8 x 2 hav ing the ends spread slightly as shown in Fig 4 The cotter pins when pressed between the splines force the balls into the clutch and after clutch is pressed into sleeve cotter pins can be removed A 22933 Fig 4 Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only Cf Ui uv Lb ee Main drive gear 23 Bearing snap rings 24 Main drive gear bearing retainer 29 Synchronizer blocking
47. over Power take off drive gear Mainshaft 6 Capscrew right side Shifter shaft rear cover 7 Poppet spring cover Countershaft overdrive Shifter shafts 8 Control cover gear Mainshaft low and reverse 9 Poppet spring Countershaft 3rd speed sliding gear 10 Poppet ball drive gear Shifter fork low and re 11 Interlock pin Drain plug verse 12 Shifter fork direct and Reverse drive gear Shifter fork 2nd and 3rd overdrive Countershaft 2nd speed speed 13 Retainer gasket drive gear Mainshaft 2nd and 3rd 14 Main drive gear bearing Countershaft low speed speed sliding gear 15 Main drive gear bearing drive gear Mainshaft 3rd speed retainer Countershaft rear bearing constant mesh gear 16 Main drive gear Countershaft rear bearing Shifter shaft lock screw 17 Mainshaft sliding clutch lock nut Mainshaft gear lock washer 18 Mainshaft overdrive gear Rear bearing retainer Constant mesh reverse 19 Countershaft bearing Mainshaft rear bearing idle gear retainer Speedometer drive gear Reverse drive gear PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section F Page 2 TRANSMISSIONS MODELS F 52 and F 52 C The Model F 52 transmission S A 430 is constructed having five forward speeds and one reverse Fifth speed is overdrive Fig 3 illustrates the shift diagram Fig 2 Shifting Diagram F 52 The Model F 52 C tr
48. p rings should be used throughout the unit When reassembling mainshaft assembly always replace lock key and washer and make sure the gears are neither tight nor loose after they are assembled Make sure that all gears in the unit are replaced in their proper position Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION Section G Page l TRANSMISSIONS F 54 AND F 54 B Y P 0 JC duc bw Shift lever Dust cover Spring retainer Spring Shift lever cover Capscrew Lockwasher Control cover Interlock pin Shifter fork direct and overdrive Retainer gasket Main drive gear bearing Main drive gear bearing retainer Main drive gear Main drive gear bearing retaining nut Mainshaft front bearing Snap ring Mainshaft sliding clutch Snap ring Expansion plug Spacer Countershaft front bearing K 29 30 3 32 25 26 27 28 Fig F 54 and F 54 B Sol mee e lransmission case Countershaft drive gear Key Power take off drive gear Mainshaft overdrive gear Countershaft overdrive gear Countershaft 3rd speed drive gear Reverse drive gear Countershaft 2nd speed drive gear
49. pin Place cover in vise grasp lower end of control lever spring 4 with a large pliers and twist it from its lugs Spring may also be removed by use of a pinch bar and forcing spring over the retaining lugs With the spring removed releasing spring retainer 3 the lever 1 can be lowered through shift lever cover 5 c Remove capscrews 6 and poppet spring and ball cover plate 7 re leasing poppet springs 9 and balls 10 Cut lockwire at reverse shift block and remove lockscrew Drive shift rail 42 toward rear of cover driving out shift rail cover 41 Pull shift rail out releasing reverse shift block on inside of cover CAUTION Do not lose poppet spring 9 and ball 10 d Remove interlock ball retainer cap located on left outside of cover directly below poppet spring and ball housing releasing the interlock ball and pin 11 Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION Section F Page 3 e Continue disassembly operation in the same manner as described in paragraph c removing the balance of shift rails 42 covers 41 shift forks 12 44 poppet springs and balls and interlock ball CAUTION In reassembling the control cover assembly care must be exer cised to see that all parts are replaced in their correct positions and none of the small interlocking parts are lost or omitted 4 Disassemble mainshaft assembly
50. ring 19 Mainshaft sleeve 5th gear Flange nut retainer 20 Mainshaft 5th gear Flange lockwasher Expansion plug snap ring 21 Mainshaft 3rd speed washer Flange Mainshaft sliding clutch 22 3rd speed constant mesh Mainshaft rear bearing Main drive gear bearing gear Countershaft rear bearing Mainshaft pilot bearing PRINTEO IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION Section E Page 2 L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL VA TRANSMISSIONS MODELS 51 and F 51C The Model F 51 transmission 5 A 330 has five speeds forward and one reverse Fifth speed is overdrive Fig 2 illustrates the shift diagram A 22886 Fig 2 Shifting Diagram F 51 The Model F 51 C transmission 5 A 33 is constructed having five forward speeds and one reverse speed Fifth speed is direct Fig 3 illustrates the shift diagram 22882 Fig 3 Shifting Diagram F 51 C Fig 1 illustrates construction details of the F 51 and F 51 C transmissions and figure numbers in parentheses throughout this section will refer to this illustration Item 20 on Fig 1 will be referred to as Mainshaft Fifth Speed Gear although due to change in diameter on F 51 C direct in fifth transmission it is used as fourth speed gear DISASSEMBLING AND REASSEMBLING With a few exceptions the assembling is simply the reverse of disassembling T
51. ring 26 Transmission cover 21 Expansion plug 28 Shifting plate 29 Clutch sleeve second and direct 30 Interlock plunger 3l Poppet ball and spring 32 Shift fork second and third 33i Shift lever 34 Shifting shaft 35 Shift fork low and reverse 36 Mainshaft second speed gear Shift rail 38 Mainshaft low and reverse gear 39 Expansion plug 40 Transmission cover gasket 41 Oil retainer washer 42 Mainshaft rear bearing retainer 43 44 Mainshaft bearing snap ring PRINTED IN UNITED STATES OF AMERICA Mainshaft rear bearing Oil seal Mainshaft Mainshaft flange nut Speedometer drive gear Countershaft thrust washer inner Countershaft thrust washer outer Counter shaft Lock plate Lock plate capscrew Reverse idler shaft Reverse idler gear bushing Reverse idler gear Countershaft gear cluster Countershaft thrust washer front Countershaft roller bearing Transmission case Countershaft bearing spacer Oil retainer washer Main drive gear bearing Clutch hub second and direct Mainshaft pilot bearing TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL i TRANSMISSION T 87 D 17 18 19 6 20 5 21 4 22 3 23 2 E 24 E de E p SOQ CWB Sit WA EE P Se e 26 ns Wei 4 27 Ji 28 ZZ 39 _ 3l WT Lm S BRE 33 AN 34 35 Fig ome No Descripion i Ne Description
52. ring cap and gasket Place countershaft and gear assembly in position in case Install countershaft rear bearing cup in place in bore of case Install countershaft rear bearing cap gasket and shims There should be no perceptible bindor end play in the countershaft assembly Make this assembly in such manner that there is a distinct drag felt and then add one 003 shim Remove front countershaft bearing cap Remove countershaft rear bearing cap gasket and shims Drive countershaft assembly toward rear of case forcing rear bearing cup from position in bore of case Allow countershaft to lay in bottom of case Press bearing cone against shoulder of main drive gear Place front bearing cover over main drive gear shaft Install drive gear bearing spacer over shaft Install shims over spacer Install front bearing cone in cover Install companion flange Donated by John amp Susan Hansen For Personal Use Only AUXILIARY A TRANSMISSION ANDA Section I L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL Page 4 VN V 17 Install companion flange nut 30 Using bar through power take off open ing raise countershaft assembly into 18 There should be no perceptible bind place or end play in the main shaft assembly Make this assembly in such manner that 31 Install countershaft rear bearing cup there is a distinct drag felt and then add one 003 shim 32 Bolt countershaft rear bearing cap
53. ront bearing shims Mainshaft underdrive gear oil seal Countershaft rear bearing Mainshaft overdrive gear 1l Drive gear oil seal cover cap Shifter fork lock screw 12 Companion flange Countershaft rear bearing Shifter fork lock screw 13 Mainshaft nut retainer capscrew lockwire 14 Drive gear bearing spacer Mainshaft rear bearing Mainshaft clutch collar 15 Mainshaft drive gear spacer washer Overdrive shifter fork 16 Countershaft front bearing Mainshaft rear bearing Mainshaft clutch gear 17 Countershaft front bearing Companion flange Mainshaft pocket bearing retainer cap Mainshaft nut Main gears 18 Transmission housing Mainshaft rear oil seal Main gear front bearing 19 Countershaft gear snap ring cover spacer shims PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AUXILIAR Y TRANSMISSION Section I Page 2 L LINE MOTOR TRUCK SERVICE MANUAL INTERNATIONAL NTERNATIONAL The Brown Lipe Model No 5531 Auxiliary Transmission is constructed with three speeds forward with Direct Drive on second speed and Overdrive on third speed There are no speeds in Reverse As an Auxiliary Transmission it is designed to be used in conjunction with standard four or five speed transmissions The Gear Ratios of the Brown Lipe No 5531 Auxiliary Transmission are Direct 1 00 to 1 00 Overdrive 72 to 1 00 Underdrive 2 00 to 1 00 The
54. se Only AUXILIAR Y 4 ATUM TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL SSC VV Page 3 The Fuller Model 2 A 45 Auxiliary Trans 20 Remove speedometer gear and key mission is designed to be used in conjunction with regular transmissions 2l Remove inner bearing spacer The gear ratios of the two speed Model 22 Force main shaft out of rear bearing 2 A 45 Auxiliary Transmission are as follows through main drive gear bearing bore in front of case removing main shaft Direct 1 00 to 1 underdrive bushed gear and washer as Underdrive 1 3 to 1 shaft emerges The following procedure will be found help 23 Remove main shaft pilot bearing from ful in servicing the unit shaft 24 Remove main shaft sliding clutch gear A Dismantle Transmission 25 Remove main shaft underdrive gear 1 Remove capscrews holding side cover sleeve washer from shaft or power take off 26 Remove main shaft underdrive gear 2 Remove cover or power take off and sleeve and key from shaft gasket 27 Force countershaft toward rear and out 3 Remove poppet spring retainer screw of case removing countershaft front bearing spacer washer countershaft 4 Remove shifter fork lock screw drive gear gear spacer and counter shaft underdrive gear as shaft emerges 5 Withdraw shifter bar CAUTION Do not lose poppet spring 28 Remove countershaft rear bearing lock and ballas shifter bar emerges nut and washer 6 Remove shifter fork 29
55. shims and gasket into place 19 Remove companion flange nut 33 Bolt countershaft front cover and gasket 20 Remove companion flange into place 21 Remove front cover front bearing 34 Using bar through power take off open and bearing spacer with sbims ing raise main shaft and gear assembly into place 22 Bolt front main shaft bearing cover in place to housing 35 Install main shaft rear bearing 23 Install main drive gear and inner bear 36 Bolt main shaft rear bearing cap and ing in position through top of case gasket into place 24 Assemble drive gear bearing spacer 37 Install main shaft rear bearing oil shims and outer bearing as previously slinger oil seal and dirt slinger in prepared place 25 Install oil slinger oil seal and dirt 38 Install companion flange shield 39 Install companion flange nut and cotter 26 Install companion flange key 21 Install companion flange nut and cotter 40 Install shifter housing and fork assembly key in place with shifter forks in proper position 28 Install main drive gear pocket bearing in hole in main drive gear 41 Install shifter housing cover capscrews Sue Shai Bee pIEviously 42 Install power take off cover and gasket prepared and place in position in bous ing with pilot of shaft inside pocket bearing in main drive gear 43 Fill with lubricant 6 pints AUXILIARY TRANSMISSION Section J Page 1 Donated by John amp Susan Hans
56. sing spring retainer 3 the lever 1 can be lowered through shift lever cover 5 c Cut lockwire and remove shift fork lockscrew 58 starting with upper shift rail 50 Drive shift rail 50 out toward rear of cover driving out shift rail cover thimble 49 Shift fork can be lifted out of cover CAUTION Do not loose poppet springs 56 and balls 55 d Continue disassembly operation re moving the balance of shift rails 50 interlock pin 9 shifter forks 52 53 10 interlcck balls shift blocks and stop pins CAUTION In reassembling the control cover care should be exercised to see that all parts are replaced in their correct positions and none of the small interlocking parts are lost or omitted i IMA v Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL TRANSMISSION Section G Page 3 4 To remove mainshaft assembly a b c Main shaft 7 sliding clutch Main shaft gear D S Main shaft UN Cove m 222222 Remove mainshaft rear bearing re tainer 47 and countershaft rear bear ing 38 Slide off speedometer drive gear 41 and remove key After lock ing gears by engaging two speeds the countershaft rear bearing lock nut 37 is removed from end of counter shaft Drive mainshaft assembly toward rear of case sufficiently to expose rear bearing snap ring 40 Install suitable puller and remo
57. smission 1 2 3 Install countershaft front bearing cup in position in front of case Install front bearing retainer and gasket Place countershaft and gear assembly in position in case and tap toward front of case until gear contacts inside face of case Install countershaft rear bearing cup in place in bore of case Install rear bearing cap gasket and shims Add or remove shims at rear bear ing retainer to provide an adjustment of 000 to 003 loose Such an adjustment will allow the counter shaft to revolve freely and with no perceptible end place or drag Remove front bearing retainer and proceed with the assembly L LINE MOTOR TRUCK SERVICE MANUAL 8 10 ll 12 13 14 15 INTERNATIONAL Holding the mainshaft and gear assembl together with fingers in clutch colla groove tilt the shaft and install i case being careful to hold underdriv gear and clutch collar in position With the mainshaft gears resting on the countershaft slide the underdrive clutch gear through rear bore onto the mainshaft and into the underdrive clutch collar NOTE Beveled enc of gear toward rear of case Place overdrive clutch collar on direct and overdrive clutch gear with clutch collar teeth toward front Install main drive gear and retainer assembly previously assembled Install rear bearing cups cones speed ometer drive gear and bearing re tainer with shims Adjust mainsh
58. ssembly Remove underdrive clutch gear and collar Remove mainshaft underdrive gear Remove snap ring from ront end of mainshaft Remove direct and overdrive clutch gear and collar Remove overdrive gear and roller bearings NOTE There are 47 needle bearings in each of the two rows used with a spacer sleeve between the rows Dismantle shifter housing assembly Cut lockwires and remove shift fork lock screws Remove poppet retaining plugs releasing balls and springs Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR TRUCK SERVICE MANUAL AUXILIARY TRANSMISSION section J Page 3 5 Pull overdrive shift rail out through front of cover and remove shift fork Pull underdrive shift out through front of cover and remove shift fork Remove shift rails interlock pin and seals E Dismantle main drive gear assembly F 1 Remove four oil retainer capscrews and lockwashers and lift off oil retainer and gasket Lift out spacing washer Press on end of main drive gear shaft to remove shaft spacer sleeve shims and inner bearing cone from retainer NOTE Keep shim pack together Press inner and outer bearing cups out of retainer together with oil sleeve Remove pilot bearing from main drive gear Assemble the main drive gear assembly l Install inner bearing race in the re tainer then place the oil sleeve or lubricant dam sleeve in the retainer witht
59. t ing assembly Also remove front bear ing thrust 53 The countershaft front bearing is disassembled by removing snap ring 56 from groove and drive retainer 55 from case The counter shaft front bearing 54 may now be removed from case d To disassemble the countershaft as sembly remove snap ring 52 from countershaft Using adapter plates press countershaft drive gear 49 spacer 50 fifth speed gear 46 and third speed gear 45 from counter shaft 44 and remove gear keys 51 CAUTION Inreassembling NEW snap rings should be used throughout the unit Donated by John amp Susan Hansen For Personal Use Only Donated by John amp Susan Hansen For Personal Use Only TRANSMISSION L LINE MOTOR TRUCK SERVICE MANUAL os TRANSMISSIONS F 52 AND F 52 C 50 51 48 A ASSAN LN 4Z Es Zi ss A tes 6 15 TZ T ate 40 39 m nonam lA 98 Naess EAS i SH 9 37 E 19 ad TY EN 7 32 7 22 SN Let 22 Ee 2 2 Sh m We L e 72 LLL 72 77b EZTA MIF 7 23 24 25 26 27 28 29 30 31 Fig F 52 and F 52C B 4757 1 Shift lever Countershaft gear key Mainshaft rear grease seal 2 Dust cover Countershaft front bearing Cotter pin 3 Spring retainer Transmission case Nut 4 Spring Countershaft drive gear Washer 5 Shift lever c
60. t assembly through rear bore of case as far as necessary to clear main drive gear 1 and lift out through top of case CAUTION Be sure to catch pilot needle bearings 14 sixteen in number when removing mainshaft as sembly A helpful suggestion in re assembling pilot needle bearing 44 use a rubber band to hold the sixteen needle bearings in place until the as sembly is started in the main drive gear and then the rubber band is removed be fore completing the assembly e To disassemble mainshaft assembly re more retainer snap ring and use sliding gear 17 to tap synchronizer assembly and bushed gear 15 from mainshaft Y Donated by John amp Susan Hansen For Personal Use Only L LINE MOTOR IRUCK SERVICE MANUAL TRANSMISSION Section B Page 3 5 To disassemble main drive gear a Remove snap ring 2 holding bearing 42 on main drive gear 1 Push the drive gear and bearing assembly back into case until outside snap ring seats snuggly against case Using a soft ham mer tap the mainshaft gently toward inside of case until bearing is freed and the mainshaft can then be lifted out through top of case CAUTION Do not damage bearing during this operation 6 disassemble countershaft assembly a b Remove capscrew 32 and lock plate 31 releasing countershaft 30 and reverse idler shaft 33 Drive counter shaft 30 out through rear of case using a brass
61. terlocking parts are lost or omitted d To remove control lever 13 from cover 11 turn off the housing cap 14 releasing retainer washer spring 16 and fulcrum ball 15 With the fulcrum ball and control lever assembly removed the control lever pivot pin can be removed from cover 4 To remove the mainshaft assembly a Lock transmission by engaging two speeds and remove flange nut 33 b Remove capscrews five in number and lift off mainshaft rear bearing retainer 30 revealing speedometer gear 35 bearing 31 and snap rings Slide speedometer gear 35 off of mainshaft 34 Disassemble main drive gear bearing retainer 1 by removing capscrews and lockwashers revealing main drive gear bearing 3 and snap rings 2 and 4 c Remove main drive gear bearing snap ring 2 and pull main drive gear 5 and bearing 3 out through front of case sufficiently to expose bearing snap ring 4 Apply bearing puller and re move bearing 3 from main drive gear 5 Tap mainshaft assembly toward rear of case and pull mainshaft rear bearing 31 Push mainshaft assembly through rear bore in case to clear main drive gear 5 and tilt front end upward and lift out through top of case CAUTION Be sure to catch pilot needle bearing sixteen in number when removing mainshaft assembly When reassembling front bearing retainer 1 be sure to locate oil drain hole at bottom 5 To disassemble main drive gear
62. ugs The shift lever 17 may now be lowered through the control cover 10 Control lever pivot pin can also be removed from cover CAUTION In reassembling the controls care should be exercised that all parts are replaced in their respective positions 4 Disassembling main drive gear and main shaft assembly a Lock transmission and disassemble flange nut 37 washer 38 and flange 39 Remove six capscrews and lock washers from mainshaft rear bearing retainer 35 Lift retainer and gasket 32 from case Slide speedometer drive gear 34 from mainshaft 30 and remove speedometer gear drive key 33 b Drive mainshaft assembly toward rear of case sufficiently to expose rear bearing 40 snap ring Install suitable puller and pull bearing 40 from main shaft 30 c Remove six capscrews 3 and lock washers from main drive gear bearing retainer 4 and lift off retainer 4 and gasket 5 Remove main drive gear 1 and bearing 58 and also main shaft pilot bearing 59 out through front of case d Lift mainshaft 30 and gears out through top of case tilting front end upward and leaving low and reverse speed gear 29 in case With the mainshaft as sembly removed lift out low and re verse speed gear 29 out of case 5 disassemble mainshaft assembly a Slide mainshaft second and third speed gear 27 from mainshaft and also the mainshaft sliding clutch 57 from op posite end of mains
63. untershaft overdrive Clutch collar 12 Mainsha t flange nut gear Mainshaft drive gear 13 Speedometer drive gear Countershaft drive gear Seal 14 Speedometer driven gear Countersha t bearing front Shift fork 15 Mainshaft rear bearing re 26 Bearing retainer front Spacers PRINTED IN UNITED STATES OF AMERICA Donated by John amp Susan Hansen For Personal Use Only AUXILIAR Y TRANSMISSION Section J Page 2 The Brown Lipe Models No 6231 and 6231 A auxiliary transmissions are constructed having three speeds forward There are no speeds in reverse As an auxiliary transmission it is designed 12 to be used in conjunction with standard trans mission The gear ratios of the Brown Lipe No 6231 auxiliary transmission are 13 Direct 1 00 to Overdrive 69 to 1 Underdrive 2 14 to 1 14 The gear ratios of the Brown Lipe No 6231 A auxiliary transmission are Direct 1 00 to 1 I5 Overdrive 86 to 1 Underdrive 1 24 to 1 The following instructions will be found helpful in servicing the unit 1 A Dismantle transmission 2 1 Drain transmission 2 Remove six cover retaining capscrews 3 and lift off cover assembly and gasket 3 Remove companion flange nut and 4 flange front 4 Remove companion flange nut and 5 flange rear 5 Remove power take off covers and C gaskets l 6 Remove countershaft rear bearing cover and shims 2 7 Remove mainshaft rear bearing re ta
64. ve bearing 46 from mainshaft 33 By tilting the main shaft assembly front end upward the entire unit comes out easily leaving sliding gears 51 54 inside case After shaft assembly is removed the sliding gears may then be lifted out of case To disassemble the mainshaft remove the pilot bearing 16 and sliding clutch 18 using the latter part to free the bearing After removing key 59 Fig 4 rotate gear retainer washer until its inside lugs line up with grooves in shaft and then remove Ngee ZEE eee A Ny Key Washer Fig 4 The bushed gears 27 57 and sleeve are removed by using rear gear 57 to start the sleeve Also remove sleeve key from shaft 5 To disassemble main drive gear a Remove four capscrews from main drive gear retainer 13 and lift off retainer The main drive gear 14 bearing 12 and lock nut 15 can then be withdrawn through front of case PRINTED IN UNITED STATES OF AMERICA A 22941 b Remove peened over material from slot in drive gear shaft 14 and turn off drive gear bearing lock nut 17 NOTE Nut is left hand threaded Press bear ing 12 from main drive gear 14 6 To disassemble countershaft and reverse idler gears a c To disassemble reverse idler gear or gears remove capscrews and lock plates from groove in idler shafts A simple method of pulling shaft or shafts use a short piec
65. with lubricant 10 pints Donated by John amp Susan Hansen For Personal Use Only AUXILIARY L LINE MOTOR TRUCK SERVICE MANUAL sank door Page l BROWN LIPE AUXILIARY TRANSMISSION MODEL 5531 54 53 52 51 40 48 47 46 45 44 48 42 41 40 88 38 37 f 36 er d Rid IN MAS dl elle Le TES ZU S B Ino iss a E SE m AR Seil l gt e d 4 A NE S 727 am 8 14 S Naz Hi 15 APA SZ 7 22 16 E NEUE 17 D a m NYS er 18 aN RNS A 7 1 20 21 22 23 24 25 26 27 28 29 A 23183 Fig Shifter housing Countershaft drive gear Mainshaft rear oil seal Shifter rod gland cover Woodruff key Mainshaft rear bearing retainer Mainshaft rear bearing retainer gasket Drain plug Power take o f gear Woodruff key Shifter rod packing gland Shifter rail direct and overdrive 5 Mainsha t front bearing Countershaft overdrive Mainshaft clutch gear cap gasket gear Mainshaft clutch collar 6 Mainshaft inner bearing Countershaft underdrive Breather assembly 7 Mainshaft front bearing cap gear Overdrive and underdrive 8 Mainshaft outer bearing Counter shaft gear spacer 9 Drive gear front bearing Countershaft rear bearing Underdrive shifter fork oil slinger Countershaft rear bearing Underdrive shifting rod 10 Drive gear f

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