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Service Manual

1. 7 In Vehicle Service Procedure How to Install the Neutral Switch Special Instructions None Special Tools Typical service tools 47 Procedure 1 Install a new gasket 2 Install the neutral switch Tighten it to 15 20 Ibs ft 20 27 Nem of torque 3 Connect the wiring to the switch 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft In Vehicle Service Procedure Reverse Switch Operation and Testing Special Instructions The reverse switch is a normally open ball switch When the transmission is shifted into reverse a ramp on the reverse yoke bar contacts and raises a pin The pin depresses the ball on the switch which closes the switch contact allowing current to flow through the switch and light up the vehicle s backup lights Special Tools Typical service tools Volt Ohm meter Procedure 1 Disconnect the wiring from the switch 2 Connect an ohm meter to check for continuity 3 Place the transmission shift lever in any position except reverse If the switch is working properly the ohm meter should read open or infinity If it is not remove the switch and recheck it for continuity Replace as necessary 4 Place the transmission shift lever in the reverse position If the switch is working properly the ohm meter should regis ter continuity or a small reading If it does not remove the switch and recheck it for continuity Replace it a
2. 67 3 Remove interlock parts pin spring and sleeve 4 From the shift bar housing rim remove the retaining cap screws 5 To break the gasket seal jar the shift bar housing 6 Remove the shift bar housing 7 Inspect the roll pin replace if damaged 8 Remove the gasket and clean all mounting surfaces of gas ket material 9 If the three 3 sets of tension springs and balls from the housing top bores are loose tilt the assembly and remove them Bench Service Procedure 68 w 1 rj o z ix o y 3 i ix 1 2 17 Bench Service Procedure How to Install the Shift Bar Housing Special Instructions There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other loca tions except the left front corner at the roll pin location This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes The slave valve and interlock parts must be removed prior to installing the shift bar housing Special Tools Typical service tools Procedure 1 Place the shift bar housing and shift blocks in the neutral position 2 Place the mainshaft sliding clutches in the neutral position 3 Position a new shift bar housing gasket on the shift bar housing mounting surface Note The slave valve and interlock assembly must remain off until the shift ba
3. Bench Service Procedure 5 From the auxiliary housing rear remove the bearing cup and spacer 6 From the auxiliary housing front remove the remaining bearing cup 7 Some models have a one piece bearing race Remove it from the bearing bore w rj co I ix y zt o I a 77 90 Bench Service Procedure 91 8 9 From the output shaft remove the bearing inner spacer Use the output shaft assemble gear front face as a base press the output shaft through the bearing and gear Bench Service Procedure How to Assemble the Output Shaft Assembly Special Instructions Make sure the magnetic plugs are installed in the auxiliary housing Output shaft stack up should be done on a clean flat surface When heating the bearings do not heat above 275 F 136 C When installing the rear bearing race the proper depth is when the race shoulder is seated on bearing bore top Because the collar becomes distorted when compressed do not use an old nylon collar in the rear bearing cover Special Tools See Tool Information Toolmaker s dye Heat lamp or hot plate and oil Oil seal installation tool Procedure 1 Usetoolmaker s dye and mark the LO range gear for timing purposes 2 Markany two 2 adjacent teeth on the LO range gear Repeat the procedure for the two 2 adjacent teeth directly opposite the first set marked w I rJ L Z z r
4. Atthis time remove the air line and insert the mainshaft key Be careful not to move the gears while doing this proce dure the tolerance washers are unlocked and can rotate which would cause the gears to drop 159 27 Some models use a flat key at the front Install the spline washer that is retained by this key then insert this key 28 Remove the mainshaft from the vise 29 On the shaft front align the sliding clutch missing internal spline with the mainshaft key and install the front sliding clutch Engage the sliding clutch external splines with the gear clutching teeth Bench Service Procedure 160 w IJ rj L Z go oO y E ix I a Bench Service Procedure How to Install the Mainshaft Special Tools See Tool Information Item T15 Mainshaft hook A piece of rope 161 Procedure 1 Secure the upper countershaft up and away from the trans mission center TIP A large screwdriver or prybar can be inserted between the main drive gear and countershaft as shown Hold the reverse gear against the next gear and lower the mainshaft assembly into position while guiding the shaft rear through the case bore A mainshaft hook or piece of rope can be used to hold on to the mainshaft 3 Move the mainshaft forward to position the mainshaft pilot end into the input shaft rear 4 The reverse idler gear will not be fully installed at this time Note
5. How to Remove the Standard Torque Auxiliary Drive Gear Assembly 0000 111 How to Disassemble the Upper and Lower Reverse Idler Gear Assembly 2 00000005 112 How to Remove the Upper and Lower Countershaft Bearings 114 How to Remove the Input Shaft and Main Drive Gar ius oddone cae de tensed tee ee hs 116 How to Remove the Mainshaft Assembly 119 How to Disassemble the Mainshaft Assembly 121 How to Disassemble the Mainshaft Assembly with Low Force Gearing 5 125 How to Remove the Countershaft Assemblies 127 How to Disassemble the Countershaft Assemblies 129 How to Disassemble the Auxiliary Drive Gear Assembly 0 00 cece eae 132 Assemble Front Section How to Prepare the Main Case for Assembly 133 How to Assemble the Auxiliary Drive Gear Assembly 0 0 c cence eee 134 How to Assemble the Lower Reverse Idler Gear Assembly 0 0 ccc cece ee eee eee 136 How to Assemble the Mainshaft Assembly with Low Force Gearing 138 How to Assemble the Countershaft Assemblies 141 How to Install the Auxiliary Countershaft Assembly 144 How to Install the Lower Countershaft Bearings 147 How to Install the Input Shaft and Main Drive Gear cece cece eee ees 150 Mainshaft Assembly 0000 0 152 How to Install the Mainshaft Assembly with Selective Adjustable Thickn
6. IJ rj L Z go ix y 3 ix I a 130 Bench Service Procedure 131 4 Inspect the keys and roll pin Remove and replace if dam aged Bench Service Procedure How to Disassemble the Auxiliary Drive Gear Assembly 1 Snap Ring 5 Retainer 2 Retainer 6 Capscrew 3 Snap Ring 7 Auxiliary Drive Gear 4 Bearing Procedure 1 If so equipped remove the snap ring retainer with two screwdrivers 2 Remove the snap ring from the auxiliary drive gear hub 3 Use a press if necessary to remove the gear from the bear ing ow D E x E N D 2 5 mz Er e 2 3 S c 132 Bench Service Procedure How to Prepare the Main Case for Assembly 133 Thoroughly clean case of metal particles Remove the gasket material from flange surfaces Inspect flange surfaces for dam age Inspect bearing bores for damage or excessive wear Replace as necessary If necessary replace any damaged or worn clutch housing or rear support studs Apply Eaton Fuller thread sealant 71205 or equivalent to any replacement studs before installing them Verify the three magnetic discs are firmly attached to the bottom of the main case If they are not firmly attached apply 3M scotch grip or equivalent adhesive to the bottom of the discs and attach them to the main case Bench Service Procedure How to Assemble the Auxiliary Drive Gear Assembly Special In
7. Light Blue Current Part Size Color Code 14711 248 250 White 14712 253 255 Green 14713 258 260 Orange 14714 263 265 Purple 14715 268 270 Yellow 14716 273 275 Black Washers for 6 Sided Key OBSOLETE These Washers are not available Part and Color are Listed Here for Reference Only These Washers are replaced by Washers S for Hex Key shown above Replaced By s are indicated A Obsolete Current Part Color Code E 18701 14711 White Red 18702 14712 Green Red E 18703 14713 Orange Red a 18704 14714 Purple Red 18705 14715 Yellow Red 18706 14716 Black Red 154 Bench Service Procedure 155 Procedure 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with brass jaws or wood blocks 2 If previously removed install the roll pin in keyway 3 With the washer flat side up position a gear tolerance washer white in the mainshaft 1st or bottom groove Rotate the washer until the washer splines and mainshaft splines align 4 Start at the mainshaft bottom and install a 1 8 or 5 32 diameter plastic line in the keyway to lock the washer in place As limit washers and gears are installed continue to push the plastic line up 5 Against the 4th speed gear washer position a spacer washer against the tolerance washer 6 With clutching teeth down and engaged with the spacer external splines position th
8. Meshing marked countershaft drive gear teeth with marked main drive gear teeth After placing the mainshaft assembly into the case the countershaft bearings are installed to complete installation of the countershaft assem blies When installing the bearings on the left countershaft mesh the countershaft drive gear marked tooth with either set of main drive gear two marked teeth Repeat the procedure when installing the bearings on the right countershaft make use of the remaining set of main drive gear two marked teeth to time assembly Timing Procedure Auxiliary Section 4 Marking the helical auxiliary countershafts Mark any two teeth on the LO range gear Then mark two teeth located directly opposite the first marked Prior to placing each auxiliary countershaft assembly into housing mark the tooth on each auxiliary countershaft assembly LO range gear stamped with the two O s Repeat the procedure on each auxiliary countershaft reduction gear Follow the assembly procedures in the How to Install the Auxiliary Section With Tapered Bearings on page 165 28 Air System How to Remove Compression Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage A CAUTION Small air lines are available in 1 8 or 5 32 sizes Make sure 1 8 air lines are used with 1 8 fittings and 5 32 air lines are use
9. Note Do not use an air gun Tighten by hand until the cap screws are snug ow D 5 2 E N e Iz e n e D 2 e 146 Bench Service Procedure How to Install the Lower Countershaft Bearings Special Instructions The lower reverse idler assembly should be installed before the lower countershaft The front bearing inner race must be pressed on the countershaft front The flanged end driver must cover the bearing outer race for proper installation Special Tools See Tool Information Item T7 Flanged end bearing driver Item T8 Bearing driver Item T9 Countershaft support tool Procedure 1 Move the countershaft to the rear and insert the counter shaft support tool to center shaft in rear case bore 2 Obtain a spare inner countershaft race 147 Bench Service Procedure 3 Temporarily install the spare countershaft inner race inside the front roller bearing for installation 4 Use a flanged end driver to start the front bearing in case bore 5 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 6 Move the countershaft forward into the bearing 7 Use a flanged end bearing driver and maul to completely seat the front bearing in the case bore Note Make sure to contact only the bearing and not the temporary race with the driver The temporary race should fall out when installation is complete 8 On the countershaft front po
10. loosen the 15 16 capscrew and retainer Do not remove the capscrew 83 3 Install countershaft retaining strap 4 Usea soft bar and maul to drive the output shaft forward far enough to partially unseat the bearing 5 Support the auxiliary countershaft while removing the auxil iary countershaft retaining strap 6 Remove the auxiliary countershaft 7 Remove the auxiliary countershaft bearing race from bore Bench Service Procedure 84 w rj co I ix y zm o I a 77 Bench Service Procedure 85 8 If necessary secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing separator and jaw pullers Bench Service Procedure How to Disassemble the Synchronizer Assembly Special Instructions Place the synchronizer assembly on a clean flat surface Cover the synchronizer assembly with a shop rag to prevent losing the three 3 springs under pressure from the HI range synchronizer pin locations Special Tools Typical service tools 1 Spring 2 Synchronizer Hi 3 Sliding Clutch 4 Synchronizer Lo Procedure 1 Place the larger LO range synchronizer ring on the bench w LJ rj L Z z ix y n ix D Z 2 Cover the synchronizer with a shop rag to contain the springs 3 Grab both sides of the HI range synchronizer and pull 4 From the synchronizer ring LO r
11. of torque Note Make sure the retaining capscrews are properly torqued Plunger Pin 5 Spri mem sv Sirevi Air Line Fittings Air System 40 In Vehicle Service Procedure How to Remove the Gear Shift Lever Remote Shift Control Special Instructions The air lines must be disconnected from the transmission or from the Roadranger valve Different detent springs are available to increase or decrease shifting effort Note and record specific locations for specific springs In some cases a stiffer spring is installed in the top rail position Remote control housings are removed the same way as gear shift levers Special Tools Typical service tools 1 Housing 2 Capscrew 3 Gasket 41 Procedure 1 From the gear shift lever base shift control housing remove the four 4 retaining capscrews To break the gasket seal lightly jar the gear shift shift con trol housing Remove the gear shift lever housing A CAUTION Make sure the detent springs do not fall into the transmis sion Remove detent springs as needed Remove the gasket and clean the area the replacement gas ket will contact In Vehicle Service Procedure How to Install the Gear Shift Lever Remote Shift Control Special Instructions Remote control housings are installed the same way as gear shift levers For standard and forward shift bar housings make sure the detent springs and ball
12. shims have a smaller outside diameter 173 Bench Service Procedure 10 Remove the shim tool 11 Install the shim and place a new gasket around the auxiliary countershaft bore 12 Apply Eaton Fuller thread sealant 71205 or equivalent to the auxiliary countershaft rear bearing cover capscrews and auxiliary countershaft rear bearing cover 13 Install the auxiliary countershaft rear bearing cover and secure it with the capscrews Make sure the shim is in proper location and is not pinched between the cover and the housing Tighten the capscrews to 35 45 Ibs ft 54 61 Nem TIP Use a thick grease to hold the shim in position when installing the cover 14 Repeat this procedure for the remaining countershaft Feeler Gauge Shim Thickness Standard Shim Oil Pump Shim Color Code Average Gap Part Number Part Number 072 075 033 034 4302345 4302346 Gold 69 0715 036 037 21452 21472 Red 066 0685 039 040 21453 21473 Pink Ed 063 0655 042 043 21454 21474 Brown z 060 0625 045 046 21455 21475 Tan 4 057 0595 048 049 21456 21476 Orange amp 054 0565 051 052 21457 21477 Yellow 3 051 0535 054 055 21458 21478 Green 2 048 0505 057 058 21459 21479 Light Blue T 045 0475 060 061 21460 21480 Lavender 042 0445 063 064 21461 21481 White 039 0415 066 067 21684 21686 Black 036 0385 069 070 21685 21687 Silver 174 Ben
13. 1 Place the countershaft assembly vertical on a clean flat surface If previously removed use the proper driver and maul to install the countershaft bearings 2 Mark each countershaft for correct timing Locate the O s stamped on the countershaft and mark the teeth with highly visible toolmaker s dye or paint 144 Bench Service Procedure 145 3 Place the countershafts in the fixture or on a flat surface for reassembly Turn the countershafts so that the two teeth marked on each LO range gear are towards the middle 4 Alignthe output shaft between the countershafts match the timing marks 5 With range yoke offset side facing down install into the synchronizer sliding slot 6 Place the auxiliary housing over the countershaft assem blies and the output shaft assembly 7T Make sure the output shaft bearing spacer is on the output shaft 8 Heatthe rear output bearing cone and install the bearing tapered side down on the shaft 9 Position a new gasket on the rear bearing cover mounting surface Bench Service Procedure 10 Position the rear bearing cover 11 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews 12 Install the six 6 retaining capscrews in the non chamfered hole tighten to 35 45 Ibs ft of torque 13 Install the bearing races 14 Install each auxiliary countershaft retaining strap with 2 3 8 NC x 1 and 1 3 8 NC x 21 2 clean capscrews
14. 3 Notify the customer that it is only a weep and it is not considered to be detrimental to the life of the transmission 4 Repair is complete Rear Seal 1 Do not repair Rear seal is designed to allow minimal seepage refer to Roadranger TCSM 0912 Seal Maintance Guide 2 Ensure lube is to proper level Determine if it is a Weep or a Leak Leak Extremely wet or dripping of oil in the contaminated area 1 Determine the origin of the leak path 2 If origin of leak is obvious skip to Step 3 3 If the origin of the oil leak is not obvious then use either of the two following steps to determine the oil leak Note Do not use a high pressure spray washer to clean the area Use of a high pressure spray may force contamination into the area of concern and temporarily disrupt the leak path i Clean area with a clean dry cloth or mild soluble degreaser and fill the transmission to the proper lube level OR ii Clean the area as noted above and insert tracer dye into the transmission lube and fill transmission to proper lube level Operate vehicle to normal transmission operating temperature and inspect the area for oil leak s visually or if tracer dye was introduced use an UVL Ultraviolet Light to detect the tracer dye s point of origin Note When inspecting for the origin of the leak s make sure the assumed leak area is not being contaminated by a source either forward or above the i
15. For spec ing or service assistance call 1 800 826 HELP 4357 or visit our web site at Roadranger www roadranger com In Mexico call 001 800 826 4357 E T N Roadranger Eaton Dana and other trusted partners providing the best products and services in the industry ensuring more time on the road 02009 Eaton Corporation All rights reserved Eaton Corporation eTruck Components Operations e PO Box 4013 Kalamazoo MI 49003 U S A e www roadranger com Printed in USA
16. Install the retaining capscrews tighten to 35 45 Ibs ft of torque 10 To finish installation see See Shim Procedure With A Shim Tool For Tapered Bearings on page 168 Procedure To install the auxiliary section in the vertical posi tion 11 With blocks under the clutch housing to prevent input shaft damage place the transmission in the vertical position clutch housing down 12 Position a new gasket on the transmission mounting sur face 13 Install a steel bar through the yoke 14 Attach a lifting chain to the steel bar 15 Position the auxiliary section over the two 2 dowel pins 16 Slide the auxiliary section down the dowels 17 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews w rj co I ix y E ix I a 77 170 Bench Service Procedure 171 18 Install the retaining capscrews tighten to 35 45 Ibs ft of torque 19 Remove the steel bar and chain 20 To finish installation see See Shim Procedure With A Shim Tool For Tapered Bearings on page 168 Bench Service Procedure Shim Procedure With A Shim Tool For Tapered Bearings Special Instructions If you are not using a shim tool go to the procedure Shim Procedure Without a Shim Tool for Tapered Bearings A CAUTION Use genuine Eaton replacement gaskets for the auxiliary housing and countershaft bearing cover Do not omit the gaskets Bearing endplay
17. Rubber 1 4 Air Hoses Special Instructions For the 1 4 I D air hoses install the fixed nut end first Special Tools Typical service tools Procedure 1 Remove all air line brackets and ties 2 Remove swivel end 3 Remove fixed end 33 How to Install Rubber 1 4 Air Hoses Special Instructions For the 1 4 D air hoses install the fixed nut end first Special Tools Typical service tools Procedure 1 If necessary apply Eaton Fuller thread sealant 71205 or equivalent to threads 2 Install and tighten fixed end first then install and tighten swivel end 3 Replace all air line brackets and ties Air System 34 Air System How to Install the Air Filter Regulator Special Instructions The air filter regulator has two 2 O rings located between the filter regulator and the range cylinder cover Special Tools Typical service tools Procedure Position the air filter regulator Apply Eaton Fuller Sealant 71205 or equivalent to the two 2 retaining capscrews Install the two 2 retaining capscrews tighten to 8 12 Ibs ft of torque 35 Air System How to Remove the Air Filter Regulator Special Instructions The air filter regulator has two 2 O rings located between the filter regulator and the auxiliary section Special Tools Typical service tools Procedure 1 Remove the air lines from the air filter regulator 2 From the air filter regulator rem
18. Use only Eaton Fuller 71205 liquid thread sealant or liquid equivalent on the yoke retaining capscrews Do not use any type of thread locking tape on the end yoke retaining capscrews This may cause the capscrews threads to strip and cause the end yoke to loosen 3 Reinstall driveshaft per OEM guidelines 56 In Vehicle Service Procedure How to Remove the Auxiliary Section with Tapered Bearings Special Instructions There can be different capscrew lengths note their location Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position Auxiliary countershaft retaining straps may be installed to hold the countershafts in place You can make retaining straps from 3 x 1 bar stock Auxiliary can be removed without straps use caution Special Tools See Tool Information Item T2 Auxiliary section hanger bracket for horizontal removal A steel bar longer than the width of the output yoke for vertical removal A hoist with a lifting chain Auxiliary countershaft retaining straps Procedure 1 Toremove the auxiliary section in the horizontal position Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 57 In Vehicle Service Procedure 2 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the
19. a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races Introduction Capscrews e To prevent oil leakage and loosening use Eaton Fuller sealant 71205 on all capscrews Gaskets e Use new gaskets throughout the transmission as it is being rebuilt Make sure all gaskets are installed An omission of any gasket can result in oil leakage or misalignment of bearing covers Initial Lubrication e Coat all limit washers and shaft splines with Lubricant during assembly to prevent scoring and galling of such parts O Rings e Lubricate all O rings with silicon lubricant Universal Joint Companion Flange or Yoke e Pull the companion flange or yoke tightly into place with the output shaft nut using 450 500 Ibs ft of torque Make sure the speedometer drive gear or a replacement spacer of the same width has been installed Failure to pull the com panion flange or yoke tightly into place can result in damage to the mainshaft rear bearing IMPORTANT See the appropriate Illustrated Parts Lists specified by model number to ensure that proper parts are used during assembly of the transmission Model Designations Serial Tag Information and Model Nomenclature Transmission model designation and other transmission identification information are stamped on the serial tag To identify the transmission model and serial number locate the tag on the transmission and then locate the numbers as shown F
20. al ea ec bs Flange and Retaining Capscrews 55 rs ERO LE DM CHINE Ai How to Install the Output Yoke Power FIOW ssss e 25 Pange and Rau EADS CIES etsi eni 3 Timing Auxiliary Section Timing Procedures 000ccceeeees 27 How to Remove the Auxiliary Section with Front SOCHOM oss iste sustento tdi e enii 27 Tapered Bearings ee eene ce 97 Auxiliary Section 00 anaana 28 How to Install the Auxiliary Section in Chassis 60 In Vehicle Service Procedure Transmission Overhaul Procedures Bench Service Air System How to Remove Compression Type Fittings 29 Shift Bar Housing How to Install Compression Type Fittings 30 How to Disassemble the Gear Shift Lever 63 How to Remove Push To Connect Type Fittings 31 How to Assemble the Gear Shift Lever 65 How to Install Push To Connect Type Fittings 32 How to Remove the Shift Bar Housing 67 How to Remove Rubber 1 4 Air Hoses 33 How to Install the Shift Bar Housing 69 How to Install Rubber 1 4 Air Hoses 34 How to Disassemble the Shift Bar Housing 71 How to Install the Air Filter Regulator 35 How to Assemble the Shift Bar Housing 73 How to Remove the Air Filter Regulator 36 i u How to Remove a Roadranger Valve 37 Disassemble Auxiliary Section How to Install a Roadranger Valve 38 How to Remove th
21. and Yoke Lockscrews 35 45 7 16 20 Secure with lockwire 16 Shift Bar Housing and 4 Shift Lever Housing 35 45 3 8 16 Apply Loctite 242 to threads Capscrews 1 Reverse Signal Switch Plug 35 50 9 16 18 2 Support Stud Nuts 170 185 5 8 18 Use lockwashers 1 Oil Drain Plug 45 55 3 4 Pipe 6 Mainshaft Rear Bearing Retainer Capscrews 35 45 3 8 16 Secure with lockwire 1 Oil Fill Plug 25 35 1 1 4 Pipe 2 Reverse Idler Shaft Nuts 50 60 5 8 18 6 Small PTO Cover Capscrews 20 25 3 8 16 Apply Loctite 242 to threads 8 Large PTO Cover Capscrews 50 65 7 16 14 Apply Loctite 242 to threads 4 Hand Hole Cover Capscrews 20 25 5 16 18 2 Countershaft Front Bearing Retainer Capscrews 90 120 5 8 18 Secure with lockwire 4 Clutch Housing Capscrews Aluminum housing 1 2 13 Use lockwashers 12 N D e 9 z a Specifications Torque Auxiliary Section Description Torque Value Thread Additional Comments Ibs ft Size 2 Air Filter Regulator Mounting Capscrews 8 12 1 4 20 Apply Loctite 242 to threads 1 Range Cylinder Shift Bar Nut 70 85 5 8 18 2 Range Shift Yoke Capscrews 50 65 1 2 20 Secure with lockwire 6 Mainshaft Rear Bearing Cover Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 4 Range Cylinder Mounting Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 4 Range Cylinder Cover Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 8 Counter
22. and remove the offset washer 126 Bench Service Procedure How to Remove the Countershaft Assemblies Special Instructions Except for the PTO gears the upper and lower countershaft assemblies are the same Mark the countershafts as UPPER or LOWER as you remove them The mainshaft and main drive gear must be removed before removing the countershaft assemblies Special Tools Typical service tools Procedure 1 Mark the countershafts as UPPER or LOWER as you remove them Note The mainshaft and main drive gear must be removed before removing the countershaft assemblies 2 Remove the rear snap ring from the rear upper countershaft bearing 3 From inside the case use a long soft bar to drive the upper countershaft rear bearing rearward off the shaft Note Damage will likely occur to this bearing during removal It is strongly recommended that this bear ing is discarded 4 Remove the capscrew and the retainer from the upper countershaft front 5 Slide the lower countershaft forward This will move the front bearing forward to expose the external snap ring 127 Bench Service Procedure 6 Use the appropriate bearing puller Tool ID T6 or two pryb ars to remove the lower front bearing from its bore 7 Move the upper countershaft to the rear until the front bear ing journal clears the front case bore 8 Swing the front of the countershaft to the center of the case and lift out the counters
23. companion flange or yoke Weights include SAE No 1 cast iron clutch housing and standard controls control valve gear shift lever and housing assem bly and air lines less clutch release parts All weights are approximate il Capacities are approximate depending on inclination of engine and transmission Always fill transmission with proper grade and type of lubricant to level of filler opening See Lubrication on page 14 11 Torque Ratings specifications Correct torque application is extremely important to assure long transmission life and dependable performance Overtightening or under tightening can result in a loose installation and in many instances eventually cause damage to transmission gears shafts or bearings Use of a thread sealer locking compound is recommended for all capscrews Do not torque capscrews dry Torque Front Section 70 75 Cast Iron Housing 90 100 Description Torque Value Thread Additional Comments lbs ft Size 1 Main Drive Gear Bearing Nut 250 300 Apply Loctite grade 277 sealant Stake to input shaft 6 Front Bearing Cover Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 6 Clutch Housing Nuts Aluminum housing 5 8 18 Use lockwashers 170 175 Cast Iron Housing 180 190 4 Slave Air Valve Capscrews 8 12 1 4 20 Apply Loctite 242 to threads 1 Neutral Signal Switch Plug 35 50 3 4 16 5 Shift Block
24. cover gasket is in place Install a new gasket if rear bearing cover was removed Output Yoke Retaining Nut Check the output yoke retaining nut for tightness Torque the output yoke retaining nut to 450 500 Ibs ft Do not over torque the output nut PTO Covers and Openings Check the capscrews for tightness Apply Eaton Sealant 71205 to the cap screw threads Tighten 6 bolt PTO capscrews to 35 45 Ibs ft Tighten 8 bolt PTO capscrews to 50 65 Ibs ft Gray Iron Parts Check front bearing cover front case shift bar housing rear bearing cover and clutch housing for cracks or breaks Replace parts found to be damaged Front Bearing Cover Check return threads for damage If threads damaged replace the input shaft Check the capscrews for tightness Tighten the capscrews to 35 45 Ibs ft Oil Cooler and Oil Filter Check all connectors fittings hoses and filter element for tightness Tighten any loose fittings Oil Drain Plug Oil Fill Plug Check the oil drain plug and the oil fill plug for leakage Torque the oil drain plug to 45 55 Ibs ft Torque the oil fill plug to 60 70 Ibs ft 24 a 5 lt 1 lt 17 2 E 1 5 2 rJ ow Power Flow Power Flow The transmission must efficiently transfer the engine s power in terms of torque to the vehicle s rear wheels Knowledge of what takes p
25. down install offset washer flat surface up Rotate the washer until the washer splines and mainshaft splines align Start at the mainshaft bottom and install a plastic line in the marked keyway to lock the washer in place With clutching teeth down position the 4th gear on the mainshaft Install the flat washer Rotate the washer until the washer splines and mainshaft splines align LAT PET Te UOISSIWSULIL Y as i oO 1 a wo e wo ow rj 1 rJ ow 138 Transmission Overhaul Procedures Bench Service 139 10 11 12 13 14 With clutching teeth up and against the spacer install the 3rd gear Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main shaft splines align Push the air line up to lock the washers on the mainshaft With the missing internal splines aligned with the plastic line install the proper sliding clutch Position the next offset washer in the next available groove Rotate the washer until the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft With clutching teeth down position the 2nd gear on the mainshaft Position the flat washer against the gear Rotate the washer until the washer splines and mainshaft splines align Transmission Overhaul Procedures Bench Service 15 With clutching teeth up install the 1
26. is influenced by the compressed thickness of the gasket 011 012 or 28 30 mm The bearing endplay must be checked and adjusted any time a countershaft bearing or housing is replaced If during reassem bly the same countershaft bearings housing and shims are reused and kept in the same location it is not necessary to reset bearing endplay The following procedure is used to adjust the endplay for the auxiliary countershaft tapered bearings By correctly following this procedure each countershaft will have 001 005 03 12 mm endplay Special Tools See Tool Information Item T3 Shim tool Procedure 1 Theauxiliary countershaft bearing covers and shims should be removed Make sure all old gasket material is cleaned from the gasket mounting surfaces on the countershaft bearing covers and the auxiliary housing 2 Verify that the auxiliary section is in gear When the output shaft is rotated the countershafts must also rotate If not shift the auxiliary into gear by applying shop air to the high range air port on range cylinder to shift into gear wo ow rj co 1 z ix 17 y i ix aa a Z to 3 Clean and lightly oil the threads of two countershaft bearing cover capscrews Thread these capscrews into two oppos ing capscrew holes in the housing They must thread in easily If necessary run a 3 8 16 tap into the holes to clean the threads 4 Install the 100 shim tool and
27. not shift the auxiliary into gear by applying shop air to the high range air port on range cylinder to shift into gear 3 Make sure a 0 100 countershaft rear bearing shim is installed Be sure the countershaft rear bearing races are 175 Bench Service Procedure seated in the bearing bores 4 Install two 2 clean 3 8 x 1 capscrews without washers directly across from each other in each bearing cover Tapped holes in auxiliary case must be free of thread adhe sive 5 Evenly tighten the capscrews to 7 Ibs in of torque Do not install the countershaft rear bearing cover gasket The gap between the bearing cover and the housing surface should be even from side to side Note 7 Ibs in is slightly more than finger tight Do not overtighten the capscrews If the capscrews are too tight the bearing cover will become distorted 6 Rotate the output shaft 4 times clockwise and 4 times coun terclockwise The rotation will seat and align the rollers in each tapered bearing Re torque the capscrews to 7lbs in If the countershafts do not rotate the range sliding clutch or deep reduction sliding clutch is in neutral Apply shop compressed air to shift cylinders to shift the sliding clutches into gear w I rj Z I z o 7a y zt o o I a 77 7 Useafeeler gauge as close to each capscrew location as possible and measure the gap between the countershaft rear bearing cover and the auxiliary ho
28. sliding clutch recessed side up place the sliding clutch on the LO range synchronizer pins 94 Bench Service Procedure 3 Inthe HI range synchronizer bores install the three 3 springs 4 Place the HI range synchronizer ring over the LO range syn chronizer ring Rotate the HI range synchronizer until the springs are seated against the pins 5 Cover the assembly with a shop rag 6 Apply downward pressure to the HI range synchronizer ring while twisting counterclockwise This compresses the springs to fully seat HI range on the LO range synchronizer This should be done with a rapid twist and push motion Note Make sure there are three springs and they are fully compressed Note Make sure you can move the sliding clutch from HI to LO range and back 95 How to Install the Oil Seal Special Tools See Tool Information Eaton Aftermarket Tools for part numbers Oil seal driver Oil seal slinger driver Procedure 1 Install the seal into the rear bearing cover using the proper seal driver The seal is fully installed when the flange on the seal is flush with the shoulder in the bore 2 Install a new slinger on the seal sleeve or output yoke using a slinger driver Note Some versions use a sealing ring which is pressed into a groove on the seal sleeve rear Make sure this seal is in place on this design level Bench Service Procedure 96 o 1 3 r L N o Fr 17 Y i Lr
29. the nut to 67 75 Ib ft 90 to 101 Nem of torque Note For Capscrew Fastener Design Apply Eaton Fuller thread sealant 71205 or equivalent to the capscrew threads and install the capscrew and washer Tighten the capscrew to 67 75 Ib ft 90 to 101 Nem of torque Note For Snap ring design Install the washer and snap ring on the idler shaft using a 1 1 8 29 mm socket Push the snap ring over the tapered end of the shaft until fully seated in groove How to Assemble the Mainshaft Assembly with Low Force Gearing Transmission Overhaul Procedures Bench Service Special Instructions The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft It still utilizes Non Selective Non Adjustable Tolerance Washers but the 1st and reverse gears and sliding clutch have been redesigned In this configuration the 1st reverse sliding clutch rides on a clutch hub and the 1st and reverse gears have been redesigned to accommodate this change The proper mainshaft key must always be used with the proper design mainshaft washers If necessary refer to the parts manual for your specific model to confirm the proper parts Special Tools e A piece of 5 32 air line 1 long e Vise with brass jaws Procedure 1 With mainshaft pilot end down secure the mainshaft in a vise equipped with brass jaws or wood blocks If previously removed install the roll pin in keyway With mainshaft pilot end
30. the shim in position when installing the cover 16 Repeat this procedure for the remaining countershaft Note Make sure capscrews are properly torqued Note Make sure the input shaft rotates 177 Bench Service Procedure SHIM TABLE Feeler Gauge Shim Thickness Standard Shim Oil Pump Shim Color Code Average Gap Part Number Part Number 072 075 033 034 4302345 4302346 Gold 69 0715 036 037 21452 21472 Red 066 0685 039 040 21453 21473 Pink 063 0655 042 043 21454 21474 Brown 060 0625 045 046 21455 21475 Tan 057 0595 048 049 21456 21476 Orange 054 0565 051 052 21457 21477 Yellow 051 0535 054 055 21458 21478 Green 048 0505 057 058 21459 21479 Light Blue 045 0475 060 061 21460 21480 Lavender 042 0445 063 064 21461 21481 White 039 0415 066 067 21684 21686 Black 036 0385 069 070 21685 21687 Silver 178 w 1 rJ L ce 1 T z rJ 17 a 7 o rJ 1 17 Copyright Eaton Corporation and Dana Limited 2009 Eaton and Dana 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 National Institute for SERVICE EXCELLENCE
31. valve shaft Special Tools Typical service tools Volt Ohm meter Procedure 1 Disconnect the wiring from the switch 2 Connect an ohm meter to check for continuity or a small reading 3 Place the transmission shift lever in the neutral position The ohm meter should register continuity or a small read ing If it does go to the next step If it does not remove the switch and replace it 4 Shiftthe transmission into all gear positions The ohm meter should read open or infinity If it does not remove the switch Then depress the switch ball and check for con tinuity The ohm meter should read open or infinity when the ball is depressed 5 Lookinto the neutral switch hole and verify that the air valve shaft moves as the transmission is shifted from neutral into gear e If it does replace the switch e If not remove the shift bar housing and check the air valve and shift rails for excessive wear Also check the slave valve plunger and spring for free movement 45 How to Remove the Neutral Switch Special Instructions None Special Tools Typical service tools Procedure 1 Remove 2 screws retaining wire terminals 2 Remove the switch using a 7 8 deep well socket or box end wrench In Vehicle Service Procedure 1 Neutral Light Switch 2 Gasket 3 Shift Bar Housing 4 Gasket 5 Air Valve Shaft 46 7 lt 1 ex 7 N 1 lt rJ 7 v rJ ow 2
32. version and remove yoke activator Note On version with snap ring do not remove pivot pin if parts will not be replaced 72 Bench Service Procedure How to Assemble the Shift Bar Housing 73 Procedure 1 2 3 Install the plunger in the 1st amp reverse shift yoke bore plunger shank to the outside Install the spring into the bore over the plunger shank Install the plug and tighten to compress the spring 4 5 T After plug bottoms out back the plug out 1 1 1 2 turns Complete the block assembly process by staking the plug through the small hole in block CAUTION Overtorquing of lockscrew can result in distortion and binding of yoke bar Make sure yoke bar has free movement Lockwire lockscrew Install the reverse yoke bar reverse yoke and direct over drive yoke on x actuator versions The yoke bar neutral notches must be positioned in line with the detent ball bores Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole Torque the lockscrews to 35 45 Ibs ft Install air valve shaft Bench Service Procedure 74 w I rj Z I z o 7a y zt o ix I a 77 Bench Service Procedure 8 Install one 3 4 interlock ball 9 Insert small pin into middle yoke bar Note The yoke bar and pin must be kept in line with the interlock ball bore If the yoke bar is rotated the pin can slide out and bind i
33. 1 2 o Bench Service Procedure How to Assemble the Range Cylinder Assembly Special Instructions Apply Eaton lubricant 71214 or equivalent to shift cylinder assembly and insert valve O rings so a film covers the entire surface of each O ring Procedure 1 If previously removed in the cylinder housing bore install the small O ring m If previously removed on the piston I D and O D install the piston O rings 3 Position a new gasket on the range cylinder housing mounting surface 4 Install the cylinder housing 5 Apply Eaton Fuller sealant 771205 or equivalent to the retaining capscrews 6 Install the capscrews tighten to 20 25 Ibs ft of torque 97 7 Lean auxiliary section back with range cylinder upward 8 Insert the piston Push it in as far as it will go 9 Slide range bar through the cylinder and yoke aligning grooves on range bar with bolt holes in range yoke 10 Apply Eaton Fuller sealant 71205 or equivalent to range yoke bolts Install bolts and torque to 50 65 Ibs ft of torque 11 Secure the piston with the retaining nut tighten to 70 85 Ibs ft of torque 12 Position a new gasket on the cylinder housing cover mount ing surface Bench Service Procedure 98 w I rj Z I z o y E ix I a 77 Bench Service Procedure 99 13 Over the gasket position the range cylinder cover 14 Apply Eaton Fuller s
34. 1 2 drive Torque Wrench General torquing of fasteners typically 15 80 Ibs ft 0 600 Ibs ft 3 4 or 1 drive Torque Wrench Torquing of output nut to 500 Ibs ft 0 50 Ibs in 3 8 drive Torque Wrench General torquing of fasteners 0 30 Ibs in 1 4 drive Torque Wrench Torquing of capscrews to 7 Ibs in during auxiliary countershaft bearing endplay setting procedure 70 MM or 2 2 4 Socket Standard Depth To remove the output yoke nut Large Brass Drift Used to protect shafts and bearings during removal Large Dead Blow Hammer or Maul To provide force for shaft and bearing removal Snap Ring Pliers Large Standard External To remove the snap rings at the auxiliary drive gear input shaft bearing and countershaft bearings 2 E 3 2 E Feeler Gauges To set mainshaft washer endplay and auxiliary tapered bearing endplay Rolling Head Crow s Foot Prybar To remove the auxiliary drive gear bearing 2 Air Pressure Gauges 0 100 PSI 0 1034 kPa To troubleshoot and verify correct operation of air system Universal Bushing Driver To remove and install clutch housing bushings Bushing OD 1 125 ID 1 000 16 Tool Information Eaton Fuller Model Special Tools The following special tools are designed for this Eaton Fuller transmission The addresses and phone numbers of the tool suppliers are listed aft
35. 246 1 83 1 34 1 00 3 38 788 788 29 5 624 26 14 78 749 3 283 12 RTX 11709H 1055 7 41 5 23 3 79 2 77 1 95 1 38 1 00 2 99 88 788 28 91 664 25 5 12 11 33 743 3 301 RTX 11710B 10 99 8 18 6 07 446 3 32 246 1 83 1 36 1 00 74 2 52 788 788 28 9 604 26 11 23 734 1 274 12 RTX 12709H 1055 7 41 5 23 3 79 2 77 1 95 1 38 1 00 amp 7 2 99 788 788 28 91 664 25 5 12 11 33 743 3 301 RTX 12710B 10 99 8 18 6 07 446 3 32 246 1 83 1 36 1 00 74 2 52 788 788 28 9 606 26 11 23 734 1 275 12 RTX 13709H 1055 7 41 5 23 3 79 2 77 1 95 1 38 1 00 7 2 99 788 788 28 91 664 25 5 12 11 33 743 3 301 RTX 13710B 10 99 8 18 6 07 446 3 32 246 1 83 1 36 1 00 74 2 52 788 788 28 9 611 26 11 23 734 1 277 12 RTX 14709H 1055 7 41 5 23 3 79 2 77 1 95 1 38 1 00 z 7 2 99 788 788 28 91 664 25 5 12 11 33 743 3 301 RTX 14710B 10 99 8 18 6 07 446 3 32 246 1 83 1 36 1 00 74 2 52 788 788 29 5 624 26 11 23 749 3 283 12 RTX 16709H 1055 7 41 5 23 3 79 2 77 1 95 1 38 1 00 z 2 99 88 788 28 91 664 25 5 12 11 33 743 3 301 RTX 16709B 1246 7 41 5 23 3 79 2 77 1 95 1 38 1 00 3 43 788 788 29 50 693 25 5 12 13 03 749 3 314 Lengths measured from face of clutch housing to front bottoming surface of
36. 3 4 9 6 T 26 o z D ma Timing Timing Procedures Special Instructions It is essential that both countershaft assemblies of the front and auxiliary sections are timed This assures proper tooth contact is made between mainshaft gears seeking to center on the mainshaft during torque transfer and mating countershaft gears that distribute the load evenly If not properly timed serious damage to the transmission is likely to result from unequal tooth contact causing the mainshaft gears to climb out of equilibrium Timing is a simple procedure of marking the appropriate teeth of a gear set prior to installation and placing them in proper mesh while in the transmission In the front section it is necessary to time only the drive gear set And depending on the model only the LO range deep reduction or splitter gear set is timed in the auxiliary section Procedure Front Section 1 27 Marking countershaft drive gear teeth Prior to placing each countershaft assembly into the case clearly mark the tooth located directly over the drive gear keyway as shown This tooth is stamped with an O to aid identification Marking main drive gear teeth Mark any two adjacent teeth on the main drive gear Mark the two adjacent teeth located directly opposite the first set marked on the main drive gear As shown to the left there should be an equal number of unmarked gear teeth on each side between the marked sets
37. 7 Washer Jg te Q Reverse Idler Shaft Reverse Bearing Idler Gear Washer Snap Ring 166 5 wo rJ 4 wo z rJ 17 y i rJ 1 3 5 Bench Service Procedure 167 Secure the shaft in position according to one of the proce dures below Note For Nut Fastener Design Inspect the nylon locking insert in the nut and replace the nut if it is exces sively worn After inspecting and or replacing the nut install the nut and washer on shaft front Tighten the nut to 67 75 Ib ft 90 101 Nem of torque Note For Capscrew Fastener Design Apply Eaton Fuller thread sealant 71205 or equivalent to the capscrew threads and install the capscrew and washer Torque the capscrews to 67 75 Ib ft 90 101 Nem Note For Snap ring design Install the washer and snap ring on the idler shaft using a 1 1 8 29 mm socket Push the snap ring over the tapered end of the shaft until fully seated in groove Bench Service Procedure How to Install the Standard Torque Auxiliary Drive Gear Assembly Procedure 1 Install the auxiliary drive gear assembly on the mainshaft rear Use a flanged end driver to fully seat the assembly in the case bore Apply Eaton Fuller thread sealant 71205 or equivalent to the capscrew threads and install the six 6 capscrews Torque the capscrews to 35 45 Ibs ft Note On some previous designs lock wire was used on the caps
38. Fuller Heavy Duty Transmissions E T N Roadranger More time on the road Service Manual Fuller Heavy Duty Transmissions TRSM0440 August 2009 RTX 11709A RTX 15710C RTX 11709B RTX 15715 RTX 11709H RTX 16709B RTX 11710B RTX 16709H RTX 11710C RTX 16710B RTX 12709A RTX 16710C RTX 12709B RTXF 11709H RTX 12709H RTXF 11710B RTX 12710B RTXF 11710C RTX 12710C RTXF 12709H RTX 13709H RTXF 12710B RTX 13710B RTXF 12710C RTX 13710C RTXF 13709H RTX 14709A RTXF 13710B RTX 14709B RTXF 13710C RTX 14709H RTXF 14709H RTX 14710B RTXF 14710B RTX 14710C RTXF 14710C RTX 15710B RTXF 15710B RTXF 15710C Warnings and Precautions Warnings and Precautions AWARNIN Before starting a vehicle always be seated in the driver s seat place the transmission in neutral set the parking brakes and disengage the clutch Before working on a vehicle place the transmission in neutral set the parking brakes and block the wheels Before towing the vehicle place the transmission in neutral and lift the rear wheels off the ground remove the axle shafts or disconnect the driveline to avoid damage to the transmission during towing The description and specifications contained in this service publication are current at the time of printing Eaton Corporation reserves the right to discontinue or modify its models and or procedures and to change specifications at any time without notice Any reference to brand name in this publication is made as an ex
39. Install the reverse idler bearing and inner race into the reverse idler gear Place the gear in its approxi mate location The gear s long hub is positioned for ward 5 Slide the mainshaft reverse gear rearward 6 While holding the mainshaft reverse gear rearward install the snap ring into the reverse gear 7 To temporarily hold the mainshaft rear in position slide the auxiliary drive gear assembly over the mainshaft rear and into the case bore Do not complete installation of the auxil iary drive at this time Bench Service Procedure 162 ow D 5 2 E N e Iz e n a e D 2 e Bench Service Procedure How to Install the Upper Countershaft Bearings Special Instructions The front bearing inner race must be pressed on the countershaft front The flanged end driver must cover the bearing outer race for proper installation Temporarily use the assembled auxiliary drive gear to hold the mainshaft in the input shaft pilot A CAUTION The upper countershaft bearings must be installed after the installation of the mainshaft Special Tools See Tool Information Item T7 Flanged end bearing driver Item T8 Bearing driver Item T9 Countershaft support tool Procedure 1 Make sure the lower countershaft and main drive gear tim ing marks are aligned 2 Mesh the upper countershaft marked tooth with the two remaining main drive gear marked teeth 3 Move the countershaft to the rear a
40. J a zt rJ I a S 77 92 Bench Service Procedure 3 With splined washer facing up place the washer on the out put shaft shoulder 4 With LO range gear clutching teeth down position LO range gear on the output shaft engage the washer splines 5 With chamfer side up position the LO range gear rear washer on the output shaft against the LO range gear 6 With tapered side up use heat or appropriate driver and install the output shaft rear bearing 7 On the output shaft position the bearing inner spacer Set aside 8 Laythe auxiliary housing front face down on a clean flat surface Install the bearing race in the bearing bore 93 Bench Service Procedure How to Assemble the Synchronizer Assembly Special Instructions Assembly should be done on a clean flat surface slightly lower than your waist Pins on the LO range synchronizer must line up with the chamfered holes on the sliding clutch bottom When compressing the HI range synchronizer springs cover with a shop rag In the event compression is not achieved the first time this prevents the springs from leaving the bench area Special Tools Typical service tools 1 Spring 2 Synchronizer Hi 3 Sliding Clutch 4 Synchronizer Lo wo wo rj Eo ow z ix 17 y i ix aa a Z to Procedure 1 On the bench place the larger LO range synchronizer ring face down with pins up 2 With the
41. Level Improper Oil Level Proper Oil Level Hole Hole Oil Filter For transmissions equipped with oil filter P N 4304827 e For highway use Inspect filter for leaks or damage replace as necessary e For off highway use Change filter every two years 14 rc oO 2 o E Lubrication If your vehicle has a transmission oil filter you must change the filter when fluid or lubricant is changed Transmission Operating Angles If the transmission operating angle is more than 12 degrees improper lubrication will occur The operating angle is the transmis sion mounting angle in the chassis plus the percent of upgrade expressed in degrees For operating angles over 12 degrees the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication Operating Temperatures with Oil Coolers The transmission must not be operated consistently at temperatures above 250 F Operation at temperatures above 250 F 121 C causes loaded gear tooth temperatures to exceed 350 F 177 C which will ultimately destroy the heat treatment of the gears If the elevated temperature is associated with an unusual operating condition that will reoccur a cooler should be added or the capacity of the existing cooling system increased The following conditions in any combination can cause operating temperatures of over 250 F 121 C e Operating consistently at slow speed e High am
42. air fittings 6 Slide the cover into position on the Roadranger valve 7 Install the Roadranger valve cover mounting screws Note Make sure the air lines are seated fully 38 Air System How to Remove a Slave Valve Special Instructions A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the vehicle air tanks must be exhausted Special Tools Typical service tools Procedure 1 Record or mark air line locations 2 Remove all air lines Note Remove three 1 4 ID air hoses at swivel fitting at range cylinder location Remove air line bracket at rear of transmission Remove slave valve with air hoses still attached 3 Remove the retaining capscrews around valve perimeter 4 Remove slave valve and gasket 5 Fromthe transmission case remove the sleeve spring and plunger pin Unger Pin IL D Sleeve 6 Inspect the air fittings replace if damaged Air Line Fittings 39 How to Install a Slave Valve Special Instructions None Special Tools Typical service tools Procedure 1 2 Clean gasket surface and install air fittings Lightly lubricate and install plunger pin spring and sleeve into case Install any necessary air hoses at this time Install new gasket Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews Install the retaining capscrews Tighten to 8 12 Ibs ft
43. ample of the types of tools and materials recommended for use and should not be considered an endorsement Equivalents may be used This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow A specific instructions may result in personal injury and or component damage Departure from the instructions choice of tools materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator Warning Failure to follow indicated procedures creates a high risk of personal injury to the service technician Caution Failure to follow indicated procedures may cause component damage or malfunction Note Additional service information not covered in the service procedures Tip Helpful removal and installation procedures to aid in the service of this unit Always use genuine Eaton replacement parts Table of Contents General Information E 5 Purpose and Scope of Manual Output Yoke Companion Flange Disassemble Precautions eibi eli bes 4 How to Remove the Output Yoke a Serial Tag and Model Nomenclature 8 Companion Flange and Nut 51 e Model Options sheds i usa eli SA E pd n How to Install the Output Yoke S Gear iine ANTO V eie dandi eet T Companion Flange and Nut 54 D GE Ratings Sigs a aaa a ahah a a a ir How to Remove the Output Yoke
44. and squarely P N 4301158 included in kit K 2394 Output Seal Driver To install output seal For 7 series Eaton P N 5564501 driver For 9 series Use Eaton P N 5564509 adapter with 5564501 driver Both parts included in Complete Eaton Seal Kit P N K 3651 Output Seal Slinger Driver To install output seal slinger For 7 series Eaton P N 71223 For 9 series Eaton P N 4303829 Preventative Maintenance Preventative Maintenance Everyday there are countless vehicles operating over the highways with transmissions in such a neglected mechanical condition they can be referred to as failures looking for a place to break down They lack a proper and organized preventive maintenance program Preventive maintenance is a general term which applies to all procedures necessary to have maximum life and satisfactory ser vice at the lowest possible cost short of removing and repairing the unit m E oO E LZ 5 oO E D E 5 gt E Er D A number of conditions contrary to good preventive maintenance can generally be pointed to when inspecting a failed transmis sion Taking a few minutes every so many hours or miles to do a few simple checks could help avoid eventual breakdown or reduce the repair cost If the transmission is not cared for it will breakdown Preventative Maintenance Check Points 6 5 Note Transmission appearance may differ the procedure is th
45. ange pins remove the slid ing clutch 86 Bench Service Procedure How to Disassemble the Output Shaft Assembly Special Instructions When using the soft bar and maul on the output shaft be careful not to damage the threads When removing the rear bearing cover the rear bearing cone drops from the housing bore Special Tools Vise with brass jaws or wood blocks Press Soft bar and maul 87 Bench Service Procedure 11 OEM supplied d _ OEM supplied adjustable Cu non adjustable E speedometer Fi speedometer sensor p sensor Threaded Non Threaded TEER RSSITVET E RTTET 1 Speedo rotor assembly 13 Rear housing 2 O ring 14 Slinger 3 Oil seal kit 15 Lifting eye 4 Capscrew 16 Capscrew 5 Rear bearing cover assembly 19 Speedo drive gear 6 Gasket 20 Speedo spacer assembly 7 Capscrew 21 Oil seal w slinger 8 Capscrew 22 Capscrew 9 Cover 23 Speed sensor kit 10 Gasket 24 Bushing 11 Shim Kit 25 O ring 12 Gasket 26 Rear bearing cover assembly 88 Bench Service Procedure 89 Procedure 1 Usea soft bar and maul to drive the output shaft forward and through the rear bearing assembly 2 From the auxiliary housing rear remove the rear bearing retaining capscrews cover and gasket 3 Clean the gasket mounting surface of gasket material 4 Inspect the rear bearing cover oil seal for damage remove if damaged
46. assembly from the transmis sion e Check the tension spring and washer for set and wear e Check the gear shift lever spade pin and slot for wear e Check bottom end of gear shift lever for wear and check slot of yokes and blocks in shift bar housing for wear at contact points with shift lever Checks With Drive Line Dropped Universal Joint Companion Flange or Yoke Nut 10 e Check for tightness Tighten to recommended torque Output Shaft Not Shown e Pry upward against output shaft to check radial clearance in mainshaft rear bearing 21 Preventative Maintenance Checks With Universal Joint Companion Flange or Yoke Removed Note If necessary use solvent and shop rag to clean sealing surface of companion flange or yoke Do not use crocus cloth emery paper or other abrasive materials that will mar surface finish Splines on Output Shaft Not Shown e Check for wear from movement and chucking action of the universal joint companion flange or yoke a 5 lt 1 E lt 17 2 E 1 5 2 rJ 17 Mainshaft Rear Bearing Cover 13 e Check oil seal for wear 22 Preventative Maintenance Oil Leak Inspection Process 23 Inspect for Oil Leak Weep Stained damp no drips light oil film dirt adhered to the contaminated area 1 Clean suspected oil weep area with a clean dry cloth or mild soluble degreaser 2 Ensure lube is to proper level
47. bient temperatures e Restricted air flow around transmission e Use of engine retarder e High horsepower operation Note Transmission coolers must be used to reduce the operating temperatures when the above conditions are encountered Oil Cooler Chart Transmission Oil Coolers are Recommended With engines of 350 H P and above Required e With engines 399 H P and above and GCW s over 90 000 Ibs With engines 399 H P and above and 1400 Ib ft or greater torque With engines 1500 Ib ft and above Tool Information Tool Information Some repair procedures pictured in this manual show the use of specialized tools Their actual use is recommended as they make transmission repair easier faster and prevent costly damage to critical parts But for the most part ordinary mechanic s tools such as socket wrenches screwdrivers etc and other standard shop items such as a press mauls and soft bars are all that is needed to successfully disassemble and reassemble any Eaton Fuller Trans mission Recommended Tools The following tables list and describe the typical tools required to properly service this model transmission above and beyond the necessary basic wrenches sockets screwdrivers and prybars General Tools The following tools are available from several tool manufacturers such as Snap On Mac Craftsman OTC and many others TOOL PURPOSE 0 100 Ibs ft
48. cap screws are snug 3 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary sec tion 4 Insert the two 2 longest capscrews in the housing flange tapped holes Tighten evenly to move the auxiliary section away from the front box Go far enough to break the gasket seal c lI 2 e N lt x ro TU a I D 2 e 5 Remove the capscrews from the tapped holes 6 Attach an auxiliary section hanger bracket to the auxiliary section top 7 Attach a lifting chain to the auxiliary section hanger bracket 8 Move assembly to the rear until auxiliary section is free 9 Remove the gasket and clean all mounting surfaces of gas ket material 58 In Vehicle Service Procedure 59 Procedure 1 To remove the auxiliary section in the vertical position With blocks under the clutch housing to prevent input shaft damage place transmission in the vertical position clutch housing down Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim Clean the gasket surface area Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap screws are snug From the auxiliary section housing remove the retaining capscrews that attach the front box to the auxi
49. ch Service Procedure Shim Procedure Without a Shim Tool for Tapered Bearings Special Instructions The shim procedure can be done in the horizontal or vertical position The procedure is done the same A CAUTION Use genuine Eaton replacement gaskets for the auxiliary housing and countershaft bearing cover Do not omit the gaskets Bearing endplay is influenced by the compressed thickness of the gasket 011 012 or 28 30 mm The bearing endplay must be checked and adjusted any time a countershaft bearing or housing is replaced If during reassem bly the same countershaft bearings housing and shims are reused and kept in the same location it is not necessary to reset bearing endplay The following procedure is used to adjust the endplay for the auxiliary countershaft tapered bearings By correctly following this procedure each countershaft will have 001 005 03 12 mm endplay Shims must be aligned properly or else the rear bearing cover may be damaged when final torque is applied Special Tools Typical service tools Shims and Feeler gauge Procedure 1 Theauxiliary countershaft bearing covers or countershaft straps and shims should be removed Make sure all old gasket material is cleaned from the gasket mounting sur faces on the countershaft bearing covers and the auxiliary housing 2 Verify that the auxiliary section is in gear When the output shaft is rotated the countershafts must also rotate If
50. configurations Refer to the specific model parts catalog if you are uncertain if parts are applicable The following illustra tions may differ slightly from the exact model and design level you are servicing Procedure 1 Remove reverse gear 2 Remove reverse gear spline spacer e Tilt the mainshaft up and from the opposite end remove the sliding clutch 4 Some models use a flat key at the front remove this key Rotate the spline washer that is retained by this key to remove the front gear and washers TIP To make disassembly easier clamp the mainshaft front in a vise with brass jaw protectors 5 Place the mainshaft in a vertical position 121 Bench Service Procedure 6 From the mainshaft rear pull the mainshaft key from the mainshaft key way 7 Turn the reverse gear limit washer to align its splines with the mainshaft and remove the washer 8 Remove the reverse 1st speed sliding clutch w I rj Z I o 7a y ix I a 77 122 Bench Service Procedure 123 9 0 Lift and turn 1st gear to align the limit washer splines Remove the limit washer spacer and 1st gear 11 Turn the 2nd gear limit washer to align its splines with the mainshaft Remove 2nd gear and its limit washer 12 Remove the 2nd 3rd sliding clutch 13 Remove each remaining gear limit washer and spacer 14 Inspect the roll pin remove if damaged Benc
51. contact the speedometer rotor In Vehicle Service Procedure 5 Install the output shaft nut tighten to 450 500 Ibs ft of torque 6 Make sure the output shaft nut is properly torqued and unlock the transmission or remove the yoke holding tool ow zx e ow co ow S ix ow y z oO 1 a to 54 In Vehicle Service Procedures How to Remove the Output Yoke Flange and Retaining Capscrews Special Instructions None Special Tools e Typical service tools Procedure 1 Remove drive shaft from transmission Reference OEM removal guidelines Remove the end yoke retaining capscrews and washer from auxiliary mainshaft Remove the end yoke flange 95 In Vehicle Service Procedures How to Install the Output Yoke Flange and Retaining Capscrews Special Instructions For proper cleaning and maintenance see TCSM0912 Seal Maintenance Guide Special Tools e Typical service tools Procedure 1 Install end yoke retaining washer and capscrews Apply Eaton Fuller 71205 liquid thread sealant to capscrews and then snug each capscrew to 35 Ibs ft 47 N m 2 Fully tighten both retaining capscrews to specified torque rating 74 81 Ibs ft 100 110 N m gt X E E lt N D E Note This fastening design employs Spiralock V threads A conventional metric thread pitch tap cannot be used for thread restoration on this product A WARNING
52. crews lock wire as needed Install the snap ring in the mainshaft groove rear The main shaft may need to slide rearward 168 w I rj Z I ix y E ix I a Bench Service Procedure How to Install the Auxiliary Section With Tapered Bearings Special Instructions There are different capscrew lengths install in the correct location Auxiliary sections can be installed either with the transmission in the horizontal position or the vertical position To install in the vertical position the clutch housing must be installed Special Tools See Tool Information Item T2 Auxiliary section hanger bracket for horizontal removal A steel bar longer than the width of the output yoke for vertical removal A hoist with a lifting chain Procedure To install the auxiliary section in the horizontal position 1 169 Position a new gasket on the transmission mounting sur face Attach an auxiliary section hanger bracket to the auxiliary section top Attach a lifting chain to the auxiliary section hanger bracket Position the auxiliary section on the two 2 dowel pins Slide the auxiliary section on until the hanger bracket con tacts the front section back Remove the auxiliary section hanger bracket Slide the auxiliary section the rest of the way into position Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews Bench Service Procedure 9
53. d with 5 32 fittings Mixing sizes can cause air leaks or damage to fittings exhaust the vehicle air tanks Before removing the air lines and hoses label or record their location Special Tools Typical service tools Procedure 1 2 3 4 29 Exhaust the vehicle air tanks before continuing Loosen the nut on the fitting and slide it back out of the way Pull the air line and attached collet from the fitting Inspect the fitting air line collet and nut for damage or wear Replace as necessary 1 Connector 2 Collet 3 Nut 4 Air Line Air System How to Install Compression Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tanks A CAUTION Small air lines are available in 1 8 or 5 32 sizes Make sure 1 8 air lines are used with 1 8 fittings and 5 32 air lines are used with 5 32 fittings Mixing sizes can cause air leaks or damage to fittings Special Tools Typical service tools N lt ch 5 3 Procedure 1 Check the threads of the fitting for thread sealant If no seal ant is present apply Eaton Fuller thread sealant 71205 or equivalent 2 Install the fitting Note Do not overtighten the nut Overtightening can com press the collet too much and cause an air line restriction 3 Install th
54. d Thrust Notched Thrust Inner Washer Inner Washer Q Slotted Thrust Washer 9 V Slotted Thrust Washer _ Reverse Idler Reverse Idler xd Shaft ES ui Shaft i Reverse Reverse Bearing Idler Gear Idler Gear Washer Washer Capscrew Snap Ring Procedure 1 Position the reverse idler bearing and inner race into the reverse idler gear 2 Hold the reverse idler gear and flat thrust washer in place in the main case and insert the idler shaft threaded end to the front through the rear case bore and into the gear Do not insert the reverse idler shaft into the main case support boss yet ow D E 2 E N e Iz e mz LI D 2 e 3 Position the slotted thrust washer in front of the gear with a slot facing up Note the word FRONT on the slotted washer and make sure it faces the front of the transmission Con tinue to feed the idler shaft forward through this washer and into the hole in the case boss 4 Slide the reverse idler shaft into the support boss bore and with a soft bar and driver drive the reverse idler shaft fully into position 136 Bench Service Procedure 137 Secure the shaft in position according to one of the proce dures below Note For Nut Fastener Design Inspect the nylon locking insert in the nut and replace the nut if it is exces sively worn After inspecting and or replacing the nut install the nut and washer on shaft front Tighten
55. d countershaft bearing cover Secure the bearing covers with the capscrews Install sealer Tighten the capscrews to 40 45 Ibs ft 54 61 Nem 15 Connect all removed air hoses and lines Use Eaton Fuller amp thread sealant 71205 or equivalent as necessary 16 Connect the driveshaft and U joint and refill the transmis sion with the recommended lubricant For lubrication instructions refer to Lubrication lt 3 ex z N D Q v A i x 62 Bench Service Procedure How to Disassemble the Gear Shift Lever Special Instructions If total disassembly is needed the Roadranger valve must be removed first Release the spring one coil at a time Special Tools Vise with brass jaws or wood blocks 1 Pin 8 Capscrew 2 Bushing 9 Gasket 3 Upper Lever 10 O ring 4 Snap Ring 11 Washer 5 Rubber Boot 12 Lower Lever 6 Spade Pin 13 Stepped Washer 7 Housing 14 Tension Spring 63 Procedure 1 On a non isolated shift lever remove the Roadranger valve using the How to Remove a Roadranger Valve on page 37 If the shift lever is equipped with a lever isolator remove the snap ring bushing and cross pin to disconnect and remove the upper lever Slide the rubber boot up and off the shift lever shaft With housing bottom facing up secure the assembly in a vise Use large screwdriver to twist between the spring and housing forcing the spri
56. dentified area such as the engine shift tower shift bar housing top mounted oil cooler etc Step 3 Once the origin of the leak is identified repair the oil leak using proper repair procedures from the designated model service manual After the repair is completed verify the leak is repaired and operate the vehicle to normal transmission operating temperature Inspect repaired area to ensure oil leak has been eliminated If the leak s still occurs repeat steps or contact the Roadranger Call Center at 1 800 826 4357 Inspection Preventative Maintenance Part to Inspect What to Check For Action to be Done Speedometer Connections Speedometer cables should not be loose Applied hydraulic thread sealant 71208 to threads Torque speedometer sleeve to 35 50 Ibs ft Should be an O ring or gasket between the mating speedometer sleeve and the rear bearing cover Replace the O ring gasket if damaged or missing Rear Bearing Cover Capscrews Gasket and Nylon Collar Check retaining capscrews for tightness Apply Eaton Sealant 71205 to the cap screw threads Torque capscrews to 35 45 Ibs ft Verify nylon collar and gasket are installed at the chamfered hole aligned near the mechanical speedometer open ing Use new parts if need to replace Apply Eaton Sealant 71205 to the cap screw threads Torque capscrews to 35 45 Ibs ft Verify that a rear bearing
57. e gear on the countershaft 4 Align 3rd smallest diameter gear keyway with the counter shaft key long hub to countershaft front and press the gear on the countershaft ow D E rJ E c e E ix e n a ix D 2 e 142 Bench Service Procedure 5 Align PTO gear keyway with the countershaft key bullet nose of teeth facing up shaft rear Align drive gear keyway with the countershaft key long hub against PTO gear and press both gears on the countershaft 6 On each countershaft front install the drive gear retaining snap ring in groove 7 Use a flanged driver or the press to install the bearing inner race on the countershaft front against the drive gear Note Make sure all gears are pressed into place Note Make sure the bearing inner race is installed 143 Bench Service Procedure How to Install the Auxiliary Countershaft Assembly Special Instructions To make auxiliary section assembly easier you can make an auxiliary section fixture out of a 2 x 12 piece of wood 3 This fixture is designed to ease the assembly of the auxiliary gearing Set the auxiliary countershaft rear bearings in the 3 holes Set the assembled auxiliary mainshaft between the countershafts with the timing marks aligned Special Tools Auxiliary countershaft retaining straps Toolmaker s dye wo wo rJ co wo z rJ 3 y rJ wo 3 5 Procedure
58. e mz a e D 2 e 9 Install the nuts with washers or lock washers on the studs tighten to 180 190 Ibs ft of torque 10 Install the capscrews with lock washers tighten to 90 100 Ibs ft of torque Note Make sure the capscrews are properly torqued Note Depending on the transmission model the clutch housing may have 10 or 12 bolts 110 Bench Service Procedure How to Remove the Standard Torque Auxiliary Drive Gear Assembly Procedure 1 Remove the mainshaft rear groove snap ring 2 Remove the six 6 auxiliary bearing retainer ring cap screws and bearing retainer ring 3 Inserta prybar into the main case gearing and use it to slide the mainshaft assembly rearward to move the auxiliary drive gear bearing from its bore 4 If it does not move easily it may be necessary to install three capscrews in the threaded holes on the retainer plate Tighten the three screws evenly to force the auxiliary drive gear assembly from the case The 3 threaded holes are only found on earlier models 111 Bench Service Procedure How to Disassemble the Upper and Lower Reverse Idler Gear Assembly Special Instructions The new reverse idler shaft uses a snap ring on the front in place of the capscrew Lower reverse idler gear removal is the same but the mainshaft and countershafts must be removed Special Tools e Slide Hammer T5 see Table 6 Previous Design Current Design Snap Ring Snap Ring Notc
59. e Auxiliary Section with How to Remove a Slave Valve 005 39 Tapered Bearings sisse 77 How to Install a Slave Valve 0 40 How to Disassemble the Range Cylinder Assembly 80 How to Remove the Auxiliary Countershaft Shift Bar Housing Assembly HUMO d ENTE 83 How to Remove the Gear Shift Lever Remote How to Disassemble the Synchronizer Assembly 86 Shift Control x sei i ace mse eh ect centran 41 How to Disassemble the Output Shaft Assembly 87 How to Install the Gear Shift Lever Remote t Shift Control Eurus uade S di qe 42 Assemble Auxiliary Section How to Adjust the Remote Shift Control How to Assemble the Output Shaft Assembly 92 LRC Type sees M EE 43 How to Assemble the Synchronizer Assembly 94 Ne aE Snom Operation ANE SSUIIB cs studi gc P How to Install the Oil Seal sss 96 How to Remove the Neutral Switch Puig d se Ria 46 How to Assemble the Range Cylinder Assembly 2 97 How to Install the Neutral Switch AT How to Install the Countershaft Assemblies 100 Reverse Switch Operation and Testing 48 How to Remove the Reverse Switch 49 How to Install the Reverse Switch 50 Table of Contents Disassemble Front Section How to Remove the Clutch Housing with Internal Oil Tube 04 106 How to Install the Clutch Housing with Internal Oil Tube 05 108
60. e air line collet and nut If installing a new fitting place the collet in the fitting and loosely install the nut Do not tighten the nut yet Insert the air line through the nut and into the collet Tighten the nut as usual 1 Connector 2 Collet 3 Nut 4 Air Line 4 Enable the vehicle air system Allow the air tanks to pres surize and check for leaks Repair as necessary 30 Air System How to Remove Push To Connect Type Fittings Special Instructions A WARNING A sudden release of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tanks A CAUTION Make sure only 5 32 air lines are used with push to connect fittings Using sizes other than 5 32 can cause air leaks or damage to fittings Before removing the air lines and hose label or record their location Special Tools See Tool Information For push to connect fittings the Eaton service tool kit K 2394 is recommended The kit contains the release tool and the tubing cutter Procedure Exhaust the vehicle air tanks before continuing 2 Use the air line release tool from kit K 2394 to press the release sleeve down while pulling the air line from the fit ting 3 Inspect the fitting for damage or wear Remove and replace as necessary 31 Air System How to Install Push To Connect Type Fittings Special Instructions A WARNING A sudden relea
61. e cylinder cover remove the capscrews cover and gasket 2 Clean the gasket mounting surfaces of all gasket material 3 From the range cylinder housing bore remove the 15 16 nut 4 Remove 3 4 bolts from range yoke ao 5 3 Q L N o rr ow Y i Lr 1 2 o 80 Bench Service Procedure 81 5 6 T Pull range shaft out of cylinder and remove range yoke from synchronizer From the cylinder housing bore remove the range piston Inspect the range piston O rings remove if damaged Bench Service Procedure 8 From the range cylinder housing remove the housing and gasket 9 Clean the gasket mounting surfaces of all gasket material 10 Inspect the O ring inside the range cylinder housing bore remove if damaged ow D E E N e Lx e n n e D 2 e 82 Bench Service Procedure How to Remove the Auxiliary Countershaft Assembly Special Instructions For ease of disassembly mount the auxiliary section upright in a vise Both countershafts are removed the same As the countershaft strap is removed the countershaft can fall Special Tools See Tool Information Vise with brass jaws or wood blocks Item T11 Bearing Puller Soft bar and maul Procedure 1 To hold the auxiliary countershafts from turning place a shop rag or equivalent between the splitter gear and one countershaft 2 From the output shaft
62. e proper gear on the mainshaft If necessary refer to the illustrated parts list to determine gear order Bench Service Procedure 7 With clutching teeth up and against this gear install the next and spacer washer 8 With the washer flat side down position a tolerance washer against the spacer Rotate the washer until the washer splines and mainshaft splines align 9 Push the air line up to lock the washer on the mainshaft w I rj Z I oO y zt o I a 77 10 Insert two large screwdrivers between the two gears Apply slight downward pressure to spread gear evenly Between the gear hub and mainshaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer Refer to information before stepped procedures for further information 11 With the missing internal splines aligned with the plastic line install a sliding clutch 12 With the washer flat side up position tolerance washer white in the next available groove Rotate the washer until the washer splines and mainshaft splines align 156 Bench Service Procedure 13 Push the air line up to lock the washer on the mainshaft 14 Install a gear spacer 15 With clutching teeth down position the next gear on the mainshaft engaging with spacer external splines 157 20 21 22 With clutching teeth up install the next gear on shaft a
63. e same 20 Preventative Maintenance Air System and Connections 1 e Check for leaks worn air lines loose connections and capscrews Clutch Housing Mounting 2 e Check all capscrews of clutch housing flange for looseness Clutch Release Bearing Not Shown e Remove hand hole cover and check radial and axial clearance in release bearing e Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches Clutch Pedal Shaft and Bores 4 e Pry upward on shafts to check wear e f excessive movement is found remove clutch release mechanism and check bushings on bores and wear on shafts See OEM literature Lubricant 5 e Change at specified service intervals e Use only the types and grades as recommended See Recommended Lubrication Chart Filler and Drain Plugs 6 e Remove filler plugs and check level of lubricant at specified intervals Tighten fill and drain plugs securely Capscrews and Gaskets 7 e For applicable models check all capscrews especially those on PTO covers and rear bearing covers for looseness which would cause oil leakage e Check PTO opening and rear bearing covers for oil leakage due to faulty gasket Gear Shift Lever 8 e Check for looseness and free play in housing If lever is loose in housing proceed with Check No 9 Gear Shift Lever Housing Assembly 9 e f present remove air lines at air valve or slave valve Remove the gear shift lever housing
64. ealant 71205 or equivalent to the retaining capscrews 15 Install the capscrews tighten to 20 25 lbs ft of torque Final Check Make sure all capscrews are tighten to their proper torque Make sure gaskets were used at the appropriate positions Bench Service Procedure How to Install the Countershaft Assemblies Special Instructions To make auxiliary section assembly easier you can make an auxiliary section fixture out of a 2 x 12 3 Make sure to use an auxiliary drive gear retaining bolt with thread sealant material Special Tools See Tool Information Toolmaker s dye Item T12 Bearing driver Shim gauges or countershaft retaining straps Procedure 1 If previously removed install the countershaft bearings on each of the countershafts IMPORTANT Locate the O stamped in each countershaft and mark the adjoining teeth with a highly visible paint or dye w I rj Z I z o 7a a zt o o I a 77 100 Bench Service Procedure 101 2 Place the two countershaft in the fixture or on a flat bench with the large HI range gears down 3 Position the output shaft LO range and synchronizer assembly between the two countershaft 4 Checkthe timing marks on the LO range gear making sure the countershaft gear timing marks are aligned between the LO range gear teeth 5 Place the range yoke assembly into the synchronizer sliding clutch Bench Service Pr
65. ench Service Procedure How to Remove the Mainshaft Assembly Special Instructions None Special Tools See Tool Information Item T15 Mainshaft hook 119 Procedure Secure the upper countershaft to the side and away from the mainshaft Optional Insert prybar between upper coun tershaft and main drive gear as shown Insert the mainshaft hook tool or rope around the main shaft Note Keep the upper countershaft forward against the case front wall Pull the mainshaft to the rear to free the pilot from the input shaft pocket WARNING Be careful when removing the mainshaft A assembly The sliding clutch on the front and the reverse gear on the back can slip off the shaft Bench Service Procedure 4 Tilt the mainshaft front up and lift the assembly from the Case wo 1 rj co 1 z ix o y 3 ix 1 2 17 120 Bench Service Procedure How to Disassemble the Mainshaft Assembly Special Instructions During disassembly lay all parts on a clean bench in order of removal to facilitate reassembly When removing limit washers spacers and gears note their location Keep the internal splined washers and external splined spacers with the gear from which they were removed There is only one limit washer and one spacer belonging to each gear Mainshaft assembly construction varies with transmission model type Some of the following steps will only apply to certain model
66. ent ball ow D 5 2 E N e Iz e n A e D 3 e 76 Bench Service Procedure How to Remove the Auxiliary Section with Tapered Bearings Special Instructions There can be different capscrew lengths note their location Auxiliary sections can be removed either with the transmission in the horizontal position or the vertical position Auxiliary countershaft retaining straps may be installed to hold the countershafts in place You can make retaining straps from 3 x 1 bar stock Auxiliary can be removed without straps use caution Special Tools See Tool Information Item T2 Auxiliary section hanger bracket for horizontal removal A steel bar longer than the width of the output yoke for vertical removal A hoist with a lifting chain Auxiliary countershaft retaining straps Procedure 1 Toremove the auxiliary section in the horizontal position Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 77 Bench Service Procedure 2 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 1 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap screws are snug 3 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary sec tion ow D 5 2 E N e Iz e n a e D 2 e 4 Insert
67. er the table This list is provided as a convenience to our customers These tools are manufactured by inde pendent companies with no relationship to Eaton Fuller Eaton Fuller does not warrant the fit or function of the listed tools To obtain the tools contact the tool supplier directly REF TOOL PURPOSE G amp WTOOL GREAT LAKES OTC TOOL NO NO TOOL NO NO Ti Output Yoke Puller May be required to remove a rusted SP 450 7075 output yoke T2 Auxiliary Section Hanger To support or hang the auxiliary sec G 40 T 125 5061 tion in the horizontal position T3 Auxiliary To hold the auxiliary countershafts in G 250 T 311 5062 Countershaft position while installing the auxiliary Support and Shim Tool section in the horizontal position Also to simplify the checking and setting of the auxiliary countershaft bearing endplay T4 Shift Lever Spring To install the shift tower tension G 116 T 170 Installation Tool spring Tension Spring Driver T5 Slide Hammer To remove the output seal and reverse G 70 T 150 1155 Slide idler shafts Requires 1 2 13 threads Hammer Optional idler shaft can be driven out 8007 1 2 13 from front Adapter T6 Bearing Puller To remove front section countershaft G 10 or G 15 T 100 7070A Kit bearings T7 Bearing Driver To install front section countershaft G200 Kit T 101 Kit bearings 3 97 OD 1 78 ID T8 Bearing Driver To install the fr
68. ershaft bearings To remove the mainshaft assembly only the upper countershaft bearings need to be removed Performing the following instructions will damage the bearings and should be not be done unless bearing replacement is planned The bearing inner race remains pressed on the countershaft after removal of the front bearings Special Tools See Tool Information on page 16 Soft bar and maul Item T6 Bearing puller or pry bars Procedure 1 To keep the mainshaft pilot from falling out of the input shaft pocket temporarily install the auxiliary drive gear on the mainshaft 2 From each countershaft rear groove remove the snap ring 3 Remove six capscrews from front bearing cover and remove front bearing cover w 1 rj o z o o y n i o 1 2 o 4 From inside the case use a soft bar and maul to drive the countershaft rear bearings rearward off the shaft CAUTION Damage will likely occur to this bearing during removal It is strongly recommended that this bearing is discarded 114 Bench Service Procedure 115 From the front of each countershaft remove the capscrew and front retainer plate Use the soft bar and maul to drive each countershaft to the rear as far as possible This partially unseats the front bear ings Return to the case rear and drive each countershaft for ward as far as possible This exposes the external snap ring Use the appr
69. ess Tolerance Washers 153 How to Install the Mainshaft 161 How to Install the Upper Countershaft Bearings 163 How to Assemble the Upper Reverse Idler Gear Assembly 0 0 0 0 cence ee 166 How to Install the Standard Torque Auxiliary Drive Gear Assembly 0 0 cece eens 168 Install Auxiliary Section How to Install the Auxiliary Section With Tapered Bearings 0 cee eee ee 169 Shim Procedure With A Shim Tool For Tapered Bearings 0 cece eee ee 172 Shim Procedure without a Shim Tool for Tapered Bearings aa 175 Introduction Purpose and Scope of Manual This manual is designed to provide information necessary to service and repair the Eaton Fuller transmissions listed on the front How to use this Manual 5 So 2 o The service procedures have been divided into two sections In Vehicle Service Procedures and Transmission Overhaul Proce dures Bench Service In Vehicle Service Procedures contain procedures that can be performed while the transmission is still installed in the vehicle Transmission Overhaul Procedures contain procedures that are performed after the transmission has been removed from the vehicle The procedure sections are laid out with a general heading at the top outside edge of each page followed by more specific head ings and the procedures To find the information you need in these sections first go to the secti
70. eter is installed towards the shaft Use a bearing driver that con tacts both the bearing inner race and outer race 14 Inthe countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torqued Note Make sure the rear snap ring is in place Bench Service Procedure How to Install the Upper Reverse Idler Gear Assembly Special Instructions The installation procedure is the same as that for the lower reverse idler shaft The new reverse idler shaft uses a snap ring in place of the capscrew Previous Design Snap Ring Notched Thrust Washer Reverse Idler Shaft Slotted Thrust Washer Reverse Bearing Idler Gear Washer Capscrew Special Tools e Typical service tools Procedure 1 Liftthe mainshaft reverse gear to allow the reverse idler gear to drop into mesh and into the proper position 2 Placeand hold the idler flat thrust washer at the back of the gear 3 While holding the gear and washer in position feed the reverse idler shaft through the flat thrust washer and gear 4 Position the slotted thrust washer in front of the reverse idler gear with one of the slots facing up and continue to feed the idler shaft forward Make sure the word FRONT faces the front of the main case 5 With a soft bar and driver drive the reverse idler shaft fully into position Current Design Snap Ring Notched Thrust 3 Washer Inner Race Slotted Thrust i
71. eutral position Move the gear shift lever sideways toward reverse until you feel resistance from the reverse plunger spring DO NOT shift to reverse The shift finger must remain in this position while you are making all the adjustments Remove the cotter pin castle nut and ball joint A see figure A from the selection lever Do not remove the ball joint from the pivot link Loosen the capscrew B see figure A and remove the shift arm from the inner shift shaft Do not disconnect the selec tion lever from the shift arm Turn the shift arm until it is at a right angle 90 to the selection lever as viewed from the side see figure B Note Ideally the shift arm should be adjusted 90 to the selection lever as described but in some chassis configurations it may be necessary to index the shift arm in the vertical position Indexing the shift lever is done to prevent shift lever jump out This type of adjustment will cause an unequal amount of gear shift lever travel between neutral and a forward lever position as compared to neutral and a rearward lever position Install the shift arm on the splines of the inner shift shaft You may have to move the shift arm 4 or 5 to align the splines of the two parts Disregard any movement of the gear shift lever at this point The gear shift lever will be adjusted later Tighten the capscrew B see figure A on the shift arm Connect the pivot link assembly ball joint to the se
72. evenly thread in the two 172 Bench Service Procedure cleaned capscrews Do not install the gasket at this time 5 Evenly tighten the two capscrews to 7 Ibs in inch pounds The gap between the shim tool and the housing surface should be even from side to side Note 7 Ibs in is slightly more than finger tight Do not overtighten the capscrews If the capscrews are too tight the shim tool will warp 6 Rotate the output shaft 4 times clockwise and 4 times coun terclockwise The rotation will seat and align the rollers in each tapered bearing Re torque the capscrews to 7 Ibs in If the countershafts do not rotate the range sliding clutch is in neutral Shift the range clutch to either high or low range 7 Useafeeler gauge to measure the gap between the shim tool and the auxiliary housing gasket surface Measure and record the gap at both capscrew locations Gap 1 060 Gap 2 050 Total Gap 060 050 110 Average 110 2 055 Select yellow shim as indicated in the shim chart at the end of this section 8 Average the two feeler gauge measurements by adding the measurements together and dividing by 2 as shown in Example 1 9 Locate the feeler gauge average measurement in the shim chart at the end of this section to determine the required shim and color code Note The oil pump shim is used when an auxiliary oil pump or PTO is mounted on the countershaft The oil pump
73. fter assembly To aid in determining the reuse or replacement of any transmission part consideration should also be given to the unit s history mileage application etc Recommended inspection procedures are provided in the following checklist Bearings e Wash all bearings in clean solvent Check balls rollers and raceways for pitting discoloration and spalled areas Replace bearings that are pitted discolored spalled or damaged during disassembly e Lubricate bearings that are not pitted discolored or spalled and check for axial and radial clearances e Replace bearings with excessive clearances e Check bearing fit Bearing inner races should be tight to shaft outer races slightly tight to slightly loose in case bore If the bearing spins freely in the bore the case should be replaced Bearing Covers e Check covers for wear from thrust of adjacent bearing Replace covers damaged from thrust of bearing outer race e Check cover bores for wear Replace those worn or oversized Clutch Release Parts e Check clutch release parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pads e Check pedal shafts Replace those worn at bushing surfaces Gears e Check gear teeth for frosting and pitting Frosting of gear teeth faces presents no threat of transmission failure Often in continued operation of the unit frosted gears heal and do not progress to the pitting stage In most cases gears with light to moderate p
74. gainst the previously positioned gear Position another spacer against the previously positioned gear engaging the spacer external splines with gear clutch ing teeth With washer flat side down position the tolerance washer against the spacer Rotate the washer until the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft Insert two large screwdrivers between the two gears Apply slight downward pressure to spread the gears evenly Between the gear hub and mainshaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the washer against the mainshaft spacer Refer to information before stepped procedures for further informa tion Align the sliding clutch missing internal spline with the mainshaft key and install the reverse speed sliding clutch With the flat side up place a washer blue or white in the next available groove Rotate the washer until the washer splines and mainshaft splines align Bench Service Procedure 158 ow D 5 2 E N D x e mz e D 2 e Bench Service Procedure 23 Push the air line up to lock the washer on the mainshaft 24 Against the tolerance washer position reverse speed gear spacer 25 Install reverse gear on the mainshaft Engage the gear clutching teeth with spacer external splines and sliding clutch Move the reverse gear down against the 1st speed gear 26
75. h Service Procedure 124 5 ao rj c ow z ix o y 3 ix 1 2 17 Transmission Overhaul Procedures Bench Service How to Disassemble the Mainshaft Assembly with Low Force Gearing Special Instructions The design of the mainshaft with Low Force Gearing is slightly different from the standard mainshaft It still utilizes Non Selective Non Adjustable Tolerance Washers but the 1st and reverse gears and sliding clutch have been redesigned In this configuration the 1st reverse sliding clutch rides on a clutch hub and the 1st and reverse gears have been redesigned to accommodate this change Lay all parts on a clean bench in order of removal to facilitate assembly Special Tools e Typical service tools Procedure 1 Laythe mainshaft on its side and from the front remove the 4th or overdrive and 5th sliding clutch 2 Place the mainshaft in a vertical position pilot end down Remove the reverse gear clutch hub and sliding clutch 3 Remove the snap ring and key Mark keyway location 125 Transmission Overhaul Procedures Bench Service 4 Remove the offset washer and 1st gear 5 Remove the flat washer and 2nd gear D o O gD D 5 2 a HE 77 ae D s5 3 THE gt S lt ae 5S 2 ae s D 6 Remove the offset washer and sliding clutch and then re move the offset washer and 3rd gear 7 Remove the flat washer remove the 4th or overdrive gear
76. haft assembly Note A large hook or piece of rope may help support the countershaft Note Follow the same procedure for lower countershaft removal o 1 3 r L N o Fr o Y Lr 1 2 17 128 Bench Service Procedure How to Disassemble the Countershaft Assemblies Special Instructions As you disassemble the countershafts mark each part as belonging to the upper or lower countershaft and mark the gears for front or back orientation Except for the PTO gears the left and right countershaft assemblies are identical and disassembled in the same manner Special Tools See Tool Information Snap ring pliers Press 15 1 Snap Ring 6 Key 11 Drive Gear 2 Bearing 7 2nd Gear 12 Snap Ring 3 Countershaft 8 8rd Gear 13 Bearing 4 Key 9 4th Gear 14 Retainer 5 Roll Pin 10 PTO Gear 15 Capscrew 129 Bench Service Procedure Procedure 1 Remove the front countershaft snap ring CAUTION NEVER USE THE PTO GEAR AS A PRESSING BASE The narrow face width of this gear makes it very susceptible to breakage 2 Place the countershaft in the press as shown Using the rear face of 3rd Overdrive speed gear as a base press the drive gear PTO gear and 3rd Overdrive speed gear from each countershaft This removes the front bearing inner race from the countershaft 3 Position the countershaft in the press as shown Press the next two gears from the shaft w
77. he transmission specified in the model number is the input torque capacity in Ib ft Various torque ratings are available For more information call the Roadranger Help Desk at 1 800 826 HELP 4357 Two types of shift bar housings are available for this transmission Both are described and shown below Shift Bar housings Standard The standard shift bar housing has a gear shift lever opening that is located toward the rear of the transmission The housing is shown in figure 1 2 QOO O Fig 1 2 Model Designations Forward Opening The forward opening shift bar housing has a gear shift lever opening located three inches closer to the front of the transmission than the standard opening This forward design allows greater flexibility in mounting the transmission and in indicated by an F in the model number The housing is shown in figure1 3 2 D i D cul e E D E Fig 1 3 Lubrication Pumps Two types of lubrication pumps are available for use on this transmission and are described below PTO Driven A PTO driven pump is externally mounted on the 6 or 8 bolt PTO openings and driven off the PTO gear Auxiliary Countershaft An auxiliary countershaft pump is mounted on the rear of the transmission and driven off the auxiliary countershaft Power Take Off PTO Usage PTOs can be mounted in the following ways 6 or 8 Bolt The 6 or 8 bolt openings are standard with the transmission The PTO
78. heck neutral notches of shift bars for wear from interlock balls Sliding Clutches e Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat e Check engaging teeth of sliding clutches for partial engagement pattern Splines e Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub has wear marks in the spline sides replace the specific shaft effected Synchronizer Assembly e Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles e Check blocker pins for excessive wear or looseness e Check synchronizer contact surfaces on the synchronizer cups for wear Washers e Check surfaces of all washers Washers scored or reduced in thickness should be replaced Assembly Precautions Make sure that case interiors and housings are clean It is important that dirt and other foreign materials are kept out of the trans mission during assembly Dirt is an abrasive and can damage polished surfaces of bearings and washers Use certain precau tions as listed below during assembly Axial Clearances e Maintain original axial clearances of 006 to 015 for mainshaft gears Bearings e Use a flange end bearing driver for bearing installation These special drivers apply equal force to both bearing races preventing damage to balls rollers and races while maintaining correct bearing alignment with bore and shaft Avoid using
79. hed Thrust Notched Thrust iinei Washer inner Washer Race Race Slotted Thrust m UY Slotted Thrust 1 E aA O Reverse Idler T S Reverse Idler Shaft Q Shaft Reverse Reverse Bearing Idler Gear Bearing Idler Gear Washer Washer Capscrew Capscrew Procedure 1 Remove the capscrew or nut on the front of the reverse idler shaft Note If idler shaft spins place a large screwdriver between reverse idler boss to keep shaft from spinning ow ow Ss Q L d 1 lt rr 17 Y i Lr 1 a to 2 On new design idler shafts remove the snap ring 112 Bench Service Procedure 113 Thread a slide hammer puller Tool ref ID T5 into the rear of the reverse idler shaft The threads are M12x1 75 Note Not all shafts styles had threads Using the slide hammer remove the reverse idler shaft Note If a slide hammer is not available the reverse idler can be driven out as shown in the photo Note While removing the reverse idler shaft the lube spacer and washer can drop to the transmission case bottom Note If desired the upper reverse idler gear can be removed without removing the mainshaft To do so remove the snap ring from the mainshaft reverse gear and move the mainshaft reverse gear forward Bench Service Procedure How to Remove the Upper and Lower Countershaft Bearings Special Instructions The following instructions are used to remove the upper and lower count
80. igure 1 1 below shows the tag which is located on the transmission When calling for service assistance or parts have the model and serial numbers handy Do not remove or destroy the transmission identification tag 2 D i D cul e E D E Eaton Fuller gums Transmissions Fig 1 1 Transmission Tag and Location Model Number The model number gives basic information about the transmission and is explained below Use this number when calling for ser vice assistance or replacement parts RT 12609394 RT Roadranger Twin Countershaft _ Ratio Set RTF w Forward Shift Bar Housing RTO w Overdrive RTOO w Double Overdrive Forward Speed RTOF w Overdrive and Forward Shift 5 Spur Gearing Bar Housing n l RTOOF w Double Overdrive and Forward 6 Multi Mesh Gearing Shift Bar Housing 7 Helical Auxilary Gearing and RTX w Overdrive and Direct Shift Pattern Multi Mesh Front Gearing RTXF w Overdrive Direct Shift Pattern and Forward Shift Bar Housing This x 100 Nominal Torque Capacity Serial Number The serial number is the sequential identification number of the transmission Before calling for service assistance write the number down as it may be needed Bill of material or Customer number This number may be located below the model and serial numbers It is a reference number used by Eaton Model Designations Model Options Torque Rating The torque rating of t
81. ion 151 Mainshaft Assembly There are three distinct mainshaft washer and mainshaft key designs They are listed from oldest design to newest design e Six 6 sided mainshaft key with selective adjustable thickness tolerance washers e Three 3 sided mainshaft key with selective adjust able thickness tolerance washers e Three 3 sided mainshaft key with non selective non adjustable tolerance washers Note Between 1993 and 1996 some models were produced with a mixture of selective thickness washers and non selective tolerance washers on the same mainshaft The proper mainshaft key must always be used with the proper design mainshaft washers If necessary refer to the parts man ual for your specific model to confirm the proper parts Previous design levels can be updated to the current design Bench Service Procedure 152 wo wo rJ N wo rJ wo v rJ wo 5 Bench Service Procedure How to Install the Mainshaft Assembly with Selective Adjustable Thickness Tolerance Washers Special Instructions Each mainshaft gear must have its inside snap ring installed before placement on the mainshaft Do not install reverse gear inside snap ring at this time Gear tolerance washers are internally splined and locked to the mainshaft by the key Gear spacers are externally splined to engage with gear hub clutching teeth There is one tolerance washer and one spacer fo
82. is mounted to the opening and driven from the PTO gear on the front countershaft Thru Shaft The thru shaft PTO mounts on the rear of the transmission It requires a special auxiliary housing and main case countershaft with internal splines 10 Model Designations Gear Ratios Model Speed Gear Ratios Relative Speed Length Weight Oil Cap PTO Gear To In mm Lbs Kgs Pints Input R P M 7 At Liters 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10 Reverse Right Btm RT 11709H 13 29 9 16 6 53 4 80 3 57 2 56 1 83 1 34 z 3 89 696 696 28 90 606 25 5 12 13 89 734 1 275 RT 11710B 14 78 11 00 817 600 446 3 31 246 1 83 1 34 1 00 3 38 788 788 28 9 604 26 14 78 734 1 274 12 RT 12709H 13 29 9 16 6 53 4 80 3 57 2 56 1 83 1 34 E 3 89 696 696 28 90 606 25 5 12 13 89 734 1 275 RT 12710B 14 78 11 00 817 600 446 3 31 246 1 83 1 34 1 00 3 38 788 788 28 9 606 26 14 78 734 1 275 12 RT 13709H 13 29 9 16 6 53 4 80 3 57 2 56 1 83 1 34 E 3 89 696 696 28 90 606 25 5 12 13 89 734 1 275 RT 13710B 14 78 11 00 817 600 446 3 31 246 1 83 1 34 1 00 3 38 788 788 28 9 611 26 14 78 734 1 277 12 RT 14709H 13 29 9 16 6 53 4 80 3 57 2 56 1 83 1 34 3 89 696 696 28 90 606 25 5 12 13 89 734 1 275 RT 14710B 14 78 11 00 817 600 446 3 31
83. ith the main section CAUTION The auxiliary section should slide into place fairly easily DO NOT force it on or pull it into place with the capscrews Excessive force may damage the transmission If excessive force is nec essary the gearing is likely out of time If the auxiliary section does not install fully slide it back and check the following a The output yoke and nut should be installed to pull back and center the auxiliary mainshaft assembly b The countershaft support tool center capscrew should be snug to level the countershafts c The dowel pins and auxiliary housing mating holes should be clean and well oiled d The internal gearing on the auxiliary section must have been properly timed during reassembly Apply Eaton Fuller thread sealant 71205 or equivalent to the all the retaining capscrew threads Install the cap screws to secure the auxiliary section to the main case Torque the capscrews to 40 45 Ibs ft 54 61 Nem In Vehicle Service Procedure 13 If the countershaft countershaft bearings or auxiliary housing have been replaced or if the countershafts bear ings or shims were not marked and reassembled in the same location the bearing endplay must be checked and set by shimming Shim the countershaft bearings using Shim Procedure Without a Shim Tool for Tapered Bear ings on page 171 14 If shimming is not required remove the support tools and install the proper shim gasket an
84. itted teeth have considerable gear life remaining and can be reused but gears in the advanced stage of pitting should be replaced e Check for gears with clutching teeth abnormally worn tapered or reduced in length from clashing during shifting Replace gears found in any of these conditions e Check axial clearance of gears Gear Shift Lever Housing Assembly e Check spring tension on shift lever Replace tension spring if lever moves too freely e f housing is disassembled check gear shift lever bottom end and shift finger assembly for wear Replace both gears if excessively worn Introduction Gray Iron Parts e Check all gray iron parts for cracks and breaks Replace parts found to be damaged Oil Return Threads and Seals e Check oil return threads on the input shaft If return action of threads has been destroyed replace the input shaft 5 So 2 ix E e Check oil seal in rear bearing cover If sealing action of lip has been destroyed replace seal O Rings e Check all O rings for cracks or distortion Replace if worn Reverse Idler Gear Assemblies e Check for excessive wear from action of roller bearings Shift Bar Housing Assembly e Check for wear on shift yokes and blocks at pads and lever slot Replace excessively worn parts e Check yokes for correct alignment Replace sprung yokes e Check lockscrews in yoke and blocks Tighten and rewire those found loose e If housing has been disassembled c
85. lace in the transmission during torque transfer is essential when troubleshooting and making repairs Front Section Power Flow All Models Power torque from the vehicle s engine is transferred to the transmission s input shaft 1 Splines of input shaft engage internal splines in hub of main drive gear 2 Torque is split between the two countershaft drive gears 3 Torque is delivered along both countershafts to mating countershaft gears of engaged mainshaft gear The cross sec tion views illustrate 1st 6th speed gear engagement 4 Internal clutching teeth in hub of engaged mainshaft gear transfers torque to mainshaft through sliding clutch 5 Mainshaft transfers torque directly to rear auxiliary drive gear 6 Auxiliary Section Power Flow LO RANGE All Models 25 The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 7 Torque is delivered along both auxiliary countershafts to the engaged LO RANGE gear on range mainshaft or output shaft 8 Torque is transferred to range mainshaft or output shaft through sliding clutch 9 Torque is delivered to driveline as LO RANGE 1st 10 Power Flow Auxiliary Section Power Flow HI RANGE All Models The auxiliary drive gear transfers torque directly to the range mainshaft or output shaft through engaged sliding clutch 7 Torque is delivered through the range mainshaft and or output shaft to driveline as HI RANGE 6th 8
86. lection lever Secure it with the castle nut and cotter pin Loosen the jam nuts C see figure C on the pivot link Check to be sure the inner shift finger is still in place Rotate the pivot link until the curved end of the selection lever is parallel with the shift arm as viewed from the rear see figure C Tighten the pivot link jam nuts C see figure C Loosen both capscrews on the turnbuckle D see figure A Check to be sure inner shift finger is still in place Rotate the turnbuckle to obtain the proper forward back ward neutral position of the gear shift lever in the cab Tighten one turnbuckle D capscrew see figure A Move the gear shift lever to the desired position Turn the second turnbuckle D capscrew Check for linkage obstructions in all gear positions In Vehicle Service Procedure Figure C 1 Selection Lever 2 L H Thread 3 R H Thread 4 Shift Arm 5 Parallel 7 lt 1 ex 7 N 1 lt rJ 7 v rJ ow 2 7 44 In Vehicle Service Procedure Neutral Switch Operation and Testing Special Instructions The neutral switch is a normally closed switch An electrical current flows through it when the transmission shifter is in the neu tral position When the transmission shifter is in gear the switch is open and no current flows through it Likewise the switch is open when the ball is depressed The switch is actuated by the air
87. liary section Install a steel bar through the yoke Attach a lifting chain to the steel bar Lift assembly from the front section In Vehicle Service Procedure How to Install the Auxiliary Section in Chassis Special Instructions None Special Tools See Tool Information Item T3 Countershaft support tools Item T14 Auxiliary section removal adapter plate A hoist with lifting chain Procedure 1 Install the countershaft support tools on the auxiliary sec tion countershafts to center and hold the countershafts in position Install a 3 8 16 X 2 1 2 long capscrew into coun tershaft center 2 If removed slide the output yoke over the output shaft Lightly oil the threads and install the output nut on the out put shaft Torque the nut to 450 500 Ibs ft 610 677 Nem c lI e e N D R lt Er im a e D 2 Note To prevent the output shaft from rotating while installing the nut place a clean shop rag in the gear mesh Note Due to chassis interference it may not be possible to install the yoke at this step However the output shaft must be drawn fully into position to prevent it from sagging when the auxiliary section is installed in the chassis If the chassis causes interference the yoke can be temporarily installed to draw up the out put shaft and then removed before the auxiliary sec tion is installed 3 Use crocus cloth or a wire wheel to clean rust and pai
88. n the detent ball bore Slide yoke bar through shift block and yoke while installing bar into center housing bore Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole Torque the lockscrews to 35 45 Ibs ft CAUTION Overtorquing of lockscrew can result in distortion and binding of yoke bar Make sure yoke bar has free movement Lockwire lockscrew 10 Install the 2nd 3 4 interlock ball 11 Install the third yoke bar into the housing Slide through the remaining shift block and shift yoke Start the lockscrews by hand to assure proper engagement of the cone into the yoke bar hole Torque the lockscrews to 35 45 Ibs ft CAUTION Overtorquing of lockscrew can result in distortion and binding of yoke bar Make sure yoke bar has free movement Lockwire lockscrew B BH P y 75 Bench Service Procedure 2 Install the oil trough and oil trough capscrews Torque the lockscrews to 8 12 Ibs ft If applicable lockwire the screws If lockwire holes are not present clean threads and use a thread locking compound to retain the capscrews 13 Insert reverse switch pin Install gasket and reverse light switch or plug Torque to 15 20 Ibs ft 14 Install gasket and neutral switch or plug Torque to 15 20 Ibs ft 15 If used install breather 16 Install the three 3 detent balls one in each housing top bore 17 Install the three 3 detent springs one over each det
89. nd insert the counter 163 Bench Service Procedure shaft support tool to center shaft in rear case bore 4 Obtain a spare inner countershaft race 5 Temporarily install a spare countershaft inner race inside the front roller bearing for installation w IJ rj L Z go oO y zt o I a 77 6 Use a flanged end driver to start the front bearing in case bore 7 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 8 Move the countershaft forward into the bearing 9 Use a flanged end bearing driver and maul to completely seat the front bearing in the case bore Note Make sure to contact only the bearing and not the temporary race with the driver The temporary race should fall out when installation is complete 164 Bench Service Procedure 165 10 On the countershaft front position the retainer plate with 11 roll pin in hole at shaft end Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller thread sealant 71205 or equivalent Torque the capscrew to 90 120 Ibs ft Note Earlier models may have a roll pin in the retainer This roll pin is not required and was removed on units built after 1994 From the rear remove the countershaft support tool Install the rear countershaft bearing Position the bearing so that the larger chamfer on the bearing inside diam
90. ng from under the housing lugs one coil at a time From inside the housing tower remove the tension spring washer and gear shift lever In models so equipped from the housing bore remove the nut and washer From the housing tower spade pin bore remove and inspect the spade pin discard if damaged From the housing tower inside groove inspect the O ring discard if damaged Bench Service Procedure 64 w go rj Z ix y 3 oO e a Bench Service Procedure How to Assemble the Gear Shift Lever Special Instructions Inspect tension spring and washer for wear Apply Eaton rust preventative lubricant 71212 or equivalent to the shift lever pivot ball A rust preventative lubricant film should cover all surfaces between and including the pivot ball Seat the tension spring one coil at a time Special Tools Vise with brass jaws or wood blocks Item T4 Tension Spring Driver 4 1 Pin 8 Capscrew 2 Bushing 9 Gasket 3 Upper Lever 10 O ring 4 Snap Ring 11 Washer 5 Rubber Boot 12 Lower Lever 6 Spade Pin 13 Stepped Washer 7 Housing 14 Tension Spring 65 Procedure 1 With housing bottom facing up secure the assembly in a vise 2 Ifthe spade pin is damaged replace and install the spade pin in housing tower bore 3 n models so equipped install the nut and washer in the housing bore 4 Ifthe O ring is damaged replace lubricate the O ring
91. nt from the dowel pins before installing them CAUTION If the dowel pins are not installed in the main case to the proper depth the auxiliary section will not properly align with the main case and bear ing or synchronizer failure may occur 60 In Vehicle Service Procedure 61 4 10 11 Install the dowel pins into the main case so that 3 8 1 2 of the shoulder is exposed or pin is flush with front of case ear Clean all rust and paint from the dowel pin holes in the aux iliary section housing and lightly grease the dowel pins on the main case and the dowel pin holes on the auxiliary sec tion housing Make sure the auxiliary section is in low range If not blow shop air max 100 PSI into the low range supply port to shift the range synchronizer to low If necessary make sure the deep reduction clutch is engaged into gear Position the gasket onto the main case mounting surface Mount the auxiliary section on the lifting device or jack Tighten the center capscrew on the countershaft support tools to draw the countershafts into a level position Do not overtighten the capscrews The output yoke and shaft must be able to rotate Position the auxiliary section in line with the main case and slide the housing onto the dowel pins Mesh the counter shafts with the auxiliary drive gear Rotate the output yoke and shaft slightly to help the gears mesh and slide the auxil iary section forward until it is flush w
92. ocedure 6 Place the auxiliary housing over the output shaft and coun tershaft assemblies 7 Install the two rear countershaft bearing races in the auxil iary section bores 8 Place the shim gauges over each bearing install capscrews 1 2 1 2 x 3 8 and 2 1 x 3 8 o 1 3 r L N o Fr 17 Y i Lr 1 2 o 9 TIGHTEN ALL CAPSCREWS ONLY UNTIL SNUG Counter shaft retaining straps may also be used 102 Bench Service Procedure 10 Install range cylinder into auxiliary section bore 11 Torque capscrews to required torque 12 Place range piston in cylinder bore 13 Torque piston retaining nut to recommended specification 103 14 Position new gasket and range cylinder cover on the range cylinder and tighten to recommended torque 15 Install bearing spacer on the output shaft 16 Heat the rear bearing and place it on the output shaft until seated Note Do not heat the bearing above 275 F 136 use a bearing heater if possible 17 Position the rear bearing cover and gasket on housing tighten bolts to recommended torque Note One rear bearing capscrews hole is chamfered the nylon collar and brass washer must be installed at this location to correctly seal the rear bearing cover DO NOT REUSE OLD NYLON COLLAR Bench Service Procedure 104 ainpardidg avila ysueg Bench Service Procedure 18 Spacer must be installed between bearing and speed
93. ometer drive gear 19 Install output yoke and nut on output shaft for installation of auxiliary section to the main case 105 Bench Service Procedure How to Remove the Clutch Housing with Internal Oil Tube Special Instructions Removal of the clutch housing is performed in the horizontal position The clutch release mechanism must be removed Some early production models do not have an oil tube behind the clutch housing For these models skip step 5 Special Tools Typical service tools Procedure 1 From inside the clutch housing remove the nuts and wash ers Note Depending on the transmission model the clutch housing may have 10 or 12 bolts 2 From inside the clutch housing remove the capscrews 3 Jar clutch housing to break gasket seal 4 Pull the clutch housing from the studs and transmission case 5 If oil tube is not being removed skip to step 10 ow D 5 2 E N e 5 e me A e D 3 e 6 Remove oil tube 106 Bench Service Procedure 7 Remove the gasket and clean all mounting surfaces of gas ket material a Without oil tube channel Older style b With oil tube channel New style Note Clutch housing with oil channel can be used on transmis sions without the oil tube 107 Bench Service Procedure How to Install the Clutch Housing with Internal Oil Tube Special Instructions Installation of the clutch housing is performed in the h
94. on that contains the procedure you need Then look at the heading at the top and outside edge of each page until you find the one that contains the procedure you need Transmission Overhaul Procedures follow the general steps for complete disassembly and then assembly of the transmission Note In some instances the transmission appearance may be different from the illustrations but the procedure is the same Disassemble Precautions It is assumed in the detailed assembly instructions that the lubricant has been drained from the transmission the necessary link age and vehicle air lines disconnected and the transmission has been removed from vehicle chassis Removal of the gear shift lever housing assembly or remote control assembly is included in the detailed instructions How to Remove the Gear Shift Lever This assembly MUST be detached from the shift bar housing before the transmission can be removed Follow closely each procedure in the detailed instructions make use of the text illustrations and photographs provided Assemblies e When disassembling the various assemblies such as the mainshaft countershafts and shift bar housing lay all parts on a clean bench in the same sequence as removed This procedure will simplify assembly and reduce the possibility of losing parts Bearings e Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use Remove bearings planned to be reused with
95. ont countershaft rear G200 Kit T 101 Kit bearings 3 5 OD 1 6 ID T9 Countershaft To support and locate the front G 50 G 51 T 1458 7109 Support Tools 2 section countershafts during G 58 bearing removal and installation T10 Input Bearing Driver To install input bearing on input shaft G 35 T 120 5066 2 shaft T11 Bearing Puller To remove the auxiliary countershaft G 247A 1123 927 tapered bearings G 247G T12 Bearing Driver To install the auxiliary countershaft G200 Kit T 101 Kit tapered bearings T13 Output Seal Removal Tool To remove the output seal in Use 27315 chassis Can use slide hammer hook with 1155 slide hammer Tool numbers are referenced in the service procedures Tool Information REF TOOL PURPOSE G amp WTOOL GREAT LAKES OTC TOOL NO NO TOOL NO NO T14 Auxiliary Section Removal To attach transmission jack to G 115 49611 Adapter Plate auxiliary section for auxiliary Used with OTC section removal in chassis transmission jack P N 5019 T15 Mainshaft Hook To assist in lifting of mainshaft from G 225 T 165 front section T16 Input Bearing Puller To remove input bearing G 38 7070A Kit T17 Bearing Race Puller To remove the auxiliary countershaft G 247B T 157 with 7136 puller tapered bearing outer races attached to G T 150 attached to 70 impact 1155 slide puller hammer T18 Bearing Race Installer To install the auxiliary co
96. opriate bearing puller or pry bars to remove the countershaft front bearings Bench Service Procedure How to Remove the Input Shaft and Main Drive Gear Special Instructions None Special Tools See Tool Information Item T16 Bearing puller Soft bar and maul Procedure 1 From the front bearing cover remove the six 6 retaining capscrews and cover Remove any remaining gasket mate rial from the case and cover 2 present remove and discard the rubber seal ring on the input shaft The ring is used only to seal the transmission during shipment ao ow 3 Q L N ow Fr 1 Y o Lr ow a 17 116 Bench Service Procedure 117 3 From the input shaft groove remove the bearing retaining snap ring 4 Usea soft bar and maul to drive the input shaft toward the case rear as far as possible Pull the input shaft forward 5 Install the bearing puller tool and remove the input bearing from the case and input shaft or use pry bars or screwdriv ers to complete removal of the bearing 6 From the drive gear front remove drive gear spacer Bench Service Procedure 7 Remove the drive gear internal snap ring 8 Pull the input shaft forward and out of the drive gear 9 From inside the case remove the drive gear 10 Inspect the bushing in the input shaft pocket replace if damaged o 1 3 r L N o Fr 17 Y i Lr 1 2 o 118 B
97. orizontal position IMPORTANT Some early production models do not have an oil tube behind the clutch housing For these models skip steps 3 4 and 5 The oil tube comes in two different lengths The older units extend 2 3 of the way through the front box The new units go into the intermediate wall that separates the main case from the auxiliary case see step 5 Special Tools Typical service tools Procedure 1 Position a new gasket on the housing mounting surface with the bead toward the case Note If the front bearing cover was removed it needs to be installed before the clutch housing to ensure correct alignment of the clutch housing 2 Make sure gasket is orientated so that all bolt holes and lube passage holes are showing ow D 5 2 E N e Iz e mz a e D 2 e 3 If oil tube is not being replaced follow steps 8 10 4 Inspect O rings on oil tube and replace if damaged 108 Bench Service Procedure 5 Apply Eaton Fuller silicone lubricant 71203 to O rings and install oil tube in case 6 Press oil tube firmly into place 109 Bench Service Procedure 7 The oil tube has two different lengths Older units extend 2 3 of the way into the main case and newer units go into the intermediate wall Make sure the lube tube seats prop erly 8 Install the clutch housing on the front box pilot it on the six studs and front bearing cover ow D 5 2 E N e Iz
98. ove the two 2 capscrews 36 Air System How to Remove a Roadranger Valve Special Instructions A sudden release of air pressure can injure you or damage equipment To prevent injury or equipment damage the vehicle air tanks must be exhausted Special Tools Typical service tools Procedure 1 From the Roadranger valve cover remove the two 2 mounting screws 2 Slide the Roadranger valve cover down 3 From the air fittings disconnect the air lines 4 From the Roadranger base loosen the jam nut Rotate the Roadranger valve until the valve is removed 5 Inspect the parts nut valve cover air lines sheathing and O rings from the lever shaft 6 Inthe Roadranger valve inspect the air fittings and remove if damaged 37 Air System How to Install a Roadranger Valve Special Instructions To position the Roadranger valve the range lever must be to the front or the splitter button to the left when facing forward Special Tools Typical service tools Procedure 1 Make sure the nut valve cover air lines sheathing and O rings are in position on the lever shaft 2 If previously removed replace the air fittings and torque to 84 120 Ibs in 3 Place the Roadranger valve on the lever shaft and rotate so the range selector faces the vehicle front 4 From the Roadranger valve bottom tighten the jam nut to 35 45 Ibs ft of torque 5 Connect the air lines to the
99. pullers designed for this purpose Cleanliness e Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Dirt is an abrasive and can damage bearings It is always a good practice to clean the outside of the unit before starting the planned disassembly Input Shaft e The input shaft can be removed from the transmission without removing the countershafts mainshaft or main drive gear Special procedures are required and provided in this manual Snap Rings e Remove snap rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose Introduction When Using Tools to Move Parts e Always apply force to shafts housings etc with restraint Movement of some parts is restricted Never apply force to driven parts after they stop solidly The use of soft hammers soft bars and mauls for all disassembly work is recom mended Inspection Precautions Before assembling the transmission check each part carefully for abnormal or excessive wear and damage to determine reuse or replacement When replacement is necessary use only genuine Eaton Fuller Transmission parts to assure continued perfor mance and extended life from your unit Since the cost of a new part is generally a small fraction of the total cost of downtime and labor avoid reusing a questionable part which could lead to additional repairs and expense soon a
100. r each mainshaft gear Axial clearance end play limits are 006 015 for all mainshaft gears If the axial clearance is less than the minimum 006 tolerance the tolerance washer should be replaced with a thinner tolerance washer This will increase the axial clearance between the gears If the axial clearance is greater than the maximum 015 toler ance a thicker tolerance washer should be installed This will decrease the axial clearance between the gears If necessary refer to the parts manual for your specific transmission model to determine the correct position of each mainshaft gear The mainshaft you are using may have 3 grooves in certain gear positions The middle groove is not used with the selective washer design Selective Mainshaft Washers Use the following chart to specify and order Washers Washers are required to set correct tolerance or end play between main shaft gears A set of five selective Washers is required for proper mainshaft assembly Do not mix Key and Washer designs Always match Washers with appropriate Key shape 6 Sided Key 3 Sided Key 153 Bench Service Procedure Selective Mainshaft Washers Table Current Part Size Color Code 4300830 244 Blue Light Blue 4300382 249 White Light Blue 4300383 204 Green Light Blue 4300384 259 Orange Light Blue 4300385 264 Purple Light Blue 4300386 269 Yellow Light Blue 4300387 274 Black
101. r housing is installed to avoid damaging the interlock pin 4 As you install the shift bar housing make sure the yokes fit into the corresponding sliding clutch slots and the housing aligns with the roll pin 5 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews 69 Bench Service Procedure 6 Install interlock parts pin spring and sleeve 7 Install slave valve and tighten to specifications ow D 5 x E N e 5 ba me z o Er e 3 3 D 70 Bench Service Procedure How to Disassemble the Shift Bar Housing Special Instructions To aid in assembly mark the location and orientation of all shift yokes and blocks Procedure 1 If installed remove the oil trough capscrews and oil trough 2 If present cut and remove the lockwire on the yoke lock screws Remove the yoke lock screws Slide the yoke bar from the bore Note The remaining yoke bars must be in the neutral posi tion so that yoke bars will slide out freely 3 Remove all yoke lockscrews yoke bars yokes and shift blocks 71 Bench Service Procedure 4 Remove the two 3 4 interlock balls 5 Remove the air valve shaft 6 For the reverse yoke unscrew the plug to remove the spring and plunger w I rj Z I z ix y E ix e a 77 7 lf equipped with a yoke activator x actuator configuration remove the nut or snap ring depending on
102. s are in the shift bar housing top bores Make sure the shift block and yoke notches are aligned in the neutral position Special Tools Typical service tools Procedure 1 Thoroughly clean mounting surface 2 Position a new gear shift lever shift control housing gasket on the gear shift lever mounting surface 3 Install the detent springs lt wo re ow o lt rJ 5 7 3 o rJ 1 a o 4 Install the shift lever shift control housing Make sure the tip finger of the gear shift lever fits into the slots in the shift block 5 Apply Eaton Fuller Sealant 71205 or equivalent to the retaining capscrews 6 Install the retaining capscrews tighten to 35 45 Ibs ft of 1 Housing torque 2 Capscrew 3 Gasket Note Make sure the capscrews are properly torqued Note Make sure you can shift the transmission 42 In Vehicle Service Procedure How to Adjust the Remote Shift Control LRC Type Special Instructions The following is a typical adjustment procedure for an LRC type slave control It is recommended that the OEM Chassis Service Manual be consulted first Special Tools Typical service tools Procedure Figure A 1 1 Reach Rod 5 Shift Arm 2 Turnbuckle 6 Pivot Link Assembly 3 Selection Lever 7 Inner Shift Shaft 4 Inner Shift Finger Figure B 1 Selection Lever 2 Shift Arm 43 Move the gear shift lever forward or backward to the n
103. s neces sary Also check for sticking or excessive wear of the reverse pin lt wo e wo N wo S rJ 5 v a rJ wo 2 S a 48 In Vehicle Service Procedure How to Remove the Reverse Switch Special Instructions None Special Tools Typical service tools 1 Reverse Light Switch 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket 49 Procedure 1 2 Remove 2 screws retaining wire terminals Remove the switch using a 7 8 deep well socket or box end wrench How to Install the Reverse Switch Special Instructions None Special Tools Typical service tools Procedure 1 Insert the reverse pin in the reverse switch bore 2 Install new gasket on switch 3 Install the reverse switch Tighten it to 15 20 Ibs ft 20 27 Nem of torque 4 Connect the wiring to the switch 1 Revers 2 Gasket 3 Pin 4 Shift Bar Housing 5 Gasket In Vehicle Service Procedure gt lt 5 Ea 2 32 N wo S rJ 7 V e Light Switch E 17 53 5 50 In Vehicle Service Procedure How to Remove the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TRSM0912 Rear Seal Maintenance Guide After removal of the output yoke companion flange temporarily replace the output shaft nut to protect the outpu
104. se of air pressure can cause personal injury or damage to equipment To prevent injury or equipment damage exhaust the vehicle air tanks A CAUTION Make sure only 5 32 air lines are used with push to connect fittings Using sizes other than 5 32 can cause air leaks or damage to fittings Special Tools See Tool Information N lt z 3 For push to connect fittings we recommend Eaton service tool kit K 2394 The kit contains the release tool and the tubing cut ter Procedure 1 Checkthe threads of the fitting for thread sealant If no seal ant is present apply Eaton Fuller thread sealant 71205 or equivalent 2 Install the fitting 3 Inspect the air line for burrs or deformed areas Trim the air line if necessary using a sharp razor blade or the air line cutting tool from kit K 2394 The cut must be smooth and square If the tubing end is deformed or burred the internal O ring in the fitting will be damaged when the air line is inserted 4 Pushthe air line into the fitting It should insert approxi mately 3 4 If it does not insert far enough or is difficult to insert the fitting may be damaged and should be replaced After inserting give the air line a slight tug to make sure the line stays in place If line does not stay in place replace the fitting 5 Enable the vehicle air system Allow the air tanks to pres surize and check for leaks 32 Air System How to Remove
105. shaft Rear Bearing Cover Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 1 Speedometer Housing Plug 35 50 13 16 20 Apply Loctite 242 to threads 19 Auxiliary Housing Capscrews 35 45 3 8 16 Apply Loctite 242 to threads 1 Output Shaft Nut 450 500 2 16 Oiled at vehicle installation Lubrication Lubrication Proper lubrication procedures are the key to a good all around maintenance program Fuller Transmissions are designed so that the internal parts operate in an oil circulating bath created by the motion of the gears and shafts All parts will be properly lubricated if these procedures are closely followed e Maintain oil level Inspect regularly e Follow maintenance interval chart e Usethe correct grade and type of oil e Buy from a reputable dealer Maintain Proper Oil Level Make sure oil is level with the filler opening Being able to reach oil with your finger does not mean oil is at proper level One inch of oil level is about one gallon of oil When adding oil never mix engine oils and gear oils in the same transmission Additives and friction modifiers must not be introduced Buy from a reputable dealer The use of lubricants not meeting requirements will affect warranty coverage Lubrication Information For additional lubrication information and lube intervals see TCMT0021 or call 1 800 826 HELP 4357 For a list of approved lubricants see TCMTO0020 or call 1 800 826 HELP 4357 Dil
106. shing in the back of the input shaft 3 Temporarily position the upper countershaft up and away from the transmission center w IJ rj co I ix y zt o ix I a 77 4 From inside the case mesh the lower countershaft drive gear marked tooth with either set of main drive gear marked teeth 5 From the front engage the input shaft spline teeth into the main drive gear Note The current design input shaft spline teeth have noticeable clearance to the main drive gear internal spline teeth This is normal 150 Bench Service Procedure 6 Install the snap ring in the main drive gear inside groove 7 Install the spacer washer over the input shaft With the bearing external snap ring to the outside position the bear ing on the input shaft 8 Install the input shaft bearing over the input shaft Use a flanged end bearing driver which contacts both the bearing inner race and outer race Drive the bearing until it contacts the front case 9 Temporarily install the front bearing cover with two cap screws 10 From inside the main case drive the input shaft forward until it is fully seated 11 Install the input shaft retaining snap ring Note Do not replace the small rubber lip seal It is used only to prevent leakage during shipping 12 Do not reinstall the input bearing cover at this time Instead pull the input shaft and bearing forward to allow for main shaft installat
107. sition the retainer plate with roll pin in hole at shaft end 9 Install the front bearing retainer plate and capscrew If the capscrew is being reused apply Eaton Fuller thread sealant 71205 or equivalent Torque the capscrew to 90 120 Ibs ft Note Earlier models may have a roll pin in the retainer This roll pin is not required and was removed on units built after 1994 w I rj Z I z o 7a y zt o o I a 77 148 Bench Service Procedure 149 10 From the rear remove the countershaft support tool 11 Install the rear countershaft bearing Position the bearing so that the larger chamfer on the bearing inside diameter is installed towards the shaft Use a bearing driver that con tacts both the bearing inner race and outer race 12 In the countershaft rear groove install the rear snap ring Note Make sure the front bearing capscrew is properly torqued Note Make sure the rear snap ring is in place Bench Service Procedure How to Install the Input Shaft and Main Drive Gear Special Instructions None Special Tools See Tool Information Item T10 Input bearing driver Toolmaker s dye Procedure 1 Use a highly visible toolmaker s dye and mark the main drive gear for timing purposes To mark the gear paint tool maker s die on any two adjacent teeth and then paint the two adjacent teeth directly opposite the first two teeth 2 If necessary install the bu
108. st gear on the shaft against previously installed gear 16 Position the offset washer flat surface down against the gear Rotate the washer until the washer splines and main shaft splines align 17 From the mainshaft rear install the mainshaft key into the spline with the air line Pull the air line from the spline while installing the key 3J M YIUIg SaiNparIOid jNeysVAQ UOISSIUSULIL 18 Install the snap ring in the mainshaft groove 19 Install the 1st reverse sliding clutch 20 Install the clutch hub with the bezel facing up 21 Install the reverse gear 22 Remove the mainshaft from the vise and lay on its side In stall the front sliding clutch into position 140 Bench Service Procedure How to Assemble the Countershaft Assemblies Special Instructions Except for the PTO gears the upper and lower countershaft assemblies are the same To avoid confusion during installation mark the upper countershaft 45 tooth PTO gear with an U The lower countershaft has a 47 tooth PTO gear Special Tools Snap ring pliers Press Procedure 1 If previously removed install the keys in each countershaft keyway 2 Align smallest diameter gear keyway with the countershaft key long hub to countershaft front and press the gear on the countershaft 141 Bench Service Procedure 3 Align 2nd smallest diameter gear keyway with the counter shaft key long hub against 1st speed gear and press th
109. structions Inspect the O rings and replace if damaged Apply Eaton Lubricant 71214 or equivalent to the auxiliary drive gear O rings Because the auxiliary drive gear assembly is used in checking reverse gear axial clearances and centering mainshaft in rear bear ing bore during assembly of the mainshaft assembly it is necessary to complete the following procedure BEFORE assembling the mainshaft assembly Special Tools See Tool Information Item T10 A flanged end driver and maul Procedure 1 If previously removed install the O rings on extended front hub of auxiliary drive gear w I z rj L Z z ix a zt o o I a 77 2 Install the retainer ring on auxiliary drive gear snap ring groove facing front hub and away from gear teeth 134 Bench Service Procedure 135 4 Start the auxiliary drive gear bearing on front hub bearing snap ring facing groove in retainer ring Using both the inner and outer race of bearing as a base press the bearing on gear with snap ring in groove of retainer ring or use a bearing driver Install the snap ring in groove of front gear hub to retain bearing Bench Service Procedure How to Assemble the Lower Reverse Idler Gear Assembly Special Instructions The new reverse idler shaft uses a snap ring in place of the capscrew Special Tools e Torque Wrench 100 Ib ft capacity Previous Design Current Design Snap Ring Snap Ring Notche
110. t shaft threads during auxiliary section disassembly Special Tools See Tool Information A large breaker bar or air impact wrench Procedure 1 Engage two 2 mainshaft sliding clutches into two 2 mainshaft gears to lock the transmission or use a yoke holding tool if available 2 Usea large breaker bar or air impact wrench to remove the output shaft nut 51 In Vehicle Service Procedure 3 Remove the output yoke Use the output yoke puller Tool ref ID T1 7 zx o Z go S 0 7a y z I 0 I a 92 In Vehicle Service Procedure How to Install the Output Yoke Companion Flange and Nut Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TCSM0912 Seal Maintenance Guide Special Tools See Tool Information Torque wrench with 0 600 Ibs ft capacity Procedure 1 93 Engage two 2 mainshaft sliding clutches into two 2 mainshaft gears to lock the transmission or use a yoke holding tool if available Install the speedometer drive gear rotor or replacement spacer on the output shaft inside the rear bearing cover If the slinger on the yoke is damaged replace using a Slinger Seal kit Install the output yoke over the output shaft The yoke should slide on and stop before contacting the speedometer rotor As the output shaft nut is installed the output yoke will
111. the two 2 longest capscrews in the housing flange tapped holes Tighten evenly to move the auxiliary section away from the front box Go far enough to break the gasket seal 5 Remove the capscrews from the tapped holes 6 Attach an auxiliary section hanger bracket to the auxiliary section top 7 Attach a lifting chain to the auxiliary section hanger bracket 8 Move assembly to the rear until auxiliary section is free 9 Remove the gasket and clean all mounting surfaces of gas ket material 78 Bench Service Procedure 79 Procedure 1 To remove the auxiliary section in the vertical position With blocks under the clutch housing to prevent input shaft damage place transmission in the vertical position clutch housing down Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim Clean the gasket surface area Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews Note Do not use an air gun Tighten by hand until the cap screws are snug From the auxiliary section housing remove the retaining capscrews that attach the front box to the auxiliary section Install a steel bar through the yoke Attach a lifting chain to the steel bar Lift assembly from the front section Bench Service Procedure How to Disassemble the Range Cylinder Assembly Procedure 1 From the rang
112. untershaft G 200 Kit T 101 Kit 27524 27530 tapered bearing outer races discs used with 27488 handle and 10020 screw Tool numbers are referenced in the service procedures Shop Equipment 20 Ton capacity press To press countershaft gears from countershaft Special Tools Manufacturers Below are the addresses and phone numbers of the companies that make tools specifically for Eaton Fuller amp transmissions i S 3 9 o gt 0 T C 655 Eisenhower Dr Owatonna MN 55060 1171 800 533 6127 Great Lakes Tool 8530 M 89 Richland MI 49083 800 877 9618 G and W Tool Company 1105 E Louisville Broken Arrow OK 74012 5724 800 247 5882 The specialized tools can be obtained from a tool supplier or made from tool prints as required by the individual user Detailed Eaton Fuller Transmission Tool Prints are available upon request by writing to Eaton Corporation Truck Components Operations Technical Service P O Box 4013 Kalamazoo Michigan 49003 18 Tool Information Eaton Aftermarket Parts The following tools are available through Eaton Aftermarket Parts To obtain any of the tools listed contact your local Eaton parts distributor TOOL PURPOSE EATON PART NUMBER 5 32 Air Line Release Tool To remove 5 32 air lines from push to connect fittings P N 4301157 included in kit K 2394 Air Line Cutting Tool To cut plastic air lines smoothly
113. using gasket surface Measure and record the gap at both capscrew locations 8 Average the two feeler gauge measurements by adding the measurements together and dividing by 2 as shown in Example SHIM CHART Gap 1 060 Gap 2 050 Total Gap 060 050 110 176 Bench Service Procedure SHIM CHART Average 110 2 055 Select yellow shim as indicated in the shim chart at the end of this selection 9 Locate the feeler gauge average measurement in the shim chart to determine the required shim and color code Note The oil pump shim is used when an auxiliary oil pump or PTO is mounted on the countershaft The oil pump shims have a smaller outside diameter 10 Remove the countershaft rear bearing cover and gauging shim 11 Place the selected shim on the rear countershaft bearing race 12 Position a new gasket on countershaft rear bearing cover mounting surface 13 Position the countershaft rear bearing cover over the new gasket 14 Apply Eaton Fuller thread sealant 71205 or equivalent to the auxiliary countershaft rear bearing cover capscrews and auxiliary countershaft rear bearing cover 15 Install the auxiliary countershaft rear bearing cover and secure it with the capscrews Make sure the shim is in the proper location and is not pinched between the cover and the housing Tighten the capscrews to 40 45 lbs ft 54 61 Nem Note Use a thick grease to hold
114. with Eaton Fuller lubricant 71206 or equivalent Install the O ring in the housing tower inside groove 5 Align the lever ball slot with the spade pin and position the gear shift lever in the housing tower 6 With dished side up install the washer over the ball 7 Use a tension spring driver to install the tension spring under the housing lugs 8 Remove the assembly from the vise 9 Install a rubber boot over the gear shift lever and against the housing Note Make sure the gear shift lever can move Bench Service Procedure 66 oo ow rj 4 1 z z ix 17 y i ix aa a Z to Bench Service Procedure How to Remove the Shift Bar Housing Special Instructions Before removing the shift bar housing the air lines must be disconnected For models equipped with an oil pump and or cooler assemblies make sure to disconnect the oil line connected to the shift bar housing There are three 3 sizes of capscrews The 1 1 2 capscrews are used with the lifting eyes The 1 1 4 are used on all other loca tions except the left front corner at the roll pin location This capscrew is 1 3 4 Be careful when removing the shift bar housing to prevent damaging the oil tube with the shift yokes Special Tools Typical service tools Procedure 1 From the shift bar housing remove the two retaining cap screws securing the oil cooler Remove oil cooler and set aside 2 Remove slave valve

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