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Fuller Heavy Duty Transmissions TRSM0550

1. E E D 5 General Information Oil Return Threads and Seals 1 Check oil return threads on the input shaft If return action of threads has been destroyed replace the input shaft 2 Check oil seal in rear bearing cover If sealing action of lip has been destroyed replace seal O Rings 1 Check all O rings for cracks or distortion Replace if worn Reverse Idler Gear Assemblies 1 Check for excessive wear from action of roller bearings Shift Bar Housing Assembly 1 Check for wear on shift yokes and blocks at pads and lever slot Replace excessively worn parts 2 Check yokes for correct alignment Replace sprung yokes 3 Check lockscrews in yoke and blocks Tighten and rewire those found loose 4 If housing has been disassembled check neutral notches of shift bars for wear from interlock balls Sliding Clutches 1 Check all shift yokes and yoke slots in sliding clutches for extreme wear or discoloration from heat 2 Check engaging teeth of sliding clutches for partial engagement pattern Splines 1 Check splines on all shafts for abnormal wear If sliding clutch gears companion flange or clutch hub has worn marks in the spline sides replace the specific shaft affected Synchronizer Assembly 1 Check synchronizer for burrs uneven and excessive wear at contact surface and metal particles 2 Check blocker pins for excessive wear or looseness 3 Check synchronizer contact surfaces on the synchronizer cups for wear
2. E How to Assemble the Auxiliary Section How to Install the Countershaft Assemblies w Tapered Bearings Special Instructions For A Series go to A Series Section To make auxiliary section assembly easier you can make an auxiliary section fixture out of a 2 x 12 Make sure to use an auxiliary drive gear retaining bolt with thread sealant material Special Tools e Typical Service Tools e Auxiliary countershaft retaining straps e Toolmakers dye Procedure 1 Place the countershaft assembly vertical on a clean flat sur face If previously removed use the proper driver and maul to install the countershaft bearings 2 Mark each countershaft for correct timing Locate the O stamped on the countershaft and mark the tooth with highly visible toolmaker s dye or paint 3 Install the synchronizer assembly on output shaft front 4 Place the thrust washer the rear auxiliary drive gear the thrust washer the retainer and the 15 16 capscrew on the output shaft assembly Finger tighten the capscrew 147 How to Assemble the Auxiliary Section 5 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 6 Align the output shaft between the countershafts match the timing marks 7 With range yoke offset side facing down install into the syn chronizer sliding slot 8 Place
3. 42 Auxiliary Section How to Install the Auxiliary Section Without 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 e Typical Service Tools e An auxiliary section hanger bracket for horizontal removal e Asteel bar longer than the width of the output yoke for vertical removal e Ahoist with a lifting chain Procedure To install the auxiliary section in the hor izontal position 43 1 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 case 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 re taining capscrews Install the retaining capscrews tighten to 35 45 lb ft of torque Procedure To install the auxiliary section in the ver tical position 1 With blocks under the clutch housing to prevent input shaft damage place the tra
4. 6 On the Roadranger valve inspect the air fittings remove if damaged Air System 28 rn gt lt 1 o v 2 gt a 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 e 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 3 Place the Roadranger valve on the lever shaft and rotate into position 4 From the Roadranger valve bottom tighten the jam nut 5 Connect the air lines to the air fittings 6 Slide the cover into position on the Roadranger valve 7 Install the Roadranger valve cover two 2 mounting screws Final Check e Make sure the air lines are seated fully 29 Air System How to Remove the Range Actuator Valve Special Instructions The air lines must be depressurized Special Tools e Typical Service Tools Procedure 1 From the mounting screws bend the lockwasher retaining tabs down 2 From the range actuator valve bracket remove the two 2 mounting screws The newest design of the range actuator does not have the bracket rn gt lt 1 2 V 2 Pm o 3 Remove the range actuator valve lockwasher bracket and range actuator valve 4
5. 7 Install the bearing retainer snap ring 8 Position a new gasket on the transmission mounting sur face 9 Position the front bearing cover on the input shaft align the oil return hole in the cover with the oil return hole on the Case rn gt x lt 1 gt o V 2 P a 10 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 11 Install the retaining capscrews tighten to 35 45 lb ft of torque Final Check e Make sure the input shaft turns freely 58 Functions of a Shift Bar Housing Shift Bar Housing Identification Shift bar housings are a very important part of the transmission No matter what kind of shift bar housing your transmission has they all provide the same functions e Engage the transmission gearing e Prevents the driver from shifting into 2 gears at the same time e Prevents shifting into reverse without force e Actuates the back up lights e Actuates the neutral switches Standard Shift Bar housing Forward Shift Bar Housing w SUPER 10 on cover 59 Functions of a Shift Bar Housing New Forward Shift Bar Housing w SUPER 10 on cover N 5 i o I e E K 60 Gear Shift Lever 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 e Typical Service Tools e Avise with bra
6. WARNING Do not remove or destroy the transmission identification tag PTO Code Eaton Fuller Transmissions CO 1 1 12 Eaton Corporation n Pu NES Made J Transmission Div In Kalamazoo MI 49003 R TL 0 14 61 0 A Roadranger Twin Countershaft Gear Ratio Low Inertia Forward Speeds Overdrive uu Torque x 100 Design Level 6 Multi Mesh Gearing o D e 2 e E a 9 E D E General Information Power Flow The transmission must efficiently transfer the engine s power to the vehicle s driveline Knowledge of what takes place in the transmission is helpful when troubleshooting and making repairs 1st Gear e Power torque from the vehicle s engine is transferred to the transmission s input shaft 1 e The input shaft external splines engage the main drive gear internal splines 2 e Torque is split between the two countershaft drive gears 3 e Torque is delivered along both countershafts to the mating countershaft gears of the engaged mainshaft gear The fol lowing cross section view illustrates a 1st speed gear engagement 4 e The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which transfers torque to the mainshaft b 1 Gear Front Section e The mainshaft transfers torque directly to the rear auxiliary drive gear slidi
7. Follow the flow chart How to Disassemble the Auxiliary Section Remove the auxiliary section from the front box Remove the front auxiliary drive gear and yoke Remove the countershaft assemblies Remove the rear auxiliary drive gear o D e S E LJ 3 D oe oO qe Remove the range cylinder assembly Auxiliary Section Front Auxiliary Drive Gear and Yoke Countershaft Assemblies Rear Auxiliary Drive Gear Range Cylinder Assembly Desassemble Synchronizer Assembly Output Shaft Assembly Splitter Cylinder Assembly General Information Once the range cylinder parts have been replaced assemble the auxiliary section according to the How to Assemble the Auxiliary Section 1 Assemble the output shaft assembly 2 Assemble the synchronizer assembly if it was disassembled 3 Install the countershaft assemblies 4 Install the range cylinder assembly Output Shaft Assembly Assemble Synchronizer Assembly Countershaft Assemblies Range Cylinder Assembly Rear Auxiliary Drive Gear Splitter Cylinder Assembly Front Auxiliary Drive Gear and Yoke Auxiliary Section General Information Model Designation General Information and other transmission identification information are stamped on the transmission tag To identify the trans mission model designation and serial number locate the tag on the transmission and then locate the numbers as shown
8. Lock wire securely 12 Install the oil trough and oil trough retaining capscrews 13 Turn the shift bar housing over and install the two 2 sets of tension springs and balls Final Check e Make sure interlocking system is working can t shift into 2 gears at the same time e Make sure all capscrews are lockwired e Make sure the two 2 sets of tension springs and balls are installed shift Bar Housing 88 N ow 2 I e E K Front Section How to Disassemble the Front Section FOLLOW THE SOLID LINE THEN THE DOTTED LINE REMOVE THEN THE DASHED LINE EXTERNAL PARTS DISASSEMBLE AUXILIARY AUXILIARY DRIVE GEAR DRIVE GEAR ASSEMBLY UPPER REVERSE IDLER GEAR REVERSE IDLER GEAR ASSEMBLY ape REMOVE UPPER COUNTERSHAFT DISASSEMBLE COUNTERSHAFT BEARINGS MAINSHAFT rl BEARINGS gt MAINSHAFT COUNTERSHAFT LOWER COUNTERSHAFT BEARINGS COUNTERSHAFT ASSEMBLY DISASSEMBLE COUNTERSHAFT UPPER LOWER COUNTERSHAFT ASSEMBLY LOWER REVERSSE IDLER GEAR INPUT SHAFT ASSEMBLY 89 How to Disassemble the Front Section How to Remove the Auxiliary Drive Gear Assembly Special Instructions Before removing the auxiliary drive gear the auxiliary section must be removed Special Tools e Typical Service Tools e Large pair of snap ring pliers Procedure 1 Remove the auxiliary bearing retainer ring ca
9. On the output shaft position the bearing inner spacer Set aside gt X 2 lt N D e E li Pe 144 Output Shaft Assembly A Series Only 145 7 Lay the auxiliary housing front face up on a clean flat sur face Install the front bearing cup 8 Turn the auxiliary housing over install the rear bearing spac er and rear bearing race in the bearing bore 9 With the auxiliary housing rear up set the housing over the output shaft 10 With tapered side down use heat or appropriate driver and install the output shaft rear bearing 11 Position a new gasket on the rear bearing cover mounting surface making sure the gasket oil return holes align with the case oil return holes 12 If previously removed use an oil seal installation tool and in stall the oil seal in the rear bearing cover Output Shaft Assembly A Series Only 13 Position the rear bearing cover over the new gasket 14 Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews 15 Install the five 5 retaining capscrews in the non chamfered hole tighten to 35 45 Ib ft of torque 16 Install the nylon collar and brass washer in the chamfered hole tighten to 35 45 Ib ft of torque Final Check e Make sure the rear bearing is seated e Make sure the rear bearing capscrews are properly torqued e Make sure the output shaft rotates freely 146 P X 2 lt N 5
10. note the direction the insert valve was positioned nipple in or out Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 From the splitter cylinder cover remove the capscrews cov er and gasket 2 Clean the gasket mounting surface of gasket material 3 From the cylinder housing remove the yoke bar 4 From the auxiliary housing remove the splitter cylinder housing 137 How to Disassemble the Auxiliary Section From the splitter cylinder cover remove the insert valve re taining nut and insert valve Inspect the insert valve and the cover bore for damage Inspect the yoke bar O ring remove if necessary Inside the cylinder housing bore inspect the small O ring remove if damaged 138 gt T 2s 2 lt 7 5 ce i Auxiliary Section How to Assemble the Auxiliary Section AUXILIARY SECTION ASSEMBLE SYNCHRONIZER ASSEMBLY COUNTERSHAFT ASSEMBLY RANGE CYLINDER ASSEMBLY REAR AUXILIARY DRIVE GEAR SPLITTER CYLINDER ASSEMBLY FRONT AUXILIARY DRIVE GEAR AND YOKE AUXILIARY SECTION 139 How to Assemble the Auxiliary Section How to Assemble the Output Shaft Assembly Special Instructions For A Series go to A Series Section 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 hea
11. 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 Check the cap screws for tightness If threads damaged replace the input shaft Tighten the capscrews to 35 45 Lbf ft Oil Cooler and Oil Fil ter Check all connections fittings hoses and filter el ement 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 drain plug to 45 55 Lbf ft Torque the oil fill plug to 60 70 Lbf ft 20 me e lt e 5 o E 2 D r4 e Preventive Maintenance Oil Leak Inspection Process Inspect for Oil Leak Determine if it is a Weep or a Leak Weep Stained damp no drips light oil film Leak Extremely wet or dripping of oil in the dirt adhered to the contaminated area contaminated area Rear Seal 1 Clean suspected oil weep 1 Do not repair Rear seal is 1 Determine the origin of the leak path area with a clean dry cloth designed to allow minimal 2 If origin of leak is obvious skip to Step 3 or mild soluble degreaser seepage refer to Roadranger 3 If the origin of the oil leak is not obvious then TCSM 0912 Seal Maintance use either of the two following steps to determine 2 Ensure lube is to proper Guide the oil leak level 2 Ensure lub
12. Inspect the air fittings remove if damaged 5 From the range actuator valve bore remove the actuating pin 6 Inspect the actuating pin for damage replace if necessary 30 Air System How to Install the Range Actuator Valve Special Instructions Apply Eaton lubricant 71214 or equivalent to the O ring so a film covers the entire surface of each O ring Special Tools e Typical Service Tools Procedure 1 Install the actuating pin in the range actuator valve bore 2 If previously removed replace the air fittings 3 Install the range actuating valve 4 Position the range actuating valve bracket and lockwasher over the capscrew openings The newest design of the range actuator does not have the bracket Apply Eaton sealant 71205 or equivalent to the retaining capscrews ome c1 m p 31 Air System 6 Install the retaining capscrews tighten to 8 12 lb ft of torque 7 Bend the retaining tabs on the lockwasher up Final Check e Make sure the capscrews are properly torqued rn gt x lt 1 o me 2 m a 32 Air System How to Remove the Top 2 Valve Assembly Special Instructions The air lines must be depressurized Special Tools e Typical Service Tools 33 Procedure 1 3 From the 3 way connector disconnect the wire harness From the air fittings disconnect the air lines From the Top 2 valve assembly remove
13. Inspect the pin replace if dam aged P X 2 lt N D e E 134 How to Disassemble the Auxiliary Section 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 e Typical Service Tools e Vise with brass jaws or wood blocks e Press e Soft bar and a maul Procedure 1 Useasoft bar and maul to drive the output shaft forward and through the rear bearing assembly 2 Fromthe auxiliary housing rear remove the rear bearing re taining 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 135 How to Disassemble the Auxiliary Section 5 From the auxiliary housing rear remove the bearing cup and spacer 6 From the auxiliary housing front remove the remaining bearing cup 7 From the output shaft remove the bearing inner spacer 8 Use the output shaft assemble gear front face as a base press the output shaft through the bearing and gear P X 2 lt N D e E COT EA 136 How to Disassemble the Auxiliary Section How to Disassemble the Splitter Cylinder Assembly Special Instructions When removing the splitter cylinder cover insert valve
14. Parts 22 How to Assemble the External Parts 23 How to Remove the Air Lines and Hose 24 How to Install the Air Lines and Hose 25 How to Remove the Air Filter Regulator 26 How to Install the Air Filter Regulator 27 How to Remove a Roadranger Valve 28 How to Install a Roadranger Valve 29 How to Remove the Range Actuator Valve 30 How to Install the Range Actuator Valve 31 How to Remove the Top 2 Valve Assembly 33 How to Install the Top 2 Valve Assembly 34 How to Remove the Gear Shift Lever 35 How to Install the Gear Shift Lever 36 How to Remove the Shift Bar Housing 37 How to Install the Shift Bar Housing 38 How to Remove the Output Yoke Companion Flange 39 How to Install the Output Yoke Companion Flange 40 How to Remove the Auxiliary Section Without Tapered Bearings 41 How to Install the Auxiliary Section Without Tapered Bearings 43 How to Remove the Auxiliary Section With Tapered Bearings ssssssss 45 How to Install the Auxiliary Section With Tapered Bearings s
15. Rear Bearing Cover Check oil seal for wear Inspection Table 1 Preventive Maintenance Part to inspect What to Check For Action to be Done Speedometer Con nections Speedometer cables should not be loose Should be an O Ring or gasket between the mating speedometer sleeve and the rear bearing cover Applied hydraulic thread sealant 71208 to threads Torque speedometer sleeve to 35 50 Lbf ft Replace the O ring gasket if damaged or missing Rear Bearing Cover capscrews Gasket and Nylon Collar Check retaining capscrews for tightness Verify nylon collar and gasket are installed at the cham fered hole aligned near the mechanical speedom eter opening Verify that a rear bearing cover gasket is in place Apply Eaton Sealant 71205 to the capscrew threads Torque capscrews to 35 45 Lbf ft Use new parts if need to replace Apply Eaton Sealant 71205 to the capscrew threads Torque cap screws to 35 45 Lbf ft Install a new gasket if rear bearing cover was removed Output Yoke Retain ing Nut Check the output yoke retaining nut for tightness Torque the output yoke retaining nut to 450 500 Lbf ft Do not over torque nut PTO Covers and Openings Check the capscrews for tightness Apply Eaton Sealant 71205 to the capscrew threads Tighten 6 bolt PTO capscrews to 35 45 Lbf ft Tighten 8 bolt PTO capscrews to 50 65 Lbf ft Grey Iron Parts Check front bearing cover front case
16. Sealant 71205 or equivalent to the re taining capscrews 10 Install the retaining capscrews tighten to 35 45 Ib ft of torque 11 Repeat Steps 1 8 for the other countershaft rear bearing cover Final Check e Make sure capscrews are properly torqued e Make sure the input shaft rotates Table 1 Feeler Standard Oil Pump Gauge oun Shim Part Shim Part Color Code Average Thickness number Number Gap 088 089 042 043 21454 21474 Brown 085 0875 045 046 21455 21475 Tan 51 Auxiliary Section Table 1 ae Shim Standard Oil Pump Average Thickness Shim Part Shim Part Color Code number Number Gap 082 0845 048 049 21456 21476 Orange 079 0815 051 052 21457 21477 Yellow 076 0785 054 055 21458 21478 Green 073 0755 057 058 21459 21479 Light Blue 070 0725 060 061 21460 21480 Lavender 067 0695 063 064 21461 21481 White 064 0665 066 067 21684 21686 Black 061 0635 069 070 21685 21687 Silver 058 0605 072 074 21452 21452 21472 21472 Red Red 055 0575 075 077 21452 21453 21472 21473 Red Pink 052 0545 078 080 21452 21454 21472 21474 Red Brown 049 0515 081 083 21452 21455 21472 21475 Red Tan 046 0485 084 086 21452 21456 21472 21476 Red Orange 043 0455 087 089 21452 21457 21472 21477 Red Yellow 040 0425 090 092 21452 21458 21472 21478 Red Green 038 0
17. Section 5 Over the input shaft install the drive gear spacer 6 With the bearing external snap ring to the outside position the bearing on the input shaft 7 Use a flanged end driver and maul to seat the input shaft bearing 8 Temporarily install the front bearing cover 9 From inside the case use a soft bar and maul to drive the in put shaft through the bearing Remove the front bearing cover m z S gt co D ri m 10 Install the bearing retainer snap ring 106 How to Assemble the Front Section 107 11 Position a new gasket on the bearing cover mounting sur face making sure to align the gasket oil return hole with case oil return hole 12 Position the front bearing cover making sure to align the cover oil return hole with case oil return hole 13 Secure the front bearing cover with six 6 capscrews tight en to 35 45 Ib ft of torque Final Check e Make sure the drive gear is timed with the lower Coun tershaft e Make sure the front bearing cover capscrews are tight en properly How to Assemble the Front Section How to Install the Mainshaft Assembly Special Instructions The lower countershaft bearings and the input shaft must be installed Check to make sure the lower countershaft drive gear marked tooth is in time with main drive gear set of marked teeth Special Tools e Typical Service Tools e A large hook or 3 piece of rope Procedure 1 Block
18. Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks e Bearing driver and a maul e Toolmaker s dye e Large snap ring pliers Procedure 1 Place the countershaft assembly vertical on a clean flat sur face If previously removed using the proper driver and maul install the countershaft bearing race 2 Inthe countershaft rear bearing bore using the proper driv er and maul install the countershaft bearing gt T 2s 2 lt 7 5 ce i 150 Countershaft Assembly A Series Only 3 Temporarily install the rear bearing cover use two 2 cap screws and no gasket The cover holds the bearing as the countershaft is driven into the bearing 4 Use toolmaker s dye and mark the smaller LO range gear tooth that aligns with countershaft gear marked with an O 5 Position the countershaft in the auxiliary housing Mesh the countershaft marked tooth with either set of LO range gear marked teeth 6 Usea sort bar and maul and drive the countershaft into the countershaft bearing 151 Countershaft Assembly A Series Only 7 From the auxiliary housing rear remove the countershaft bearing cover and install the rear countershaft snap ring in the snap ring groove 8 Position a new gasket on the countershaft bearing cover mounting surface 9 Position the countershaft bearing cover over the gasket 10 Apply Eaton Fuller sealant 71205 or equivalent to the re taining
19. air line up 119 5 Against the 3rd speed gear washer position the 3rd speed gear spacer 6 With clutching teeth down and engaged with the spacer ex ternal splines position the 3rd speed gear on the mainshaft 7 Against 3rd speed gear position a mainshaft spacer 8 With the washer flat side down position the limit 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 Mainshaft Assembly 120 T i E m ce oO ri i EJ Mainshaft Assembly 121 10 11 12 13 14 15 16 17 Between the gear hub and mainshaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the limit against the mainshaft spacer See Special Instructions for further information With the flat side up position the 1st speed gear limit wash er white in the next available groove Rotate the washer un til the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft Against the limit washer position the mainshaft spacer With clutching teeth up position the 1st speed gear on the mainshaft against the spacer Position 1st speed gear spacer against 1st speed gear en gaging the spacer external splines with gear clutching teeth With washer flat side down position the limit washer against the spacer Ro
20. drive gear hub inspect the O rings remove if damaged 111 Auxiliary Drive Gear Assembly How to Assemble the Auxiliary Drive Gear Assembly Special Instructions Inspect the O rings and replace if damaged Apply Eaton Lubricant 71214 or equivalent to the auxiliary drive gear O rings Special Tools e Typical Service Tools e A flanged end driver and a maul Procedure 1 Lay the front auxiliary drive gear on a clean flat surface 2 Install the O rings on the front auxiliary drive gear hub 3 With snap ring groove away from gear teeth install the re taining ring on the front auxiliary drive gear E i E N oO ri i EJ 4 With bearing snap ring facing groove in bearing ring install the bearing 112 Auxiliary Drive Gear Assembly 113 5 To retain the bearing install the snap ring in front gear hub groove 6 With grooved side down use a flanged end driver and install the outer retainer ring Final Check e Make sure the outer retainer ring is seated Countershaft Assembly How to Disassemble the Countershaft Assembly Special Instructions Never use the PTO gear as a pressing base The narrow width of this gear can cause breakage Special Tools e Snap Ring pliers e Press Procedure 1 From each countershaft front remove the drive gear retain ing snap ring 2 Using the rear face of 3rd speed gear as a base press the drive gear PTO gear and 3rd speed gear from each c
21. element over the inner el ement Integral Oil Pump 172 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 001 800 826 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
22. flat surface 4 While removing the bottom yoke bar remove the shift yoke 83 Shift Bar Housing 5 While removing the top yoke bar remove the shift yoke as sembly and block assembly 6 Remove the interlock pin 7 From the middle yoke bar drive center block roll pin out N 5 ow 2 I e E K 8 Pull the center bar to the right and remove the shift select block 84 Shift Bar Housing 85 9 From the 1st amp reverse shift yoke remove the snap ring washer spring and plunger From the 3rd speed block re move the plug spring and plunger 10 Inspect the yoke or block parts replace the worn parts shift Bar Housing How to Assemble the New Forward Shift Bar Housing w Super 10 on cover Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The sealant should be applied so that at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the way of any part interference Keep yoke bars in neutral while assembling Special Tools e Typical Service Tools Procedure 1 Assemble the 1st amp reverse shift yoke assembly a I
23. four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 2 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean cap screws WARNING Do not use an air gun Tighten by hand until the capscrews are snug Auxiliary Section 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 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 rn gt x lt 1 o V 2 m a Procedure To remove the auxiliary section in the ver tical position 1 With blocks under the clutch housing to prevent input shaft damage place transmission in the vertical position clutch housing down 2 Remove the four 4 capscrews and the auxiliary counter shaft rear bearing cover gasket and rear bearing shim 3 Install the auxiliary countershaft retaining straps with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean caps
24. gasket on the gear shift lever mounting surface rn gt x lt 1 o V 2 Pm a 2 Fit the gear shift lever into the shift block 3 Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews 4 Install the retaining capscrews tighten to 35 45 lb ft of torque Final Check e Make sure the capscrews are properly torqued e Make sure you can shift the transmission 36 Shift Bar Housing 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 lube line connected to the shift bar housing There are two 2 sizes of capscrews The 17 capscrews are used with the lifting eyes Note their location Special Tools e Typical Service Tools Procedure 1 From the shift bar housing rim remove the retaining cap screws 2 From the alignment stud remove the nut and washer 3 To break the gasket seal jar the shift bar housing 4 Remove the shift bar housing 5 Remove the gasket and clean all mounting surfaces of gas ket material 6 If the two 2 sets of tension springs and balls from the housing top bores are loose tilt the assembly and remove them The anti rotating pin can be removed also Newer shift bar housings do not have the anti rotating pin 37 shift Bar Housing How to Install the Shift B
25. gear internal splines 2 e Torque is split between the two countershaft drive gears 3 e Torque is delivered along both countershafts to the mating countershaft gears of the engaged mainshaft gear The fol lowing cross section view illustrates a 8th speed gear engagement 4 o D e 2 e E a 9 E D E e The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which transfers torque to the mainshaft 5 8 Gear Front Section e The mainshaft transfers torque directly to the front auxiliary drive gear sliding clutch which is in the forward position 6 e The front auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 7 e Torque is delivered along both countershafts to the rear auxiliary drive gear 8 e Torque is transferred to the range synchronizer sliding clutch which is in the forward position delivering torque directly to the output shaft 9 e The output shaft delivers torque to the driveline components 10 Auxiliary Section HI Range 12 Timing Timing Procedures 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
26. included in the detailed instructions External Parts Shift Bar Housing How to Remove the Gear Shift Lever however this assembly MUST be detached from the shift bar housing before transmission can be removed CAUTION Follow closely each procedure in the detailed instructions make use of the text illustrations and photographs provid ed Assemblies 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 Carefully wash and lubricate all usable bearings as removed and protectively wrap until ready for use Remove bearings planned to be reused with pullers designed for this purpose Cleanliness Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Dirt is an abrasive and can damage bearings It is always good practice to clean the outside of the unit before starting the planned disassembly Input Shaft The input shaft can be removed from the transmission without removing the countershaft mainshaft or main drive gear Special procedures are required and provided in this manual Snap Rings Remove snap rings with pliers designed for this purpose Snap rings removed in this manner can be reused if they are not sprung or loose When using Tools to Move Parts Always apply force to sh
27. lubricate the O ring 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 63 Gear Shift Lever 7 Use a tension spring driver to install the tension spring un der the housing lugs 8 Remove the assembly from the vise 9 Install a rubber boot over the gear shift lever and against the housing Final Check e Make sure the gear shift lever can move N ow 2 I e E K 64 Shift Bar Housing How to Disassemble the Standard Shift Bar Housing Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom shift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical Service Tools Procedure 1 If the two 2 sets of tension springs and balls from housing bores and the anti rotating pin have not been removed place the shift bar housing on its side to remove them 2 With the housing rear to the right lay the assembly on a flat surface If installed remove the oil trough re
28. on until the hanger bracket con tacts the front section back 6 Remove the auxiliary section hanger bracket 7 Slide the auxiliary section the rest of the way into position 8 Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews 9 Install the retaining capscrews tighten to 35 45 Ib ft of torque 10 To finish installation see The Shimming Procedure for Ta pered Bearings 48 Auxiliary Section 49 Procedure To install the auxiliary section in the ver tical position 1 10 With blocks under the clutch housing to prevent input shaft damage place the transmission in the vertical position clutch housing down Position a new gasket on the transmission mounting sur face Install a steel bar through the yoke Attach a lifting chain to the steel bar Position the auxiliary section over the two 2 dowel pins Slide the auxiliary section down the dowels Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews Install the retaining capscrews tighten to 35 45 lb ft of torque Remove the steel bar and chain To finish installation see The Shimming Procedure for Ta pered Bearings Final Check e Make sure capscrews are properly torqued e Make sure the input shaft rotates Auxiliary Section The Shimming Procedure For Tapered Bearings Special Instructions The shimming procedure can be done in the horizontal or vertical position The
29. procedure is done the same Shims must be aligned properly or else the rear bearing cover may be damaged when final torque is applied Special Tools e Typical Service Tools Procedure 1 Remove the countershaft straps Make sure a 0 125 coun tershaft rear bearing shim is installed Be sure the counter shaft rear bearing races are seated in the bearing bores rn gt x lt 1 gt o me 2 a 2 Install two 2 clean 3 8 x 1 capscrews without washers di rectly across from each other in each bearing cover Tapped holes in auxiliary case must be free of thread adhesive 3 Tighten the capscrews to 7 Lbf in of torque Do not install the countershaft rear bearing cover gasket 50 Auxiliary Section 4 Rotate the output shaft six 6 times clockwise then six 6 times counterclockwise to seat the countershaft rear bear ings Use a feeler gauge as close to each capscrew location as possible and measure the gap between the countershaft rear bearing cover and the auxiliary case Record the mea surements Using the average measurement refer to the shimming chart to identify the proper shim 5 Remove the countershaft rear bearing cover and gauging shim 6 Place the selected shim on the rear countershaft bearing race 7 Position a new gasket on countershaft rear bearing cover mounting surface 8 Position the countershaft rear bearing cover over the new gasket 9 Apply Eaton Fuller
30. race in the bearing bore P X 2 lt N D e E 142 Output Shaft Assembly A Series Only How to Assemble the Output Shaft Assembly A Series 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 bearings 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 old nylon collar on rear bearing cover Special Tools 143 Typical Service Tools Toolmaker s dye Heat lamp or hot plate and oil Oil seal installation tool Procedure 1 Use toolmaker s dye and mark the LO range gear for timing purposes Mark any two 2 adjacent teeth on the LO range gear Re peat the procedure for the two 2 adjacent teeth directly op posite the first set marked 2 With splined washer facing up place the washer on the out put shaft shoulder Output Shaft Assembly A Series Only 3 With LO range gear clutching teeth down position LO range gear on the output shaft engage the washer splines 4 With chamfer side up position the LO range gear rear wash er on the output shaft against the LO range gear 5 With tapered side up use heat or appropriate driver and in stall the output shaft front rear bearing 6
31. the housing air passage 16 Over the gasket position the range cylinder cover 17 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 18 Install the capscrews tighten to 20 25 Ib ft of torque Final Check e Make sure all capscrews are tighten to their proper torque e Make sure gaskets were used at the appropriate posi tions gt T 2s 2 lt 7 5 ce i 156 How to Assemble the Auxiliary Section How to Install the Rear Auxiliary Drive Gear Special Instructions None Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks e Output yoke and breaker bar Procedure 1 Temporarily install the output yoke 2 To keep the output shaft from turning insert and hold the breaker bar 3 Tighten the auxiliary drive gear retainer bolt to 90 120 Ib ft of torque Remove the breaker bar and output yoke Final Check e Make sure the auxiliary drive gear retainer bolt is prop erly torqued 157 How to Assemble the Auxiliary Section How to Assemble the Splitter Cylinder Assembly Special Instructions Apply Eaton lubricant 71214 or equivalent to all shift cylinder assembly and insert valve O rings so a film covers the entire surface of each O ring Apply Eaton rust preventative 71213 or equivalent to all shift cylinder walls and yoke bars cover the entire yoke bar surface that comes in contact with the shift cylinder O ring
32. the shaft passes through the case bore position the reverse idler gear on the shaft long hub to the front Insert the thrust washer between the reverse idler gear and the case support boss Finish inserting the idler shaft 5 Make sure the reverse idler shaft is seated in the support boss bore m z S gt co J ri m 6 Install the washer and lock nut on shaft front Tighten the stop nut to 50 60 Ib ft of torque 100 How to Assemble the Front Section 101 7 Use a bearing driver and a maul and install the auxiliary countershaft front bearing outer race against the idler plate Final Check e Make sure the stop nut is properly torqued e Make sure the bearing outer race is installed against the idler plate How to Assemble the Front Section How to Install the Countershaft Assemblies Special Instructions Make sure the countershaft assemblies have been marked for proper position 47 tooth PTO gear in the lower position On the drive gear of each countershaft assembly mark the tooth aligned with the gear keyway and stamped with an O for easy identification A highly visible color of toolmaker s dye is recommended for making timing marks Special Tools e Toolmaker s dye Procedure 1 Mark the countershaft drive gear for timing purposes 2 Place the lower 47 tooth PTO gear assembly in the case the inner bearing race end to the front 3 Position as far to the left as possible the
33. the two 2 cap screws Air System How to Install the Top 2 Valve Assembly Special Instructions The air lines must be depressurized Special Tools e Typical Service Tools Procedure 1 Install the two 2 retaining capscrews tighten to 35 45 Ib ft of torque rn gt lt 1 gt o me o c 2 Connect the air lines to the air fittings 3 Connect the 3 way connector to the harness 34 Shift Bar Housing How to Remove the Gear Shift Lever Special Instructions The air lines must be disconnected from the transmission or from the Roadranger valve Remote control housings are removed the same way as gear shift levers Special Tools e Typical Service Tools Procedure 1 From the gear shift lever base remove the four 4 retaining Capscrews 2 To break the gasket seal lightly jar the gear shift housing 3 Remove the gear shift lever housing 4 Remove the gasket and clean all mounting surfaces of gas ket material 35 shift Bar Housing How to Install the Gear Shift Lever Special Instructions Remote control housings are installed the same way as gear shift levers For standard and forward shift bar housings make sure the two 2 balls and tension springs are in the shift bar housing top bores Make sure the shift block and yoke notches are aligned in the neutral position Special Tools e Typical Service Tools Procedure 1 Position a new gear shift lever
34. 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 technical or vehicle operator Warning Failure to follow indicated procedures creates a high risk of personal injury to servicing technician Caution Failure to follow indicated procedures amy cause component damage of 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 General Information General Service Practices and Part Inspection 1 How to use this Manual ees 5 Model Designation seeeee 8 PoWer FlOW 6i ihre ne re teas 9 Timing Procedures sse 13 Tool Reference essere 15 Preventive Maintenance I UbDEIGab OTT cet entire n 16 Preventative Maintenance eee 18 nS pectloTr i oet ied eem bo eee 20 Rear Seal Maintenance ncen 21 External Parts How to Disassemble the External
35. to Disassemble the Output Shaft Assembly 135 How to Disassemble the Splitter Cylinder Assembly 137 How to Assemble the Auxiliary Section 139 How to Assemble the Output Shaft Assembly 140 How to Assemble the Output Shaft Assembly A Series tete eed 143 How to Install the Countershaft Assemblies w Tapered Bearings 147 How to Install the Countershaft Assemblies w Ball Bearings A Series 150 How to Assemble the Range Cylinder Assembly 153 How to Install the Rear Auxiliary Drive Gear 157 How to Assemble the Splitter Cylinder Assembly 158 How to Install the Front Auxiliary Drive Gear 161 How to Disassemble the Synchronizer Assembly 162 How to Assemble the Synchronizer Assembly 163 Options How to Remove the Integral Oil Pump 165 How to Install the Integral Oil Pump 167 How to Disassemble the Integral Oil Pump 169 How to Assemble the Integral Oil Pump 171 General Information General Service Practices and Part Inspection Disassembly 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
36. way of any part interference Keep yoke bars in neutral while assembling Special Tools e Typical Service Tools Procedure 1 Assemble the 1st amp reverse shift yoke assembly a Install the plunger in the 1st amp reverse shift yoke bore plunger shank to the outside b Install the spring into the bore over the plunger shank N ow 2 I e E K c Position the washer over the plunger shank d Install the snap ring 2 Assemble the 3rd speed block assembly a Install the plunger in the 3rd shift block bore plunger shank to the outside b Install the spring into the bore over the plunger shank c Install the plug and tighten to compress the spring d After plug bottoms out back the plug out 1 11 2 turns e Complete the block assembly process by staking the plug through the small hole in block 74 shift Bar Housing 15 With the housing rear to the right lay the assembly on a flat surface Install the center rail in the middle boss As the center rail passes through the first boss install the shift block Drive the center block roll pin through the center bar to hold the center block in position Install the interlock pin centered between bosses While installing the top yoke bar position the shift yoke as sembly and block assembly The block assembly aligns with shift select block ear Install the lockscrews tighten to 35 45 Ib ft of torque Lock wire
37. 05 or equivalent to the re taining capscrews 12 Install and tighten the retaining capscrews to 20 25 Ib ft of torque Final Check e Make sure the retaining nut and capscrews are tighten to proper torque e Make sure gaskets were used at appropriate positions 160 P X 2 lt N 5 E How to Assemble the Auxiliary Section How to Install the Front Auxiliary Drive Gear Special Instructions Make sure the splitter yoke bar lockscrew hole aligns with the yoke lockscrew hole Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 Place the shift yoke in splitter sliding clutch slot Install the clutch and yoke on the splitter yoke bar 2 Install the lockscrew and tighten to 35 45 Ib ft of torque Lockwire securely 161 Synchronizer Assembly 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 e Shop rag Procedure 1 Place the larger LO range synchronizer ring on the bench 2 Grab both sides of the HI range synchronizer and pull 3 From the synchronizer ring LO range pins remove the slid ing clutch ez 2x 2 lt 7 1 ce i 162 Synchronizer Assembly How to Assemb
38. 3 With the housing rear to the right lay the assembly on a flat surface 4 While removing the bottom yoke bar remove the shift yoke 77 shift Bar Housing 5 While removing the top yoke bar remove the shift yoke as sembly and block assembly 6 Remove the interlock pin 7 From the middle yoke bar drive center block roll pin out N 5 ow 2 I e E K 8 Pull the center bar to the right and remove the shift select block 78 Shift Bar Housing 79 9 From the 1st amp reverse shift yoke remove the snap ring washer spring and plunger From the 3rd speed block re move the plug spring and plunger 10 Inspect the yoke or block parts replace the worn parts shift Bar Housing How to Assemble the Forward Shift Bar Housing w Super 10 on cover Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The sealant should be applied so that at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the way of any part interference Keep yoke bars in neutral while assembling Special Tools e Typical Service Tools Procedure 1 As
39. 395 093 095 21452 21459 21472 21479 Red Lt Blue 92 m gt lt mi 1 E E 2 U 2 7 Clutch Housing How to Remove the Clutch Housing Special Instructions Removal of the clutch housing is done in the horizontal position Special Tools e Typical Service Tools Procedure 1 From inside the clutch housing remove the nuts and wash ers 2 From inside the clutch housing remove the bolts 3 Jar clutch housing to break gasket seal 4 Pull the clutch housing from the studs and transmission case 5 Remove the gasket and clean all mounting surfaces of gas ket material 53 Clutch Housing How to Install the Clutch Housing Special Instructions Installation of the clutch housing is done in the horizontal position Special Tools e Typical Service Tools Procedure 1 Position a new gasket on the housing mounting surface 2 Install the clutch housing on the front box pilot it on the six studs and drive gear bearing cover rn E 1 5 E v c 3 Install the nuts with washers or lockwashers on the studs tighten to 35 Ib ft 47 N m 90 CW rotation or 175 Ib ft 237 N m of torque 4 Install the capscrews with lockwashers tighten to 115 Ib ft 156 N m of torque Final Check e Make sure the capscrews are properly torqued 54 Changing The Input Shaft How to Remove the Input Shaft Without Disassembling the Transmission S
40. Apply Eaton lockwire 1619 or equivalent to the shift yoke capscrews The lockwire should anchor each capscrew head securely to the yoke or to the second capscrew which fastens to the yoke bar The lockwire should be twisted together trimmed and bend out of the way of other parts Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 If previously removed in the cylinder housing bore install the small O ring 2 If previously removed on the piston O D install the piston O ring gt T 2s 2 lt 7 5 ce i 158 How to Assemble the Auxiliary Section 159 Place the auxiliary housing upright in a vise Position a new gasket on the cylinder housing mounting sur face From the rear with the air passage towards the rear bearing cover install the cylinder housing From the rear insert the piston Make it flush with the cylin der housing If previously removed install in the cylinder cover bore the insert valve nipple in the proper direction If previously removed install over the insert valve the insert valve retaining nut Tighten the retaining nut to 40 50 Ib ft of torque Position a new gasket on the cylinder housing cover mount ing surface The gasket air passage must align with the housing air passage How to Assemble the Auxiliary Section 10 Position the splitter cylinder cover over the gasket 11 Apply Eaton Fuller sealant 712
41. Front Section 7 Pull the input shaft forward and out of the drive gear 8 From inside the case remove the drive gear 9 Inspect the bushing in the input shaft pocket remove if dam aged TI i E N rs ri 5 e EJ 98 Front Section How to Assemble the Front Section FOLLOW THE SOLID LINE THEN THE DOTTED LINE THEN THE DASHED LINE LOWER REVERSE IDLER GEAR REVERSE IDLER GEAR ASSEMBLY UPPER REVERSE IDLER GEAR ASSEMBLE COUNTERSHAFTS LOWER COUNTERSHAFT Porcine COUNTERSHAFT ASSEMBLIES INSTALL COUNTERSHAFT BEARINGS ASSEMBLE MAINSHAFT INPUT SHAFT ASSEMBLY ASSEMBLE AUXILIARY DRIVE GEAR UPPER COUNTERSHAFT BEARINGS MAINSHAFT ASSEMBLY AUXILIARY DRIVE GEAR ASSEMBLY 99 How to Assemble the Front Section How to Install the Reverse Idler Gear Assembly Special Instructions If you install the bottom reverse idler gear assembly make sure the three 3 magnetic discs are securely in place at case bottom Use Eaton Adhesive 71210 or equivalent Special Tools e Typical Service Tools Procedure 1 If reverse gear assembly is disassemble position the needle bearing and inner race into the reverse idler gear 2 Thread the pipe plug into the reverse idler shaft and tighten 3 On the reverse idler shaft position the idler shaft plate flat side to the front 4 Insert the idler shaft into the case bore threaded end to the front As
42. Service Manual Fuller Heavy Duty Transmissions TRSMO550 July 2010 RTLO 11610B RTLO 11610B T2 RTLO 12610B RTLO 12610B T2 RTLO 13610B RTLO 13610B T2 RTLO 14610B T2 RTLO 15610B RTLO 15610B T2 RTLO 16610B RTLO 16610B T2 RTLO 17610B RTLO 17610B T2 RTLO 18610B RTLO 18610B T2 RTLO 14610A RTLOF 11610B RTLOF 11610B T2 RTLOF 12610B RTLOF 12610B T2 RTLOF 13610B RTLOF 13610B T2 RTLOF 14610B RTLOF 14610B T2 RTLOF 15610B RTLOF 15610B T2 RTLOF 16610B RTLOF 16610B T2 RTLOF 17610B RTLOF 17610B T2 RTLOF 18610B RTLO 14610B ETN Powering Business Worldwide BACKED BY Roadranger SUPPORT Precautions Warnings and Precautions A WARNING 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 example of
43. Washers 1 Check surfaces of all washers Washer scored or reduced in thickness should be replaced General Information Assembly 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 precautions as listed below during assemble Axial Clearances Maintain original axial clearances of 006 to 015 for mainshaft gears Bearings 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 a tubular or sleeve type driver whenever possible as force is applied to only one of the bearing races Capscrews To prevent oil leakage and loosening use Eaton Fuller sealant 71205 on all capscrews Gaskets 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 Coat all limit washers and shaft splines with Lubriplate during assembly to prevent scoring and galling of such parts O Rings Lubricate all O rings with silicon lubricant Universal Joint Companion Flange or Yoke Pull the companion flange or yoke tightly into
44. afts 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 recommended General Information Inspection 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 amp 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 after 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 1 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 2 Lubricate bearings that are not pitted discolored or spalled and check for axial and radial clearances 3 Replace bearings with excessive clearances 4 Check bearing fit Bearing inner races should be tight to shaft outer races slightly tight to slightly loo
45. al Tools e Typical Service Tools 165 Procedure 1 Straighten tube lock on suction tube 2 Remove suction tube from oil pump If necessary remove O ring from suction tube 3 Remove three 3 allen head capscrews and washers that re tain the integral oil pump to the case 4 Remove the integral oil pump assembly from inside the case T Remove the integral oil pump retainer plate from inside the case If necessary the front case plug can be removed from the case To remove insert a bar from inside the case and tap the plug out Inspect the plug O ring replace if damaged Integral Oil Pump 166 Integral Oil Pump How to Install the Integral Oil Pump Special Instructions Lubricate the case front plug O ring with Eaton Fuller lubricant 71206 or equivalent Special Tools e Typical Service Tools Procedure 1 If removed replace the front case pump plug O ring lubri cate the grove of the plug install the O ring onto the plug and then lubricate the outer diameter of the O ring 2 Seat the front case pump plug in the case bore by hand Do not install the pump plug using any type of impact tool i e hammer maul etc Note P N 4303107 retainer plate which has a smaller out side diameter must be used with maincase machined after April 1995 If an older oil pump assembly is in stalled into a new case P N 20510 retainer plate will not seat properly in the spot face machin
46. ar Housing Special Instructions There are two 2 sizes of capscrews The 1 capscrews are used with the lifting eyes Special Tools e Typical Service Tools Procedure 1 Place the shift bars in the neutral position 2 Placethe mainshaft sliding clutches in the neutral position rn gt x lt 1 o V 2 m a 3 Position a new shift bar housing gasket on the shift bar housing mounting surface 4 As you install the shift bar housing make sure the yokes fit into the corresponding clutch gears slots 5 Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews 6 Install the retaining capscrews tighten to 35 45 Ib ft of torque 7 Install the washer and nut on the alignment stud Final Check e Make sure the capscrews are properly torqued 38 Output Yoke Companion Flange How to Remove the Output Yoke Companion Flange Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TCSM 0912 Seal Maintenance Guide After removal of the output yoke companion flange temporarily replace the output shaft nut to protect the output shaft threads during auxiliary section disassembly Special Tools e Typical Service Tools e 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 2 Use a large brea
47. auls and soft bars are all that is needed to successfully disassemble and reassemble any Eaton Fuller Trans mission 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 Roadranger Literature Services Attn Contract 4 CA 182 1750 Wallace Ave St Charles IL 60174 3404 Phone 888 ETN INFO 386 4636 Lubrication Application Information Lubrication For a list of Eaton Approved Synthetic Lubricants see TCMT 0021 or call 1 800 826 HELP 4357 The use of lubricants not meeting these requirements will affect warranty coverage Additives and friction modifiers must not be introduced Never mix engine oils and gear oils in the same transmission Buy from a reputable dealer For a list of approved and reputable dealers write to mr e e 5 c E 2 E D r4 e Eaton Corporation Worldwide Marketing Services P 0 Box 4013 Kalamazoo MI 49003 Transmission Operating Angles If the transmission operating angle is more than 12 improper lubrication will occur The operating angle is the transmission mounting angle in the chassis plus the percent of upgrade expressed in degrees For operating angles over 12 the transmission must be equipped with an oil pump or cooler kit to insure proper lubrication Operating Temperatures with Oil Coo
48. can fall Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks e Bearing puller e Soft bar and a maul Procedure 1 Onthe output shaft temporarily install a output yoke 2 To keep the output shaft from turning insert a breaker bar 3 From the output shaft loosen the 15 16 capscrew and re tainer Do not remove the capscrew Remove the bar and output yoke gt T 2s 2 lt 7 5 ce i 126 How to Disassemble the Auxiliary Section 127 4 Useasort 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 countershafts 7 f necessary secure the countershaft assemblies in a vise and remove both the front and rear bearings with a bearing separator and jaw pullers Countershaft Assembly A Series Only How to Remove the Countershaft Assemblies w Ball Bearings A Series Special Instructions For ease of disassembly mount the auxiliary section upright in a vise Both countershafts are removed the same When driving that countershaft to the rear be careful not to damage the bearing inner race As the rear bearing is removed the countershaft will fall Special Tools e Typical Service Tools e Vise with brass jaws or wood blocks e Bearing puller e Soft bar and a maul Procedure 1 From the cou
49. capscrews 11 Install the capscrews tighten to 35 45 Ib ft of torque 12 Repeat all steps for other countershaft installation Final Check e Check both countershafts for timing the output shaft should rotate freely e Check capscrews for proper torque 152 P X 2 lt N D e E How to Assemble the Auxiliary Section How to Assemble the Range Cylinder Assembly Special Instructions Apply Eaton lubricant 71214 or equivalent to all shift cylinder assembly and insert valve O rings so a film covers the entire surface of each O ring Apply Eaton rust preventative 71213 or equivalent to all shift cylinder walls and yoke bars cover the entire yoke bar surface that comes in contact with the shift cylinder O ring Apply Eaton lockwire 1619 or equivalent to the shift yoke capscrews The lockwire should anchor each capscrew head securely to the yoke or to the second capscrew which fastens to the yoke bar The lockwire should be twisted together trimmed and bent out of the way of other parts Special Tools e Typical Service Tools Procedure 1 If previously removed install the interlock pin in the cylinder housing A Series Only 2 If previously removed install the roll pin A Series Only 153 How to Assemble the Auxiliary Section 3 f previously removed in the cylinder housing bore install the small O ring 4 If previously removed on the piston I D and O D in
50. crews WARNING Do not use an air gun Tighten by hand until capscrews are snug 46 Auxiliary Section 4 From the auxiliary section housing remove the retaining capscrews that attach the front box to the auxiliary section 5 Install a steel bar through the yoke 6 Attach a lifting chain to the steel bar 7 Lift assembly from the front section 8 Remove the gasket and clean all mounting surfaces of gas ket material 47 Auxiliary Section 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 e Typical Service Tools e An auxiliary section hanger bracket for horizontal removal e Asteel bar longer than the width of the output yoke for vertical removal e Ahoist with a lifting chain rn gt x lt 1 o me 2 m a Procedure To install the auxiliary section in the hor izontal position 1 Position a new gasket on the transmission mounting sur i face 2 Attach an auxiliary section hanger bracket to the auxiliary section top 3 Attach a lifting chain to the auxiliary section hanger bracket 4 Position the auxiliary section on the two 2 dowel pins 5 Slide the auxiliary section
51. d Gaskets Check all capscrews especially those on PTO covers and rear bearing covers for looseness which would cause oil leak age Check PTO opening and rear bearing covers for oil leakage due to faulty gasket Gear Shift Lever Check for looseness and free play in housing If lever is loose in housing proceed with Check No 9 Gear Shift Lever Housing Assembly Remove air lines at slave valve and remove the gear shift lever housing assembly from the transmission Check the tension spring and washer for set and wear Check the gear shift lever spade pin and slot for wear 18 me e lt e 5 o E 2 Ld D r4 e Preventive Maintenance 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 10 Universal Joint Companion Flange or Yoke Nut Check for tightness Tighten to recommended torque 11 Output Shaft Pry upward against output shaft to check radial clearance in mainshaft rear bearing 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 12 Splines on Output Shaft Check for wear from movement and chucking action of the universal joint companion flange or yoke 13 Mainshaft
52. e is to proper Note Do not use a high pressure spray washer to 3 Notify the customer that it level clean the area Use of a high pressure spray may is only a weep and it is not force contamination into the area of concern and considered to be detrimental temporarily disrupt the leak path to the life of the transmission i Clean area with a clean dry cloth or mild 4 Repair is complete 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 identified area such as the engine shift tower shift bar housing top mounted oil cooler etc 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 Ca
53. e mainshaft key and install the 3rd Drive gear sliding clutch Engage the sliding clutch external splines with the 3rd speed gear clutching teeth Final Check e Make sure reverse gear is against 1st speed gear e Make sure the mainshaft key is in the keyway e Make sure the 3rd speed sliding clutch is engaged into 3rd speed gear Auxiliary Section How to Disassemble the Auxiliary Section AUXILIARY SECTION FRONT SECTION DRIVE GEAR amp YOKE COUNTERSHAFT ASSEMBLIES REAR AUXILIARY DRIVE GEAR RANGE CYLINDER ASSEMBLY DISASSEMBLE SYNCHRONIZER ASSEMBLY OUTPUT SHAFT ASSEMBLY gt zi 5 lt N ow o SPLITTER CYLINDER ASSEMBLY 124 How to Disassemble the Auxiliary Section How to Remove the Front Auxiliary Drive Gear Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 From the splitter cylinder shift yoke remove the lockwire and capscrew 2 Pullthe sliding clutch and shift yoke straight out to remove them 125 How to Disassemble the Auxiliary Section How to Remove the Countershaft Assemblies w Tapered Bearings Special Instructions For A Series go to A Series Section For ease of disassembly mount the auxiliary section upright in a vise Both countershafts are removed the same Make sure the countershaft retaining straps are installed As the countershaft strap is removed support the countershaft it
54. e relief valve roll pin From the relief valve housing bore remove the relief valve spring From the housing bore remove the relief valve Inspect all parts for damage replace damaged parts Integral Oil Pump 170 Integral Oil Pump How to Assemble the Integral Oil Pump Special Instructions When installing the drive shaft keys the round key goes in the round keyway and the square key in the square keyway Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 Install the relief valve in the integral oil pump housing 2 Install the relief valve spring in oil pump housing 3 Secure the oil pump housing in a vice 4 Depress the relief valve spring and drive the relief valve re tention roll pin into the roll pin bore 5 If removed replace the drive shaft snap ring on the pump drive shaft 6 Insert the drive shaft through the pump housing bore 7 Install the two 2 keys on the drive shaft 8 Align the inner element keyways with the drive shaft keys and install the integral oil pump inner element 171 Install the inner element retention snap ring in drive shaft snap ring groove Install drive gear key in drive shaft keyway Align drive gear keyway with drive shaft key and install the drive gear on the drive shaft Install the outer drive gear retention snap ring in drive shaft groove Install the outer integral oil pump
55. earings on the right countershaft make use of the remaining set of main drive gear two marked teeth to time assembly t MEC T FS Or voit i ia ee gt 2 Auxiliary Section A Timing the auxiliary countershafts Standard Auxiliary Section 1 Mark any two teeth on the LO range gear Then mark two teeth located directly opposite the first marked 2 Prior to placing each auxiliary countershaft assembly into housing mark the tooth on each auxiliary countershaft assembly LO range gear stamped with the O 3 Follow the assembly procedures in the Auxiliary Section Helical Auxiliary Section 1 Markany tooth on the LO range gear Then mark a tooth located directly opposite the first marked 2 Priorto placing each auxiliary countershaft assembly into housing mark the two teeth on each auxiliary countershaft assembly LO range gear stamped with the two O s Repeat the procedure on each auxiliary countershaft reduction gear 3 Follow the assembly procedures in the Auxiliary Section 14 i D e 2 S E 9 E D E Tool Reference Tool Reference 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 m
56. ed in the case wall 3 With the retainer bore facing the case rear install the integral oil pump over the alignment pin inside the case 4 Align oil pump with retainer and alignment pin and install the integral oil pump assembly 167 5 Install three 3 allen head capscrews and washers through the case front and into the pump housing Tighten the cap screws to 8 12 Ib ft of torque 6 Replace the O ring on the suction tube 7 Install the tube under the case rib and into the integral oil pump 8 Bend the suction tube lock over the case rib Final Check e Make sure the integral oil pump drive gear can turn Integral Oil Pump 168 Integral Oil Pump How to Disassemble the Integral Oil Pump Special Instructions None Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks 169 Procedure 1 From the assembly remove the outer oil pump element 2 From the drive shaft remove the drive gear retaining snap ring 3 From the pump drive shaft remove the drive gear 4 From the drive shaft keyway remove the key 5 From the drive shaft remove the element snap ring 6 From the drive shaft remove the internal oil pump element 7 From the drive shaft keyways remove the two 2 keys From the integral oil pump housing remove the drive shaft If damaged from the drive shaft remove the rear drive gear retention snap ring From the pump housing remove th
57. elect block ear 11 Install the lockscrew tighten to 35 45 lb ft of torque Lock wire securely 12 Install the oil trough and oil trough retaining capscrews 13 Turn the shift bar housing over and install the two 2 sets of tension springs and balls Final Check e Make sure interlocking system is working can t shift into 2 gears at the same time e Make sure all capscrews are lockwired e Make sure the two 2 sets of tension springs and balls are installed shift Bar Housing 82 N ow 2 I e E K shift Bar Housing How to Disassemble the New Forward Shift Bar Housing w Super 10 on cover Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom shift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical Service Tools Procedure 1 If the two 2 sets of tension springs and balls from housing bores have not been removed place the shift bar housing on its side to remove them Check the condition of the align ment pin replace if necessary 2 If installed remove the oil trough retaining capscrews and oil trough 3 With the housing rear to the right lay the assembly on a
58. ench 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 Special Tools e Typical Service Tools Procedure 1 Remove reverse gear 2 Remove reverse gear spline spacer 3 Tilt the mainshaft up and from the opposite end remove the sliding clutch 4 Place the mainshaft in a vertical position 5 Remove the mainshaft key snap ring 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 117 Remove 1st gear and spline spacer Remove 1st gear spacer Turn the 1st gear limit washer to align its splines with the mainshaft and remove the washer Turn the 3rd gear limit washer to align its splines with the mainshaft and remove the washer Remove the 3rd gear spacer Remove 3rd gear Remove 3rd gear spline spacer Turn the 3rd gear limit washer to align Its splines with the mainshaft and remove the washer Inspect the roll pin remove if damaged Mainshaft Assembly 118 T E Lnd 4 ri Ed i E Mainshaft Assembly How to Assemble the Mainshaft Assembly Spec
59. he Countershaft Bearings 93 How to Remove the Mainshaft Assembly 95 How to Remove the Countershaft Assemblies 96 How to Remove the Input Shaft Assembly 97 How to Assemble the Front Section 99 How to Install the Reverse Idler Gear Assembly 100 How to Install the Countershaft Assemblies 102 How to Install the Countershaft Bearings 103 How to Install the Input Shaft Assembly 105 How to Install the Mainshaft Assembly 108 How to Install the Auxiliary Drive Gear Assembly 109 How to Disassemble the Auxiliary Drive Gear Assembly 110 How to Assemble the Auxiliary Drive Gear Assembly 112 How to Disassemble the Countershaft Assembly 114 How to Assemble the Countershaft Assembly 115 How to Disassemble the Mainshaft Assembly 117 How to Assemble the Mainshaft Assembly 119 Table of Contents Auxiliary Section How to Disassemble the Auxiliary Section 124 How to Remove the Front Auxiliary Drive Gear 125 How to Remove the Countershaft Assemblies w Tapered Bearings sss 126 How to Remove the Countershaft Assemblies w Ball Bearings A Series 128 How to Remove the Rear Auxiliary Drive Gear 130 How to Disassemble the Range Cylinder Assembly 131 How
60. ial Instructions Each mainshaft gear must have its I D snap ring installed before placement on the mainshaft Do not replace reverse gear I D snap ring Gear limit 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 limit washer and one spacer for 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 limit washer should be replaced with a thinner limit washer This will increase the axial clearance between the gears If the axial clearance is greater than the maximum 015 tolerance a thicker limit washer should be installed This will decrease the axial clearance between the gears Special Tools e Avise with brass jaws or wood blocks e Feeler gauges e Apiece of 5 32 air line 1 long 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 the 3rd speed gear lim it washer white in the mainshaft 1st or bottom groove Ro tate the washer until the washer splines and mainshaft splines align 4 Start at the mainshaft bottom and install the air line in the keyway to lock the washer in place As limit washers and gears are installed continue to push the
61. interference Keep yoke bars in neutral while assembling Special Tools e Typical Service Tools Procedure 1 Assemble the 1st amp reverse shift yoke assembly a Install the plunger in the 1st amp reverse shift yoke bore plunger shank to the outside b Install the spring into the bore over the plunger shank N ow 2 I e E K c Position the washer over the plunger shank d Install the snap ring 2 Assemble the 3rd speed block assembly a Install the plunger in the 3rd shift block bore plunger shank to the outside b Install the spring into the bore over the plunger shank c Install the plug and tighten to compress the spring d After plug bottoms out back the plug out 1 11 2 turns e Complete the block assembly process by staking the plug through the small hole in block 68 shift Bar Housing 69 3 With the housing rear to the right lay the assembly on a flat surface 4 Install the select tube in the middle boss with key in the key slot 5 As the select tube passes through the first boss install the shift select block 6 From the right install the select interlock bar 7 Install the range interlock bar chamfered end in notched side down 8 At the middle yoke bar front end install the washer plain nut and jam nut 9 Install the interlock pin centered between bosses 10 While installing the top yoke bar position the shift yoke as sembly a
62. is likely to result from unequal tooth contact causing the mainshaft gears to climb out of equilibrium Timing is a simply 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 Front Section A Marking countershaft drive teeth 1 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 B Marking main drive gear teeth 1 Mark any two adjacent teeth on the main drive gear 2 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 FIN iol Timing C 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 coun tershaft assemblies 1 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 2 Repeat the procedure when installing the b
63. k or rope around the mainshaft 6 Pull the mainshaft to the rear to free the pilot from the input shaft pocket 7 Tilt mainshaft front up and lift assembly from the case 95 How to Disassemble the Front Section How to Remove the Countershaft Assemblies Special Instructions Expect for the PTO gears the upper and lower countershaft assemblies are the same Make sure and mark each as they are re moved Special Tools e Typical Service Tools Procedure 1 Movethe upper countershaft assembly to the rear as far as possible 2 Swing the countershaft front to middle of the case 3 Liftthe countershaft assembly from the case E i E Lnd N r i E 96 How to Disassemble the Front Section How to Remove the Input Shaft Assembly Special Instructions None Special Tools e Typical Service Tools e Soft bar and a maul Procedure 1 6 97 If the front bearing cover is still installed remove the six 6 retaining capscrews and cover Remove the any remaining gasket material from the case and cover From the input shaft groove remove the bearing retaining snap ring Use a soft bar and maul and drive the input shaft toward the case rear as far as possible Pull the input shaft forward Use pry bars or screwdrivers to complete removal of the bearing From the drive gear front remove drive gear spacer Remove the drive gear internal snap ring How to Disassemble the
64. ker bar or air impact wrench to remove the output shaft nut 3 Pull the yoke or flange straight to the rear and off the output shaft 39 Output Yoke Companion Flange How to Install the Output Yoke Companion Flange Special Instructions You must remove the shift bar housing in order to lock the transmission For proper cleaning and maintenance see TCSM 0912 Seal Maintenance Guide Special Tools e Typical Service Tools e Torque Wrench 500 Ib ft Capacity Procedure 1 Engagetwo 2 mainshaft sliding clutches into two 2 main shaft gears to lock the transmission rn gt x lt 1 gt o V 2 a 2 Install the speedometer drive gear rotor or replacement spacer on the output shaft inside the rear bearing cover 3 Ifthe slinger on the yoke is damaged replace using a Sling er Seal kit 4 Slide the companion flange or yoke onto the output shaft 5 Install the output shaft nut tighten to 450 500 Ib ft of torque Final Check e Make sure the output shaft nut is properly torqued e Unlock the transmission 40 Auxiliary Section How to Remove the Auxiliary Section Without 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 Special Tools 41 Typical Service Tools An auxiliary section hanger bracket f
65. le the Synchronizer Assembly Special Instructions Assembly should be done on a clean flat surface slightly lower than your waist Pins on the Low range synchronizer must line up with the chamfered holes on the sliding clutch bottom When compress 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 e Shop rag Procedure 1 On the bench place the larger LO range synchronizer ring face down with pins up 2 With the sliding clutch recessed side up place the sliding clutch on the LO range synchronizer pins 3 In the HI range synchronizer bores install the three 3 springs 163 synchronizer Assembly 4 Place the HI range synchronizer ring over the LO range syn a 8 837 chronizer ring Rotate the HI range synchronizer until the springs are seated against the pins 5 With the shop rag cover the assembly 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 Final Check e Make sure there are three springs and are fully com pressed e Make sure you can move the sliding clutch from HI to LO range and back gt X 2 lt N D e E 164 Integral Oil Pump How to Remove the Integral Oil Pump Special Instructions None Speci
66. lers The transmission must not be operated consistently at temperatures above 250 F However intermittent operating temperatures to 300 F do not harm the transmission Operating temperatures above 250 F increases the lubricant s oxidation rate and shortens its effective life When the average operating temperature is above 250 F the transmission can require more frequent oil changes or external cooling The following conditions in any combination can cause operating temperatures of over 250 F a b C d e Operating consistently at slow speeds High ambient temperatures Restricted air flow around transmission Exhaust system too close to transmission High horsepower operation External oil coolers are available to reduce operating temperatures when the above conditions are encountered 16 Lubrication Application Information Oil Cooler Chart Transmission Oil Coolers are Recommended With engines of 350 H P and above Required 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 450 H P and above Preventive 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 p
67. lines and hose 3 Inspect air fittings remove if damaged 24 Air System How to Install the Air Lines and Hose Special Instructions Make sure air lines and hose are not damaged Install the air lines and hose at their proper location All externally threaded 1 8 or 5 32 air lines and pipe fittings that are not coated with pre applied thread sealant must be coated with Eaton sealing material 71209 or equivalent for at least 5 complete and consecutive threads All externally threaded 1 4 air fittings that are not coated with pre applied thread sealant must be coated with Eaton sealing ma terial 71209 or equivalent for at least 3 complete and consecutive threads For the 1 4 D air hoses install the fixed nut end first To install the air lines and hose the air filter regulator must be in position If you are unsure of the air lines and hose location see the Air System Troubleshooting Operation Guide TRTS 0920 Special Tools e Typical Service Tools e For push to connect fittings we recommend Eaton Service Tool Kit K 2394 The kit contains the release tool and a tubing cutter Procedure 1 Replace removed air fittings 2 Connect all removed air lines and hose Final Check e Make sure fittings are tight e Make sure air lines are not kinked 25 Air System How to Remove the Air Filter Regulator Special Instructions The air filter regulator has two 2 O rings located between the filter reg
68. ll Center at 1 800 826 4357 21 How to Disassemble the External Parts How to Disassemble the External Parts EXTERNAL PARTS AIR Clutch SYSTEM Housing CHANGING THE INPUT SHAFT ien LLL AUXILIARY SECTION AIR FILTER ROADRANGER OUTPUT YOKE REGULATOR UE COMPANION FLANGE GEAR SHIFT LEVER m gt lt r 1 E x Y o9 7 LEGEND gt OPTIONAL PATH TYPICAL PATH SHIFT BAR HOUSING 22 How to Assemble the External Parts How to Assemble the External Parts EXTERNAL PARTS OUTPUT YOKE CLUTCH COMPANION HOUSING FLANGE AUXILIARY SHIFT BAR SECTION HOUSING AIR GEAR SHIFT SYSTEM LEVER AIR FILTER REGULATOR CHANGING THE INPUT SHAFT ROADRANGER VALVE AIR LINES AND HOSE LEGEND gt OPTIONAL PATH TYPICAL PATH 23 Air System How to Remove the Air Lines and Hose Special Instructions Before removing the air lines and hose label or record their location If after you remove the air lines and hoses you are unsure of their location see the Air System Troubleshooting Operation Guide TRTS 0920 Special Tools e Typical Service Tools e For push to connect fittings we recommend Eaton service tool kit K 2394 The kit contains the release tool and the tubing cutter Procedure 1 Disconnect all air lines and hose rn gt x lt 1 o V 2 P a 2 Inspect the air
69. ller 112 13 threaded end and remove the shaft from case bore As the idler shaft and idler plate are removed remove the thrust washer and gear Inspect the reverse gear assembly remove the inner race and needle bearing if damaged E i E N r i E 92 How to Disassemble the Front Section How to Remove the Countershaft Bearings Special Instructions The following instructions are used to remove the upper and lower countershaft 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 e Typical Service Tools e Soft bar and a maul e 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 From inside the case use a soft bar and maul to drive the countershaft rear bearings from the case bores 93 How to Disassemble the Front Section 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 fr
70. nd block assembly The block assembly aligns with shift select block ear 11 Install the lockscrews tighten to 35 45 Ib ft of torque Lock wire securely 12 While installing the bottom yoke bar position the shift yoke The block assembly aligns with shift select block ear 13 Install the lockscrew tighten to 35 45 Ib ft of torque Lock wire securely 14 Turn the shift bar housing over and install the anti rotating pin and the two 2 sets of tension springs and balls Final Check e Make sure interlocking system is working can t shift into 2 gears at the same time e Make sure all capscrews are lockwired e Make sure the anti rotating pin and the two 2 sets of tension springs and balls are installed shift Bar Housing 70 7 gt i D o 5 amp Shift Bar Housing How to Disassemble the Standard Shift Bar Housig w Super 10 on cover Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom shift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical Service Tools Procedure 1 If the two 2 sets of tension springs and balls from housing bores have not been removed
71. ng clutch which is in the rearward posi tion 6 e The rear auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 7 e Torque is delivered along both countershafts to the LO range gear in the auxiliary section 8 e The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch 9 e The output shaft delivers torque to the driveline components 10 Auxiliary Section LO Range 2nd Gear General Information Power torque from the vehicle s engine is transferred to the transmission s input shaft 1 The input shaft external splines engage the main drive gear internal splines 2 Torque is split between the two countershaft drive gears 3 Torque is delivered along both countershafts to the mating countershaft gears of the engaged mainshaft gear The fol lowing cross section view illustrates a 2nd speed gear engagement 4 o 1 3 1 o 5 i 3 2 i 3 The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which transfers torque to the mainshaft 5 2 Gear Front Section The mainshaft transfers torque directly to the auxiliary drive gear sliding clutch which is in the forward position 6 The auxiliary drive gear splits torque between the two auxiliary countershaft drive gears 7 Torque is delivered along both countershafts to the LO range gear in the auxiliary secti
72. nsmission in the vertical position clutch housing down 2 Position a new gasket on the transmission mounting sur face 3 Install a steel bar through the yoke 4 Attach a lifting chain to the steel bar 5 Position the auxiliary section over the two 2 dowel pins 6 Slide the auxiliary section down the dowels 7 Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews 8 Install the retaining capscrews tighten to 35 45 Ib ft of torque 9 Remove the steel bar and chain Final Check e Make sure capscrews are properly torqued e Make sure the input shaft rotates Auxiliary Section 44 rn gt lt 1 o me o m a Auxiliary Section 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 Auxiliary can be removed without straps use caution Special Tools 45 Typical Service Tools An 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 To remove the auxiliary section in the horizontal position 1 Remove the
73. nstall the plunger in the 1st amp reverse shift yoke bore plunger shank to the outside b Install the spring into the bore over the plunger shank N ow 2 I e E K c Position the washer over the plunger shank d Install the snap ring 2 Assemble the 3rd speed block assembly a Install the plunger in the 3rd shift block bore plunger shank to the outside b Install the spring into the bore over the plunger shank c Install the plug and tighten to compress the spring d After plug bottoms out back the plug out 1 11 2 turns e Complete the block assembly process by staking the plug through the small hole in block 86 Shift Bar Housing 87 With the housing rear to the right lay the assembly on a flat surface Install the center rail in the middle boss As the center rail passes through the first boss install the shift block Drive the center block roll pin through the center bar to hold the center block in position Install the interlock pin centered between bosses While installing the top yoke bar position the shift yoke as sembly and block assembly The block assembly aligns with shift select block ear Install the lockscrews tighten to 35 45 Ib ft of torque Lock wire securely 10 While installing the bottom yoke bar position the shift yoke The block assembly aligns with shift select block ear 11 Install the lockscrew tighten to 35 45 lb ft of torque
74. ntershaft rear bearing cover remove the cap Screws cover and gasket 2 Clean the gasket mounting surface of gasket material 3 From the countershaft rear remove the snap ring P X 2 lt N D e E 128 Countershaft Assembly A Series Only 4 Useasort bar and maul to drive the countershaft forward far enough to partially unseat the bearing 5 Usea soft bar and maul to drive the countershaft to the rear This exposes the bearing snap ring 6 Use a bearing puller and remove the countershaft bearing and countershaft 7 Inspect the countershaft bearing inner race remove if nec essary 129 How to Disassemble the Auxiliary Section How to Remove the Rear Auxiliary Drive Gear Special Instructions None Special Tools e Typical Service Tools e Avise with brass jaws or wood blocks Procedure 1 Retainer rectangular in shape From the output shaft remove the 15 16 capscrew and re tainer Retainer round in shape From the output shaft remove the 15 16 capscrew and re tainer and thrust washer 2 Fromthe output shaft remove the auxiliary drive gear If the retainer from Step 1 is round there will also be a thrust washer behind the auxiliary drive gear to remove P X 2 lt N D e E 130 How to Disassemble the Auxiliary Section How to Disassemble the Range Cylinder Assembly Special Instructions When removing the range cylinder cove
75. on 8 The LO range gear delivers torque to the output shaft through the range synchronizer sliding clutch 9 The output shaft delivers torque to the driveline components 10 Auxiliary Section LO Range 10 General Information 7th gear Power torque from the vehicle s engine is transferred to the transmission s input shaft 1 The input shaft external splines engage the main drive gear internal splines 2 Torque is split between the two countershaft drive gears 3 Torque is delivered along both countershafts to the mating countershaft gears of the engaged mainshaft gear The fol lowing cross section view illustrates a 7th speed gear engagement 4 The external clutching teeth of the sliding clutch engage with the internal clutching teeth of the mainshaft gear which transfers torque to the mainshaft 5 7 Gear Front Section The mainshaft transfers torque directly to the rear auxiliary drive gear sliding clutch which is in the rearward posi tion 6 Torque is delivered to the back of the rear auxiliary drive gear The range synchronizer sliding clutch is in the forward position transferring torque directly to the output shaft 7 The output shaft delivers torque to the driveline components 8 Auxiliary Section HI Range General Information 8th Gear e Power torque from the vehicle s engine is transferred to the transmission s input shaft 1 e The input shaft external splines engage the main drive
76. ont bear ings Return to the case rear and drive each countershaft forward as far as possible This exposes the bearing snap rings Use a bearing puller or pry bars to remove the countershaft front bearings If a bearing puller is used the front bearing cover has to be removed 94 nm al e E co D ri m How to Disassemble the Front Section How to Remove the Mainshaft Assembly Special Instructions Be careful when removing the mainshaft assembly the sliding clutch on the end can slip off the mainshaft Reverse gear is also free and can fall off the shaft Special Tools e Typical Service Tools e Large hook or 3 foot piece of rope Procedure 1 From the mainshaft remove the reverse gear retaining snap ring 2 Movethe mainshaft reverse gear as far to the rear as possi ble and remove reverse gear D snap ring 3 Move the reverse gear forward and against the next gear en gaging the mainshaft sliding clutch spline A WARNING If not removing the upper reverse idler gear as sembly you must remove the upper reverse idler gear as sembly shaft and roll the gear to the outside see How to Remove the Reverse Idler Gear Assembly steps 1 4 4 Use alarge screwdriver and block the upper countershaft as sembly against the case wall A WARNING If removing the upper reverse idler gear assem bly see How to Remove the Reverse Idler Gear Assembly at this time 5 Position the hoo
77. opposition side as the lower reverse idler gear assemble E i E N D ri i EJ 4 Place the upper 45 tooth PTO gear assembly in the case the inner bearing race end to the front 5 Position as far to the right as possible the same side as the lower reverse idler gear assemble Final Check e Make sure the upper and lower countershafts are in the right place e Make sure the timing marks are visible 102 How to Assemble the Front Section How to Install the 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 Special Tools e Typical Service Tools e Countershaft support tool e Flanged end driver and maul Procedure 1 Movethe countershaft to the rear and insert the countershaft support tool to center shaft in rear case bore 2 Use a flanged end driver to start the front bearing in case bore 103 How to Assemble the Front Section 3 Use a screwdriver inserted in the countershaft capscrew bore to help center the countershaft 4 Move the countershaft forward into the bearing 5 Use a flanged end bearing driver and maul to completely seat the front bearing in case bore 6 On the countershaft front position the retainer plate with roll
78. or horizontal removal A steel bar longer than the width of the output yoke for vertical removal A hoist with a lifting chain Procedure To remove the auxiliary section in the horizontal position 1 From the auxiliary section housing remove the retaining capscrews that attach the front section to the auxiliary sec tion 2 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 Auxiliary Section 3 Remove the capscrews from the tapped holes 4 Attach an auxiliary section hanger bracket to the auxiliary section top 5 Attach a lifting chain to the auxiliary section hanger bracket 6 Move assembly to the rear until auxiliary section is free 7 Remove the gasket and clean all mounting surfaces of gas ket material Procedure To remove the auxiliary section in the vertical position 1 With blocks under the clutch housing to prevent input shaft damage place transmission in the vertical position clutch housing down rn gt lt 1 o V o m c 2 From the auxiliary section housing remove the retaining capscrews that attach the front box to the auxiliary section 3 Install a steel bar through the yoke 4 Attach a lifting chain to the steel bar 5 Liftassembly from the front section 6 Remove the gasket and clean all mounting surfaces of gas ket material
79. ounter shaft This removes the front bearing inner race E E N rs ri i EJ 3 Inspectthe key and roll pin remove if damaged 114 Countershaft Assembly How to Assemble the Countershaft Assembly 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 e Snap ring pliers e Press Procedure 1 If previously removed install the roll pin and key in counter shaft keyway 2 Align 3rd speed gear keyway with the countershaft key and press the gear on the countershaft 3 Align PTO gear keyway with the countershaft key and press the gear on the countershaft 4 Align drive gear keyway with the countershaft key and press the gear on the countershaft 115 5 On each countershaft front install the drive gear retaining snap ring in groove 6 Use a flanged driver or the press to install the bearing inner race on the countershaft front against the drive gear Final Check e Make sure all gears are pressed into place e Make sure the bearing inner race is installed Countershaft Assembly 116 m z S gt co I ri m Mainshaft Assembly How to Disassemble the Mainshaft Assembly Special Instructions During disassembly lay all parts on a clean b
80. pecial Instructions Remove the transmission from the vehicle Special Tools e Typical Service Tools Procedure 1 Remove the front bearing cover and gasket 2 Remove the input shaft snap ring 3 Drive the input shaft towards the transmission rear through the bearing as far as possible 4 Pullthe input shaft forward to expose the bearing snap ring 5 To complete bearing removal use pry bars 6 From the drive gear front remove the drive gear spacer 55 Changing The Input Shaft 7 Remove the drive gear snap ring 8 Pull the input shaft forward out of the drive gear and trans mission case rn gt x lt 1 o V 2 Pm a 56 Changing The Input Shaft How to Install the Input Shaft Without Disassembling the Transmission Special Instructions Check the bushing in the input shaft pocket replace if worn Special Tools e Typical Service Tools e nput Shaft Bearing Driver Procedure 1 Install the new input shaft into main drive gear splines 2 Position the input shaft just far enough into the gear to ex pose the drive gear D snap ring groove 3 Install the drive gear I D snap ring 4 Install the drive gear spacer on the input shaft 5 With the external snap ring to the outside slide the drive gear bearing on the input shaft and position into the case bore 57 Changing The Input Shaft 6 With the input shaft bearing driver seat the bearing
81. pin in hole at shaft end 7 Secure with capscrew tightening to 90 120 Ib ft of torque 8 From the rear remove the countershaft support tool 9 With the larger I D lead chamfer to the shaft front use a flanged end bearing driver and install the rear bearing 10 In the countershaft rear groove install the rear snap ring Final Check e Make sure the front bearing capscrew is properly torqued m z S gt co J ri m e Make sure the rear snap ring is in place 104 How to Assemble the Front Section How to Install the Input Shaft Assembly Special Instructions As part of assembling the input shaft assembly the mainshaft drive gear must be installed and timed Replace the pilot bushing if worn Apply Eaton lubricant 71215 or equivalent to the pilot bushing so that a film of lubricant covers the entire internal surface of the bushing Special Tools e Typical Service Tools e Toolmaker s dye Procedure 1 In I D of main drive gear install the snap ring 2 Usetoolmaker s dye and mark the main drive gear for timing purposes Mark any two 2 adjacent teeth on the drive gear Repeat the procedure for the two 2 adjacent teeth directly opposite the first set marked 3 Inside the case mesh the lower countershaft drive gear marked tooth with either set of marked teeth on the main drive gear 4 Slide the input shaft through the main drive gear 105 How to Assemble the Front
82. place the shift bar housing on its side to remove them 2 If installed remove the oil trough retaining capscrews and oil trough 3 With the housing rear to the right lay the assembly on a flat surface 4 While removing the bottom yoke bar remove the shift yoke 71 shift Bar Housing 5 While removing the top yoke bar remove the shift yoke as sembly and block assembly 6 Remove the interlock pin 7 From the middle yoke bar drive center block roll pin out N 5 ow 2 I e E K 8 Pull the center bar to the right and remove the shift select block 72 Shift Bar Housing 73 9 From the 1st amp reverse shift yoke remove the snap ring washer spring and plunger From the 3rd speed block re move the plug spring and plunger 10 Inspect the yoke or block parts replace the worn parts shift Bar Housing How to Assemble the Standard Shift Bar Housing w Super 10 on cover Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The sealant should be applied so that at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the
83. place with the output shaft nut using 450 500 Lbf ft of torque Make sure the speed ometer drive gear or a replacement spacer of the same width has been installed Failure to pull the companion 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 series to ensure that proper parts are used during assemble of the transmission i e e S E E E D E General Information How to use this Manual This manual is designed to provide detailed information necessary to service and repair the Eaton Fuller transmissions listed on the front As outlined on the first page the manual has been divided into its main components external parts shift bar housing front sec tion auxiliary section and options if applicable Each component has its own tabbed section Each tabbed section has its own table of contents and procedural flow charts The table of contents lists the procedures The flow charts represent the order in which the transmission should be disassembled or assembled The procedures have two parts disassembly or removal and re assembly or installation As mentioned the flow charts represent the order in which the transmission should be disassembled or assembled The following is an example of how to disassemble the auxiliary section specifically the range cylinder assembly General Information
84. pscrews 2 Remove the mainshaft rear groove snap ring 3 From inside the auxiliary drive gear assembly remove the splined washer 4 Insert three 3 of the capscrews in the specially tapped holes of the retainer ring 5 Tighten the capscrews evenly to force the auxiliary drive gear assembly from the case 6 Remove the auxiliary drive gear from the mainshaft mn al e gt co D ri m 7 From the mainshaft remove the splined washer 90 How to Disassemble the Front Section How to Remove the Reverse Idler Gear Assembly Special Instructions The following instructions are used to remove upper and lower reverse idler gears Before the upper reverse idler gear assembly can be removed mainshaft reverse gear must be positioned forward against the next gear While removing the reverse idler shaft the thrust washer can drop to the transmission case bottom The mainshaft reverse gear must be moved in order to remove the upper reverse idler gear see How to Remove the Mainshaft Assembly steps 1 3 Special Tools e Typical Service Tools e Jaw Pullers or Impact Puller Procedure 1 From the reverse idler gear bore use inside jaw pullers or an impact puller to remove the auxiliary countershaft front bearing 2 From the idler shaft remove the loosened lock nut and washer 91 How to Disassemble the Front Section From the idler shaft rear remove the pipe plug Install an impact pu
85. r the mainshaft must be completely installed Special Tools e Typical Service Tools e Large pair of snap ring pliers e Flanged end driver and maul Procedure 1 Install the splined washer on the mainshaft against the re verse gear retaining snap ring 2 Position the auxiliary drive gear assembly on the mainshaft 3 Use a flanged end driver and maul to seat the auxiliary drive gear bearing 4 Align the retainer ring capscrew holes with the tapped holes 5 Apply Eaton Fuller sealant 71205 or equivalent to the re taining capscrews 6 Install the retaining capscrews tighten to 35 45 Ib ft of torque 7 Install the splined washer inside the auxiliary drive gear as sembly 8 Install the auxiliary drive gear retaining snap ring in the mainshaft snap ring groove 109 Auxiliary Drive Gear Assembly How to Disassemble the Auxiliary Drive Gear Assembly Special Instructions To disassemble the auxiliary drive gear must be removed Special Tools e Typical Service Tools e A large pair of snap ring pliers Procedure 1 Lay the front auxiliary drive gear on a clean flat surface 2 From the front auxiliary drive gear hub use a screwdriver to pry off the snap ring retainer 3 From the front auxiliary drive gear hub remove the snap ring TT RET TUR 4 Usethe front hub as a base and press the retaining ring and bearing off 110 Auxiliary Drive Gear Assembly 5 From the front auxiliary
86. r insert valves note the direction the insert valve was positioned nipple in or out Special Tools e Typical Service Tools Procedure 1 From the range cylinder cover remove the capscrews cov er and gasket 2 Clean the gasket mounting surfaces of all gasket material 3 From the range cylinder housing bore remove the nut 4 Fromthe auxiliary section front remove the two 2 yoke bar retaining capscrews 131 How to Disassemble the Auxiliary Section 5 From the cylinder housing bore remove the yoke bar 6 From the shaft pull the synchronizer shift yoke and the syn chronizer assembly 7 From the cylinder housing bore remove the range piston 8 Inspect the range piston O rings remove if damaged gt X 2 lt N D e E 132 How to Disassemble the Auxiliary Section 9 From the range cylinder housing remove the housing and gasket 10 Clean the gasket mounting surfaces of all gasket material 11 Inspect the O ring inside the range cylinder housing bore remove if damaged 12 Place the range cylinder cover in a vise remove one insert valve retaining nut and insert valve 13 Inspect the insert valve and the cover bore for damage Re peat for other insert valve For 14610A Models go to Steps 14 and 15 14 Place the range cylinder housing in a vise remove the roll pin 133 How to Disassemble the Auxiliary Section 15 Remove the interlock pin
87. rogram 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 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 Checks Before Transmission Removal 1 Air System and Connections Check for leaks worn air lines loose connections and capscrews See SERVICING AIR SYSTEM Clutch Housing Mounting Check all capscrews of clutch housing flange for looseness Clutch Release Bearing Not Shown Remove hand hole cover and check radial and axial clearance in release bearing Check relative position of thrust surface of release bearing with thrust sleeve on push type clutches Clutch Pedal Shaft and Bores Pry upward on shafts to check wear If excessive movement is found remove clutch release mechanism and check bushings on bores and wear on shafts See OEM literature Lubricant Change at specified service intervals Use only the types and grades as recommended See LUBRICANTS Filler and Drain Plugs Remove filler plugs and check level of lubricant at specified intervals Tighten fill and drain plugs securely Capscrews an
88. se in case bore If bearing spins freely in bore case should be replaced Bearing Covers 1 Check covers for wear from thrust of adjacent bearing Replace covers damaged from thrust of bearing outer race 2 Check cover bores for wear Replace those worn or oversized 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 bushing surfaces Gears 1 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 pitted teeth have considerable gear life remaining and can be reused but gears in the advanced stage of pitting should be replaced 2 Check for gears with clutching teeth abnormally worn tapered or reduced in length from clashing during shifting Re place gears found in any of these conditions 3 Check axial clearance of gears Gear Shift Lever Housing Assembly 1 Check spring tension on shift lever Replace tension spring if lever moves too freely 2 If housing is disassembled check gear shift lever bottom end and shift finger assembly for wear Replace both gears if excessively worn Gray Iron Parts 1 Check all gray iron parts for cracks and breaks Replace parts found to be damaged i e e S E
89. securely 10 While installing the bottom yoke bar position the shift yoke The block assembly aligns with shift select block ear 11 Install the lockscrew tighten to 35 45 lb ft of torque Lock wire securely 12 Install the oil trough and oil trough retaining capscrews 13 Turn the shift bar housing over and install the two 2 sets of tension springs and balls Final Check e Make sure interlocking system is working can t shift into 2 gears at the same time e Make sure all capscrews are lockwired e Make sure the two 2 sets of tension springs and balls are installed shift Bar Housing 76 N i 2 I e E K Shift Bar Housing How to Disassemble the Forward Shift Bar Housing w Super 10 on cover Special Instructions The shift bar housing must be removed from the transmission During disassembly lay all parts on a clean bench in order of removal to facilitate assembly Shift bars not being removed must be kept in the neutral position or the interlocking parts lock the bars Start with the bottom shift bar Cut the lockwire and remove the lockscrews from each bar just before their removal Special Tools e Typical Service Tools Procedure 1 If the two 2 sets of tension springs and balls from housing bores have not been removed place the shift bar housing on its side to remove them 2 If installed remove the oil trough retaining capscrews and oil trough
90. semble the 1st amp reverse shift yoke assembly a Install the plunger in the 1st amp reverse shift yoke bore plunger shank to the outside b Install the spring into the bore over the plunger shank N i 2 I e E K c Position the washer over the plunger shank d Install the snap ring 2 Assemble the 3rd speed block assembly a Install the plunger in the 3rd shift block bore plunger shank to the outside b Install the spring into the bore over the plunger shank c Install the plug and tighten to compress the spring d After plug bottoms out back the plug out 1 11 2 turns e Complete the block assembly process by staking the plug through the small hole in block 80 Shift Bar Housing 3 With the housing rear to the right lay the assembly on a flat surface 4 Install the center rail in the middle boss 5 Asthe center rail passes through the first boss install the shift block 6 Drivethe center block roll pin through the center bar to hold the center block in position 7 Install the interlock pin centered between bosses 8 While installing the top yoke bar position the shift yoke as sembly and block assembly The block assembly aligns with shift select block ear 9 Install the lockscrews tighten to 35 45 Ib ft of torque Lock wire securely 81 10 While installing the bottom yoke bar position the shift yoke The block assembly aligns with shift s
91. ss jaws or wood blocks Procedure 1 Slide the Boot up the shift lever shaft and remove 2 With housing bottom facing up secure the assembly in a vise 3 Uselarge screwdriver to twist between the spring and hous ing forcing the spring from under the housing lugs 4 From inside the housing tower remove the tension spring washer and gear shift lever 5 n models so equipped from the housing bore remove the nut and washer 61 Gear Shift Lever 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 N ow 2 I e E K 62 Gear Shift Lever 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 e Typical Service Tools e Avise with brass jaws or wood blocks e Tension Spring Driver 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 In models so equipped install the nut and washer in the housing bore 4 If the O ring is damaged replace
92. sssssss 48 The Shimming Procedure For Tapered Bearings 50 How to Remove the Clutch Housing 53 How to Install the Clutch Housing 54 How to Remove the Input Shaft Without Disassembling the Transmission 55 Table of Contents How to Install the Input Shaft Without Disassembling the Transmission 57 Shift Bar Housing Shift Bar Housing Identification 59 How to Disassemble the Gear Shift Lever 61 How to Assemble the Gear Shift Lever 63 How to Disassemble the Standard Shift Bar Housing 65 How to Assemble the Standard Shift Bar Housing 68 How to Disassemble the Standard Shift Bar Housig w Super 10 on cover 71 How to Assemble the Standard Shift Bar Housing w Super 10 on cover 74 How to Disassemble the Forward Shift Bar Housing w Super 10 on cover 77 How to Assemble the Forward Shift Bar Housing w Super 10 on cover 80 How to Disassemble the New Forward Shift Bar Housing w Super 10 on cover 83 How to Assemble the New Forward Shift Bar Housing w Super 10 on cover 86 Front Section How to Disassemble the Front Section 89 How to Remove the Auxiliary Drive Gear Assembly 90 How to Remove the Reverse Idler Gear Assembly 91 How to Remove t
93. stall the piston O rings 5 Position anew gasket on the cylinder housing mounting sur face 6 From the rear with the air passage away from the rear bear ing cover install the cylinder housing 7 Place the range shift yoke with the threaded yoke hub up and HI range synchronizer towards the front in the sliding clutch slot 8 Place the range shift yoke and synchronizer assembly on the output shaft engaging the sliding clutch splines gt T 2s 2 lt 7 5 ce i 154 How to Assemble the Auxiliary Section 155 9 With the yoke bar threaded end insert the yoke bar into the range cylinder housing bore through the range shift yoke hub Align the bar notches with range shift yoke lockscrew holes 10 Install the two 2 yoke bar retaining capscrews tighten to 50 65 Ib ft of torque 11 From the rear insert the piston Push it in as far as it will go 2 Secure the piston with the retaining nut tighten to 70 85 Ib ft of torque How to Assemble the Auxiliary Section 13 If previously removed install in one of the cylinder cover bores the insert valve nipple in the proper direction 14 If previously removed install over the insert valve the in sert valve retaining nut Tighten the retaining nut to 40 50 Ib ft of torque Repeat for other insert valve 15 Position a new gasket on the cylinder housing cover mount ing surface The gasket air passage must align with
94. t bearings 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 e Typical Service Tools e Toolmaker s dye e Heatlamp or hot plate and oil e Oil seal installation tool Procedure 1 Usetoolmaker s dye and mark the LO range gear for timing purposes Mark any two 2 adjacent teeth on the LO range gear Re peat the procedure for the two 2 adjacent teeth directly op posite the first set marked 2 With splined washer facing up place the washer on the out put shaft shoulder gt X E lt N D e E 140 How to Assemble the Auxiliary Section 3 With LO range gear clutching teeth down position LO range gear on the output shaft engage the washer splines 4 With chamfer side up position the LO range gear rear wash er on the output shaft against the LO range gear 5 With tapered side up use heat or appropriate driver and in stall the output shaft front rear bearing 6 On the output shaft position the bearing inner spacer Set aside li E TIRE 141 How to Assemble the Auxiliary Section 7 Lay the auxiliary housing front face up on a clean flat sur face Install the front bearing cup 8 Turn the auxiliary housing over install the rear bearing spac er and rear bearing
95. taining cap screws and oil trough 3 While removing the bottom yoke bar remove the shift yoke 65 4 While removing the top yoke bar remove the shift yoke as sembly and block assembly 5 Remove the interlock pin 6 From the middle yoke bar remove the jam nut plain nut and washer 7 Remove the range interlock bar 8 From the middle yoke bar remove the select interlock bar to the right 9 Pull the select tube to the left and remove the shift select block shift Bar Housing 66 N gt ow D a E amp Shift Bar Housing 67 10 Remove the select tube with key to the left 11 From the 1st amp reverse shift yoke remove the snap ring washer spring and plunger From the 3rd speed block re move the plug spring and plunger 12 Inspect the yoke or block parts replace the worn parts shift Bar Housing How to Assemble the Standard Shift Bar Housing Special Instructions Inspect shift blocks and shift yokes for wear Apply Eaton sealant 71208 or equivalent to the shift bar housing plugs which are used to plug oil cooler provision holes The sealant should be applied so that at least 5 complete threads are covered Apply Eaton lockwire 1819 or equivalent to all shift bar housing assembly set screws in both blocks and yokes The wire should anchor the capscrew at least 2 complete 360 turns The lockwire ends should be trimmed and bent out of the way of any part
96. tate the washer until the washer splines and mainshaft splines align Push the air line up to lock the washer on the mainshaft 18 20 21 22 Between the gear hub and mainshaft spacer insert 006 feeler gauge and 015 feeler gauge If out of tolerance change the limit against the mainshaft spacer See Special Instructions for further information Align the sliding clutch missing internal spline with the mainshaft key and install the 1st Reverse speed sliding clutch With the flat side up position the Reverse speed gear limit washer white 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 Against the limit washer position reverse speed gear spac er Mainshaft Assembly 122 TI i E N rs ri i E Mainshaft Assembly 123 Install reverse gear on the mainshaft Engage the gear clutching teeth with spacer splines and sliding clutch Move the reverse gear down against the 1st speed gear At this time remove the air line and insert the mainshaft key WARNING Be careful not to move the gears while doing this procedure the limit washers are unlocked and can rotate which would cause the gears to drop Install the mainshaft key snap ring Remove the mainshaft from the vise On the shaft front align the sliding clutch missing internal spline with th
97. the auxiliary housing over the countershaft assemblies and the output shaft assemble 9 Heat the rear output bearing cone and install the bearing ta pered side down on the shaft 10 Position a new gasket on the rear bearing cover mounting surface T 2 mia udi Am 148 P X 2 lt N D e E How to Assemble the Auxiliary Section 149 11 12 13 14 Position the rear bearing cover Apply Eaton Fuller Sealant 71205 or equivalent to the re taining capscrews Install the five 5 retaining capscrews in the non chamfered hole tighten to 35 45 Ib ft of torque Install the nylon collar and brass washer in the chamfered hole tighten to 35 45 Ib ft of torque Install each auxiliary countershaft retaining strap with 2 3 8 NC x 1 and 1 3 8 NC x 2 1 2 clean capscrews WARNING Do not use an air gun Tighten by hand until the capscrews are snug Countershaft Assembly A Series Only How to Install the Countershaft Assemblies w Ball Bearings A Series Special Instructions For ease of assembly mount the auxiliary section in a vise When Installing the countershaft assemblies into the countershaft bearings keep the countershaft assemblies straight Do not cock the countershafts If when the countershaft bearing cover is removed and you can not see the snap ring groove install the cover and drive the coun tershaft further until you can see the groove
98. the upper countershaft against the case wall 2 With reverse gear forward against the next speed gear lower the mainshaft assembly while pulling the shaft rear through the case bore 3 Move the mainshaft pilot end into the input shaft pilot bush ing Mesh the mainshaft gears with the corresponding for ward countershaft assembly gears 4 Center the mainshaft rear in case bore and temporarily posi tion the auxiliary drive gear on the mainshaft Partially seat the bearing in the bore E E N I4 i EJ WARNING At this time other components of the front sec tion must be Installed before the mainshaft installation can be completed see How to Install the Countershaft Bear ings 5 Mesh the reverse gear teeth with the reverse idler gear teeth and move the reverse gear to the rear as far as possible 6 Remove the auxiliary drive gear 7 Align the reverse gear spacer external splines with the re 3 ad verse gear and move the spacer into the reverse gear i L Ps gt N gt Li arme OS g S 8 Install the reverse gear I D snap ring and move the reverse N 7 A fey gear forward on the mainshaft and against the reverse gear bi TT LP M limit washer 9 Install the reverse gear retaining snap ring in the mainshaft second snap ring groove 108 How to Assemble the Front Section How to Install the Auxiliary Drive Gear Assembly Special Instructions Before installing the auxiliary drive gea
99. ulator and the range cylinder cover Special Tools e Typical Service Tools Procedure 1 From the air filter regulator remove the two 2 capscrews rn gt x lt 1 o V 2 m a 2 From the range cylinder cover remove the two 2 O rings 3 Inspect the O rings for cracks or distortion 26 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 auxiliary section Special Tools e Typical Service Tools Procedure 1 Onthe range cylinder cover position the two 2 o rings 2 Over the o rings position the air filter regulator 3 Apply eaton fuller sealant 71205 or equivalent to the two 2 retaining capscrews 4 Install the two 2 retaining capscrews tighten to 8 12 Ib ft of torque Final Check e Make sure the capscrews are properly torqued 27 How to Remove a Roadranger Valve Special Instructions The air lines must be depressurized Special Tools e 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

Fuller Heavy Duty Transmissions TRSM0550

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