Fuller Heavy Duty Transmissions TRSM0515
Contents
1. C To Remove and Disassemble the Auxiliary Drive Gear Assembly 2 Remove the snap ring from the rear of main shaft located in bore of auxiliary drive gear b an 1 Turn out capscrews and remove the two bearing retainer rings from case 3 Tap against front of mainshaft to move the aux iliary drive gear bearing to the rear exposing the bearing snap ring FRONT SECTION DISASSEMBLY F 4 Use pry bars to remove the auxiliary drive gear 6 Press or use driver to remove bearing from aux assembly from case bore and from splines of iliary drive gear mainshaft 5 Remove snap ring from groove in auxiliary drive gear FRONT SECTION DISASSEMBLY GEAR IDLER WASHER RETAINER BEARING WASHER Cut 6385 4 79 D To Remove the Left Reverse Idler Gear W E 5 2 Remove the rear idler washer and retainer from lt bore If necessary bend holder lugs and remove washer from holder 1 Use curved pry bar to walk bearing from idler bore in case FRONT SECTION DISASSEMBLY 3 Remove reverse idler gear from case 5 Remove the front idler washer from case 4 Remove the idler bearing from reverse idler gear FRONT SECTION DISASSEMBLY GEAR MAINSHAFT 4TH OR OVERDRIVE GEAR MAINSHAFT 2ND KEY AND PIN ASSEMBLY SNAP RING WASHER WASHER WAS SLIDING WASHER SLIDING CLUTCH SURG CLUTEH MAINSHAFT2. CLUTCH GEAR MAINSHAFT 3RD GEAR MAINSHAFT 1ST REVERSE GEAR Cut 7334 E To Remove and Disassemble the Mainshaft Assembly 1 Block the right countershaft to the right as far 3 Inside hub of the 4th speed gear remove snap as possible and lift the mainshaft assembly ring from groove in mainshaft from case 2 Remove the drive gear and the 4th 5th sliding 4 Remove the 4th speed gear and washer clutch from mainshaft FRONT SECTION DISASSEMBLY 5 Remove the 3rd speed gear and washer Remove the long key from slot in mainshaft Ci T 6 Remove the 2nd 3rd speed sliding clutch 8 Remove the 2nd speed gear and washer FRONT SECTION DISASSEMBLY 9 Remove the 1st speed gear and washer 10 Remove the ist reverse sliding clutch Dana 11 Remove the reverse gear and washer FRONT SECTION DISASSEMBLY GEAR COUNTERSHAFT 3RD SNAP RING GEAR COUNTERSHAFT BEARING DRIVE RT SNAP RING BEARING GEAR C S PTO AND 2ND GEAR COUNTERSHAFT 4TH OR OVERDRIVE F To Remove the Countershaft Assemblies 3 Lift the left countershaft from case 1 Lift the right countershaft from case 2 Remove bearings from the left countershaft in the same manner in which bearings were removed from right countershaft See pages 33 and 34 FRONT SECTION DISASSEMBLY G To Disassemble the Countershaft Assemblies NOTE Both countershafts ar
3. 2 Remove nuts from the six studs and turn out the two bolts which attach clutch housing to case am 0 3 Break gasket seal and remove clutch housing A from case 2 Insert puller screws in auxiliary housing flange 4 Turn out capscrews and remove the front bear 3 Tighten puller screws evenly to move the aux ing cover Tap against drive gear from inside iliary section straight to the rear and from front case to move cover forward to break gasket section seal DISASSEMBLY V FRONT SECTION DISASSEMBLY A To Remove Bearings from Right Countershaft ail dx 3 Install snap ring in the exposed bearing snap ring groove Use snap ring which was removed from rear bearing bore Gia um 4 Loosen the capscrews at the bearing retaining 2 Using soft bar and maul against rear of counter rings on auxiliary drive gear This will allow shaft move the assembly forward as far as movement to the rear of the countershaft and possible until snap ring groove in front bearing mainshaft assemblies 15 exposed NOTE f front bearing snap ring groove can not be exposed due to variances in thickness of case use punch between hub of countershaft drive gear and inner race of bearing to move the gear forward on shaft FRONT SECTION DISASSEMBLY 5 Using soft bar and maul against front of countershaft move the countershaft assembly to the rear as far as possible This will move front bear
4. 3 O RINGS Lubricate all O Rings with silicone lubricant 4 ASSEMBLY Refer to the disassembly illustra tions as a guide to reassembly 5 INITIAL LUBRICATON Coat all thrust washers and splines of shafts with Lubriplate during instal lation to provide initial lubrication preventing scoring and galling 6 AXIAL CLEARANCES Maintain original axial clearances of mainshaft forward speed gears of 005 to 012 Mainshaft reverse gear clearance is a minimum of 005 7 BEARING Use of flanged end bearing drivers is recommended for the installation of bearings These drivers apply equal force to both races of bearing preventing damage to balls and races and maintaining correct bearing alignment with shaft and bore If tubular or sleeve type driver is used apply force only to inner race 8 UNIVERSAL JOINT COMPANION FLANGE Pull the companion flange tightly into place with the mainshaft nut using 400 450 foot pounds of torque Make sure the speedometer gear has been installed on yoke If a speedometer gear is not used a replacement spacer of the same width must be used Failure to pull the yoke or flange tightly into place will permit the shaft to move axially with resultant damage to rear bearing 9 TORQUE As you reassemble transmission refer to pages 12 and 13 for proper installation torque of capscrews nuts and plugs DISASSEMBLY RANGE SHIFT AIR SYSTEM ASSEMBLY FILTER REGULATOR ASSEMBLY Cut
5. 772 5 uli m con Cut 7001 D 7 84 A Removal B Installation 1 Disconnect the black and white 1 8 OD air lines A and B from between the slave air valve and the range shift control valve 2 Disconnect the two 1 4 ID air lines from between the slave air valve and the range shift cylinder 1 Connect the black and white 1 8 OD supply air line between the forward port on the slave air valve and the rear port on the range shift control valve 2 Install the black 1 8 OD signal air line between the rear port on the slave air valve and the forward port on the range control valve 3 Use the chart to install the 1 4 ID air lines between the slave air valve side cap and the range shift cylinder AIR SYSTEM VI RANGE CONTROL VALVE POSITION BALL 2 POSITION SPHING HOUSING FRONT Cui amp 15E 1124 OUTLET BLACK AIR LINE A Removal and Disassembly 1 Disconnect the air lines and loosen the clamp securing the valve to the gear shift lever Remove valve 2 Remove the four screws to separate the front and rear housings and remove the slide and two sets of position springs and balls 3 Remove the valve plate insert O rings and wave washer from the valve bodies 4 If necessary remove the two felt seals Punch out the roll pin to remove the button from the slide HOUSING CONTROL BUTTON FELT SEAL 21 IHLE WHITE AIR LINE ATTACHES TO THIS PORT O
6. x Proper Level Improper Oil Level 2 Proper Oil Level Make sure oil is level with filler opening Be cause you can reach oil with your finger does not mean oil is at proper level One inch of oil level is about one gallon of oil Draining Oil Drain transmission while oil is warm To drain oil remove the drain plug at bottom of case Clean the drain plug before re installing Refilling Clean case around filler plug and remove plug from side of case Fill transmission to the level of the filler opening If transmission has two filler openings fill to level of both open ings The exact amount of oil will depend on the transmission inclination and model Do not over fill this will cause oil to be forced out of the transmission When adding oil types and brands of oil should not be mixed because of possible in compatibility Above 10 F 12 C Below 10 F 12 C LUBRICATION Operating Temperatures With Eaton Roadranger CD50 Transmission Fluid Heavy Duty Engine Oil and Mineral Oil The transmission should not be operated con sistently at temperatures above 250 F 120 C However intermittent operating temperatures to 300 F 149 C will not harm the transmis sion Operating temperatures above 250 F increase the lubricant s rate of oxidation and shorten its effective life When the average operating temperature is above 250 F the transmission may require more frequent oil changes o
7. 17 Install the 2nd 3rd speed sliding clutch align ing slot in sliding clutch with key engage with 2nd speed gear Oat 18 Install 3rd gear splined washer on mainshaft at 3rd speed gear location It will be necessary to pull long key upward slightly in order to fit splined washer over key cross pin and to fit key in keyway Re position key so that cross pin rests on top of washer 19 Install the 3rd speed gear on mainshaft fitting gear splines on those of washer FRONT SECTION REASSEMBLY ry ee m P 20 Install the 4th speed gear on mainshaft 22 Install snap ring in groove in mainshaft which clutching teeth up and against 3rd speed will hold the 4th speed gear in position on gear shaft D nii 21 Install the 4th speed gear splined washer on 23 Install the 4th 5th speed sliding clutch on mainshaft and in hub of 4th speed gear mainshaft engage clutch with 4th speed gear The side marked front should be facing up FRONT SECTION REASSEMBLY CIm m 24 IMPORTANT Mark timing teeth on drive gear 26 Remove the assembly from vise and install the 5th speed gear reverse gear on rear of mainshaft engaging a Mark two adjacent teeth on drive gear splines of gear with those of splined washer on b Mark the two adjacent teeth on drive gear mainshaft which are directly opposite the first set marked There should be the same number of teeth between markings on each side of F To
8. a If there is a steady leak out exhaust of range control valve there are defective parts or O rings in the range control valve b If there is a steady leak out breather on slave valve there is a defective O ring in the slave valve or there is a leak past O rings on the range shift cylinder piston c If transmission fails to shift into low range or is slow to make the shift and the transmis sion case is pressurized see Check Point E d Tighten all loose connections and replace defective parts or O rings 3 Check Point A Air Regulator With normal line pressure and gear shift lever in neutral check exhaust port of air regulator There should be no leak from this port Cut off the vehicle air pressure and install air gauge in line at output port of air regulator Bring vehicle air pressure to normal Regulated pressure should be 57 5 to 62 5 Only as a last resort should an adjustment be made with the screw in bottom of regulator This adjustment has been set for correct operating limits Any deviation from these limits especially on regulators which have been in operation for some time will in most cases be caused by dirt or worn parts Adjustment of screw will give only a temporary remedy 1 Turning screw in clockwise raises air pres sure 2 Turning screw out lowers air pressure Air regulator is not serviceable and should be re placed if defective 4 Check Point B With normal vehicle air pressure an
9. inserting inner races into the partially installed outer races IMPORTANT Timing countershaft gears with low speed gears As the countershafts are in stalled mesh the marked low speed gear tooth on each countershaft between each set of mark ed gear teeth on the low speed gear AUXILIARY REASSEMBLY Lacu 4 Install the speedometer gear rear washer on tailshaft and against bearing champh ered ID 7 Install bearing on front of tailshaft towards bearing and install the speedometer gear or replace merit spacer on shaft and against washer 5 If previously removed install oil seal in rear bearing cover lip of seal to the rear The spring in the seal should be toward the inside of the transmission 6 Install the rear bearing cover with the speed ometer bore up and to the left tighten cap Screws securely FRONT SECTION REASSEMBLY FRONT SECTION REASSEMBLY A To Install the Right Reverse Idler Gear Assembly 1 Apply a heavy coat of white grease on the reverse idler gear front washer and install it on pin in lower right of case 2 Set reverse gear in position next to washer machined surface of gear hub to the rear a a 3 Install needle bearing through rear bore and in to hub of reverse gear ito 4 Place rear washer in holder if previously remov ed and bend lugs to secure washer 5 Place washer and holder into reverse gear case bore holder flange to the re
10. 7001D 7 84 A To Remove the Range Shift Control Valve 1 Disconnect the two nylon air lines at air valve on 2 Disconnect the two nylon air lines at the control transmission valve on gear shift lever and remove the ball NOTE f desired the gear shift lever housing grip from gear shift lever lever and range control valve can now be remov ed from the transmission as a unit by turning out the four capscrews which attach the hous ing to the transmission DISASSEMBLY Au 3 Loosen the mounting clamp and remove the range control valve and mounting clamp from lever 4 Remove nylon air lines sheathing and O ring clamp from the gear shift lever B To Remove Air Regulator and Filter Assembly I m 1 Disconnect and remove the air line between the slave valve and air regulator m Aden rum 2 Remove street ell and reducer from regulator if necessary 3 Turn the nipple from air regulator 4 Turn out capscrews and remove the air regula tor and filter assembly from transmission C To Remove the Slave Valve amp DOT x 1 Remove the two air lines between the slave valve and range cylinder in auxiliary 2 Turn out the four capscrews and remove the slave valve from transmission Remove sleeve from slave valve 4 Remove the actuating spring and pin from bore in transmission SHIFTING CONTROLS IX GEAR SHIFT LEVER HOUSING CLAMP LOCKWASHER NUT NUT
11. 73 Drive Gear Bearing Driver obtained from Fuller Ser vice Dept No T 18042 69 59 Bearing and seal driver Ask for tool print 7551 CHANGING CLUTCH INPUT SHAFT SPECIAL PROCEDURE FOR CHANGING CLUTCH INPUT SHAFT In some cases in field repair it may be necessary to replace only the input shaft due to clutch wear on the splines In these instances the input shaft can be remov ed without disassembling the transmission other than removing the shifting bar housing Removal of the clutch housing is optional Following is the detailed procedure Disassembly 1 Remove gear shift lever housing and shift bar housing from transmission 2 Remove the front bearing cover 3 Remove snap ring from input shaft 4 Move the drive gear assembly as far forward as possible and remove the drive gear bearing 5 Remove the washer from input shaft 6 From the front remove the snap ring from ID of drive gear 7 Pull the input shaft forward and from splines of drive gear Reassembly Install bushing in new input shaft 1 Install new input shaft into splines of drive gear just far enough to expose snap ring groove in ID of drive gear 2 Install snap ring in ID of drive gear 3 Install washer on shaft 4 Move the fourth fifth speed sliding clutch gear forward to contact end of input shaft in hub of drive gear Block between rear of sliding clutch and front of the fourth speed gear When installing bearing
12. 800 826 4357 Roadranger Eaton and trusted partners providing the best products and services in the industry ensuring more time on the road Eaton Corporation Vehicle Group PO Box 4013 Kalamazoo MI 49003 USA 800 826 HELP 4357 www eaton com roadranger Printed in USA E TeN Roadranger Powering Business Worldwide SUPPORT
13. BEVEL WASHER STUD GASKET RETAINER SS 3 uasuer SPRING SPRING Cut 7288B 8 84 Cut 7288A 11 84 SHIFT CONTROLS A Removal and Disassembly 1 Turn out the capscrews jar lightly to break the gasket seal and remove the gear shift lever hous ing from the shift bar housing 2 Secure the housing in a vise and use a large screwdriver to twist between the spring and side of the housing forcing the spring from under the three lugs Do one coil at a time Remove the spring 3 Remove the washer and gear shift lever 4 Remove the spade pin or pivot pin nut and washer from the bore in the housing If necessary remove the O ring from the housing B Reassembly and Installation 1 Install the spade pin or pivot pin nut and washer in the bore in the housing If previously removed install the O ring in the groove 2 Install the gear shift lever in the housing fitting the slot in the lever ball over the spade pin 3 Place the tension spring washer over the lever ball with the dished side up 4 Seat the tension spring under the lugs in the housing seating one coil at a time Use of a spring driving tool is recommended 5 Make sure that the three tension springs and balls are in the shift bar housing bores and install the gear shift lever housing and gasket on the shift bar housing DISASSEMBLY Ill SHIFTING BAR HOUSING SPRING COVER CAPSCREW GASKET LIFTIN ACTUATING RING PI
14. Install Mainshaft Assembly gear E _ ia 1 Move right countershaft toward case wall as far as possible 25 Install the drive gear on mainshaft and against the 4th speed gear snap ring groove in drive 2 gear to the front Place mainshaft assembly in position in case FRONT SECTION REASSEMBLY 208 3 If previously removed install bushing in pocket 5 Center mainshaft in rear bore of case and install of input shaft flush with rear of shaft auxiliary drive gear on splines of mainshaft ime 4 Install input shaft through bore of case and onto 6 Seat auxiliary drive gear bearing in rear bore of mainshaft This will prevent the mainshaft as case sembly from dropping to bottom of case FRONT SECTION REASSEMBLY pos 7 Install the two bearing retainer plates and lock 9 With large screwdriver move mainshaft assem ing tabs on case bly to rear to expose snap ring groove on rear of mainshaft Install snap ring on rear of main shaft 8 Tighten capscrews and secure by bending lock ing tangs over capscrews 10 Install the input shaft in the splines of drive gear by moving drive gear forward against in side wall of case FRONT SECTION REASSEMBLY a AA zu LI 11 Mesh the marked timing tooth of left counter shaft drive gear with the two marked timing teeth of the main drive gear 13 Install drive gear spacer on input shaft 12 Install snap ri
15. and shift progressively through 1st 2nd 3rd and 4th to 5th 6 When is 5th and ready for the next upward shift PULL the Range Control Button UP and move the lever to 6th speed As the lever passes through the neutral position the transmission will automati cally shift from low range to high range 7 With the transmission in high range you may now shift progressively through 7th 8th and 9th to 10th Driving tip always start vehicle moving in first speed gear A shift diagram should be in your vehicle If your shift diagram has been misplaced write to Service Department Eaton Corporation Transmission Division Kalamazoo Michigan for replacement Please specify model number of transmission OPERATION Downshifting To get to low range push button DOWN while in 6th speed then move lever to 5th speed 1 When shifting down move the lever from 10th through each succes sive lower speed to 6th das 2 When in 6th and ready for the next downward shift PUSH the Range Control Button DOWN and move the lever to 5th speed As the lever passes through the neutral position the transmission will automatically shift from high range to low range 3 With the transmission in low range shift down ward through each of the four remaining steps Use Range Control Button only as described Don t shift from high range to low range at high speeds Don t make range shifts with the vehicle moving in reverse gear Ski
16. chamfer to the rear and in bore 6 Set the tailshaft with the forward end down and place auxiliary housing over rear of shaft so that shaft extends through rear bore AUXILIARY REASSEMBLY AUXILIARY CYLINDER QE wr CLOCKWASHER y AING YOKE BAR NOTE Use lociswirg af this position during reassert B To Install the Range Shift Air Cylinder YON I AM i ra THE 1 Install O ring in slot in small bore in cylinder 2 Install range cylinder in housing with air port in Lubricate O ring with silicone lubricant cylinder aligned with air port in top of auxiliary housing AUXILIARY REASSEMBLY 3 Install dust cover and airport extension through housing and into bore of air cylinder C To Reassemble the Synchronizer Assembly OIF 3 Install the three springs in bores in high range synchronizer ring WIB 1 Place the larger low range synchronizer ring face down on bench with pins up 2 Place the sliding clutch recessed side up on pins of low range synchronizer 4 Place the high range synchronizer ring over pins of the low speed synchronizer ring seating springs against pins AUXILIARY REASSEMBLY 5 Seat the direct ring fully on the low speed pins by pushing down and twisting to compress the Sees 3 Place yoke in slot of sliding clutch threaded end of piston shaft is towards the larger low D To Install the Synchronizer and Range range synchronizer Shift Air Cylinder A
17. movement and chuck ing action of the universal joint compan ion flange 11 Mainshaft Rear Bearing Cover a Check oil seal for wear 12 Output Shaft a Pry upward against output shaft to check radial clearance in mainshaft rear bearing PREVENTATIVE MAINTENANCE CHECK CHART TORQUE RECOMMENDATIONS YOKE LOCKSCREWS 35 45 Ft Lbs Secure with Lock Wire REVERSE SIGNAL SWITCH PLUG 35 50 Ft Lbs 9 16 18 Threads FRONT BEARING COVER CAPSCREWS 35 45 Ft Lbs 3 8 16 Threads Coated with Encapsulated Loctite STUDS 60 Ft Lbs Minimum Driven Until Bottomed 5 8 11 Thread CLUTCH HOUSING NUTS 5 8 18 Threads 180 200 Ft Lbs a Use Lockwasher pa SHIFT LEVER HOUSING CAPSCREWS 5 45 Ft Lbs 3 8 16 Threads Coated with ncapsulated Loctite SHIFT BAR HOUSING CAPSCREWS 35 45 Ft Lbs 3 8 16 Threads Coated with Encapsulated Loctite RANGE SHIFT YOKE CAPSCREWS Ft Lbs 3 8 24 Threads Secure with Lock Wire RANGE CYLINDER SHIFT BAR NUT 60 70 Ft Lbs 1 2 20 Threads AIR FILTER REGULATOR MOUNTING CAPSCREWS 8 12 Ft Lbs AIR FILTER PLUG 17 21 Ft Lbs 1 1 2 18 Threads 2 2 NZ 7 25571 y RNY EN N M a ZR CESSIT 72 2 AUXILIARY HOUSING CAPSCREWS 35 45 Ft Lbs 3 8 16 Threads Coated with Encapsulated Loctite OIL FILL PLUG 60 75 Ft Lbs 1 1 4 Pipe Threads CLUTCH HOUSING CAPSCREWS 80 100 Ft Lbs Use Lockwasher Cut
18. on the drive gear 2 Mark the two adjacent teeth on the drive Pd Cut 7300A gear which are directly opposite the first set marked There should be an equal number of teeth between the markings on each side of gear See Illustration B b B DRIVE GEAR TEETH CORRECTLY MARKED FOR TIMING C Meshing marked countershaft gear teeth with marked drive gear teeth After installing drive gear and main shaft assemblies the countershaft bearings are installed to complete countershaft installation 1 When installing bearings on the left countershaft mesh the marked counter shaft gear tooth between two marked teeth on the drive gear Repeat the procedure when installing the right countershaft bear ings See Illustration C La ri C COUNTERSHAFT GEAR TEETH MESHED WITH DRIVE GEAR TEETH FOR CORRECT TIMING D Timing auxiliary section In the auxiliary section the low speed gear set is marked for timing instead of the drive gear set 1 Mark any two adjacent teeth on the large mainshaft low speed gear then mark the two adjacent teeth directly opposite the same procedure as used when marking the front section drive gear On each auxiliary countershaft assembly mark the tooth on the small low speed gear which is stamped with an O Install the low speed gear and tailshaft assembly in auxiliary housing Partially install outer races of countershaft rear bearings in case bores Place the auxilia
19. valve to the airport marked P in hexagonal end cap of air valve 2 Install the control valve on gear shift lever with clamp and replace ball grip on gear shift lever Position top of control valve button at least six inches below ball grip 7 Install the white nylon air line from the IN port o conte valve to the tee in supply port of air valve I n a 3 If air lines are to be replaced measure lines and sheathing for correct length 4 Install sheathing on lines and draw under O ring clamp on lever 5 Connect the black nylon air line to the port marked OUT on the control valve and connect the white nylon air line to the port marked IN on the control valve TOOL REFERENCE TOOL REFERENCE Very few special tools are needed to repair the Fuller Twin Countershaft Transmis sions Ordinary socket wrenches screwdrivers etc which are found in every mechanics tool box can be used Other standard shop items are necessary such as a press bearing pullers bearing drivers mauls and soft bars Special tools which are needed consist mostly of snap ring pliers Listed below are the illustrations which show these tools PAGE TOOL HOW OBTAINED 38 45 amp 74 Snap ring pliers large Tool Supplier 37 amp 69 Snap ring pliers medium Needle point type Tool Supplier 46 amp 47 Bearing pullers small Tool Supplier 79 Torque Wrench 1000 ft lb capacity Tool Supplier Tool print of this can be
20. vertical bore in front web 4 Install plunger in vertical bore in rear web pma 5 Install the 2nd 3rd speed shift bar in center bore and install yoke on bar lockscrew hole to the rear of fork insert interlock pin in bore in neutral notch Install yoke lockscrew and safety wire ox 6 Install interlock ball in vertical bore in front web T4 7 previously removed install the reverse stop plunger in the reverse yoke Make sure that the plunger is fully seated in the bore FRONT SECTION REASSEMBLY y Vu EAE 8 Install the spring in the bore and on the plunger 11 Remove assembly from vise and install the three tensions balls one in each bore in top of housing Keep bars in neutral 8 9 Partially install the plug Use the of the gear shift lever to push the plunger back into the bore to compress the spring Tighten the plug fully and then back off 1 2 1 1 2 turns Stake the plug amp VIT a 12 Install the three tension springs one in each bore in top of housing 1 10 Install first reverse shift bar in upper bore neu tral notches to the front installing yoke on bar fork to the rear 13 Install the tension spring cover Tighten cap Install yoke lockscrew and safety wire screws securely FRONT SECTION REASSEMBLY B To Install the Shifting Bar Housing Assembly 3 Install the shifting bar housing on transmis sion fitting yo
21. 7190D 7 84 Mio OUTPUT SHAFT NUT 400 450 Ft Lbs Oiled at Vehicle Installation RANGE SHIFT CYLINDER COVER CAPSCREWS 35 45 Ft Lbs 3 8 16 Threads AUX DRIVE GEAR BEARING RETAINER CAPSCREWS 35 45 Ft Lbs 3 8 16 Thread Secure with Locking Tangs OIL DRAIN PLUG 45 55 Ft Lbs 3 4 Pipe Threads THERMOCOUPLE PLUG 40 50 Ft Lbs 1 2 Pipe Threads TORQUE RECOMMENDATIONS SLAVE VALVE CAPSCREWS 8 12 Ft Lbs 1 4 20 Threads Tos the ES SMALL COVER CAPSCREWS 18 23 Ft Lbs 3 8 16 Threads Coated with Encapsulated Loctite LARGE COVER CAPSCREWS 50 65 Ft Lbs 716 14 Threads Coated with REAR BEARING COVER CAPSCREWS Encapsulated Loctite 35 45 Ft Lbs 3 8 16 Threads HAND HOLE COVER CAPSCREWS 20 25 Ft Lbs 5 16 18 Threads Cut 7191D 7 84 AIR SYSTEM LOW RANGE HIGH RANGE CONNECTORS CYLINDER AIR SYSTEM AIR FLOW DNLY IN LOW Canstant air ows through the air valve bo aitfier Ur high or low range air iid dependimg upon tfo s i paairiaan of rhe range contral D LOW RANGE bution 1 8 OD NYLAFLOW Mckee E valve 5 opem and passes through to end port af air valve AIR FILTER CONSTANT AIR Basic Installation and Trouble Shooting Guide NOTE If the transmission is equipped with a A 5010 Roadranger valve see the Air Systems Troubleshooting Guide TRS
22. Dom 7 Insert two large screw drivers between hub of reverse gear and auxiliary drive gear applying light downward pressure on handles of screw drivers 10 Remove long key from keyway in mainshaft Install 1st speed gear splined washer on main shaft at 1st speed gear location and re install the long key to lock splined washer to shaft 8 Check clearance between the two gears with feeler gauge Clearance can be adjusted by re lacing reverse gear splined washer with dif erent thickness washer Proper clearance at this location should be a minimum of 005 After proper reverse gear clearance has been set remove snap ring from rear of mainshaft in vise place front pilot end of mainshaft in vise FRONT SECTION REASSEMBLY lt Remove the long key from keyway in main 11 Install 1st speed gear on mainshaft clutching 13 teeth down fitting gear splines on those of shaft washer 14 Install 2nd speed gear splined washer on main shaft and into hub of 2nd speed gear 12 Install 2nd speed gear on mainshaft clutching teeth up and against 1st speed gear a CINE a Toas 15 Install long key in keyway in mainshaft to lock washer to shaft FRONT SECTION REASSEMBLY i a 16 Insert 2 large screwdrivers between the 2 gears Apply slight downward pressure then insert feeler gauge between the hubs of the gears to check axial clearance Correct clear ante should be 005 to 012 ER a
23. M 0920 for operation and assembly instructions Operation The range shift air system consists of an air filter regulator air valve control valve range air cylinder which is built into the auxiliary housing fittings and connecting lines Range shifts can only be made when the gear shift lever is in or passing through neutral Thus the range desired can be pre selected while the shift lever is in a gear position As the lever is moved through neutral an actuating plunger in the shift bar housing releases the inter lock piston allowing it to move to the range position selected Constant regulated air is supplied to the S port of air valve and to the IN port of range con trol valve With control button down the control valve is open and air passes through control valve and to the P port of slave valve This permits air from the constant supply to flow through the low range port in slave valve to the air cylinder in aux iliary housing Air at the cylinder moves the shift piston and shaft to the rear to engage the low range gear With the control button up the control valve is closed and air is removed from end port of slave valve This permits movement of the air valve poppet air from the constant supply to flow through the high range port of the slave valve and to the high range port of range cylinder cover in auxiliary housing The shift piston and shaft are moved forward to engage the high range or direct gear Whe
24. MAINSHAFT GEARS Axial Clearance End Play Limits Are Reverse speed gear Minimum of 005 Forward speed gears 005 to 012 Washers are used to obtain the correct limits Five thicknesses are available as follows LIMITS COLOR CODE 259 261 Orange 264 266 Purple 269 271 Yellow 274 276 Black 279 281 Red Refer to lllustrated Parts Lists for washer part numbers Always use the low limit washer in the 1st GEAR and 3rd SPEED GEAR positions as shown at right Refer to the service manual covering mainshaft reassembly for method of assembling parts Reverse gear clearance must be set as low as possible to the minimum 005 Clearance can be measured before the mainshaft assembly is in stalled in the case This is done by securing the reverse gear in position on mainshaft with the reverse gear snap ring and the front snap ring then secure auxiliary drive gear assembly in posi tion at rear of mainshaft with the rear snap ring On overdrive models the 4th speed gear be comes 5th speed gear T OVERDRIVE ln mm al poet a o a o De Tti QS CR REVET ASE 2 E l Cul 7134 FRONT SECTION REASSEMBLY OTT q P Li oom 6 Install snap ring in groov rear of m shaft pring ii groove araar Gt mskan 9 Install the 1st reverse clutch over front of main shaft and against reverse gear splined washer Align slot in sliding clutch with key
25. PE SENE CLIP PLUG AIRVALVE SHAFT TR STEEL BALL CAPSCREW x CAPSCREW LOCKWASHE me i LIFTING EYE ee Pee Vi SHIFT Bar SPRING LOCKSCREW SHIFTYOKEREV Ze S PLUG a RI PLUNGER Cut 6227 6 86 SHIFT YOKE 2ND SPEED SHIFT YOKE DIRECT Note Use lock wire at Cut 6282A 9 85 these positions A To Remove and Disassemble the Shifting Bar Housing 1 Turn out the attaching capscrews jar to break 2 Turn out the two capscrews and remove the gasket seal and lift the shifting bar housing tension spring cover from top of housing from transmission 3 Remove the three tension springs installed under cover DISASSEMBLY 4 Tilt housing and remove the three tension balls 5 e installed under springs Place the housing in a vise with the plunger side up front of housing will be to the right Starting with the upper bar move all bars to the right and out front of housing as detailed in the following instructions Cut lockwire and remove lockscrews from each bar just prior to its removal NOTE During disassembly lay all parts on a clean bench in the order of removal to facilitate reassembly Bars not being removed must be kept in the neutral position or interlock parts will lock bars 8 Move center bar to the right and out of hous 7 Move top shifting bar to the right and out of housing removing shifting yoke from bar con ing removing shifting yoke f
26. RING INSEAT VALVE B Reassembly and Installation 1 Refer to the drawing for proper reassembly Use a VERY SMALL amount of silicone lubricant on the O rings to avoid clogging the ports A small amount of grease on the position springs and balls will help to hold them in place during reassembly 2 Install the air lines with their sheathing and O rings on the gear shift lever 3 Secure the valve on the gear shift lever with the clamp The control button should face to the front and be approximately 6 below the centerline of the shift knob or selector valve 4 Attach the air lines AIR SYSTEM AIR FILTER AND REGULATOR PLUG END CAP HOUSING Cut an AIR REGULATOR The air filter contains a replaceable filter element which can be removed by turning out the end cap and removing the spring and tension plate This element should be cleaned at each oil change or more often under high humidity conditions PRECAUTIONS DISASSEMBLY It is assumed in the detailed disassembly instruc tions that the lubricant has been drained from the transmission the necessary linkage and air lines removed and the transmission has been removed from the chassis Removal of the gear shift lever housing assembly is included in the detailed in structions however this assembly must also be removed from transmission before removing unit from vehicle Follow each procedure closely in each section making use of both the text and pict
27. Remove hand hole cover and check wear and axial clearance in release bearing b Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches 4 Clutch Pedal Shaft and Bores a Pry upward on shafts to check wear b If excessive movement is found remove clutch release mechanism and check bushings in bores and wear on shafts 5 Gear Lubricant a Change at specified service intervals b Use only gear oils as recommended See Lubrication section 6 Filler and Drain Plugs a Remove filler plugs and check level of lubricant at specified intervals Tighten filler and drain plugs securely 7 Gear Shift Lever a Check for looseness and free play in hous ing If lever is loose in housing proceed with Check No 8 8 Gear Shift Lever Housing Assembly a Remove air lines at air valve and remove the gear shift lever housing assembly from transmission b Check tension spring and washer for set and wear c Check the gear shift lever pivot pin and pivot pin slot for wear d 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 9 Universal Joint Companion Flange Nut Not Shown a Check for tightness Tighten to recom mended torque CHECKS WITH UNIVERSAL JOINT COMPANION FLANGE REMOVED 10 Splines on Output Shaft a Check for wear from
28. Service Manual Fuller Heavy Duty Transmissions TRSMO515 October 2007 E BACKED BY Powering Business Worldwide Roadranger SUPPORT TABLE OF CONTENTS Timing Description Operations Lubrication Preventive Maintenance Torque Recommendations Air System Precautions Disassembly Front Section Disassembly Auxiliary Disassembly Auxiliary Reassembly Front Section Reassembly Reassembly Tool Reference Changing Clutch Input Shaft Eaton Corporation Transmission Division Kalamazoo Mich 49007 TIMIMG It is essential that the two countershafts are timed This assures that the countershaft gears will con tact the mating mainshaft gears at the same instant allowing the mainshaft gears to seek their equilibrium position This prohibits the mainshaft gears from climbing out of position and prevents unequal tooth contact Timing one set of gears the drive gear set is all that is necessary It is a simple procedure consist ing of marking the proper teeth prior to installation and meshing the teeth so marked A Marking countershaft drive gear teeth 1 Prior to placing each countershaft assem bly into case clearly mark on each drive gear the gear tooth which is directly over the keyway in gear See illustration A This tooth is stamped with an O to aid iden tification A TOOTH ON COUNTERSHAFT DIRECTLY OVER KEYWAY MARKED FOR TIMING B Marking drive gear teeth 1 Mark any two adjacent teeth
29. ar 6 Install the auxiliary countershaft front bearing into the reverse gear case bore to hold the reverse idler gear assembly in position NOTE The front portion of the auxiliary counter shaft is used as a journal for the reverse idler gear FRONT SECTION REASSEMBLY B To Assemble the Countershaft Assemblies NOTE Countershafts are identical and are assem bled in the same manner Gm 1 If previously removed install roll pin long key and woodruff key in slots in countershaft 4 Press the 4th speed gear on shaft long hub to the front 2 Press the PTO 2nd speed gear cluster on counter shaft PTO gear to the front FRONT SECTION REASSEMBLY 1 C To Mark Timing Teeth and Position Countershaft Assemblies On the drive gear of each countershaft mark the gear tooth which is aligned with the keyway in shaft This tooth will be stamped with an O 2 Place the left countershaft into position in case Ging 6 Install snap ring in groove at front of shaft install bearings as shown in illustrations 4 5 6 and 7 Te me v ET aas 3 Place the right countershaft into position in case do not install bearings FRONT SECTION REASSEMBLY 4 Center rear of left countershaft in rear bore of case with block 7 Install snap ring in groove in rear bore of case D To Assemble Auxiliary Drive Gear Assembly aor 5 Install fro
30. art is generally a small frac tion of the total cost of downtime and labor should the use of a questionable part make additional re pairs necessary before the next regularly scheduled overhaul Recommended inspection procedures are set forth in the following check list PRECAUTIONS A Bearings 1 Wash all bearings in clean solvent Check balls rollers and races for pits and spalled areas Replace bearings which are pitted or spalled 2 Lubricate bearings which are not spalled or pit ted and check for axial and radial clearances Replace bearings with excessive clearances 3 Check fit of bearings in case bores Bearings should be tight to shaft slightly tight to slightly loose to bearing bore B Gears 1 Check operating gear teeth for pitting on the tooth faces Gears with pitted teeth should be replaced 2 Check all engaging gear teeth Gears with teeth worn tapered or reduced in length from clashing in shifting should be replaced 3 Check axial clearances of gears Where exces sive clearance is found check gear snap ring washer spacer and gear hub for excessive wear Maintain 005 to 012 axial clearance of mainshaft forward speed gears 005 minimum on reverse gear C Splines 1 Check splines on all shafts for wear If sliding clutch gears companion flange or clutch hub have worn into the sides of the splines the shafts in this condition should be replaced D Thrust Washers 1 Check surface
31. d the gear shift lever in the neutral position pull the control button up to high range and disconnect the 1 8 nylon air line from out port of control valve at the air valve a When control button is pushed down a steady blast of air will flow from disconnected line Air will shut off when button is pulled up This indicates that control valve is operating cor rectly Reconnect air line b If control valve does not operate correctly check for restrictions and leaks leaks indi cate bad O rings 5 Check Point C With normal vehicle air pressure and gear shift lever in the neutral position push the control but ton down to the low range position and disconnect the high range air line either at fitting on shift cylinder or at side port or slave valve a Pull the control button up There should be a steady flow of air from the high range port Push button down to shut off air b Make sure vehicle engine is off and move the gear shift lever to a gear position Pull the but ton up there should be no air at high range port Move the gear shift lever to neutral there should now be a steady flow of air from the high range port Push button down to shut off air and reconnect the high range air line c If air system operates incorrectly this in dicates that the slave valve is defective or that actuating parts in shifting bar housing are jammed or defective AIR SYSTEM 6 Check Point D With normal vehicle air pressur
32. e and gear shift lever in the neutral position pull the control button up to high range and disconnect the low range air line either at fitting on range cylinder or at bottom port of air valve a Repeat procedures under Check Point C reversing the position of the control button in order to check the low range operation 7 Check Point E If any of the seals in the range shift cylinder are defective the range shift will be affected The de gree of lost air will govern the degree of failure from slow shift to complete failure a Leak at seal A or B as shown in diagram re sults in failure to shift into either low or high range steady leak out air valve breather in both ranges b Leak at seal C results in failure to shift into low range pressurizing of transmission Air Valve Pre Selection An actuating pin protruding from the shifting bar housing prevents the poppet slave valve from moving while the gear shift lever is in a gear position and releases the poppet when Cut 7422 Check Point E Cross section of range shift cylinder showing location of seals the lever is moved to or through neutral See detailed installation of air valve for installa tion precaution concerning the actuating pin AIR SYSTEM IV RANGE SHIFT AIR LINESA ALL MODELS RANGE CONTROL VALVE 1 E Iq T i RANGE CYLINDER AN gt AX RA TNI TE E Yi wi L iy 1 Ap 11
33. e been in stalled 1 Install auxiliary section on front section align ing auxiliary section on dowel pins and the ex tended portion of auxiliary countershafts with reverse idler gears It may make assembly eas ier if someone slowly rotates input shaft during installation FRONT SECTION REASSEMBLY 2 Secure the auxiliary with attaching capscrews C To Install the Companion Flange or Yoke Bhd NOTE The auxiliary can also be installed with front section in a vertical position Place clutch housing on blocks and use chain hoist to lower 2 amp i auxiliary section into position x i ses 1 Lock transmission by engaging two gears with the mainshaft sliding clutches FRONT SECTION REASSEMBLY sana 4 Install the companion flange nut Tighten securely using the correct torque rating 2 Make sure the speedometer gear washer and the speedometer gear or replacement spacer are installed on tailshaft 3 natal gne companion flange on splines of tailshaft FRONT SECTION REASSEMBLY IV SHIFTING BAR HOUSING A To Reassemble the Shifting Bar Housing Assembly adr 1 Place the housing in a vise with the front of housing to the right 2 Install the 4th 5th speed shift bar in bottom bore with neutral notches to the front installing yoke on bar fork towards front Install yoke lock Screw and safety wire keep bar in neutral posi tion L 883 3 Install interlock ball in
34. e d IT b L3 SPRING SYNCHRONIZER HIGH 1 CEH Gust ed TH C To Remove the Range Shift Air Cylinder and Synchronizer Assemblies 1 Turn out capscrews and remove the air oylin der cover 2 Remove the nut and lockwasher from air cylin der piston shaft 3 Use air to remove piston CAUTION DO not 4 stand in front of cylinder opening If necessary remove O ring from OD of piston AUXILIARY DISASSEMBLY 9 Place the larger low range synchronizer ring on bench 10 Pull upward to remove the high range synchro nizer from pins CAUTION There are three springs located in housing of high range synchronizer which will be released as high range synchronizer is removed from pins It may be helpful to cover assembly with rag to prevent losing springs ki 6 Move the synchronizer assembly shift yoke mum and piston shaft forward and out of housing 11 Remove the sliding clutch from low range as a complete assembly synchronizer pins D To Remove and Disassemble the Air Cylinder Assembly LEG 7 Remove the shaft and yoke from synchronizer assembly 4 8 Cut lockwire turn out the two lock screws and 1 Important Remove the dust seal and air port remove yoke from shaft extension from top of housing AUXILIARY DISASSEMBLY E To Remove and Disassemble the Low Speed Gear and Tailshaft Assembly eT 1 Drive or press again
35. e disassembled in the same manner as construction is iden tical 3 Press the 4th speed gear from shaft 1 Remove snap ring from front of countershaft 4 Using the rear face of the PTO gear as a base in press the 3rd speed gear and the PTO 2nd speed gear cluster from shaft 5 If necessary remove woodruff key long key and roll pin from shaft 2 Press the drive gear from shaft H To Remove the Right Reverse Idler Gear The right reverse idler gear assembly is identical to the left and is disassembled in the same manner FRONT SECTION DISASSEMBLY VI AUXILIARY DISASSEMBLY BEARING COUNTERSHAFT ASSEMBLY D d BEARING Cut 6482 D2 80 A To Remove the Auxiliary Countershaft Assemblies 1 D08i 2 Turn out capscrews and remove the rear bear ing cover 1 Use pullers to remove bearing from front of tailshaft Bae 3 If necessary remove the rear seal from cover AUXILIARY DISASSEMBLY 4 Remove the speedometer gear or replacement spacer from tailshaft 7 Pull the counters shafts forward and out of 5 Remove the speedometer gear washer housing 6 From inside housing use long punch to move outer races of countershaft rear bearings to 16 rear move races approximately one half inch 8 If necessary pull bearing inner races from front and rear of countershaft Rear race removal is shown AUXILIARY DISASSEMBLY quit
36. e procedures in the world are not going to keep the transmission running or assure long transmission life Eaton Fuller Transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Thus all parts will be amply lubricated if these procedures are closely followed 1 Maintain oil level Inspect regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy from a reputable dealer Lubrication Change and Inspection Eaton Roadranger CD50 Transmission Fluid HIGHWAY USE First 3 000 to 5 000 miles 4827 to 8045 Km Every 10 000 miles 16090 Km Every 250 000 miles Change transmission 402336 Km fluid OFF HIGHWAY USE Factory fill Initial drain Check fluid level Check for leaks Factory fill First 30 hours Initial drain Every 40 hours Inspect fluid level Check for leaks Every 500 hours Change transmission fluid where severe dirt conditions exist Every 1 000 hours Change transmission fluid Normal off highway use Heavy Duty Engine Lubricant or Mineral Gear Lubricant HIGHWAY USE First 3 000 to 5 000 miles 4827 to 8045 Km Every 10 000 miles Factory fill initial drain Inspect lubricant level 16090 Km Check for leaks Every 50 000 miles Change transmission 80450 Km lubricant OFF HIGHWAY USE First 30 hours Change transmission lubricant on
37. ing forward on shaft 7 Use puller or pry bars to remove front bearing P 8 Use a maul and punch from inside the case to drive the rear bearing to the rear and from the 6 Using soft bar and maul against rear of counter case bores shaft again move the countershaft as far for NOTE Removal procedures will damage the ward as possible to unseat front bearing from bearings and removal should not be attempted case bore unless replacement of the bearings is planned FRONT SECTION DISASSEMBLY BEARING SPACER SNAP RING lt 6 SNAP RING 1 Move the drive gear and shaft forward as far as possible oon 2 Remove the bearing retaining snap ring from groove in shaft GEAR MAIN DRIVE RT INPUT SHAFT BUSHING f 8l4 3 Push down on input shaft to cock bearing in bore Drive input shaft toward rear of transmiss ion through bearing as far as possible Pull in put shaft forward to expose snap ring of bear ing EET 4 Use pry bars to complete removal of bearing FRONT SECTION DISASSEMBLY Gi 8 If necessary remove bushing from pocket in clutch shaft Le rS 9 Move the drive gear to the rear and against the get 4th speed gear engaging teeth of sliding clutch gear 6 Remove the snap ring from groove in ID of drive gear DEI 7 Pull shaft forward and from splines of drive gear FRONT SECTION DISASSEMBLY RETAINER SNAP RING Cut 6421 2 80
38. ing pattern TWICE the first time with the transmission engaged in low gear or low range the second time engaged in high gear or high range By using the same shifting pattern twice the Gear Shift Lever Pattern and Range Control Button Positions Shift 1 2 3 4 5 Ir low range Repeal pattern in high range amd shift amp 7 3 8 10 m 3 TC FE y n Ww V U U Amna B ccc B vow UU wu 1 AT directi Models ATO overdrive Modals shift lever position for 6th speed is the same as Ist 7th the same as 2nd 8th the same as 3rd 9th the same as 4th and 10th the same as 5th Detailed Shifting Instructions In the following instructions it is assumed that the driver is familiar with motor trucks and tractors and that he can coordinate the necessary movements of the shift lever and clutch pedal to make progressive and selective gear engagements in either direction up or down Upshifting To get to high range pull button UP while in 5th speed then move lever to 6th speed Let s step into the cab 1 Move the gear shift lever to the neutral posi tion 2 Start the engine 3 Wait for air system to reach normal line pressure 4 Now look at the Range Control Button If it is up push it to the down position With the downward movement of the button the transmission will shift into low range If the button was down when the truck was last used the transmission is already in low range 5 Now start the vehicle
39. kes into yoke slots of correspond 1 Make sure the shift bars are in the neutral posi ing clutch gears tion ia 4 Install the attaching capscrews tighten securely 2 Place the sliding clutches on the mainshaft in the neutral position FRONT SECTION REASSEMBLY RANGE SHIFT AIR SYSTEM A To Install the Air Valve NOTE f previously removed install fittings on slave valve 3 Install the slave valve on transmission tighten capscrews evenly and securely Actuating plunger in case fits into alignment sleeve in air valve 1 Install the actuating pin and spring in bore in transmission 4 Install the high range air line between the air port in the rear cover of the range cylinder and the H port of the slave valve 2 Make sure the alignment sleeve is installed in air valve REASSEMBLY peu 6 Install air line between output port of air regula 5 Install the low range air line from air port in top tor and the tee in supply port of air valve of cylinder to the street ell in the L port of the slave valve B To Reassemble and Install the Air Regulator and Filter Assembly para 5 Install the air regulator and filter assembly on mounting surface on the range cylinder tighten capscrews securely REASSEMBLY C To Install the Range Control Valve 1 Install O ring clamp on gear shift lever 6 Install the black nylon air line from the OUT port of control
40. n the control button is moved from one posi tion to another air from the previously charged line exhausts through the breather in range control valve AIR SYSTEM TROUBLE SHOOTING RANGE SHIFT AIR SYSTEM If transmission fails to make a range shift or shifts too slow the fault may be in the air system or actuating parts in the shifting bar housing To check the air system and pin point the trouble area the following procedures are recommended using the check points indicated by letters in the diagram on page 11 Checks are to be made with the vehicle engine off but with normal vehicle air pressure 1 Incorrect Hook up With normal vehicle air pressure and gear shift lever in the neutral position move the control but ton up and down from one range to another a If lines are crossed between the control valve and the air valve on transmission there will be a steady flow of air from the bottom ex haust in control valve with button in the up position b If lines are crossed between the air valve on transmission and the range cylinder the transmission gearing will not correspond with the button position Low range down position of button will result in high range gear engagement in the transmission and vice versa 2 Air Leaks With normal vehicle air pressure and gear shift lever in the neutral position coat all air lines and fittings with soapy water and check for leaks moving control button to both positions
41. new units Every 40 hours Inspect lubricant level Check for leaks Every 500 hours Change transmission lubricant where severe dirt conditions exist Every 1 000 hours Change transmission lubricant Normal of highway use Recommended Lubricants Fahrenheit Grade Ambien Temperature Type SAE Eaton Roadranger CD50 Transmission Fluid Heavy Duty Engine 011 MIL L 2104B C or D or 50 API SF or API CD 40 Prewous API designations 30 acceptable Above 10 E 12 C Above 10 F 12 C Below 10 F 12 C Mineral Gear Oil with rust 90 and oxidation inhibitor 80W API GL 1 The use of mild EP gear oil or multi pur pose gear oil is not recommended but if these gear oils are used be sure to adhere to the following limitations Do not use mild EP gear oil or multi pur pose gear oil when operating temperatures are above 230 F 110 C Many of these gear oils particularly 85W140 break down above 230 F and coat seals bearings and gears with de posits that may cause premature failures If these deposits are observed especially a coat ing on seal areas causing oil leakage change to Eaton Roadranger CD50 transmission fluid heavy duty engine oil or mineral gear oil to assure maximum component life and to main tain your warranty with Eaton Also see Operating Temperatures Additives and friction modifiers are not recom mended for use in Eaton Fuller transmissions
42. ng in groove 1 0 of drive gear 14 Install drive gear bearing on input shaft and in to case bore FRONT SECTION REASSEMBLY 15 Install bearing retaining snap ring groove of input shaft il JJ up Tb n ill LITT Ill jf i E a pain 16 Engage the 4th 5th sliding clutch into the 4th speed mainshaft gear This will prevent the 4th speed from dropping far enough to cause a possible timing error in the 4th speed gear set 17 Mesh the merked timing tooth of the right countershaft drive gear with the two marked timing teeth of the main drive gear making sure the left countershaft remains in time Uai 18 Hold countershaft in position and partially in stall front and rear bearings in case bores and on countershaft FRONT SECTION REASSEMBLY i 19 Shift the mainshaft sliding clutches into all the gear positions with a screwdriver If a clutch cannot be shifted into a gear it indicates that the gear set is out of time The right counter shaft bearings would then need to be removed and the countershaft retimed with the main shaft The front box is properly timed if the sliding clutches can be shifted into all the mainshaft gears Note Do not shift the trans mission into two gears at the same time This will prevent the transmission from rotating 20 Use a flanged bearing driver to complete seating of both front and rear bearings 21 Install snap ring in groove in rear b
43. nt bearing on countershaft and in f case bore with flanged driver 1 Press bearing on auxiliary drive gear snap ring in groove towards gear 6 Install rear bearing countershaft and in case 2 Install bearing retaining snap ring in groove of bore with flanged driver auxiliary drive gear shoulder FRONT SECTION REASSEMBLY E To Reassemble the Mainshaft Assembly 1 Place the mainshaft in a vise with the pilot end down Keep keyway in mainshaft clear for inser tion of key NOTE Each mainshaft gear is held in position by locking the gear splined washer to the main shaft with key There is one splined washer for each gear Splined washers for the reverse 1st 2nd and 3rd speed gears are the same diame ter the 4th speed gear splined washer is of smaller diameter 2 Install reverse gear splined washer in groove near rear of mainshaft NOTE Make sure long key is positioned with the word top on key to the outside During re assembly the long key will be removed and re in 5 stalled to assure that washers stay in position D ta 3 Install long key from the bottom in keyway in mainshaft to lock reverse gear splined washer to mainshaft am oun 4 Install reverse gear on splined washer with clutching teeth facing down Install auxiliary drive gear on mainshaft with clutching teeth facing up FRONT SECTION REASSEMBLY SETTING CORRECT AXIAL CLEARANCES FOR
44. ore of case FRONT SECTION REASSEMBLY G To Install the Left Reverse Idler Gear Assembly R DI x MON 3 Set reverse idler gear in position machined sur face of gear hub to the rear 4 Place rear washer in holder if previously remov ed and bend lugs to secure washer 1 Apply heavy coat of white grease on washer and on pin in upper left of case 5 Place washer and holder into reverse gear case bore holder flange to the rear 2 Install needle bearing in hub of reverse idler gear 6 Install the auxiliary countershaft front bearing into the reverse gear case bore to hold the reverse idler gear assembly in position NOTE The front portion of the auxiliary counter shaft is used as a journal for the reverse idler gear FRONT SECTION REASSEMBLY CLUTCH HOUSING AUXILIARY SECTION AND COMPANION FLANGE INSTALLATION A To Install the Clutch Housing Lll N Install the clutch housing attaching securely with the six nuts and two bolts 3 If so equipped install the clutch release mech anism B To Install the Auxiliary Section NOTE The two reverse gears including the washers must be in perfect alignment with center of case bores as the front of the auxiliary counter shafts must be inserted in these parts during aux iliary installation A heavy grease or lubriplate will help hold washers in place Also check rear of front pu to make sure all snap rings hav
45. p shifting is easy too Skip shifting is easy with the Roadranger trans mission Depending on the load the RT 6610 can be shifted as a 6 7 8 9 or 10 speed transmission When you skip shift going up make sure to pull the range control up to high range before the shift which passes 5th Skip shifting down make sure to push the range control down to low range before the shift which passes 6th Following are some suggested skip shifting pat terns Y a o l O 9 5 For 6 speed shifting with light loads shift 3 5 7 8 9 10 Law ra fa 1 3 9 For 7 speed shifting with medium heavy loads shift 2 4 6 7 8 9 10 Low Ranges High Fiangs mm For 8 speed shifting with heavy loads shift 2 4 5 6 7 8 9 10 Stop sign or Slow sign When slowing down for a stop or slow sign shift down through the individual short steps By following this procedure the com pression of the engine will slow the vehicle The life of chassis and trailer brakes can thus be pro longed Shifting the Fuller RT amp RTO 6610 Roadranger Transmissions Ratios e sese Tee e Te Te Rev 50 21 nn ron salle ow LUBRICATION Proper Lubrication the Key to long transmission life Proper lubrication procedures are the key to a good all around maintenance program If the oil is not doing its job or if the oil level is ignored all the maintenanc
46. per cent of upgrade expressed in degrees The chart below illustrates the safe percent of upgrade on which the transmission can be used with various chassis mounting angles For example if you have a 4 degree transmis sion mounting angle then 8 degrees or 14 percent of grade is equal to the limit of 12 degrees If you have a O degree mounting angle the transmission can be operated on a 12 degree 21 percent grade Anytime the transmission operating angle of 12 degrees is exceeded for an extended period of time the transmission should be equipped with an oil pump or cooler kit to insure proper lubrication Note on the chart the effect low oil levels can have on safe operating angles Allowing the oil level to fall 1 2 below the filler plug hole reduces the degree of grade by approxi mately 3 degrees 5 5 percent Proper Lubrication Levels are Essential Limitation for Proper Lubrication Percent of Grade Percent Grade Converted to Dearees Transmission Mounting Angle Dotted line showing 2 Quarts Low is for reference only Not recommended PREVENTATIVE MAINTENANCE CHECK CHART PREVENTIVE MAINTENANCE CHECK CHART CHECKS WITHOUT PARTIAL DISASSEMBLY 1 Air System and Connections a Check for leaks worn air lines loose con nections and capscrews See Air System section 2 Clutch Housing Mounting a Check all capscrews in bolt circle clutch housing for looseness 3 Clutch Release Bearing a
47. r external cooling The following conditions in any combina tion can cause operating temperatures of over 250 F 1 operating consistently at slow speeds 2 high ambient temperatures 3 re stricted air flow around transmission 4 ex haust system too close to transmission 5 high horsepower overdrive operation External oil coolers are available to reduce operating temperatures when the above condi tions are encountered Transmission Oil Coolers are Recommended With engines of 350 H P and above with overdrive transmissions Required With engines 399 H P and above with overdrive transmissions and GCW S over 90 000 16 With engines 399 H P and above and 1400 Lbs Ft or greater torque With engines 450 H P and above With EP or Multipurpose Gear Oil Mild EP gear oil and multipurpose gear oil are not recommended when lubricant operating temperatures are above 230 F 110 In addi tion transmission oil coolers are not recom mended with these gear oils since the oil cooler materials may be attacked by these gear oils The lower temperature limit and oil cooler restriction with these gear oils gener ally limit their success to milder applications Proper Lubrication Levels as Related to Transmission Installation Angles If the transmission operating angle is more than 12 degrees improper lubrication can oc cur The operating angle is the transmission mounting angle in the chassis plus the
48. rom bar As neutral notch in bar clears the front web remove the interlock pin from bore in neutral notch DISASSEMBLY 11 Remove the two interlock balls from front web 10 Move the lower bar to the right and out of hous ing removing shifting yoke from bar DISASSEMBLY IV COMPANION FLANGE AUXILIARY SECTION AND CLUTCH HOUSING REMOVAL GASKET PTO COVER LOCKWASHER Fah P s i CAPSCREW SS in eh Wem GASKET PUT m TUBE FRONT BEA CLUTCH i COVER ft e 7 df li Vs J 3 gt pire PLUG BUSHINGS 8 i A B AT A CAPSCR W ae E E h a ASKET 1 al I FRONT BEARING 3 LJ e 2 PLATE cT 2 COVER MM axo AJ Now Ay SELF TAPPING SCREW ul CAPSCREW HAND HOLE COVER T LOCK WASHER CAPSCREW A To Remove the Universal Joint Companion Flange or Yoke oo P 1 Lock the transmission by engaging two speeds 2 Pull the flange or yoke straight to the rear and with the mainshaft sliding clutches Use a large off shaft breaker bar to turn the output shaft nut from the output shaft DISASSEMBLY B To Remove the Auxiliary Section from C To Remove the Clutch Housing and Transmission Front Bearing Cover 1 Remove the clutch release mechanism if so equipped 2 003 1 Turn out the capscrews that attach the two sec tions
49. ry countershaft assem semblies into position meshing marked tooth on each countershaft gear between marked teeth on low speed gear Counter shafts will be partially seated in rear bear ing Fully install rear bearings to complete aux iliary countershaft installation DESCRIPTION RANGE i CONTROL VALVE LEFT SIDE GEAR SHIFT LEVER HOUSING ASSEMBLY CLUTCH HOUSING AIR REGULATOR INPUT RANGE SHAFT CO ipic AIR um y FILTER TAILSHAFT BOTTOM PTO COVER CHO RIGHT SIDE 5 amp PEED FRONT SECTION 2 SPEED RANGE SECTION 4 SHIFT BAR HOUSING ASSEMBL OPERATION SHIFTING THE 10 SPEED ROADRANGER TRANSMISSION RT 6610 SERIES General Instructions The 10 speed Roadranger Transmissions provide ten selective ratios evenly and progressively spac ed and shifted with one lever But you do NOT shift the Roadranger as you would a conventional transmission with an auxiliary or 2 speed axle because there is no split shifting The shifting of the 10 speed Roadranger Trans missions is much simpler much easier ALL SHIFTS ARE MADE WITH ONE LEVER you use the RANGE CONTROL BUTTON ONE TIME ONLY during a sequence of up shifts and ONE TIME ONLY during a down shift pattern Why is the Roadranger different The Roadranger is a 2 RANGE transmission con sisting of a5 speed front section and an automatic 2 speed auxiliary section in ONE CASE The ten forward speeds are secured by using a 5 speed shift
50. s of all thrust washers Washers scored or reduced in thickness should be replaced E Reverse Gear and Shaft 1 Check bearing sleeve for wear from action of roller bearings Gray Iron Parts 1 Check all gray iron parts for cracks and breaks Replace or repair parts found to be damaged Heavy castings may be welded or brazed providing the cracks do not extend into bearing bores or bolting surfaces G Clutch Release Parts 1 Check clutch release parts Replace yokes worn at cam surfaces and bearing carrier worn at contact pads 2 Check pedal shafts Replace those worn at bear ing surfaces H Shifting Bar Housing Assembly 1 Check yokes and blocks for wear at pads and lever slot Replace worn parts 2 Check yokes for alignment Replace those which are sprung 3 Check yokes for excessive wear replace worn yokes 4 Check lockscrews in yokes and blocks Re torque and rewire those found loose 5 If housing has been dismantled check neutral notches of shifting bars for wear from interlock balls Bars indented at points adjacent to the neutral notch should be replaced l Gear Shift Lever Housing Assembly 1 Check spring tension on shift lever Replace tension spring and washer if lever moves too freely 2 If housing is dismantled check pivot or spade pin and corresponding slot in lever for wear Re place both parts if worn J Oil Return Threads and Seals 1 Check oil return threads in fron
51. ssemblies 4 Place the entire assembly into auxiliary hous ing exgaging splines or sliding clutch with tal Ishaft and inserting piston shaft through cylinder bore 1 Place the shifting yoke on piston shaft long hub towards the rear of the shaft 2 Align slots in shaft with bores in Yoke hub and install the two lockscrews secure with safety 5 Install copper seal on threaded end of piston wire shaft AUXILIARY REASSEMBLY aoe 9 Install gasket and cylinder cover tighten the 6 Install O ring on OD of piston Apply light coat four capscrews securely of silicone lubricant to O ring E To Reassemble the Countershaft Assemblies M Fs E ytd 1 Install bearing inner race on front and rear of 7 Install piston on shaft and against copper countershaft washer flat side of piston out 2 IMPORTANT To mark countershaft gear teeth for timing Mark the tooth on the countershaft low speed gear which is stamped with 8 Install lockwasher and nut on shaf to secure piston AUXILIARY REASSEMBLY F To Install the Countershaft Assemblies po 3 With countershafts in position complete the installation of the countershaft rear bearings on shaft and into case bore Seat securely 1 Seat the outer races of the countershaft rear bearings only partially in bores just far enough to stay in place 2 Place countershafts into position in auxiliary housing
52. st rear of tailshaft to move assembly forward and from rear bearing 3 Remove O ring from small bore in cylinder if necessary LI d 2 Remove the rear washer and the low speed gear from rear of shaft AUXILIARY DISASSEMBLY tm 3 Remove spline washer from hub of low speed 4 Move the mainshaft rear bearing to the rear gear and out of housing 5 Use bearing driver to remove the countershaft rear bearings from housing AUXILIARY REASSEMBLY I AUXILIARY REASSEMBLY GEAR MAINSHAFT MAINSHAFT WASHER a WASHER WASHER SPACER SPEEDO eee 4 i i Mim H 1 FI al c Cut 6549 9 85 A To Reassemble and Install the Low Speed Gear and Tailshaft Assembly 1 Make sure magnetic cleaner is installed in recess in auxiliary case warn p 3 Place splined spacer in hub of low Speed gear shoulder toward rear Dr wold 2 IMPORTANT Mark timing teeth on the reduc tion gear a Mark any two adjacent gear teeth on low speed gear b Then mark the two adjacent teeth which are directly opposite the first set marked There should be the same number of teeth between the markings on each side of the gear E WT 4 Install the low speed gear and spacer over rear of shaft and against shoulder Clutching teeth down AUXILIARY REASSEMBLY Wot wag 5 Install the low speed gear rear washer on shaft 7 Seat mainshaft rear bearing securely on shaft and against gear
53. t bearing cover If sealing action of threads has been destroyed by contact with input shaft replace the cover 2 Check oil seal in mainshaft rear bearing cover If sealing action of lip has been destroyed replace seal PRECAUTIONS K Synchronizers 1 Check high and low range synchronizers for burrs uneven and excessive wear at contact sur face and metal particles 2 Check blocker pins for excessive wear or loose ness 3 Check synchronizer contact surfaces on the high and low range gears for excessive wear L Sliding Clutches 1 Check all yokes and yoke slots in sliding clutches for wear or discoloration from heat 2 Check engaging teeth of sliding clutches for partial engagement pattern M O Rings 1 Check all O rings for cuts cracks or distortion Replace if worn REASSEMBLY Make sure that interiors of case and housings are clean It is important that dirt be kept out of trans mission during reassembly Dirt is abrasive and can damage polished surfaces of bearings and washers Use certain precautions as listed below during reassembly 1 GASKETS Use new gaskets throughout the transmission as it is being rebuilt Make sure all gaskets are installed as omission of gasket can result in oil leakage or misalignment of bearing covers See Location of Gaskets heading 2 CAPSCREWS To prevent oil leakage use thread sealant on all capscrews See torque rating chart for recommended torque
54. this will hold input shaft in position to seat the bearing properly 5 Install drive gear bearing on shaft and into case bore making sure blocking remains in place 6 Remove blocking from mainshaft and install the snap ring on input shaft 7 Re install front bearing cover shifting bar hous ing and gear shift lever housing NOTE The above instructions are for changing the input shaft only To change the drive gear com plete disassembly of the front section must be made Copyright Eaton Corporation 2012 Eaton hereby grant their customers vendors or distributors permission to freely copy reproduce and or distribute this document in printed format It may be copied only in its entirety without any changes or modifications THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES Note Features and specifications listed in this document are subject to change without notice and represent the maximum capabilities of the software and products with all options installed Although every attempt has been made to ensure the accuracy of information contained within Eaton makes no representation about the completeness correctness or accuracy and assumes no responsibility for any errors or omissions Features and functionality may vary depending on selected options For spec ing or service assistance call 1 800 826 HELP 4357 or visit www eaton com roadranger In Mexico call 001
55. ures 1 BEARINGS Carefully wash and relubricate all bearings as removed and protectively wrap until ready for use Remove bearings with pullers de signed for this purpose 2 ASSEMBLIES When disassembling the various assemblies such as the mains shaft countershafts and shifting bar housing lay all parts on a clean bench in the same sequence as removed This procedure will simplify re assembly and reduce the possibility of losing parts 3 SNAP RINGS Remove snap rings with pliers designed for this purpose Rings removed in this manner can be reused 4 INPUT SHAFT The input shaft can be removed without removing the countershafts mainshaft or drive gear 5 CLEANLINESS Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs The outside of the unit should be carefully cleaned before starting the disassembly Dirt is abrasive and can damage bearings 6 WHEN DRIVING Apply force to shafts hous ings etc with restraint Movement of some parts is restricted Do not apply force after the part being driven stops solidly Use soft hammers and bars for all disassembly work INSPECTION Before reassembling the transmission the individ ual parts should be carefully checked to eliminate those damaged from previous service This inspec tion procedure should be carefully followed to in sure the maximum of wear life from the rebuilt unit The cost of a new p
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